WQ0006245_Final Permit_20020506

0F \NAT-1� Michael F. Easley, Governor
William G. Ross Jr -,Secretary
North Carolina Department of Environment and Natural Resources
r
-i Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
May 6, 2002
MR. JOHN E. MARSHALL, MAYOR
CITY OF STATESVILLE
POST OFFICE Box 111 I
STATESVILLE, NORTH CAROLINA 28687
Subject: Permit No. WQ0006245
City of Statesville
City of Statesville N-Viro Processing Facility and
Sta-Lime Distribution Program
Distribution of Residual Solids (503)
Iredell County
Dear Mr. Marshall:
In accordance with your permit renewal and modification application package received on
November 3, 2001 as well as the additional information received on January 23, 2002 and April 29, 2002,
we are forwarding herewith a renewed and modified Permit No. WQ0006245, dated May 6, 2002, to the
City of Statesville for the subject residuals lime stabilization facility and distribution program.
This permit shall be effective from the date of issuance until April 30, 2007; shall void Permit
No. WQ0006245, issued on March 5, 1997; and shall be subject to the conditions and limitations as
specified therein. Make note of this permit's expiration date and the fact that a permit renewal
application is due to the Division of Water Quality (Division) no later than six months prior to that date
(i.e., see Condition V1.7.), as the Division does not send reminders to apply for permit renewal.
This permit approves the continued operation of the residuals land application program for
another five-year cycle. In addition, this permit has been modified to increase the maximum allowable
volume of Class A residuals product to be generated by this facility and distributed through this program
from 3,900 dry tons per year to 7,000 dry tons permit year.
As always, remember to take the time to review this permit thoroughly, as some of the
conditions contained therein may have been added, changed, or deleted since the last issuance. Pay
particular attention to the monitoring requirements in this permit. Of special interest to you is the
following:
+ Condition III. 5. stipulates the minimum monitoring/sampling frequency for compliance with
the pathogen reduction and vector attraction reduction requirements mandated by 40 CFR
Part 503. With the March 5, 1997 issuance of this permit, the Division reduced this
frequency from once every 60 days to quarterly. Unfortunately, the Division made an error in
allowing this frequency reduction. Although 40 CFR §503.16 (a)(2) does provide for a
reduction in the monitoring for the pathogen density requirements after two years of
monitoring, the reduction is limited to facilities/programs that meet the pathogen reduction
requirements through the alternatives described in 40 CFR §503.32 (a)(5)(h) and (a)(5)(iii)
alone. For this reason, the every 60-day monitoring/sampling frequency has been
reestablished with this issuance of this permit. Note, however, that the Division has
maintained a quarterly frequency for the monitoring of pollutant, nutrient, and micronutrient
concentrations present in the Class A residuals product as was provided for in the previous
issuance of this permit. A
I L }EI
Non -Discharge Permitting Unit Internet httpl/h2o.enr.state.nc.us/ndpu
1617 Mail Service Center, Raleigh, NC 27699-1617 Telephone [phone] Fax [phone]
DENR Customer Service Center Telephone [phone]
An Equal Opportunity Action Employer 50% recycled/10% post -consumer paper

Please be aware that failure to establish an adequate system for collecting, maintaining, and
submitting the required operational information will result in future compliance problems.
If any parts, requirements, and/or limitations contained in this permit are unacceptable, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request shall be in the from of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes and filed with the Office of Administrative Hearings at 6714 Mail Service
Center, Raleigh, North Carolina 27699-6714. Unless such demands are made, this permit shall be final
and binding.
If you need any additional information concerning this matter, please contact Ms. Shannon Mohr
Thornburg by telephone at [phone], extension 353, or via e-mail at
[e-mail].
Since 1 ,
Lor Gregory J. Thorpe, Ph.D.
cc: Iredell Health Department
Mooresville Regional Office -Water Quality Section
Mooresville Regional Office -Groundwater Section
Central Office -Groundwater Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
Water Quality Central Files
NDPU Files
N

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
DISTRIBUTION OF RESIDUAL SOLIDS (503) PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
City of Statesville
Iredell County
FOR THE
continued operation of a N-Viro Processing Facility for the lime stabilization of residuals generated from
the treatment of municipal wastewater and potable water at the facilities listed in Condition 11. 3. and
consisting of the following minimum components: a conveyor belt (i.e., to be replaced with a screw -type
auger during the 2002-2003 fiscal year) to transport residuals from the Fourth Creek WWTP filter press
facilities to a 53-foot long covered, cleated, feeder conveyor, two 25-cubic yard storage hoppers for the
storage of dewatered residuals from the Third Creek WWTP and the City of Statesville's WTP; bottom
screw conveyors to transport residuals from the storage hoppers to flanged connections above the 53-foot
long covered, cleated, feeder conveyor; a 25-foot long, 12-inch diameter, twin screw mixer; two, 12-foot
diameter by 23-foot tall (i.e., 60-ton capacity), straight -wall, leg -supported silos with variable speed
volumetric feeders and a common transfer screw conveyor to transport lime and/or kiln dust to the mixer;
a covered, cleated -side wall conveyor from the end of the mixer to the truck loading station; appropriate
non -leaking transport truck(s) or approved equivalent to convey the mixted limekiln dust and residuals;
protected pulse bins into which the nixed limekiln dust and residuals are dumped and allowed to heat; a
150-foot by 300-foot curbed, asphalt curing slab onto which the mixed lime./kiln dust and residuals are
placed in windrows, allowed to continue to heat, periodically turned, and dried; a stormwater swale and
drain system draining back to the wastewater treatment plant (i_e., walled and roofed pulse bins are
located along the upslope 300-foot side of the curing slab); all necessary measuring devices to ensure that
each truck load of the mixed limekiln dust meets the requirements listed in Condition L 6.; all associated
controls, support structures, piping, and appurtenances;
and the continued operation of a program for the distribution of up to 7,000 dry tons per year of a Class A
residuals product marketed under the name Sta-Lime.

Both the facility and the program shall be operated such that no discharge of waste to surface
waters occurs, pursuant to the permit renewal and modification application package received on
November 3, 2001 as well as the additional information received on January 23, 2002 and April 29, 2002,
and in conformity with the project plan, specifications, and other supporting data subsequently filed and
approved by the Department of Environment and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until April 30, 2007; shall void Permit
No. WQ0006245, issued on March 5, 1997; and shall be subject to the following specified conditions and
limitations:
1. PERFORMANCE STANDARDS
The residuals lime stabilization facility and distribution program shall be effectively
maintained and operated as a non -discharge system to prevent the discharge of any wastes to
waters of the state resulting from the operation of this facility or program.
2. This permit shall become voidable in the event of failure of the residuals lime stabilization
facility or distribution program to adequately protect the assigned water quality standards of
the surface waters and groundwater.
The issuance of this permit shall not relieve the Permittee of the responsibility for damages to
surface water or groundwater resulting from the operation of this residuals lime stabilization
facility or distribution program.
4. In the event that the residuals lime stabilization facility or distribution program is not
operated satisfactorily, including the creation of nuisance conditions, the Permittee shall take
any immediate corrective actions as may be required by the Division of Water Quality
(Division).
5. Diversion or bypassing of untreated residuals or leachate from the residual lime stabilization
facility shall be prohibited. All leachate shall be reused as a wetting agent for the processing
of residuals or disposed of through a Division -approved method.
6. When wastewater residuals are sold or given away, one of the Class A pathogen requirements
in 40 CFR Part 503.32(a) and one of vector attraction reduction requirements in 40 CFR Part
503.33 shall be met. Additionally, an evaluation shall be performed which demonstrates the
residuals' ability to comply with this requirement. Upon request, a copy of this evaluation,
including all test results and calculations, shall be submitted.
In addition to the above, the Division has approved the following process, which has been
determined and approved to be equivalent to a Process to Further Reduce Pathogens (PFRP)
by the Pathogen Equivalency Committee (PEC), for use by the Permittee. Note that the
Permittee still has to perform the fecal col iform/Salmonella sp. bacteria density testing and
meet one of the vector attraction reduction requirements in 40 CFR Part 503.33 if this PFRP-
equivalent process is used.
ON

11.
a. N-Viro International Corporation (Toledo, Ohio)
Advanced Alkaline Stabilization with Subsequent Accelerated Drying
Alternative 1: Fine alkaline materials (i.e., cement kiln dust, quicklime fines,
pulverized lime, or hydrated lime) shall be uniformly mixed by mechanical or
aeration mixing into liquid or dewatered residuals to raise the pH to greater than
12 for seven days. If the resulting mixture is liquid, it shall then be dewatered.
The mixture shall then be air dried, while the pH remains above 12 for greater
than or equal to seven days, for greater than 30 days and until the mixture reaches
a total solids concentration greater than or equal to 65 percent. A total solids
concentration of greater than or equal to 60 percent shall be achieved in the
mixture before the pH drops below 12. The mean temperature of the air
surrounding the mixture shall be above five degrees Celsius (i.e., 41 degrees
Fahrenheit) for the first seven days.
ii. Alternative 2: Fine alkaline materials (i.e., cement kiln dust, quicklime fines,
pulverized lime, or hydrated lime) shall be uniformly mixed by mechanical or
aeration mixing into liquid or dewatered residuals to raise the pH to greater than
12 for greater than or equal to 72 hours. If the resulting mixture is liquid, it shall
then be dewatered. The mixture shall then be heated, while the pH remains
above 12, using exothermic reactions or other thermal processes to achieve
temperatures of greater than or equal to 52 degrees Celsius (i.e., 126 degrees
Fahrenheit) throughout the mixture for greater than or equal to 12 hours. The
mixture shall then be air dried, while the pH remains above 12 for greater than or
equal to three days, to a total solids concentration of greater than or equal to 50
percent.
7. No Class A residuals product that tests or is classified as a hazardous or toxic waste under 40
CFR Part 261 shall be sold or given away under the conditions of this permit.
OPERATION AND MAINTENANCE REQUIREMENTS
The residuals lime stabilization facility and distribution program shall be properly operated
and maintained at all times.
2. Upon classification of the residuals lime stabilization facility and distribution program by the
Water Pollution Control System Operators Certification Commission (WPCSOCC), the
Permittee shall employ a certified operator to be in responsible charge (ORC) of the facility
and program. The operator shall hold a certificate of the type classification assigned to the
facility and program by the WPCSOCC. The Permittee shall also employ a certified back-up
operator of the appropriate type to comply with the conditions of 15A NCAC SG .0202.
No residuals other than those generated by the following residuals source -generating facilities
shall be approved for distribution in accordance with this permit:
Source
County
Permit
_ Number
Volume
(Dry Tons/Year
N-Viro Processing Facility
Iredell
NDPU Permit No. WQ0006245
7,000
Fourth Creek WWTP
Iredell
NPDES Permit No. NCO031836
Included Above
Third Creek WWTP
Iredell
NPDES Permit No. NCO020591
Included Above
City of Statesville WTP
Iredell
PWSS ID No. 01-49-010
Included Above

4. No other residuals other than that from the residuals source -generating facility specified in
Condition Il. 3. may be lime stabilized and distributed under this permit. The Permittee shall
request and obtain a permit amendment from the Division for each additional residual source -
generating facility prior to acceptance of those residuals -for treatment in the approved
residuals lime stabilization facility and distribution through the approved residuals
distribution program.
5. All residuals and Class A residuals product shall be adequately stored to prevent leachate
runoff prior to and following treatment. Following treatment, the Class A residuals product
may be stored in an elevated silo, placed on a concrete pad, kept under shelter, covered, or
stored in a manner as otherwise approved by the Division until such time as it is distributed to
the user. The Permittee may also use the out -of -service drying beds at the Fourth Creek
WWTP to store the Class A residuals product, as long as all leachate is routed to the
wastewater treatment facility. If an alternative storage site is to be used, approval shall first
be obtained from the Division.
6. Adequate provisions shall be taken to prevent wind erosion and surface runoff from
conveying pollutants from residuals or the Class A residuals product from the residuals Iime
stabilization facility onto adjacent property or into any surface waters.
7. For a Class A residuals product to be sold or given away in bags or other container for
application to the land, the following shall be satisfied:
The Ceiling Concentrations (Dry Weight Basis) and the Pollutant Monthly Average
Concentrations (Dry Weight Basis) shall be maintained:
Ceiling Monthly Average
Concentrations Concentrations
Parameters (mg/kQ) (_mg/kg)
Arsenic
75
41
Cadmium
85
39
Copper
4,300
1,500
Lead
840
300
Mercury
57
17
Molybdenum
75
----
Nickel
420
420
Selenium
100
100
Zinc
7,500
2,800
8. A label shall be affixed to the bag or other container in which a Class A residuals product is
sold or given away for application to the land, or an information sheet shall be provided to
the person who receives the Class A residuals product sold or given away in another
container for application to the land. The label or information sheet shall contain the
following information:
a. The name and address of the person who prepared the Class A residuals product that is
sold or given away in a bag or other container for application to the land.
b. A statement that application of the Class A residuals product to the land is prohibited
except in accordance with the instructions on the label or information sheet-
4

c. The following statement shall be included to help prevent direct application of the
Class A residuals product to water supply sources and all other waters of the state. "As
with any fertilizer product, do not apply in or near any water supply source or any body
of water, including wells, streams, rivers, and lakes."
d. The Class A residuals product shall not be applied to any site that is flooded, frozen, or
snow-covered.
e. Adequate procedures shall be provided to prevent surface runoff from carrying any
disposed or stored Class A residuals product into any surface waters.
III. MONITORING AND REPORTING REQUIREMENTS
Any monitoring (i.e., including groundwater, surface water, residuals, soil, or plant tissue
analyses) deemed necessary by the Division to ensure protection of the environment shall be
established and an acceptable sampling and reporting schedule shall be followed.
2. Proper records shall be maintained by the Permittee to track all Class A residuals product
distribution activities. These records shall include, but are not necessarily limited to, the
following information:
a. Source, amount, and analysis of each Class A residuals product.
b. Name of the initial recipient of the Class A residuals product, the amount distributed, and
the intended use.
The Class A residuals product shall be analyzed to demonstrate that they are non -hazardous
under the Resource Conservation and Recovery Act (RCRA). A corrosivity, ignitability, and
reactivity'analysis as well as a Toxicity Characteristics Leaching Procedure (TCLP) analysis
shall be conducted by the Permittee annually, and the results of the analyses shall be
maintained on file by the Permittee for a minimum of five years.
The TCLP analysis shall include the following parameters (i.e., note the regulatory level in
milligrams per liter in parentheses):
Arsenic (5.0)
Barium (100.0)
Benzene (0.5)
Cadmium (1.0)
Carbon tetrachloride (0.5)
Chlordane (0.03)
Chlorobenzene(100.0)
Chloroform (6.0)
Chromium (5.0)
m-Cresol (200.0)
o-Cresol (200.0)
p-Cresol (200.0)
Cresol (200.0)
2,4-D (10.0)
1,4-Dichlorobenzene (7.5) Nitrobenzene (2.0)
1,2-Dichloroethane (0.5)
Pentachlorophenol (100.0)
1,1 Dichloroethylene (0.7)
Pyridine (5.0)
2,4-Dinitrotoluene (0.13)
Selenium (1.0)
Endrin (0.02)
Silver (5.0)
Hexachlorobenzene (0.13)
Tetrachloroethylene (0.7)
Heptachlor (and its hydroxide) (0.008)
Toxaphene (0.5)
Hexachloro-1,3-butadiene (0.5)
Trichloroethylene (0.5)
Hexachloroethane (3.0)
2,4,5-Trichlorophenol (400.0)
Lead (5.0)
2,4,6-Trichlorophenol (2.0)
Lindane (0.4)
2,4,5-TP (Silvex) (1.0)
Mercury (0,2)
Vinyl chloride (0.2)
Metboxychlor (10.0)
Methyl ethyl ketone (200.0)
5

After the Class A residuals product has been monitored for two years at an annual frequency,
the Penrnittee may submit a request to the Division for a permit modification to reduce the
frequency of this monitoring requirement. In no case, however, shall the frequency of this
monitoring be less than once per permit cycle when the Class -A residuals product is sold or
given away during that year.
4. An analysis shall be conducted by the Permittee on the Class A residuals product quarterly
from the date of permit issuance. The results of all analyses shall be maintained on file by the
Permittee for a minimum of five years. The analysis shall include the following parameters:
Aluminum
Ammonia -Nitrogen
Arsenic
Cadmium
Calcium
Copper
Lead
Magnesium
Mercury
Molybdenum
Nickel
Nitrate -Nitrite Nitrogen
Percent Total Solids
pH
Phosphorus
Potassium
Selenium
Sodium
Total Kjeldahl Nitrogen
Zinc
Plant Available Nitrogen
(by calculation)
After the Class A residuals product has been monitored for two years at a quarterly
frequency, the Permittee may submit a request to the Division for a permit modification to
reduce the frequency of this monitoring requirement. In no case, however, shall the
frequency of this monitoring be less than once per year when the Class A residuals product is
sold or given away during that year.
5. The Class A residuals product shall be monitored by the Permittee every 60 days for
compliance with Condition I. 6. of this permit. The monitoring frequency cycle shall start on
the date of permit issuance, and the results of all analyses shall be maintained on file by the
Permittee for a minimum of five years. Data to verify stabilization of the product shall be
maintained by the Permittee. The required data shall be specific to the stabilization process
utilized, but should be sufficient to demonstrate compliance with the Class A pathogen
requirements in 40 CFR Part 503.32(a) and the vector attraction reduction requirements in 40
CFR Part 503.33 clearly. In addition, the EPA certification statements concerning
compliance with pathogen requirements, vector attraction reduction requirements, and
management practices shall be completed at the above frequency by the proper authority or
authorities if more than one is involved, either the person who generates the residuals or the
person who prepares the product to be sold or given away.
6. Laboratory analyses and/or operational data, as required by Condition III. 3., and Condition
III. 4., and Condition lEIL 5_, shall be performed/gathered on the Class A residuals product as
it is to be distributed. Furthermore, analytical determinations made pursuant to the
monitoring and reporting requirements of this permit shall be made by a laboratory certified
by the Division for the required parameter(s) under 15A NCAC 2H .0800 or 15A NCAC 2H
.1100.
7%

7. Three copies of all required monitoring and reporting requirements as specified in Condition
III. L, Condition III. 2., Condition III. 3., Condition III. 4.., and Condition III. S. shall be
submitted annually on or before March IS` of the year following the distribution event to the
following address:
NCDENR-DWQ
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
8. Noncompliance Notification:
The Permittee shall report by telephone to the Water Quality Section of Division's
Mooresville Regional Office at telephone number [phone], as soon as possible, but in
no case more than 24 hours or on the next working day following the occurrence or first
knowledge of the occurrence of any of the following:
a. Any occurrence with the residuals lime stabilization facility or distribution program that
results in the land application of significant amounts of wastes which are abnormal in
quantity or characteristic.
b. Any failure of the residuals Iime stabilization facility or distribution program resulting in
a release of material to receiving waters.
c. Any time that self -monitoring information indicates that the residuals lime stabilization
facility or distribution program has gone out of compliance with the conditions and
limitations of this permit or the parameters on which the system was designed.
d. Any process unit failure, due to known or unknown reasons, that render the residuals lime
stabilization facility incapable of adequate residual treatment.
e. Any spillage or discharge from a vehicle or piping system during transportation of
residuals or Class A residuals product.
Persons reporting such occurrences by telephone shall also file a written report in letterform
within five days following first knowledge of the occurrence. This report shall outline the
actions taken or proposed to be taken to ensure that the problem does not recur.
IV. GROUNDWATER REQUIREMENTS
Applicable Boundaries:
a. The COMPLIANCE BOUNDARY for the residuals lime stabilization facility shall be as
specified by regulations in 15A NCAC 2L (i.e., "Groundwater Classifications and
Standards"). The Compliance Boundary for a disposal system individually permitted
after December 31, 1983 shall be established at either (1) 250 feet from the waste
disposal area or (2) 50 feet within the property boundary, whichever is closest to the
residuals lime stabilization facility. An exceedance of groundwater quality standards at
or beyond the Compliance Boundary shall be subject to immediate remediation action
according to 15A NCAC 2L .0106(d)(2).
b. The REVIEW BOUNDARY shall be established around the residuals lime stabilization
facility midway between the Compliance Boundary and the perimeter of the waste
disposal area. Any exceedance of groundwater quality standards at the Review Boundary
shall require action in accordance with 15A NCAC 2L .0106(d)(1).
II

2. Other Requirements:
a. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
V. INSPECTIONS
1. The Permittee or his designee shall inspect the residuals storage, transport, and treatment
facilities to prevent malfunctions and deterioration, operator errors and discharges which may
cause or lead to the release of wastes to the environment, a threat to human health, or a
nuisance. The Permittee shall maintain an inspection log or summary including at Ieast the
date and time of inspection, observations made, and any maintenance, repairs, or corrective
actions taken by the Permittee. This log of inspections shall be maintained by the Permittee
for a period of five years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
2. Any duly authorized officer, employee, or representative of the Division may, upon
presentation of credentials, enter and inspect any property, premises or place on or related to
the residuals lime stabilization facility at any reasonable time for the purpose of determining
compliance with this permit; may inspect or copy any records that must be kept under the
terms and conditions of this permit; and may obtain samples of groundwater, surface water,
or leachate.
VI. GENERAL CONDITIONS
This permit shall become voidable unless the residuals lime stabilization facility and
distribution program are operated in accordance with the conditions of this permit, the
supporting materials, and in the manner approved by the Division.
2. This permit shall be effective only with respect to the nature and volume of residuals
described in the application and other supporting data.
Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division in accordance with North Carolina
General Statutes § 143-215.6A through § 143-215.6C.
4. The annual administering and compliance fee shall be paid by the Permittee within 30 days
after being billed by the Division. Failure to pay the fee accordingly may cause the Division
to initiate action to revoke this permit, as specified by 15 NCAC 2H .0205 (c)(4).
5. The issuance of this permit does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances that may be imposed by other government agencies
(i.e., local, state, and federal) which have jurisdiction, including, but not limited to, applicable
river buffer rules in 15A NCAC 2B .0200, soil erosion and sedimentation control
requirements in 15A NCAC Chapter 4 and under the Division's General Permit NCG010000,
and any requirements pertaining -to wetlands under 15A NCAC 2B .0200 and 15A NCAC
.0500.

6. This permit may be modified, revoked, and/or reissued to incorporate any conditions,
limitations and monitoring requirements the Division deems necessary in order to protect the
environment and public health adequately.
7. The Pennittee, at least six months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Division shall review the adequacy of the
residuals lime stabilization facility and distribution program described therein, and if
warranted, shall extend the permit for such period of time and under such conditions and
limitations as it may deem appropriate.
8. This permit shall not be automatically transferable. In the event that there is a desire for the
residuals lime stabilization facility and distribution program to change ownership or to
change the name of the Permittee, a formal permit request shall be subrnitted to the Division
documentation from the parties involved and other supporting materials as may be
appropriate. The approval of this request shall be considered on its merits and may or may
not be approved.
Permit issued this thelixth day of May, 2002.
NORTH OLINA ENWONN4ENTAL MANAGEMENT COMMISSION
for Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0006245
6