WQ0006245_Final Permit_20061020

OF 1jVA]�C9 Michael F. Easley, Governor
O� pG William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
r
—1 Alan W. Klimek, P.E., Director
C Division of Water Quality
October 20, 2006
MR. R0I3ERT W HITES, JR.
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. Hites:
In accordance with your permit renewal and modification application package received on August 14,
2006, we are forwarding herewith a renewed of Permit No. WQ0006245, dated October 20, 2006, to the
City of Statesville for the subject residuals time stabilization facility and distribution program.
This permit shall be effective from the date of issuance until September 30, 2011; shall void Permit No.
WQ0006245, issued on May 6, 2002; 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 VI.
7.), as the Division does not send reminders to apply for permit renewal.
Please note that on September 1, 2006 State Administrative Code 15A NCAC Subchapter 02T — Waste
not Discharged to Surface Water was adopted. This permit does not incorporate the requirement of the
new rules since the permit renewal application was received before September 1, 2006. Upon future
permit renewal or major modifications requests, the residual program will be subject to the 02T rules. It
is recommended that the facility begin planning for any changes needed to meet the requirements of the
02T rules when they become applicable.
As always, remember to take the time to review this permit thoroughly, pay particular attention to the
monitoring requirements in this permit. 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 Cente&
NoithCarolina
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Telephone: [phone]
Internet- vvww.ncwaterquality.org Location: 2728 Capital Boulevard Raleigh, NC 27604 Fax 1: [phone]
Fax 2: [phone]
An Equal Opportunity/Affirmative Action Employer-50% Recycled110% Post Consumer Paper Customer Service: [phone]

MR. ROBERT W. HITEs, JR.
October 20, 2006
Page 2
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 Jon Risgaard by telephone
at [phone], or via e-mail [e-mail].
Sincerely,
for Alan W. Klimek, P.E.
cc: Iredell Health Department
Mooresville Regional Office- Aquifer Protection Section
Technical Assistance and Certification Unit
APS Central Files
LAU Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
LAND APPLICATION OF RESIDUAL SOLIDS 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 II.
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 lime/kiln dust and residuals; protected pulse bins into
which the mixed 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 I. 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 September 30, 2011; shall void
Permit No. WQ0006245, issued on May 6, 2002; and shall be subject to the following specified
conditions and limitations:
I. PERFORMANCE STANDARDS
1. 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.
3. 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 coliformlSahnonella 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.
2

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.
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.
II. OPERATION AND MAINTENANCE REOLTREMENTS
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 8G .0202.

3. No residuals other than those generated by the following residuals source -generating
facilities shall be approved for distribution in accordance with this permit:
Permit Volume
Source County Number 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 H. 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.
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.
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
lime stabilization facility onto adjacent property or into any surface waters.
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 m 9& m /k
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
12

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.
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
1. 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.
3. 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.
M

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) (0.00$)
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)
Methoxychlor (10.0)
Methyl ethyl ketone (200.0)
After the Class A residuals product has been monitored for two years at an annual
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 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 six
times year 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)
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.
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
31

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 III. 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 paramcter(s) under 15A NCAC 2H
.0800 or 15A NCAC 2H A 100.
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.
5. shall be submitted annually on or before March 1" of the year following the
distribution event to the following address:
NCDENR-DWQ
Information Processing 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 Iand application of significant amounts of wastes which are
abnormal in quantity or characteristic.
b. Any failure of the residuals lime 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.
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
AMlicable 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).
2. Other Requirements:
a. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
V. INSPECTIONS
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
least 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.
VL GENERAL CONDITIONS
1. 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.
91

3_ 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 211 .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.
The Permittee, 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 submitted 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 the Twentieth day of October, 2006.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
for Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ006245
9