WQ0006245_Final Permit_19920318

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street - Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
March 18,1992
Mr. Jack King, City Manager
City of Statesville
Post Office Box 1111
Statesville, North Carolina 28677
George T. Everett, Ph.D
Director
Subject: Permit No.WQ0006245
Sludge Stabilization Facility
Fourth Creek Wastewater Treatment Plant
Wastewater Treatment Facility
Iredell County
Dear Mr. King:
In accordance with your application received December 5, 1991 we are forwarding herewith Permit
No. WQ0006245 dated March 18, 1992 to City of Statesville for the construction and operation of the
subject facilities.
This permit shall be effective from the date of issuance until February 28, 19977 and shall be subject
to the conditions and limitations as specified therein. Please pay particular attention to the monitoring
requirements in this permit. Failure to establish an adequate system for collecting and maintaining the
required operational infom-iation will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
704/251-6208 9191486-1541 704/663-1699 9191733-2314 919/946-6481 919/395-3900 919/896-7007
Pollution Prevention Pays
P.O. Sox 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

City of Statesville
WQ0006245
Page Two
One set of approved plans and specifications is being forwarded to you, If you need additional
information concerning this matter, please contact Mr. John Seymour at 919/ 733-5083.
cc: Iredeil County Health Department
Mooresville Regional Office, Water Quality
Training and Certification Unit
Facilities Assessment Unit
Mooresville Regional Office, Groundwater
Groundwater, Jack Floyd
aincer
George T. Everett
PA

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
COMPOST PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina a!
amended, and other applicable Laws, Rules, and Regulations
W.R39 'I.'HWiEi7
City of Statesville
Iredell County
FOR THE
construction and operation of a wastewater treatment plant sludge stabilization facility for the stabilization
of process dewatered sludges from Fourth Creek WWTP, Third Creek WWTP, and alum sludge from
Statesville's water plant to meet PFRP requirements via pH and temperature conditions, consisting of
Fourth Creek dewatered sludge transported by an existing conveyor belt from the existing Fourth Creek
filter press facilities to a new 53 foot long covered cleated feeder conveyor, two 25 cubic yard sludge
storage hoppers (for dewatered Third Creek and alum sludges transported in) with bottom screw
conveyors to convey sludge from hopper to flanged connections above the 53 foot cleated feeder
conveyor, 25 foot long 12 inch diameter twin screw sludge mixer, two 12 foot diameter by 23 foot straight
wall (60 ton capacity) leg supported silos with variable speed volumetric feeders and a common transfer
screw conveyor to convey lime and/or kiln dust to the sludge mixer, a covered cleated side wall conveyor
from the end of the sludge mixer to the truck lading station, an appropriate nonleaking transport truck(s) or
approved equivalent to convey lime/ kiln dust mixed sludge, protected pulse bins (where truck loaded
sludge will be dumped and allowed to heat for pathogen reduction), a 150 foot by 300 foot curbed sludge
curing asphalt slab for treated sludge mix to be put in wind rows and allowed to continue to heat and then
to dry including periodic turning with stormwater swale and drain system draining back to the wastewater
treatment facilities (walled and roofed pulse bins along the up slope 300 foot side of sludge curing slab),
all necessary measuring devices to ensure that each truck load of mixed sludge reaches a pH of 12 for 2
hours and the temperature in the heated sludge is maintained at a minimum of 70 degrees C for a minimum
of 30 minutes, and all associated controls, support structures, piping, and appurtenances for the sludge
sources listed in Condition 11 3. with no discharge of wastes to the surface waters, pursuant to the
application received December 5, 1991 and in confonznity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment, Health and Natural
Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until February 28, 1997 and shall be subject
to the following specified conditions and limitations:

i;u:► in; ►1::1
1. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
29535, Raleigh, NC 27626-0535.
2. The Mooresville Regional Office, phone no. 704/ 663-1699 shall be notified at least forty-
eight (48) hours in advance of operation of the installed facilities so that an in -place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays,
3. This permit shall become voidable in the event of failure of the sludge stabilization facility
to adequately protect the assigned water quality standards of the surface waters and
groundwaters and meet sludge PFRP standards.
4. The sludge stabilization program shall be effectively maintained and operated as a non -
discharge system to prevent discharge of any wastes resulting from the operation of this
program.
5. The issuance of this permit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.
6. In the event that the sludge stabilization program is not operated satisfactorily, including the
creation of nuisance conditions, the Permittee shall take such immediate corrective action as
may be required by this Department, including the construction of additional or replacement
wastewater treatment or disposal facilities.
7. Diversion or bypassing of the untreated sludge or compost drainage wastewater from the
stabilization facilities is prohibited
8. Stabilized sludge that meets PFRP standards should not be used in areas of intense public
use (schools, playgrounds, etc.). Sludges that do not meet PFRP standards should only be
disposed of in accordance with State regulations and permitted authority.
1. The facilities and disposal sites shall be properly maintained and operated at all times.
2. The sludge composting operation must be conducted under the supervision of the certified
wastewater treatment plant operator required by the Certification Commission for operation
of the Fourth Creek Wastewater Treatment Plant, NPDES Permit No. NC0031836.
N

3. No sludges other than the following are hereby approved for composting in accordance -
with this permit:
Permit
Fourth Creek WWTP Iredell NC0031836
Third Creek WWTP iredell NC0020591
Statesville Water Plant Ir dell
4. All stabilized and unstabilized sludges shall be stored at the appropriate Fourth Creek
Wastewater Treatment Plant facilities until such time as it is disposed of. If an alternate
storage site is to be used, approval must be obtained from the Division of Environmental
Management.
5. No stabilized sludge shall be disposed of or marketed that does not meet the criteria for the
Process to Further Reduce Pathogens (PFRP), which for this facility a lime/ kiln dust
mixed sludge reaches a pH of 12 for 2 hours and the temperature in the heated sludge is
maintained at a minimum of 70 degrees C for a minimum of 30 minutes. The use of any
other stabilizing method shall require a permit amendment prior to the distribution of any
such compost.
6. Any sludge which does not meet PFRP criteria can only be disposed of as per a specific
disposal permit.
111 INO2"—tarlwk, : & 1 : 3 ' 411641i►`C�1114 Bill 1 1114 0115l DIZO 0
1. Any monitoring (including groundwater, surface water, sludge, soil, or plant tissue
analyses) deemed necessary by the Division of Environmental Management to insure
protection of the environment will be established and an acceptable sampling and reporting
schedule shall be followed
2. The City of Statesville shall maintain records including, but not limited to the following:
a. volume, source, and analysis of dewatered sludge
b. date, time, pH and duration after mixing, duration and temperature during
heating, on a per batch basis
c. name and location of PFRP sludge disposal site or recipient, volume applied or
received, and intended use
An annual summary report (three copies) of the records required above shall be submitted
on or before March 1 of the following year by City of Statesville to the following address:
NC Division of Environmental Management
Water Quality Section
Facility Assessment Unit
PO Box 29535
Raleigh, NC 27626-0535
3

3. The City of Statesville shall present to each recipient of stabilized sludge written
information that clearly states that stabilized sludge cannot be used on areas where root or
leaf crops for direct human consumption are to be grown within one (1) year of the last
application of sludge to the site. The City of Statesville shall also include written
recommendations to the compost recipients for satisfactory uses of compost material such
as horticulture, silvicultural, other agricultural uses not specifically prohibited, etc.
4. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone no.
744/ 663-1699, 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 sludge program which results in the stabilizing of
significant amounts of wastes which are abnormal in quantity or characteristic.
b. Any failure of the sludge program resulting in a discharge of wastes to receiving
waters.
C. Any time that self -monitoring information indicates that the facility 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 facility
incapable of adequate sludge treatment.
e. Any leakage or spillage that occurs during the transfer or transport of the sludge
material.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 days following first knowledge of the occurrence. This report must outline
the actions taken or proposed to be taken to ensure that the problem does not recur.
IA' Id3#liQ "I'i' - - M61111 &TI Bpi,
1. Any groundwater quality monitoring as deemed necessary by the Division of
Environmental Management shall be provided.
1. The Permittee or his designee shall inspect the sludge storage, transport, and composting
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 Pennittee shall keep 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 Pem-ittee
for a period of three years from the date of the inspection and shall be made available upon
request by the Division of Environmental Management or other permitting authority.
4

2. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the composting facility and 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; or may obtain
samples of groundwater, surface water, or leachate.
1. This permit shall become voidable unless the land application activities are carried out in
accordance with the conditions of this permit and in the manner approved by this Division.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data
3. This permit is not transferable. In the event there is a desire for the facilities to change
ownership or a name change of the Permittee, a formal permit request must be submitted to
the Division of Environmental Management accompanied by an application fee,
documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of this request will be considered on its merits and may or may
not be approved.
4. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6.
5. The annual administering and compliance fee must be paid by the Permittee within thirty
(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).
6. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) which have jurisdiction.
7. A set of approved documents for the subject project must be retained by the applicant for
the life of the project.
8. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the
facilities described therein, and if warranted, will extend the permit for such period of time
and under such conditions and limitations as it may deem appropriate.
5

9. This permit may be modified or reissued to incorporate any conditions, limitations and
monitoring requirements the Division of Environmental Management deems necessary in
order to adequately protect the environment and public health.
Permit issued this the 18th day of March 1992
7CAR LINA ENVIRONMENTAL MANAGEMENT' COMMISSION
George Everett, ec r
Division of En o ental
ana ement
MommissionByAuthorityof eEnviroa C
Permit No. WQ0006245

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Permit No. WQ0006245
March 18,1992
ne&s Certifi
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, for the
- Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of the approved plans and specifications.
Signature
Date
7
Registration No.

RATING SCALE FOR CLASSIFICATION OF FACILITIES
rTEM
Name of Plant: Clf� d f'ft2 �ts y;11e - F-,%rL-A tert h WW rp
Owner or Contact Person: P, PrIer orbit _
Mailing Address: P.d, A-X ],[I F, S"5yjj1,t/ N-t _2S-G'T,7
County: Zbe dell Telephone:
NPDES Permit No- NC00 3 j He Nondisc. Per. No. _
IssueDate: AL&y, 1���117_Expiration Date:�&v, 3o".
Existing Facility v1 New Facility
Rated By:
Jrr
Date: aj
Reviewed
(Train.
Cert.)
Reg. Office
Reviewed
(Train.
& Cert.)
Central Office
ORC
Grade
Plant Class: (circle one) 1 Il 111 IV Total Points .5
7-h s PIr Iv J_d M11101t FI V e 0 to
Powys 74 t xis �i�� •bl iii i v
(1) Industrial Pretreatment Units and/or
Industrial Pretreatment Program
(see definition No. 33)
4
(2) DESIGN FLOW OF PLANT IN GPD
(not applicable to non -contaminated cooling waters, sludge
handling facilities for water purification plants, totally
closed cycle systems (def. No. 11), and facilities
consisting only of Item (4) (d) or Items (4) (d) and (11) (d))
0 - 20.000..........................
1
20,001 — 50.000..........................
2
50,001 — 100.000..........................
3
1D0,001 — 250.000..........................
4
250,001 500,000..........................
5
500,001--1,000,000..........................
8
1,000,001 -- 2,000.000 ........................
10
2,000,001 (and up) - rate 1 point additional for each
200,000 gpd capacity up to a
maximum of 30
(3)
Design Flow (gpd) ;
PRELIMINARY UNITS (see definition no. 32)
(a) Bar Screens ................................
r
(b) Mechanical Screens, Static Screens or
Comminuting Devices ........... .............
(c) Grit Removal ...............................
or
(d) Mechanical or Aerated Grit Removal ...........
(e) Flow Measuring Device .......................
or
(1) Instrumented Flow Measurement ..............
(g) Preaeration................................
2
1
(h) Influent Flow •Equalization ...... 2
(I) Grease or Oil Separators - Gravity .......... 2
Mechanical .......... 3
Dissolved Air Flotation. 8
67 Prechtorination .............................. 5
(4) PRIMARY TREATMENT UNITS
(a) Septic Tank (see definition no. 43) ..............
(b) Imhoff Tank ..................................
(c) Primary Clarifiers .... .......... .
(d) Settling Ponds or Settling Tanks forInorganic
Non -toxic Materials (sludge handling facilities
for water purification plants, sand, gravel,
stone, and other mining operations except
recreational activities such as gem or gold
mining) ......................................
(5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(i)Aeralion - High Purity Oxygen System
20
Diffused Air System ...........
10
Mechanical Air System (fixed,
floating or rotor) ..............
8
Separate Sludge Reaeration .....
3
(i i) Trickling Filte r
High Rate ...................
7
Standard Rate ...............
5
Packed Tower ...............
5
(iii) Biological Aerated Filter or Aerated
Biological Filter ......................
10
(iv) Aerated Lagoons .................. .
10
(v) Rotating Biological Contactors ..........
10
(vi) Sand Filters-
intermittenl biological .....
2
recirculating biological .....
3
(vie Stabilization Lagoons ...................
5
(viii)Clarifier ..............................
5
(ix) Single stage system for combined
carbonaceous removal of BOD and
nitrogenous removal by nitrification
(see def. No. 12) (Points for this item
have to be in addition to items (5) (a)
0 through (5) (a) (viu) .................
8
(x) Nutrient additions to enhance SOD
removal ...........................
5
(xi) Biological Culture ('Super Bugs') addition
to enhance organic compound removal .....
5
(b) Nitrogenous Stage
(i) Aeration - High Purity Oxygen System
20
Diffused Air System ...........
10
Mechanical Air System (fixed,
floating, or rotor) ...... ......
8
Separate Sludge Reaeralion .....
3
(ii) Trickling Filter
High Rate ..............
7
Standard Rate ............
5
Packed Tower.......... .
5
(iii) Biological Aerated Filler or Aerated
Biological Filler .........................
Jo
(iv) Rotating Biological Conlactors ............
10
(v) Sand Filler -
intermittent biological ........
2
recirculating biological ........
3
(vi) Clarifier ................................
5

(6) TERT.AFIY OR ADVANCED TREATMENT UNIT
(10) -CHEMICAL ADDITION SYSTEM (S) (See definition No. 9)
<a) Activated Carbons Beds -
(not applicable to chemical additions rated as ilem
without carbon regeneration .................. 5
(3) 0), (6) (a) (xi), (6) (a), (6) (b), (7) (b). (7) (e),
with carbon regeneration .................... 15
(9) (a), (9) (b), or (9) (c) 5 points each: List:
(b) powdered or Granular Activated Carbon Feed -
_ 5
without carbon regeneration ................. 5
5
with carbon regeneration .................... is
5
(c) Air Stripping ........................... 5
5
(d) Denitdficalion Process (separate process) ..... 10
(e) Electrodalysis ........ ..................... 5
(11) MISCELLANEOUS UNITS
(t) Foam Separation ............................. 5
(a) holding Ponds, holding Tanks or Settling Ponds
(g) Ion Exchange ................................ 5
for Organic or Toxic Materials including wastes
h Land Application of Treated Effluent
()
from mining operations containing nitrogen and/or
(see definition no. 22b) (not applicable for
phosphorous compounds in amounts significantly
sand, gravel, stone and other similar mining
greater than is common for domestic wastewater .......... 4
operations)
(b) Effluent Flow Equalization (not applicable to storage
(7 on agriculturally managed sites (See def.
basins which are inherent in land application systems). 2
No. 4) ................................... 1 0
(c) Stage Discharge (not applicable to storage basins
(ii) by high rate infiltration on non -agriculturally
inherent in land application systems..._ .................................. 5
managed sites (includes rotary distributors
(d) Pumps._-_____ ------ __ 3
and similar fated nozzle systems) ........... 4
(e) Stand -By Power Supply 3
(iii) by subsurface disposal (includes low pressure
(f) Thermal Pollution ConL•ol Device:_._ ....................................... 3
pipe systems and gravity systems except at
plants consisting of septic tank and nitrifica-
tion lines only) .................. _ ......... 4
TOTAL POINTS 5-
(7 Microscreens.................................. 5
G) Phosphorus Remoral by Biological Processes
CLASSIFICATION
(See def. No. 26) ............................ 20
(k) Polishing Ponds - without aeration ....... 2
Class 1_._ 5 - 25 Points
with aeration .......... 5
Class I[ r . __ _. 26- 50 Points
(1) Post Aeration cascade .............. 0
Class 51- 65 Points
diffused or mechanical ... 5
Class IV..._.........__».. _ 66- Up Points
(m) Reverse Osmosis ............................... 5
(n) Sand or Mixed -Media Filters - low rate ........... 2
Facilities having a rating of one through four points. inclusive,
high rate .......... 5
do not require a certified operator- Classification of all other
(o) Treatment processes for removal of metal or
facilities requires a comparable grade operator in responsible
cyanide .................................... 15
charge.
(p) Treatment processes for removal of toxic
materials other than metal or cyanide ......... 15
Facilities having an activated sludge process will be assigned
a minimum classification of Class 11.
SLUDGE TREATMENT
Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank -Heated ...............
10 or cyanide will be assigned a minimum classification of Class It.
Aerobic ...............
5
Unheated .............
or thermal)
3 Facilities having treatment processes for the biological removal
(b) Sludge Stabilization (chemical .......
t9 of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Gravity ................
2 Ill.
Vacuum Assisted .......
5
(d) Sludge Elutriation .............................
5 In -plans processes and related control equipment which are an
(e) Sludge Conditioner (chemical or thermal) ........
5 integral part of industrial production shall not be considered waste
(I) Sludge Thickener (gravity)......................
5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit
having a design flow of 1.000 gpd or less, shall not be subject to
(not applicable to a unit rates as (3) i7 .........
8 rating.
(h) Sludge Gas Utilization (including gas storage) ....
2
(i) Sludge Holing Tank - Aerated ................
5 ADDITIONAL COMMENM-
Non-aerated ............
2
(j) Sludge Incinerator - (not including activated
carbon regeneration) .....
10
(k) Vacuum Filler, Centrifuge or Filler Press or other
similar dewalering devices ....................
10
(8) SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons .... ..... . ...........................
2
(b) land Application (surface and subsurface)
(see definition 22a)
-where the facility holds the land app. permit ...
10
-by contracting to a land application operator who
holds the land application permit ................
2
-land appTication of sludge by a contractor who does
not hold the permit for the wastewater treatment
facility where the sludge,is generated .........
10
(c) Landfilled (burial) .............................
5
(9) DISINFECTION
(a) Chlorination .............................
5
(b) Dechlorinalion ........................
5
(c) Ozone ..............................
5
(d) Radiation ..........................
5