WQ0006245_Final Permit_19940321

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary p E H N Fl
A. Preston Howard, Jr., P.E., Director
March 21, 1994
Jack King, City Manager
City of Statesville
Post Office Box 1111
Statesville, North Carolina 28687
Subject: Permit No. WQ0006245
City of Statesville
Distribution of Class A Wastewater Residuals
Iredell County
Dear Mr. King:
In accordance with your application received on January 18, 1994, we are forwarding herewith
Permit No. WQ0006245 as amended, dated March 21, 1994, to the City of Statesville for the continued
operation of a wastewater residuals facility for the distribution of Class A residuals. This permit is being
amended to allow for the subject Class A product to be marketed and distributed.
This permit shall be effective from the date of issuance until February 28, 1997, shall void Permit
No. WQ0006245 issued June 26, 1992 and shall be subject to the conditions and limitations as specified
therein. Please pay particular attention to the monitoring and reporting requirements contained in this
permit. Failure to establish an adequate system for collecting and maintaining the required operational
information will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the
right to request an adjudicatory hearing upon written request within thirty (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.
If you need additional information concerning this matter, please contact Mr. Michael D. Allen at
[phone].
Sincerely,
A. Pres Howard, Jr., P.E.
cc: Iredell County Health Department
Mooresville Regional Office, Water Quality Section
Mooresville Regional Office, Groundwater Section
.lack Floyd, Groundwater Section Central Office
Training and Certification Unit
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
PERMIT FOR THE DISTRIBUTION OF CLASS A RESIDUALS
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 wastewater residuals facility for the distribution of Class A residuals consisting
of dewatered sludge from the Fourth Creek WWTP being transported by an existing conveyor belt from
the existing Fourth Creek filter press facilities to a 53 foot long covered cleated feeder conveyor, two 25
cubic yard sludge storage hoppers (for dewatered Third Creek WWTP sludge and the Water Plant alum
sludge) with bottom screw conveyors to convey sludge from hopper to flanged connections above the 53
foot cleated feeder conveyor, a 25 foot long, 12 inch diameter twin screw sludge mixer, two (2) 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/or for measuring to ensure
that all of the subject sludges meet the requirements listed in Condition I.8, and all associated controls,
support structures, piping, and appurtenances for the distribution of approximately 3,900 dry tons per year
of residuals from the sources listed in Condition 112, to serve the City of Statesville, with no discharge of
wastes to the surface waters, pursuant to the application received on January 18, 1994, and in conformity
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, shall void Permit
No. WQ0006245 issued June 26, 1992 and shall be subject to the following specified conditions and
limitations:
1. The distribution of Class A residuals program shall be effectively maintained and operated
as a non -discharge system to prevent the discharge of any wastes resulting from the
operation of this program.

2. This permit shall become voidable in the event of failure of the residuals program to
adequately protect the assigned water quality standards of the surface waters and
groundwaters.
3. 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 program.
4. In the event that the residuals program is not operated satisfactorily, including the creation
of nuisance conditions, the Permittee shall cease distributing residuals and take any
immediate corrective actions as may be required by the Division.
5. Diversion or bypassing of the untreated residuals or leachate from the residual treatment
facilities is prohibited
6. Class A residuals should not be used in areas of intense public use (schools, playgrounds,
ball fields, etc.).
7. All leachate must be reused as a wetting agent for the processing of residuals or routed to
the head of the treatment plant.
8. 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 must be met. Additionally, an evaluation must be performed which
demonstrates the residuals ability to comply with this requirement. Upon request, a copy
of this evaluation must be submitted to the Assistant Chief, Technical Support Branch,
Division of Environmental Management, Post Office Box 29535, Raleigh, NC 27626-
0535.
In addition to the above, the Division has approved the following stabilization criteria for
the City of Statesville:
a. limekiln 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° C for a minimum of 30 minutes.
b. N-Viro Soil Process
Alternative 1 Fine alkaline materials are uniformly mixed by mechanical mixing into
dewatered sludge to raise the pH to greater than 12 for seven days. The
dewatered sludge cake is then air dried (while pH remains above 12 for
at least seven days) through intermittent turning of windrows at least 30
days and until the solids levels reach and maintain a minimum of 65%
solids. A solids concentration of at least 60% is achieved before the pH
drops below 12. Mean temperature of the air surrounding the pile must
be above 511C (4111F) for the first seven days.
Alternative 2 Fine alkaline materials are uniformly mixed by mechanical mixing into
dewatered sludge to raise the pH to greater than 12 for at least 72 hours.
The sludge cake is then heated, while the pH exceeds 12, using
exothermic reactions or other thermal processes to achieve temperatutes
of at least 520 C (126 F) throughout the sludge for at least 12 hours.
The stabilized sludge is then air dried (while the pH remains above 12
for at least three days) to at least 50% solids.
9. No residuals which tests, or is classified, as a hazardous or toxic waste under 40 CFR Part
261 shall be land applied or distributed and marketed.
2

II:
OPE$ATTON AND MAINTENANCE REQUIREMENTS
1. The residuals treatment facilities shall be properly maintained and operated at all times.
2. No residuals other than the following are hereby approved for distribution in accordance
with this permit:
Permit Estimated Volume
Source CQunty Number (Dry Tons/Yea)
Fourth Creek WWTP Iredell NCO031836
Third Creek WWTP Iredell NCO020591 3,900*
Statesville Water Plant Iredell
* A maximum of 3,900 dry tons per year of combined wastewater and alum residuals
3. All residuals shall be adequately stored to prevent leachate runoff until treated. The
finished product may be placed on a concrete pad, placed under shelter or covered until
such time as it is distributed to the buyer. If an alternate storage site is to be used, approval
must be obtained from the Division of Environmental Management.
4. No other residuals other than those specified under Condition II 2 above may be
distributed. The Permittee shall request and obtain a permit amendment from the Division
of Environmental Management for each additional residual source prior to acceptance of
that residual.
5. For a Class A residual to be sold or given away in bags or other container for application to
the land, the following must be satisfied:
The Ceiling Concentrations (Dry Weight Basis) and the Pollutant Monthly
Average Concentrations (Dry Weight Basis) must be maintained:
Ceiling Monthly Average
Concentrations Concentrations
Parameters mg&g mgft
Arsenic
75
41
Cadmium
85
39
Chromium
3,000
1,200
Copper
4,300
1,500
Lead
840
300
Mercury
57
17
Molybdenum
75
18
Nickel
420
420
Selenium
100
36
Zinc
7,500
2,800
6. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified land applicadon/residuals operator to be in responsible charge (ORQ of
the residual distribution program. The operator must hold a certificate of the type
classification assigned to the land application program by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type to
comply with the conditions of Title 15A NCAC 8A, .0202.
3

7. A label shall be affixed to the bag or other container in which residuals that are sold or
given away for application to the land, or an information sheet shall be provided to the
person who receives the residuals sold or given away in an other 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 residuals that is sold or given
away in a bag or other container for application to the land.
b. A statement that application of the residuals to the land is prohibited except in
accordance with the instructions on the label or information sheet.
c. Information on all applicable buffers including a 100 foot buffer between application
site and any public or private water supply source (including wells) and any stream,
lake, river, or natural drainage way.
8. Adequate procedures shall be provided to prevent surface runoff from carrying any
disposed or stored residuals into any surface waters.
9. Adequate provisions shall be taken to prevent wind erosion and surface runoff from
conveying pollutants from the residuals treatment area onto the adjacent property or into
any surface waters.
10. Residuals shall not be applied to any site that is flooded, frozen or snow-covered.
11. Food crops, feed crops and fiber crops shall not be harvested for 30 days after residuals
application. Application sites that are to be used for grazing shall have fencing that will be
used to prevent access after each application.
1. Any monitoring (including groundwater, surface water, residuals, 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. Proper records shall be maintained by the Permittee tracking all residual activities. These
records shall include, but are not necessarily limited to the following information:
a. source, volume and analysis of each residuals
b. name of residuals' recipient, volume received, and intended use
3. A residuals analysis will be conducted every 60 days from the date of permit issuance by
the Permittee and the results maintained on file by the Permittee for a minimum of five
years.
The residuals analysis shall include but is not necessarily limited to the following
parameters:
Arsenic
Aluminum
Cadmium
Ammonia -Nitrogen
Chromium
Calcium
Copper
Nitrate -Nitrite Nitrogen
Tread
% Total Solids
Mercury
pH
Molybdenum
Phosphorus
Nickel
Plant Available Nitrogen (by calculation)
Selenium
Potassium
4

Zinc Sodium
Magnesium TKN
After the residuals have been monitored for two years at the above frequency, the Permittee
may submit a request to the Division for a permit modification for the reduction of the
frequency of monitoring for pollutant concentrations and for the pathogen density
requirements, but in no case shall the frequency of monitoring be less than once per year
when residuals sold or given away.
4. A Toxicity Characteristics Leaching Procedure (TCLP) analysis shall be conducted by the
Permittee annually. The TCLP analysis shall include the following parameters (please note
the regulatory level in mg/L in parentheses):
Arsenic (5.0)
Benzene (0.5)
Carbon tetrachloride (0.5)
Chlorobenzene (100.0)
Chromium (5.0)
m-Cresol (200.0)
Cresol (200.0)
1,4-Dichlorobenzene (7.5)
1,1-Dichloroethylene (0.7)
Endrin (0.02)
Hexachlorobenzene (0.13)
Hexachloroethane (3.0)
Lindane (0.4)
Methoxychlor (10.0)
Nitrobenzene (2.0)
Pyridine (5.0)
Silver (5.0)
Toxaphene (0.5)
2,4,5-Trichlorophenol (400.0)
2,4,5-TP (Silvex) 0.0)
Barium (100.0)
Cadmium (1.0)
Chlordane (0.03)
Chloroform (6.0)
o-Cresol (200.0)
p-Cresol (200.0)
2,4-D (10.0)
1,2-Dichloroethane (0.5)
2,4-Dinitrotoluene (0.13)
Heptachlor (and its hydroxide) (0.008)
Hexachloro-1,3-butadiene (0.5)
Lead (5.0)
Mercury (0.2)
Methyl ethyl ketone (200.0)
Pentachlorophenol (100.0)
Selenium (1.0)
Tetrachloroethylene (0.7)
Trichloroethylene (0.5)
2,4,6-Trichlorophenol (2.0)
Vinyl chloride (0.2)
5. All residuals included in this permit must be monitored every 60 days, from the date of
permit issuance, for compliance with condition 1.8 of this permit. Data to verify
stabilization of the residuals must be maintained by the Permittee. The required data is
specific to the stabilization process utilized, but should be sufficient to clearly demonstrate
compliance with the Class A pathogen requirements in 40 CFR Part 503.32(a). In
addition, the EPA certification statements concerning compliance with pathogen
requirements, vector attraction reduction requirements and management practices must be
completed every 60 days 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 residuals to be
sold or given away.
After the residuals have been monitored for two years at the above frequency, the Permittee
may request a permit modification for the reduction of the frequency of monitoring for
pollutant concentrations and for the pathogen density requirements, but in no case shall the
frequency of monitoring be less than once per year when residuals are sold or given away.
6. Three copies of all required monitoring and reporting requirements as specified in
conditions III 1,1112, III 3, 11114, and III 5 shall be submitted annually on or before March
1 of the following year to the following address:
NC Division of Environmental Management
Water Quality Section
Facility Assessment Unit
PO Box 29535
Raleigh, NC 27626-0535
5

7. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, 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 distribution program which results in the land application of
significant amounts of wastes which are abnormal in quantity or characteristic.
b. Any failure of the distribution program resulting in a release of material 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 residual treatment.
e. Any spillage or discharge from a vehicle or piping system during transportation of
residuals.
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.
IV. CiROUNDWATER_REQUIREMENTS
1. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
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 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 of Environmental Management or other permitting authority, upon request.
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 treatment site or 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 CONDIIIONS
1. This permit .shall become voidable unless the distribution activities are carried out in
accordance with the conditions of this permit, the supporting materials, and in the manner
approved by this Division.
6

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.tNG SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
Name of Facility: T- ,_t_C. - fin.
Owner or Contact Person: Y.,
Mailing Address: �7 u 1��1 ��s�,a—c�s,r«�� 1✓C 28Z7_7
County:'Telephone:
Present Classification: r,JA New Facility ✓ Existing Facility
NPDES Per. No. NC00 Nondisc. Per. No.WCrA!:ypb?,i S Health Dept.Per No.
Rated by: ItApw Telephone: Date:
Reviewed by: Health Dept. Telephone:
Regional Office Telephone:
ORC: -
Central Office
Grade:
Check Classification(s): Subsurface Spray Irrigation
Wastewater Classification: (Circle One) 1 it 111 IV
Telephone:
_Tale hone:
Land Application
Total Points:
0. J.
'/ Id -
!! a� �, ' 7/ .: 'f1 1: =a/ a•.: i -! � ! !W-1541:011111TIUNTOMIN
: a . �!-')/=... R•.a:. ll:►. ! a • 1. I
_a I111411.14@ Ra - ? 7, J 7:�. R _S /.!►
SLWLFIFAC£ CLMOFICATIpN
(d►eck all units that apply)
1. septic tanks
2. pump tanks
3. siphon or pump -dosing systems
4-sand fibers
5. grease trap/nteroeptor
moil/wafer separators
1_ gravhy subsurface treadmenl and disposal:
8. pressure subsurface treatment and disposal:
SPPAY W03ATION CLAMFICATKN
(&wck atl units that apply)
1. - _-___
preliminary treatment (definition no. 32 }
2.
lagoons
3-
septic tanks
4.
pump tanks
5, - --
Pumps
15
sand titters
7-grease
Iraptinterceptor
e.
o►l/water separators
9-disinfection
10.
chemicall addition for nutrienValgae control
11.
spray irrigadion of wastewater
In addition to the above classificstions, pretreatment of wastewater In excess of these components shall
be rated using the point rating system and will require on operator with on approprlste dual certlficatlon.
LAt10/1PPL1CATi0N/RESlDUALS CLASSIF1CATiON (Applies only to parmtt hatder)
1. y Land application of bioss lids, residuals or cordaminated soils on a designated site.
WASTEWATER TREATi 4EN7 FACILITY CLASS* CATi0N
The fonowinp systems shaA be assigned a Class I cla rOication, unless the flow is of a significant quantity or the technology Is unusually
compex, to require consideration by Ow Commission on a case -by -case basis: (Chock r Appropriate)
1. 011water Separator Systems consisting only of physics) separation, pumps and dispceal:
2 ,_Septic Tank/Sand Fitter Systems consisting only of septic tanks, dosing apparatus, pumpe,sand fitter, disinfection
and died discharye;
3` 1-agoon Systems consisting only of preliminary tmadmord, irgoons. pumps, dxenfedion, necessary chemical treatment for
algae or ruttrierd o ntrol, and dired disctmge;
4. Closed -loop Recycle Sys1wns;
b. Groundwater Remeduxtion Systems wrisistirrg only of olVwaler separators, pumps, alr-stripping, carbon adsorpilon, disinfection
and disposal;
G. Aquacullure operations with discharge to surface waters:
7. water Plant sludge handling and back -wash wales treatment;
a. Seafood processing consisting of screening and disposal.
o. _SNte-famhy discharging systems, wtth the exception of Aerobic Treatment Units, will be ciassii'ied I! permMad alter July 1,
I or M upon Lispedion by the Division. It is found that the system is not being adequalefy oWeded or maintained. Such
systems wdl be notified of the classification or mclasslf"Eon by the Commission, in writing.