WQ0006984_Final Permit_19931014

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
October 14, 1993
Joe Hubbard, Plant Manager
Delta Mills, Inc., Maiden Plant
Post Office Box 37 (408 S. Main Ave.)
Maiden, North Carolina 28650
FAA
10 PWL
C)EHNF11
Subject: Permit No. WQ0006984
Delta Mills, Inc., Maiden Plant
Land Application of Sludge
Catawba County
Dear Mr. Hubbard:
In accordance with your amendment request received July 15, 1993, we are forwarding herewith
Permit No. WQ0006984 as amended, dated October 14, 1993, to Delta Mills, Inc. for the continued
operation of the subject land application of sludge program. This permit amendment was requested by
Delta Mills, Inc. to account for an increase in flow from 2 MG to 2.5 MG and to incorporate the following
201.9 acres of land into the land application program:
Application Area [acres]
Field No. Owner/Lessee (excluding buffers)
A-1
Kate Abernathy
15.0
A-2C
Kate Abernathy
19.0
A-3c
Kate Abernathy
10.0
A-4c
Kate Abernathy
12.5
A-5a
Kate Abernathy
12.8
A-6
Kate Abernathy
8.3
H-1 c
George Hunsucker
19.0
H-2c
George Hunsucker
26.0
H-3
George Hunsucker
4.5
H-4
George Hunsucker
26.1
H-5
George Hunsucker
7.2
H-6
George Hunsucker
8.0
H-7
George Hunsucker
19.0
H-8
George Hunsucker
14.5
TOTAL ACRES 240.6
a By subsurface land application
c This land application site is covered in part by soils having a seasonal high
water table at depths ranging from 1 to 3 feet below land surface. Therefore, no
sludge shall be applied to this field during the period from November 1 through
March 31, inclusive.
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

In addition, please be advised of Condition No. 1115 which states that Calcium and Magnesium
shall be added to the fields as needed to prevent the soils from sealing due to the high sodium adsorption
ratio found in the sludge.
This permit shall be effective from the date of issuance until January 31, 1998, shall void Permit
No. WQ0006984 issued February 26, 1993 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 information 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.
If you need additional information concerning this matter, please contact Mr. Michael D. Allen at
[phone].
Sincerely,
A. Prest Howard, Jr., P.E.
A. PZst
cc: Catawba County Health Department
Mooresville Regional Office, Water Quality Section
Mooresville Regional Office, Groundwater Section
Jack Floyd, Groundwater Section Central Office
Training and Certification Unit (no revised rating)
Facilities Assessment Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
SLUDGE LAND APPLICATION 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
Delta Mills, Inc., Maiden Plant
Catawba County
FOR THE
continued operation of a sludge land application program consisting of the application of approximately
281.5 dry tons per year of sludge from the Delta Mills, Inc., Maiden Plant wastewater treatment facility to
approximately 240.6 acres of land in Catawba County with no discharge of wastes to the surface waters,
pursuant to the amendment request received July 15, 1993, 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 January 31, 1998, shall void Permit
No. WQ0006984 issued February 26, 1993 and shall be subject to the following specified conditions and
limitations:
114 111 ff 9 WIN KI-1 NUT ► ra 3 RI W41 I ► I1:: 1
1. The Mooresville Regional Office, telephone number [phone], and the appropriate
local governmental official (county manager/city manager) shall be notified at least twenty-
four (24) hours prior to the initial application of the sludge so that an inspection can be
made of the application sites and application method. 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. Also the Catawba County Manager's
office must be notified prior to the initial application so that they will be aware that the
operation has commenced.
2. This permit shall become voidable if the soils fail to adequately absorb the wastes and may
be rescinded unless the sites are maintained and operated in a manner which will protect
the assigned water quality standards of the surface waters and ground waters.
3. The land application 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.

4. 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.
5. In the event that the land application program is not operated satisfactorily, including the
creation of nuisance conditions, the Permittee shall cease applying sludge to the sites and
take any immediate corrective actions, including the construction of additional or
replacement wastewater treatment or disposal facilities.
C. No crops for direct human consumption shall be raised on these sites for a period of 18
months following sludge application.
7. Maximum slope for sludge application shall be 10% for surface application and 18%Q for
subsurface applications.
8. The following buffer zones shall be maintained:
a) 400 feet from residences or places of public assembly under separate ownership for
surface application method; however, the buffer zone requirement may be reduced
to a minimum of 100 feet upon written consent of the owner and the appropriate
DEM regional office,
b) 200 feet from residences or places of public assembly under separate ownership for
injection method; however, the buffer zone requirement may be reduced to a
minimum of 100 feet upon written consent of the owner and the appropriate DEM
regional office,
c) 100 feet from "SA and SB" classified waters and public surface water supplies for
both methods,
d) 50 feet from "WS" classified waters and other streams, creeks, lakes, rivers, and
surface water drainage ways for injection method,
e) 100 feet from "WS" classified waters and other streams, creeks, lakes, rivers and
surface water drainage ways for surface application method,
f) 100 feet from property lines for both methods; however, this requirement may be
reduced to 50 feet upon written concurrence from the adjoining property owner and
the appropriate DEM regional office,
g) 50 feet from public right of ways for surface application methods,
h) 25 feet from public right of ways for subsurface disposal methods,
i) 10 feet from upslope interceptor drains and surface water diversions for both
methods,
j) 25 feet from downslope interceptor drains, surface water diversions, groundwater
drainage systems and surface drainage ditches for both methods.
Some of the buffers specified above may not have been included in previous permits
for this land application operation. Any sites or fields that are included in this permit,
but were approved with different applicable buffers, will continue to be regulated by
those originally approved buffers. All new sites and fields will be regulated by the
buffers specified above.
9. A copy of this permit shall be kept at the land application site when sludge is being applied
during the life of this permit. A spill prevention and control plan shall be kept in all sludge
transport and application vehicles.
10. Specific sludge application area boundaries shall be clearly marked on each site prior to and
during sludge application.
11. No sludge at any time shall be stored at any application site.
0)

1. The facilities and disposal sites shall be properly maintained and operated at all times.
2. A suitable vegetative cover as listed in condition H 3, shall be maintained in accordance
with the crop management plan approved by this Division.
3. The application rates shall not exceed the following for the specified crops:
Crop PAN nbsfacrefjear
Coastal Bermuda Grass 350
Fescue 250
4. No sludges other than the following are hereby approved for land application in accordance
with this permit:
Permit Estimated
NumberSgume County Yolume (du tonaluw)
Delta Mills, Inc.
Maiden Plant Catawba NCO006190 281.5
5. The lifetime heavy metal loadings shall not exceed the following for the corresponding
Cation Exchange Capacities (CEC):
Parameter
CEC < 5
CEC 5 - 15
CEC > 1
Lead
500
1000
2000
Zinc
250
500
1000
Copper
125
250
500
Nickel
125
250
500
Cadmium
4.5
9
18
6. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class H, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
7. Adequate procedures shall be provided to prevent surface runoff from carrying any
disposed or stored sludge material into any surface waters.
8. Animals shall not be grazed on sludge applied land within a 30-day period following the
sludge application. Application sites that are to be used for grazing shall have fencing that
will be used to prevent access after each application.
9. Surface applied sludge will be plowed or disced within twenty-four (24) hours after
application on lands with no cover crop established.
10. For areas that are prone to flooding or within the 100-year flood elevation, sludge may be
applied only during periods of dry weather. The sludge must be incorporated into the soil
within twenty-four (24) hours of application.
3

11. Appropriate measures must be taken to control public access to the land application sites
during active site use and for the 12-month period following the last sludge application
event. Such controls may include the posting of signs indicating the activities being
conducted at each site.
12. Adequate provisions shall be taken to prevent wind erosion and surface runoff from
conveying pollutants from the sludge application area onto the adjacent property or into the
surface waters.
13. Sludge shall not be applied in inclement weather or until 24 hours following a rainfall event
of 1/2-inch or greater in 24 hours. Any emergency sludge disposal measures must first be
approved by the Division of Environmental Management.
14. The site shall be adequately limed to a soil pH of at least 6.5 prior to sludge application.
Sludge may be applied to sites with a pH of less than 6.5 provided a sufficient amount of
lime is also applied to achieve a final pH of the lime, sludge and soil mixture of at least 6.5.
15. Calcium and Magnesium shall be added to the fields as needed to prevent the soils from
sealing due to the high sodium adsorption ratio found in the sludge.
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. If monitoring data indicates minimal or no concern to the
Division, reduction of monitoring requirements may be pursued after two annual reporting
periods.
2. Proper records shall be maintained by the Permittee tracking all disposal activities. These
records shall include, but are not necessarily limited to the following information:
a) source of sludge
b) date of sludge application
c) location of sludge application (site, field, or zone #)
d) method of application
e) weather conditions
f) soil conditions
g) type of crop or crop to be grown on field
h) volume of sludge applied in gallons/acre and dry tons/acre
i) annual and cumulative totals of dry tons/acre of sludge, annual and cumulative
pounds/acre of each heavy metal (which shall include, but not be limited to lead,
nickel, cadmium, copper and zinc), annual pounds/acre of plant available nitrogen
(PAN), and annual pounds/acre of phosphorus applied to each field.
4

3. A representative annual soils analysis (Standard Soil Fertility Analysis) shall be conducted
of each site receiving sludge in the respective calendar year and the results maintained on
file by the Permittee for a minimum of five years. The Standard Soil Fertility Analysis
shall include, but is not necessarily limited to, the following parameters:
% Base Saturation
Magnesium
Phosphorus
Potassium
Lead1
Zinc
PH
Manganese
Cation Exchange Capacity
Sodium
Nickell
Cadmiuml
Copper
Calcium
1 Sons analysis for these parameters shall be conducted once prior to permit renewal on
soils from each site which has received sludge during the permit cycle.
4. A quarterly sludge analysis and annual Toxicity Characteristics Leaching Procedure
(TCLP) analysis shall be conducted by the Permittee and the results maintained on file by
the Permittee for a minimum of five years. If land application occurs at a frequency less
than quarterly, sludge analysis will be required for each instance of land application.
The sludge analysis shall include but is not necessarily limited to the following parameters:
% total solids
Magnesium
Chlorides
Sulfate
Phosphorus
Potassium
Lead
Zinc
Copper
Nickel
Cadmium
Chromium
Sodium
Calcium
Total Nitrogen
Ammonia Nitrogen
Nitrate/Nitrite Nitrogen
pH
Plant Available Nitrogen (by calculation)
The TCLP analysis shall include the following parameters:
Arsenic
Barium
Benzene
Cadmium
Carbon tetrachloride
Chlordane
Chlorobenzene
Chloroform
Chromium
o-Cresol
m-Cresol
p-Cresol
Cresol
2,4-D
1,4-Dichlorobenzene
1,2-Dichloroethane
1, 1 -Dichloroethylene
2,4-Dinitrotoluene
Endrin
Heptachlor (and its hydroxide)
Hexachiorobenzene
Hexachloro-1,3-butadiene
Hexachloroethane
Lead
Lindane
Mercury
Methoxychlor
Methyl ethyl ketone
Nitrobenzene
Pentachlorophenol
Pyridine
Selenium
Silver
Tetrachloroethylene
Toxaphene
Trichloroethylene
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
2,4,5-TP (Silvex)
Vinyl chloride
k

5. Three copies of all monitoring and reporting requirements as specified in conditions III 1,
III 2, 1113 and IQ 4 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
6. 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 land application program which results in the land
application of significant amounts of wastes which are abnormal in quantity or
characteristic.
b. Any failure of the land application program resulting in a release of sludge 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 sludge treatment.
e. Any spillage or discharge from a vehicle or piping system transporting sludge to the
application site.
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.
The four (4) existing monitoring wells, #1, #2, #3 and #4, shall be sampled every March,
June, September and December for the following parameters:
TUC
Copper
pH
Water Level
Chloride
Chromium
Manganese
Phenol
Iron
Zinc
Specific Conductance
Volatile Organic Compounds - In December only (by Method 1 or Method 2 below)
Method 1: Method 6230D (Capillary - Column), "Standard Methods For The
Examination of Water and Wastewater", 17th ed., 1989.
Method 2: Method 502.2 "Methods For The Determination of Organic
Compounds in Drinking Water", U.S. EPA - 600/4-88/039.

The measurement of water level must be made prior to sampling for the remaining
parameters. The depth of water in each well shall be measured from the surveyed point on
the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to
provide relative elevations of the measuring point for each monitoring well.
If TOC concentrations greater than 10 mg/1 are detected in any downgradient monitoring
well, additional sampling and analysis must be conducted to identify the individual
constituents comprising this TOC concentration. If the TOC concentration as measured in
the background monitor well exceeds 10 mg/I, this concentration will be taken to represent
the naturally occurring TOC concentration. Any exceedances of this naturally occurring
TOC concentration in the downgradient wells shall be subject to the additional sampling
and analysis as described above.
If any volatile organic compounds are detected by method 6230D, or the equivalent method
502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds
which may be present. The results of all analyses specked in the monitoring requirements,
including 604 and 611 if required, must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW-59 (Compliance Monitoring Report Form) every
April, July, October and January.
2. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15
NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary is
established at either (1) 250 feet from the waste disposal area, or (2) 50 feet within the
property boundary, whichever is closet to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to
immediate remediation action on addition to the penalty provisions applicable under General
Statute 143-215.6A(a)(1).
Also in accordance with 15A NCAC 2L, a REYIEW BOUNDARY is established around
the disposal systems midway between the Compliance Boundary and the perimeter of the
waste disposal area. Any exceedance of standards at the Review Boundary shall require
remediation action on the part of the permittee.
3. No land application of waste activities shall be undertaken when the seasonal high water
table is less than three feet below land surface.
4. Any additional groundwater quality monitoring as deemed necessary by the Division of
Environmental Management shall be provided.
UINNWZ' I MI
The Permittee or his designee shall inspect the sludge storage, transport, and disposal
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 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 Permittee
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.
7

1A-1
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 disposal site 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.
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. This permit shall become voidable unless the agreements between the Permittee and the
landowners/lessees are in full force and effect.
5. The following are approved sites for sludge application (see attached map(s)):
Application Area [acres]
Field No. Owner/Lessee (excluding buffers)
Delta Mills, Inc.
Jenkins Property
12.72 (including buffers)
26.0b (including buffers)
A-1
Kate Abernathy
15.0
A-2c
Kate Abernathy
19.0
A-3c
Kate Abernathy
10.0
A-4c
Kate Abernathy
12.5
A-5$
Kate Abernathy
12.8
A-6
Kate Abernathy
8.3
H- I c
George Hunsucker
19.0
H-2c
George Hunsucker
26.0
H-3
George Hunsucker
4.5
H-4
George Hunsucker
26.1
H-5
George Hunsucker
7.2
H-6
George Hunsucker
8.0
H-7
George Hunsucker
19.0
H-8
George Hunsucker
14.5
TOTAL ACRES
240.6
a By subsurface land application
b By surface land application
8

This land application site is covered in part by soils having a seasonal high
water table at depths ranging from 1 to 3 feet below land surface. Therefore, no
sludge shall be applied to this field during the period from November 1 through
March 31, inclusive.
6. 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 143-215.6A to 143-215.6C.
7. 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).
8. 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.
9. A set of approved documents for the subject project must be retained by the applicant for
the life of the permit.
10. 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.
11. This permit may be modified, or revoked and 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 14th day of October, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
LJ-,, , �cj. LnE 0'xjl-� /6
A. Presto Howard, Jr., .E., Acting Dire or
Division of Environmental Management
By Authority of the Environmental Management Commission
9

Abernathy Farm
>� Hunsucker Farm \P..
1 : / d3'-
i co
SCALE 1:24 WO
1 0 1 MILE
1000 0 1000 2000 3000 4000 5000 6000 7000 FEET
� LAW ENGINEERING, INC.
QUADRANGLE LOCATION ra WILMINGTON, NORTH CAROLINA
Site Location with Property Boundary DRAWN: WRD DATE: 6-9-93
DFT CHECK: ZBL SCALE: as shown
Abernathy & Hunsucker Farms
ENG CHECK: JOB: 674-08846
Maiden, North Carolina
APPROVAL: pyyC; Figure 1
REFERENCE: 7.5 min Quad, Maiden, North Carolina--USGS, 1970

Home with well
A - _
LJyYY CNN-Zl VCr—r11JV A, IlVti...
WiLMINGTON, NORTH CAROLINA
Soil Map with Field Borders DRAWN: WRD DATE- 6-9-93
DFT CHECK: SCALE: 1 in = 660 ft
Abernathy Farm
ENG CHECK: JBL JOB: 674-08846
Maiden, North Carolina APPROVAL: DWG: Figure 2
REFERENCE: Soil Survey of Catawba County, North Carolina--USDA-SCS, 1975

� tt
mB2
ImLAW ENGINEERING, INC.
WiLMINGTON, NORTH CAROLINA
Soil Map with Field Borders DRAWN: WRD DATE: 6-9-93
Hunsucker Farm DFT CHECK: SCALE: 1 in = 660 ft
Maiden, North Carolina ENG CHECK: JBL JOB: 674-08846
APPROVAL: DWG: Figure 3
REFERENCE: Soil Survey of Catawba County, North Carolina--USDA—SCS, 1975