WQ0036777_Final Permit_20140207

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NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Water Quality Programs
Pat McCrory Thomas A. Reeder John E. Skvarla, til
Governor Director Secretary
February 7, 2014
MR. STEVEN BECKEL — GENERAL MANAGER
PCS PHOSPHATE COMPANY, INC.
1530 NC HWY 306 S
AURORA, NORTH CAROLINA 27806
Subject: Permit No. WQ0036777
PCS Phosphate Aurora
Gypsums Stack 5 (GS -5)
Closed -Loop Recycle System
Beaufort County
Dear Mr. Becket:
In accordance with your permit application request received October 8, 2015, we are forwarding
herewith Permit No. WQ0036777 dated February 7, 2014, to PCS Phosphate Company for the
construction and operation of the subject wastewater treatment and closed-loop recycle facilities.
This permit shall be effective from the date of issuance until January 31, 2019 and shall be
subject to the conditions and limitations as specified therein. Please pay particular attention to the
operation and monitoring requirements listed in Sections III and N of this permit. Failure to establish an
adequate system for collecting and maintaining the required operational information shall result in future
compliance problems.
If any parts, requirements or limitations contained in this permit are unacceptable, the Permittee
has the right to request an adjudicatory hearing upon written request within 30 days following receipt of
this permit. This request shall be in the form of a written petitions, conforming to Chapter 150B bf the
North Carolina General Statutes, anA filed with the Office of Administrative Hearings at 6714 Mail
Service Center, Raleigh, NC 27699-6714. Unless such demands are made, this permit shall be final and
binding.
If PCS Phosphate Company desires to combine some or all of the close -loop recycle system
permits currently operated at the Aurora site, we encourage a letter describing the request to be submitted
to the Division- The request could be handled through minor modification and rescission of the applicable
permits. Note that a modification fee would not be required.
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this permit, please contact Cory Larsen at [phone] or
cory.larsen@ncdenr. gov.
WATER QUALITY PERMITTING SECTION
1636 Mail Service Center, Raleigh, North Carolina 27699.1636
Location: 512 N. Salisbury St., Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone]
Internet http:llporlatncdencorglweblw�c
An Equal Opportunity 1 Aflirmalive Action Employer

Mr. Steven Beckel
February 7, 2014
Page 2 of 2
Sincerely,
/hoas A. Reeder
cc: Beaufort County Health Department
Washington Regional Office, Water Quality Regional Operations Section
John Garlanger, PE — A&A Engineering, Inc.
Beth Buffington, Public Water Supply Section — Protection and Enforcement Branch
Permit File WQ0036777
Notebook File WQ0036777
N

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMAUSSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
CLOSED-LOOP RECYCLE SYSTEM 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
PCS Phosphate Company, Inc.
Beaufort County
FOR THE
construction and operation of a 35 million gallon per day (MGD) wastewater treatment and closed-loop
recycle facility consisting of
an approximately 115 acre gypsum pile No. 5, generated as a by-product during the manufacture of
phosphoric acid; underlain by a synthetic 60 -mil HPDE liner, an underdrain collection system and
perimeter dike to collect and convey pile leachate and stormwater to Cooling Pond No. 1 for recycling
back into the manufacturing process as a carrier fluid; and all associated piping, valves and
appurtenances;
to serve reactivation of Gypsum Stack 5 (GS -5) at the PCS Phosphate Aurora facility, with no discharge
of wastes to surface waters, pursuant to the application received October 8, 2013 and in conformity with
the project plans, 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 issuande until January 31, 2019 and shall be subject to the
following specified conditions and limitations:
I. SCHEDULES
In accordance with 15A NCAC 02T .0 116, upon completion of construction and prior to operation of
this permitted facility, a certification (attached) shall be, submitted from a licensed North Carolina
Professional Engineer certifying that the permitted facility has been installed in accordance with this
permit, Division approved plans and specifications, and other supporting documentation, including
the location of all monitoring wells as applicable. If this project is to be completed in phases and
partially certified the Permittee shall retain the responsibilLty to track further construction approyed
under the same permit and shall provide a final certificate of completion once the entire project has
been completed. Mail the Certification to the Division of Water Resources, Water Quality Permitting
Section, 1636 Mail Service Center, Raleigh, NC 27699-1636.
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2. The Washington Regional Office, telephone number [phone], shall be notified at least 48
hours in advance (excluding weekends and holidays) of operation of the installed facilities such that
an in-place inspection can be .made. Notification to the regional supervisor shall be made from 8:00
a.m. until 5:00 p.m. on Monday through Friday, excluding State Holidays.
No later than six months prior to the expiration of this permit, the Permittee shall request renewal of
this permit on official Division forms. Upon receipt of the request, the Division will review the
adequacy of the facilities described therein, and if warranted, will renew the permit for such period of
time and under such conditions and limitations as it may deem appropriate. Please note Rule 15A
NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal
application.
H. PERFORMANCE STANDARDS
The subject non -discharge facilities shall be effectively maintained and operated at all times so there
is no discharge to the surface waters, nor any contravention of groundwater or surface water
standards. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions due to improper operation and maintenance, the Permittee shall take immediate
corrective actions including Division required actions, such as the construction of additional or
replacement wastewater treatment or recycle facilities.
2. This permit shall not relieve the Permittee of their responsibility for damages to groundwater or
surface water resulting from the operation of this facility.
3. The facilities permitted herein shall be constructed according to the following setbacks:
a. The setbacks for storage and treatment units permitted under 15A NCAC 02T .1000 shall be as
follows (all distances in feet):
i. Any habitable residence or place of public assembly under separate ownership: 100
ii. Any private or public water supply source: 100
iii. Surface waters: 50
iv. Any well with the exception of a Division approved groundwater monitoring well: 100
v. Any property line: 50
Ill. OPERATION AND MAINTENANCE REQUIItEMENTS
fl. The facilities shall be properly maintained and operated at all times. The facilities shall be effectively
maintained and operated as a non -discharge system to prevent the discharge of any wastewater
resulting from the operation of this facility. The Permittee shall maintain an Operation and
Maintenance Plan pursuant to 15A NCAC 02T .1007, which at a minimum shall include operational
functions, maintenance schedules, safety measures and a spill response plan.
2. Upon the Water Pollution Control System Operators Certification Commission's (WPCSOCC)
classification of the subject non -discharge facilities, in accordance with 15A NCAC 08G .0200 the
Permittee shall designate and employ a certified operator in responsible charge (ORC) and one or
more certified operator(s) as back-up ORC(s). The ORC or their back-up shall visit the facilities in
accordance with 15A NCAC 08G _0200, and shall comply with all other conditions specified in the
previously cited rules.
3. Public access to the wastewater treatment facilities and closed-loop recycle system shall be
prohibited.
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4. The residuals generated from the wastewater treatment facilities shall be disposed or utilized in
accordance with 15A NCAC 02T .1100. The Permittee shall maintain a residual management plan
pursuant to 15A NCAC 02T .1008.
Diversion or bypassing of untreated or partially treated wastewater from the treatment facilities is
prohibited.
6. Freeboard in the No. 1 Cooling Pond shall not be Iess than two feet at any time.
7. A gauge to monitor waste levels in the Cooling Pond No. 1 shall be provided. This gauge shall have
readily visible permanent markings, at inch or tenth of a foot increments, indicating the following
elevations: maximum liquid level at the top of the temporary liquid storage volume; minimum liquid
level at the bottom of the temporary liquid storage volume; and the lowest point on top of the darn.
8. A protective vegetative cover shall be established and maintained on all earthen embankments (i.e.,
outside toe of embankment to maximum allowable temporary storage elevation on the inside of the
embankment), berms, pipe runs, erosion control areas, and surface water diversions. Trees, shrubs,
and other woody vegetation shall not be allowed to grow on the earthen dikes or embankments.
Earthen embankment areas shall be kept mowed or otherwise controlled and accessible.
IV. MONITORING AND REPORTING REQUIREMENTS
1. Any Division required monitoring (including groundwater, plant tissue, soil and surface water
analyses) necessary to ensure groundwater and surface water protection shall be established, and an
acceptable sampling reporting schedule shall be followed.
2. Per 15A NCAC 02H .0800, a Division certified laboratory shall conduct all Iaboratory analyses for
the required effluent, groundwater or surface water parameters.
3. A record shall be maintained of all residuals removed from this facility. This record shall be
maintained at the facility for a period of no less than five years, and shall be made available to the
Division upon request. At a minimum, this record shall include:
a. Name of the residuals hauler;
b. Non -Discharge permit number authorizing the residuals disposal, or a letter from a municipality
agreeing to accept the residuals;
c. Date the residuals were hauled; and
d. Volume of residuals removed.
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4. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone number (252)
946-6481, 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 at the facility resulting in the treatment of significant amounts of wastes that is
abnormal in quantity or characteristic, including the known passage of a hazardous substance.
b. Any process unit failure (e.g., mechanical, electrical, etc.), due to known or unknown reasons,
rendering the facility incapable of adequate wastewater treatment.
c. Any facility failure resulting in a by-pass directly to receiving surface waters.
d. Any time self-monitoring indicates the facility has gone out of compliance with its permit
limitations.
Any emergency requiring immediate reporting (e.g., discharges to surface waters, imminent failure of
a storage structure, etc.) outside normal business hours shall be reported to the Division's Emergency
Response personnel at telephone number [phone], [phone], or [phone].
Persons reporting such occurrences by telephone shall also file a written report in letter form within
five days following first knowledge of the occurrence. This report shall outline the actions taken or
proposed to be taken to ensure the problem does not recur.
V. INSPECTIONS
1. The Permittee shall provide adequate inspection and maintenance to ensure proper operation of the
wastewater treatment and recycle facilities.
2. The Permittee or their designee shall inspect the wastewater treatment and recycle facilities to prevent
malfunctions, facility deterioration and operator errors resulting in discharges, which may cause the
release of wastes to the environment, a threat to human health or a public nuisance. The Permittee
shall maintain an inspection log that includes, at a minimum, the date and time of inspection,
observations made, and any maintenance, repairs, or corrective actions taken. The Permittee shall
maintain this inspection log for a period of five years from the date of the inspection, and this log
shall be made available to the Division upon request.
3. Any duly authorized Division representative may, upon presentation of credentials, enter and inspect
any property, premises or place on or related to the wastewater treatment and recycle facilities
permitted baein at any reasonable time for the purpose of determining compliance with this permit,
may inspecil or copy any records required to be maintained under the terms and conditions of this
permit, and may collect groundwater, surface water or leachate samples.
VI. GENERAL CONDITIONS
1. Failure to comply with the conditions and limitations contained herein may subject the Permittee to
an enforcement action by the Division in accordance with North Carolina General Statutes 143-
215.6A to 143-215.6C.
2. This permit shall become voidable if the permitted facilities are not constructed in accordance with
the conditions of this permit, the Division approved plans and specifications, and other supporting
documentation.
3_ This permit is effective only with respect to the nature and volume of wastes described in the permit
application, Division approved plans and specifications, and other supporting documentation. No
variances to applicable rules governing the construction or operation of the permitted facilities are
granted, unless specifically requested and approved in this permit pursuant to 15A NCAC 02T
.0105(n).
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4. The issuance of this permit does not exempt the Permittee from complying with any and all statutes,
rules, regulations, or ordinances, which may be imposed by other jurisdictional government agencies
(e.g., local, state, and federal). Of particular concern to the Division are applicable river buffer rules
in 15A NCAC 02B .0200; erosion and sedimentation control requirements in 15A NCAC Chapter 4
and under the Division's General Permit NCG010000; any requirements pertaining to wetlands under
15A NCAC 02B .0200 and 02H .0500; and documentation of compliance with Article 21 Part 6 of
Chapter 143 of the General Statutes.
5. In the event the permitted facilities change ownership or the Permittee changes their name, a formal
permit modification request shall be submitted to the Division. This request shall be made on official
Division forms, and shall include appropriate property ownership documentation and other supporting
documentation as necessary. The Permittee of record shall remain fully responsible for maintaining
and operating the facilities permitted herein until a permit is issued to the new owner.
6. The Permittee shall retain a set of Division approved plans and specifications for the life of the
facilities permitted herein.
7. The Permittee shall maintain this permit until all permitted facilities herein are properly closed or
permitted under another permit issued by the appropriate permitting authority pursuant to 15A NCAC
02T.01050).
S_ This permit is subject to revocation or unilateral modification upon 60 days notice from the Division
Director, in whole or part for the requirements listed in 15A NCAC 02T .0110.
9. Unless the Division Director grants a variance, expansion of the permitted facilities contained herein
shall not be granted if the Permittee exemplifies any of the criteria in 15A NCAC 02T A 120(b).
10. The Permittee shall pay the annual fee within 30 days after being billed by the Division. Failure to
pay the annual fee accordingly shall be cause for the Division to revoke this permit pursuant to 15A
NCAC 02T .0105(e)(3).
Permit issued this the 7t` day of February 2014.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
1k
E
T as . Reeder, Director
Division of Water Resources
By Authority of the Environmental Management Commission
Permit Number WQ0036777
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Permit No. WQ0036777
PCS Phosphate Company, Inc.
PCS Phosphate Aurora GS -5
ENGINEERING CERTIFICATION
❑ Partial ❑ Final
Closed -Loop Recycle System
February 7, 2014
Beaufort County
In accordance with 15A NCAC 02T .0 116,
as a duly registered Professional Engineer in the State of North Carolina, having the Permittee's
authorization to ❑ periodically ❑ weekly ❑ fully observe the construction of the permitted facility,
hereby state to the best of my abilities that due care and diligence was used in the observation of the
construction, such that the facility was built within substantial compliance and intent of this permit, the
Division approved plans and specifications, and other supporting documentation.
❑ Any variation to this permit, the Division approved plans and specifications, and other supporting
documentation has been documented in the attached as -built drawings, and shall serve as the
Permittee's minor modification request to amend the permit accordingly.
Provide a brief narrative description of any variations:
Professional Engineer's Name
Engineering Firm
Mailing Address
_.._......._ ............._._......... ._....._...__._..-._ .__..:_,- ._..... .......... ...
!--...--..__....._... _,_....__....__...
City ........ ......... _--__.W_._.,.- ... r.. _ ...... I - State. Zxp
Telephone
E-mail
a
NC PE Seal, Signature & Date
THE COMPLETED ENGINEERING CERTIFICATION, INCLUDING ALL SUPPORTING
INFORMATION AND MATERIALS, SHALL BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DEPARTMENT OF ENVII20NMENT AND NATURAL RESOURCES
DIVISION OF WATER RESOURCES
WATER QUALITY PERMITTING SECTION
NON -DISCHARGE PERMITTING UNIT
By U.S. Postal Service:
1636 MAIL SERVICE CENTER
By Courier/Special Delivery:
512 N. SALISBURY ST.
RALEIGH, NORTH CAROLINA 27699-1636 RALEIGH, NORTH CAROLINA 27604
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