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Home My WebLink About3. 2011 renewal applicationaU PONT, Mrs. Dina Sprinkle NCDENR Division of Water Quality Point Source Branch 1617 Mail Service Center Raleigh, North Carolina 27699-1617 SUBJECT: NPDES Permit Renewal Apllication NPDES Permit No. NC0003573 Dear Mrs. Sprinkle: DuPont Fluoroproducts Fayetteville Warks Plant 22828 NC Highway 87 West Fayetteville, NC 28306-7332 Apri129, 2011 Pursuant to requirements of the referenced NPDES permit, the DuPont Company —Fayetteville Works is submitting the NPDES Form 1 and Form 2C (original and two copies) for permit renewal by the Division of Water Quality. Included in the permit application is a Supplemental Information document which describes the Current Operations and Proposed Changes. This site is being considered for a project to construct and operate a third manufacturing facility that will produce polyvinyl fluoride ("PVF") polymer resins. Two water balances are included in the application: one without the third PVF facility and one with the third PVF facility. The application is being submitted without the testing results for Bis(chloromethyl) ether (CAS No. 542-88-1) as these results were not available at the time of this submittal. These absent results are indicated by asterisks (***) on Page V-4 of Form 2C. This data will be submitted as an addendum when the analytical report is received and inputted into a Form 2C. Should you have any questions or need additional information, please feel free to call me at (910) 678-1155. �� D M�,Y �'' lDi1 DEt.;s:; �� "r�r2 QUALf`tY POI�d..�,::;;;riCE 13F:APICH Enclosures E.I. du Pont de Nemours and Company Environmental Manager �s i 7 34° 52' UNITED STATES DEPARTMENT OF THE INTERIOR GEOLOGICAL SURVEY DUART QUADRANGLE STATE OF NORTH CAROLINA NORTH CAROLINA DEPARTMENT OF NATURAL RESOUP 7.5 MINUTE SERIES (TOPOGRAPHIC) w' AND COMMUNITY DEVELOPMENT SE14 SAINT PAUIS IS' QUADRANGLE ,�J RATFiC;H N r 47' DUPONT COMPANY - FAY ETTEVILLE WORKS LOCATIONS OF INTAKE AND DISCHARGE STRUCTURES c�kjz� pp r t n {:rZ� • (2) Waste Fluorocarbon (corrosive, toxic) _ r t r *. * P40 jpl 44 VA AV cc 6a, N �l i{46 Form 2C, Part 111 13: WATER BALANCE WITHOUT PVF -3 PROCESS (Revised 04/29/2011) DuPont Company = Fayetteville Works Flows Unit: Gallons per Day Basis: All Production Manufacturing, using Maximum 30 day average of measured flows 749,000 11--------------- 1 3,500,000 1 I I FILTERED I WATER 1 I SYSTEM I NON -CONTACT RAW RIVER WATER COOLING WATER to/ from each unit 1,100,000 DEMINERALIZED WATER SYSTEM 17,249,000 I 1 1 1 PURCHASED 1 POTABLE WATER I 1 I I I I STORMWATER 1 I 1 I 1 I I I I I 1 I I I 1 I 1 I I I I I I 1 186,000 1 I 1 I I I 1 Stormwaler from Process Areas 46,500 Non -process Stonnwater Neutralized Regenerate I 8,000 I Sanitary Facilities NaOCI Filtered Water Demineralized Water J: 1 Evaporation fl BOILERS it NPDES PERMIT APPLICATION Cape Fear River 1 1100,000 I 10 BUTACITEtRI NAFIONtRI SENTRYGLAStRI POLYVINYL POLYVINYL POLYVINYLBUTYRAL FLUOROPRODUCT LAMINATE FLUORIDE FLUORIDE MANUFACTURING MANUFACTURING MANUFACTURING RESIN RESIN PROCESS PROCESSES PROCESS PROCESS #1 PROCESS #2 I t 682,500 90,000 100,000 65,000 65,000 IF IF IF 1,845,500 e 182,000 35,000 35,000 Evaporation 1 Evaporation Biosolids Moisture 1,032,000 20,864,500 m � � m OUTFALL ACTIVATED @ � � � SLUDGE CLARIFI- OUTFALL � � � � 002 WWrP CATION 001 U U U U t0 IO `N, c0 C C C C U U U U 20,000 BIOSCLIDS 908,000 z° z z z° DEWATER/ 4,000 DRY;NG } DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — April 29, 2011 Current Site Water Management Process wastewater and stormwater from the various manufacturing areas are collected in the respective area sumps and ultimately conveyed via a gravity flow underground process sewer pipe to the site's central wastewater treatment plant (WWTP). Sanitary sewage is conveyed via a separate underground sewer system to the WWTP. The permitted flowrate of the WWTP is 2.0 MGD, with an actual average flowrate of approximately one MGD. This process wastewater is commingled in the WWTP Influent Sump where it is pumped to an 850,000 -gallon Equalization Basin, The Equalization Basin is mixed with two floating submerged mixers. Three floating surface aerators in the basin cool and aerate the incoming wastewater. A 175,000 -gallon Emergency Retention Tank is available for temporary storage of wastewater which may need additional treatment or acclimation in the WWTP activated sludge process at a controlled rate that allows for proper biological treatment. Wastewater from the Equalization Basin is normally pumped to a 250,000 -gallon Predigester Tank in which initial biological activity with the WWTP activated sludge begins. The Predigester Tank is aerated. The partially treated wastewater from the Predigester Tank is pumped to a 1,700,000 -gallon Aeration Tank. The Aeration Tank is the site of the majority of the biological activity. The Aeration Tank is aerated primarily by a diffused air system located in the bottom of the tank. The tank can have supplemental aeration via a floating Biomixer® that injects air through submerged rotors. The biologically treated wastewater is then sent to one of two in -ground clarifiers (119,000 gallons and 168,000 gallons respectively) or an above -ground 679,000 -gallon clarifier; with all clarifiers being operated in parallel. The clarified treated effluent is discharged to and through Outfall 001. The wasted sludge is sent to a Dissolved Air Floatation (DAF) unit, then to a 47,000 gallon Sludge Storage Tank, and finally to a Rotary Filter for thickening. The thickened sludge is dewatered in a Sludge Press, and can be dried in a steam -heated dryer for additional moisture removal. The dewatered sludge or dewatered/dried sludge is transported off-site to a commercial Subtitle D landfill. Non -contact process cooling water and non -process stormwater are conveyed via surface ditches. In addition, excess riverwater flow and Outfall 001 effluent are discharged directly to a surface ditch. The combined, total flow of water from the site is discharged and monitored at Outfall 002. The DMR reported Outfall 002 maximum 30 -day average flow was 20.75 MGD during the period from 2008 to 2010. Flow variability at Outfall 002 was from 3 to 26 MGD, however, this monitored flow was the influent of river water pumped into the site, and did not include the discharge of stormwater or treated sanitary sewage. DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — April 299 2011 Proposed Changes in Operations PVF -3 Manufacturing Facy: The DuPont Company —Fayetteville Works is being considered as the location for a third DuPontTM Polyvinyl Fluoride ("PVF") manufacturing process ("PVF -3"). The manufacturing facility is in the process of being designed, and will produce PVF polymer resins. PVF resin to be manufactured at the Fayetteville plant is used in DuPontTM Tedlar® fluoropolymer film business. Tedlar® film is manufactured at other DuPont site location (not the Fayetteville plant). Tedlar® is used in the photovoltaic industry in photovoltaic cells and the aircraft industry for interior cabin surfaces, as well as many other uses. Assuming this new facility is sited at the DuPont Company — Fayetteville Works, construction would be completed in August 2013 and the unit would begin production in September 2013. The manufacturing .facility will be located near the existing PVF -1 and PVF -2 manufacturing processes. This process will produce polyvinyl fluoride ("PVF") resin (CAS No. 24981-14-4). As with most fluorochemical processes, the main wastewater stream from the PVF -3 manufacturing process would have trace or no biological oxygen demand (BODS) value. The major pollutant associated with this process wastewater would be solid resin (as Total Suspended Solids). To treat this wastewater, DuPont intends to pump the majority of the PVF -3 process wastewater directly to the third clarifier, which would remove the resin solids as part of the activated sludge removed from the WWTP system. Ultimately the resin solids would be removed from the system as part of the wasted sludge that is sent off site to a Subpart D landfill. Approximately 3% of the PVF -3 process wastewater contains a cleaning solution will be sent to the headworks of the site's WWTP. The PVF -3 Manufacturing Facility would have a process wastewater stream containing a cleaning solution or surfactant. This wastewater stream, representing approximately 3% of the total PVF -3 process wastewater, would be sent to the headworks of the site's WWTP for biological treatment. Finally, non -contact cooling, condensate, and stormwater from the PVF -3 Manufacturing Facility will be discharged directly to Outfa11002 via the site's non -contact water ditch. DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — April 29, 2011 Current Operating Conditions Butacite® Manufacturing: The DuPont Company — Fayetteville Works' Butacite® manufacturing area produces two final products. DuPontTM Butacite® Interlayer plastic sheeting is the final product used in safety glass such as automobile windshields. Polyvinyl butyral (PVB) resin is shipped off-site as a transfer to other DuPont locations for final processing. Wastewater generated from this manufacturing facility is treated in the site's biological wastewater treatment plant ("WWTP"). Nafion® Manufacturing: The DuPont Company — Fayetteville Works' Nafion® manufacturing area produces five final products. DuPontTM Nafion® Membrane is a plastic film used in the chloroalkah industry and in electrochemical fuel cells. NafionO Resins are ultimately extruded into a finished film. The FLPR Vinyl Ether and HFPO monomers are shipped to other DuPont locations to produce various fluorochemical products such as DuPontTM Teflon®. Wastewater generated from this manufacturing facility is neutralized and discharged to the WWTP. PPA Manufacturing: The DuPont Company —Fayetteville Works' PPA manufacturing area produces several polymer processing aids. The processing aids produced in this unit are used to produce fluoropolymers and fluorinated telomers, but none of the produced processing aids are used at the Fayetteville Works site. This facility was started up in November 2002. All process wastewater generated from this manufacturing facility is collected and shipped off-site for disposal. No process wastewater from this manufacturing facility is discharged to the site's biological WWTP or to the Cape Fear River. SentryGlas& Manufacturing: The DuPont Company —Fayetteville Works' SentryGlas® manufacturing area produces DuPontTM SentryGlas� Tonoplast interlayer laminate. SentryGlas® interlayer is used for laminated safety glass in side, rear, and overhead automobile windows. It is also used in architectural applications desiring safety glass. This facility was started up in June 2005. There is no contact process wastewater generated from this manufacturing facility, therefore only sanitary waste from this area is treated in the WWTP. This manufacturing facility does discharge non -contact cooling water to a surface ditch and ultimately to Outfall 002. PVF Manufacturing: The DuPont Company —Fayetteville Works' PVF manufacturi ng area produces polyvinyl fluoride resin is used in the electronics industry as a backing for photovoltaic cells, as well as many other uses. The PVF4 facility was constructed in 2006-2007 and was started up in September 2007. The PVF -2 facility was constructed in 200&2010 and was started up in June 2010. Process wastewater generated from this manufacturing facility is treated in the WWTP. DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — April 29, 2011 Form 2C Permit Application Data Unavailable The Outfall 001 and Outfa11002 analytical results for Bis(chloromethyl) ether were not available at the time of this permit renewal application submittal. These absent analytical results are indicated with asterisks (***) on Page V-4 of Form 2C. This data will be submitted as an addendum when the analytical report is received. DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — April 29, 2011 Sludge Management Plan The DuPont -Fayetteville Works operates a Class 3 Wastewater Treatment Plant which is comprised of a single -stage activated sludge biological system. Excess sludge is removed from the system by 1:7'r rt f thRlvated Sludge (at approximately 0.6% solids) from the clarifiers to a Dissolved Air Floatation ("DAF") unit for initial thickening. The sludge from the DAF (at approximately 3% solids) is transferred to a Mix Tank where polymer agents are added to enhance the dewatering process. The semi -thickened sludge is transferred from the Mix Tank to a Rotary Filter for final thickening, whereby the sludge is thickened to 6% solids. The thickened sludge is then transferred to a Screw Press where itis dewatered to a concentration of 9-20% solids. Following the Screw Press, the sludge is typically dried in steam heated dryers to a concentration of 40-55% solids. On the average, the weekly quantity of generated dried sludge is approximately 23,000 lb. The dri ed sludge, or on occasion the dewatered sludge, is transported off-site to a commercial Subtitle D landfill. This sludge is currently being disposed of at the Waste Industries "Sampson County" Landfill near Roseboro, NC. DuPont Company - Fayetteville Works NPDES Permit NC0003573 Total Volume of the Water Handling System Between Entry of Biocidal Product and NP ES Discharge Point Wastewater Treatment Plant Unit Volume milliongallons) Equalization Basin 0.850 Pre -Digester Tank 0.250 Aeration Tank 1.700 #3 Clarifier 0.679 TOTAL 3.479 Flow Diagram from Entry Point of Biocidal Product (PVF -3 Cooling Tower) to the NPDES Discharge Point (NPDES Outfall 002) PVF -3 COOLING TOWER WASTEWATER TREATMENT PLANT NPDES OUTFALL 002