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Home My WebLink AboutDEQp00020723Mr. Michael E. Johnson Environmental Manager E.I. DuPont de Nemours & Company 22828 NC Hwy 87 W Fayetteville, North Carolina 28306-7332 Dear Mr. Johnson: Michael F. Easley Governor William G. Ross, Jr., Secretary North Carolina Department of Environment and Natural Resources Alan W. Klimek, P.E., Director Division of Water Quality May 25, 2007 Subject: NPDES Permit Issuance Permit No. NC0003573 Fayetteville Works Bladen County Division personnel have reviewed and approved your application for renewal of the subject permit.. Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency dated May 9, 1994 (or as subsequently amended). The following modifications from your draft permit are included in the final permit: • Sampling frequency for conductivity was corrected to weekly. • The waiver for instream sampling that was inadvertently omitted in the draft permit is included in the footnotes for Outfall 002. • Monthly monitoring for PFOA was added to outfall 002 to gather effluent and instream data for this parameter. If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt of this letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding. Please note that this permit is not transferable except after notice to the Division. The Division may require modification or revocation and reissuance of the permit. This permit does not affect the legal requirements to obtain other permits which may be required by the Division of Water Quality or permits required by the Division of Land Resources, the Coastal Area Management Act or any .other Federal or Local governmental permit that may be required. North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone (919) 733-5083 Internet: h2o.enr.state.nc.us 512 N. Salisbury St. Raleigh, NC 27604 FAX (919) 733-0719 An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper Nope Carolina Vatarally Customer Service 1-877-623-6748 Permit No. NC0003573 Fayetteville Works WWTP Page 2 If you have any questions concerning this permit, please contact Teresa Rodriguez at telephone number (919) 733-5083, extension 553. Sincerely, /A"I/ � -4r Alan W. Klimek, P.E. Cc: NPDES Files Fayetteville Regional Office - Surface Water Protection Aquatic Toxicology Unit EPA Region 4 4., r Permit NC0003573 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY PERMIT TO DISCHARGE WASTEWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provisions of North Carolina General Statute 143-215.1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Federal Water Pollution Control Act, as amended, E.I. DuPont de Nemours & Co. is hereby authorized to discharge wastewater and stormwater from a facility located at DuPont - Fayetteville Works 22828 NC Highway 87 Duart Township Bladen County to receiving waters designated as the Cape Fear River in the Cape Fear River Basin in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, and IV hereof. The permit shall become effective July 1, 2007. This permit and the authorization to discharge shall expire at midnight on October 31, 2011. Signed this day May 25, 2007. • Alan W. Klimek, P.E., Dir or Division of Water Quality By Authority of the Environmental Management Commission i Permit NC0003573 '% SUPPLEMENT TO PERMT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and as of this issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and provisions included herein. E.I. DuPont de Nemours & Co., Inc. is hereby authorized to: Continue to operate existing wastewater treatment facilities consisting of: • equalization; • neutralization; • aerated pre -digester tank; • nutrient feed system; • aeration tank; • dual clarifiers; • effluent flow measurement; • tertiary filters • DAF unit; • rotary filter for sludge thickening; • sludge filter press; and • steam heated sludge dryers. 2. Discharge treated process wastewater from Butacite, Nafion, Teflon® PMDF, and PVF, process stormwater, sanitary wastewater, and co -neutralized regenerate from said treated facilities through internal outfall 001; 3. Discharge stormwater, non -contact cooling water, boiler blowdown and condensate, and treated wastewater effluent from 001, through outfall 002 at the location specified on the attached map into the Cape Fear River, a class C water in the Cape Fear River Basin. Permit NC0003573 A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is authorized to discharge from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS MonthlyMeasurement Daily Maximum Average Sample Sample Frequency Type Location Flow (MGD) 2.0 Continuous Recording Effluent BODS, 20° C 191.3 lbs/day 508.21bs/day 3/Week Composite Effluent Total Suspended Solids 317.8 lbs/day 10301bs/day 3/Week Composite Effluent Temperature Weekly Grab Effluent Oil & Grease Monthly Grab Effluent Chronic Tonicity See Note 1 Quarterly Composite See Note 1 pH Between 6.0 and 9.0 Standard Units 3/Week Grab Effluent 40 CFR 414 Subpart I See Condition A. (2) Notes: 1. Chronic Toxicity (Ceriodaphnia) P/F ® 3.3% February, May, August, November; see condition A. (4) of this permit. The compliance monitoring point for chronic toxicity shall be downstream of the confluence of outfall 001 and 002. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. w r a Permit NC0003573 A. (2) EFFLUENT LINIITATIONS AND MONITORING REQUIREMENTS - SUBPART I Beginning on the effective date of this permit and lasting through the expiration date, the Permittee shall comply with the limitations and monitoring frequencies established below at outfall 001: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS Monthly Average' Daily Maximum' Measurement 'Frequency Sample T e Sample Location Acenaphthene 0.174 0.465 See Note 2 Grab Effluent Acenaphthylene 0.174 0.465 See Note 2 Grab Effluent Acrylonitrile 0.757 1.909 See Note 2 Grab Effluent Anthracene 0.174 0.465 See Note 2 Grab Effluent Benzene 0.292 1.073 See Note 2 Grab Effluent Benzo(a)anthracene 0.174 0.465 See Note 2 Grab Effluent 3,4-Benzofluoranthene 0.181 0.481 See Note 2 Grab Effluent Benzo(k)fluoranthene 0.174 0.465 See Note 2 Grab Effluent Benzo(a)pyrene 0.181 0.481 See Note 2 Grab Effluent Bis(2-ethylhexyl) phthalate 0.813 2.201 See Note 2 Grab Effluent Carbon Tetrachloride 0.142 0.300 See --Note 2 Grab Effluent Chlorobenzene 0.118 0.221 See Note 2 Grab Effluent Chloroethane 0.821 2.114 See Note 2 Grab Effluent Chloroform 0.166 0.363 See Note 2 Grab Effluent 2 -Chlorophenol 0.245 0.773 See Note 2 Grab Effluent Chrysene 0.174 0.465 See Note 2 Grab Effluent Di -n -butyl phthalate 0.213 0.450 See Note 2 Grab Effluent 1,2 -Dichlorobenzene 0.608 1.286 See Note 2 Grab Effluent 13 -Dichlorobenzene 0.245 0.347 See Note 2 Grab Effluent 1,4 -Dichlorobenzene 0.118 0.221 See Note 2 Grab Effluent 1,1-Dichloroethane 0.174 0.465 See Note 2 Grab Effluent 1,2-Dichloroethane 0.536 1.665 See Note 2 Grab Effluent 1,1-Dichloroethylene 0.126 0.197 See Note 2 Grab Effluent 1,2-trans-Dichloroethylene 0.166 0.426 See Note 2 Grab Effluent 214-Dichlorophenol 0.308 0.884 See Note 2 Grab Effluent ,2-Dichloropropane 1.207 1.815 See Note 2 Grab Effluent ,3-Dichloropropylene 0.229 0.347 See Note 2 Grab Effluent Diethyl phthalate 0.639 1.602 See Note 2 Grab Effluent 2,4 -Dimethylphenol 0.142 0.284 See Note 2 Grab Effluent Dimethyl phthalate 0.150 0.371 See Note 2 Grab Effluent ,6-Dinitro-o-cresol 0.615 2.185 See Note 2 Grab Effluent ,4-Dinitrophenol 0.560 0.970 See Note 2 Grab Effluent 2,4-Dinitrotoluene 0.892 2.249 See Note 2 Grab Effluent 2,6-Dinitrotoluene 2.012 5.057 See Note 2 Grab Effluent Ethylbenzene 0.252 0.852 See Note 2 Grab Effluent Permit NC0003573 A. (2) SUBPART I REQUIREMENTS (CONTINUED) Beginning on the effective date of this permit and lasting through the expiration date, the Permittee shall comply with the limitations and monitoring frequencies established below at outfall 001: PARAMETER EFFLUENT LIMITATIONS MONITORING REQUIREMENTS Monthly Average' Daily Maximum' Measurement Frequency Sample T e Sample Location Fluoranthene 0.197 0.536 See Note 2 Grab Effluent Fluorene 0.174 0.465 See Note 2 Grab Effluent Hexachlorobenzene 0.5 µg/L Annually3 Grab Effluent Hexachlorobutadiene 0.158 0.387 See Note 2 Grab Effluent Hexachloroethane 0.166 0.426 See Note 2 Grab Effluent Methyl Chloride 0.679 1.499 See Note 2 Grab Effluent Methylene Chloride 0.316 0.702 See Note 2 Grab Effluent Naphthalene 0.174 0.465 See Note 2 Grab Effluent Nitrobenzene 0.213 0.536 See Note 2 Grab Effluent -Nitrophenol 0.323 0.544 See Note 2 Grab Effluent -Nitrophenol 0.568 0.978 See Note 2 Grab Effluent Phenanthrene 0.174 0.465 See Note 2 Grab Effluent Phenol 0.118 0.205 See Note 2 Grab Effluent Pyrene 0.197 0.529 See Note 2 Grab Effluent Tetrachloroethylene 0.174 0.442 See Note 2 Grab Effluent Toluene 0.205 0.631 See Note 2 Grab Effluent 2,4-Trichlorobenzene 0.536 1.105 See Note 2 Grab Effluent ,1,1 -Trichloroethane 0.166 0.426 See Note 2 Grab Effluent 1,1,2 -Trichloroethane 0.166 0.426 See Note 2 Grab Effluent Trichloroethylene 0.166 0.426 See Note 2 Grab Effluent Vinyl Chloride 0.821 2.114 See Note 2 Grab Effluent Notes: 1. All units are lbs/day unless otherwise noted. 2. Monitoring for the specified parameters has been waived based on a demonstration made by the Permittee in accordance with 40 CFR 122.44(a)(2)(i). This waiver is good only for the term of the permit. Please note that any exceedence of the effluent limitations found herein shall be considered a permit violation subject to appropriate enforcement action. 3. The most sensitive analytical method available shall be employed for determining the presence of hexachlorobenzene in the effluent. Permit NC0003573 A. (3) EFFLUENT LIAUTATIONS AND MONITORING REQUIREMENTS Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is authorized to discharge from Outfall 002 (boiler blowdown, once -through cooling water, and treated wastewater from outfall 001) Such discharges shall be limited and monitored by the Permittee as specified below: Notes: 1. Upstream shall be at the Permittee's river pump station; downstream shall be at the boat ramp approximately 4500 feet downstream at Prospect Hall Landing. As a participant in the Cape Fear River Basin Association, the instream monitoring requirements as stated above are waived. Should your membership in the agreement be terminated, you shall notify the Division immediately and the instream monitoring requirements specified in your permit shall be reinstated. 2. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C. 3. Daily shall be defined as every day except Saturdays, Sundays, and legal holidays. Instream temperature sampling shall be conducted weekly. 4. The samples for fluoride shall be taken downstream of the 001 discharge, unless or until, all neutralized Nafion area streams are discharged entirely into the cooling water outfall, 002. Instream fluoride monitoring shall be conducted monthly and shall coincide with effluent monitoring. 5. PFOA (Perfluorooctanoic acid) - The Cape Fear River water intake may be sampled for PFOA on a monthly basis and reported as an upstream parameter in DWQ Form — MR -3. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. EFFLUENT LIMITATIONS MONITORING REQUIREMENTS PARAMETER Monthly "Measurement Sample Sample Average daily Maximum Fr uen Type Locations Flow (MGD) Continuous Recording Effluent Effluent, Temperature, °C See Note 2 Daily3 Grab Upstream, Downstream BODS, 20°C Quarterly Composite Effluent COD Quarterly Composite Effluent Effluent, Fluoride4 7917lbs/day Weekly Grab Upstream, Downstream Dissolved Oxygen Weekly Grab Upstream, Downstream PFOA5 Monthly Grab Effluent Total Phosphorus Monthly Composite Effluent Total Nitrogen Monthly Composite Effluent (NO2+NO3+TKN) Conductivity Weekly Grab Upstream, Downstream pH Between 6.0 and 9.0 Standard Units 3/Week Grab Effluent Notes: 1. Upstream shall be at the Permittee's river pump station; downstream shall be at the boat ramp approximately 4500 feet downstream at Prospect Hall Landing. As a participant in the Cape Fear River Basin Association, the instream monitoring requirements as stated above are waived. Should your membership in the agreement be terminated, you shall notify the Division immediately and the instream monitoring requirements specified in your permit shall be reinstated. 2. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C. 3. Daily shall be defined as every day except Saturdays, Sundays, and legal holidays. Instream temperature sampling shall be conducted weekly. 4. The samples for fluoride shall be taken downstream of the 001 discharge, unless or until, all neutralized Nafion area streams are discharged entirely into the cooling water outfall, 002. Instream fluoride monitoring shall be conducted monthly and shall coincide with effluent monitoring. 5. PFOA (Perfluorooctanoic acid) - The Cape Fear River water intake may be sampled for PFOA on a monthly basis and reported as an upstream parameter in DWQ Form — MR -3. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. Permit NC0003V3 A. (4) CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) — OUTFALL 001 The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia dubia at an effluent concentration of 3.3%. The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be performed during the months of February, May, August, and November. Effluent sampling for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment processes. If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable impairment of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes, and further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form (MR -1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT -3 (original) is to be sent -to the following address: Attention: Environmental Sciences Section North Carolina Division of Water Quality 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the Environmental Sciences Section at the address cited above. Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required during the following month. Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring. Permit NC0003573 A. (5) RE -OPENER CONDITION This permit shall be modified, or revoked and reissued to incorporate additional toxicity limitations and monitoring requirements in the event toxicity testing or other studies conducted on the effluent or receiving stream indicate that detrimental effects may be expected in the receiving stream as a result of this discharge. A. (6) BIOCIDE CONDITION The permittee shall not use any biocide except those approved in conjunction with the permit application. The permittee shall notify the Director in writing not later than ninety (90) days prior to instituting use of any additional biocide used in cooling systems which may be toxic to aquatic life other than those previously reported to the Division of Water Quality. Such notification shall include completion of Biocide Worksheet Form 101 and a map locating the discharge point and receiving stream. DENR/DWQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT NPDES No. NC0003573 Summary: E.I. DuPont de Nemours & Co submitted a permit renewal application on May 2, 2006 for the renewal of its NPDES permit. The DuPont Fayetteville Works manufacturing facility includes the Butacite® plant, the Nafion® plant, the Teflon® plant, and the APFO plant. A new process will be added in 2007 to produce Polyvinyl Fluoride (PVF) resins. The process wastewaters generated from the new facility will be treated in the existing treatment plant. DuPont has requested to modify the permit to include the new process wastewaters generated by the PVF manufacturing and to eliminate outfall 006 from the permit. Manufacturing Facilities: Buticite® Manufacturing • DuPontTm Buticite® Interlayer plastic sheeting — This is the final product used in safety glass such as automobile windshields. Butacite® is manufactured in large rolls, shipped out in refrigerated trucks to glass manufacturers. The refrigeration is a requirement as Butacite sticks to itself at temperatures above 60°F. Polyvinyl butyral (PVB) resin - the resin is shipped to other DuPont facilities for final processing. Wastewaters generated at this facility are treated in the on-site wastewater treatment plant. Nafion® Manufacturinq Five products are manufactured at the Nafion® manufacturing facility: • DuPontTm Nafion® membrane — a plastic film used in the chloroalkali industry and in electrochemical fuel cells; • Nafion® resins — ultimately extruded into a finished film; • Nafion® solution — generated during the production of resin; Fact Sheet NPDES NC0003573 Page 1 Facility Information Applicant/Facility Name: E.I. DuPont de Nemours & Co — DuPont Fayetteville Works Applicant Address: 22828 NC Hwy 87W, Fayetteville, NC 28306-7332 Facility Address: 22828 NC Hwy 87W, Fayetteville, NC 28306-7332 Permitted Flow (MGD): 2 MGD — WWTP (001) Type of Waste: Industrial Facility Classification: III Permit Status: Renewal County: Bladen Miscellaneous Receiving Stream: Cape Fear River Regional Office: Fayetteville Stream Classification: C USGS Quad: Duart 303(d) Listed? No Permit Writer: Teresa Rodriguez Basin/Subbasin: 03-06-16 Date: 12/6/06 Drainage Area (rni): 4790 Lat. 340 50' 25" N Long. 780 50' 09" W Summer 7Q10 cfs 791 Winter 7Q10 (cfs): 30Q2 (cfs) Average Flow ;(cfs): 5676 IWC (%): 3.7% Summary: E.I. DuPont de Nemours & Co submitted a permit renewal application on May 2, 2006 for the renewal of its NPDES permit. The DuPont Fayetteville Works manufacturing facility includes the Butacite® plant, the Nafion® plant, the Teflon® plant, and the APFO plant. A new process will be added in 2007 to produce Polyvinyl Fluoride (PVF) resins. The process wastewaters generated from the new facility will be treated in the existing treatment plant. DuPont has requested to modify the permit to include the new process wastewaters generated by the PVF manufacturing and to eliminate outfall 006 from the permit. Manufacturing Facilities: Buticite® Manufacturing • DuPontTm Buticite® Interlayer plastic sheeting — This is the final product used in safety glass such as automobile windshields. Butacite® is manufactured in large rolls, shipped out in refrigerated trucks to glass manufacturers. The refrigeration is a requirement as Butacite sticks to itself at temperatures above 60°F. Polyvinyl butyral (PVB) resin - the resin is shipped to other DuPont facilities for final processing. Wastewaters generated at this facility are treated in the on-site wastewater treatment plant. Nafion® Manufacturinq Five products are manufactured at the Nafion® manufacturing facility: • DuPontTm Nafion® membrane — a plastic film used in the chloroalkali industry and in electrochemical fuel cells; • Nafion® resins — ultimately extruded into a finished film; • Nafion® solution — generated during the production of resin; Fact Sheet NPDES NC0003573 Page 1 • FLPR vinyl ether monomers — shipped to other DuPont locations to produce various fluorochemical products such as DuPontTm Teflon®. • HFPO monomers — shipped to other DuPont locations to produce various fluorochemical products such as DuPontTm Teflon®. Wastewaters generated at this facility are neutralized and treated in the on-site WWTP. Teflon® Manufacturing DuPontTm Teflon® FEP resin — this resin is used in the electronics industry as a coating for wire, as well as many other uses. Wastewaters generated at this facility are treated in the on-site wastewater treatment plant. Ammonium Perfluorooctanoate (APFO) Manufacturing APFO is used to produce fluoropolymers and fluorinated telomers that are shipped to other DuPont facilities. Wastewaters generated in this process are collected and shipped off-site for disposal. Sentry Glass Plus® Manufacturing DuPontTM Sentry Glass Plus® - this is an ionoplast interlayer laminate used for laminated safety glass in side, rear, and overhead automobile windows. It is also used in architectural applications desiring safety glass. This manufacturing process started in June 2005. No process wastewaters are generated from this process. Non -contact cooling water is discharged to Outfall 002. Proposed PVF Manufacturing This facility will produce Polivinyl fluoride resins (PVF) and is expected to start production in October 2007. PVF is used in DuPontTM Tedlar® fluoropolymer film manufactured at other DuPont facilities. Tedlar® is used in the photovoltaic industry in photovoltaic cells and the aircraft industry for interior cabin surfaces, as well as other uses. The wastewater generated at this site will be treated at the on-site wastewater treatment plant. Wastewater from the PVF process will contain unreacted vinyl fluoride, with little or no BOD value. The expected concentration of vinyl fluoride at outfall 0002 is 0.0035 mg/l. Non -contact cooling water, condensate and stormwater will be discharged to Outfall 002. Wastewater Treatment: Process wastewaters and stormwater from process areas are collected in sumps in the respective manufacturing areas and conveyed via gravity sewers to the wastewater treatment plant. Sanitary sewage is conveyed separately to the WWTP. The treatment system consists of the following: • Influent pump sump • 850,000 gallon Equalization basin with two floating submerged mixers • 250,000 aerated predigester tank • 1,700,000 gallon aeration tank with a bottom diffused air system with supplemental floating mixer that injects air through submerged rotors • Two clarifiers • 175,000 gallon emergency retention tank Dissolved Air Flotation Unit for sludge treatment • 47,000 gallon sludge storage tank • Rotary filter for thickening • Sludge press and steam heated dryer The treatment system discharges through Outfall 001 to the main discharge channel. Non -process cooling waters and stormwater are conveyed to ditches and discharged to the main discharge channel. The combined flows are discharged through Outfall 002 to the Cape Fear River below Lock and Dam #3. Fact Sheet NPDES NC0003573 Page 2 Effluent Guidelines: DuPont's Fayetteville Works is regulated under the Organic Chemicals, Plastics and Synthetic Fibers Category, 40 CFR 414 Subpart D. These guidelines apply to products manufactured under SIC codes 2869 and 2821. SIC code 2869 includes Nafion® solution, Vinyl Ether and HFPO monomers manufacturing. SIC code 2821 includes Teflon® resin, polyvinyl fluoride resin, polyvinyl butyral resin and Nafion® resin manufacturing. Manufacturing of Nafion membrane, Butacite® sheeting and Sentry Glass plus are classified as SIC code 3081 which is not regulated by the OCPSF guidelines. Regulated process flow for Outfall 001 is approximately 1,085,660 gpd. This flow includes the flow from PVF manufacturing process, which is set to start up in 2007. Average flow for the past 3 years was 0.832 MGD. C!, !;-;+n C. ,k-+ n _ Thnrmnnlncfin Racine Al d Al Process Clow - 1.Ubbbb MUU. The calculated limits are higher than current limits in the permit. The existing limits will remain in the permit. Compliance Summary: Outfall 001 Process Wastewater Treatment Plant Data reviewed: 1//1 /2004 - 9/30/2006 Flow Effluent Limitations Effluent Limitations Domestic WW Proposed limits Ib/d concentration Mass limits mass limits mass limits Parameter Maximum Maximum ' Monthly Daily Monthly Daily Monthly Daily Monthly < 2.6 Daily < 5 Maximum Maximum Maximum (mg/1) Average (lb/day) (lb/day) (Ib/day) , BOD 64 24 579.5 217.3 3 2 582.5 219.3 TSS 130 40 1177.1 362.2 3 2 1180.1 364.2 Process Clow - 1.Ubbbb MUU. The calculated limits are higher than current limits in the permit. The existing limits will remain in the permit. Compliance Summary: Outfall 001 Process Wastewater Treatment Plant Data reviewed: 1//1 /2004 - 9/30/2006 Flow BOD TSS Q& U ► emp MGD Ib/d Ib/d mg/1 C Ave -rage 0.0832 63.9 132.8 5.95 27 Maximum 1.275 2981 349.3 28. 30 Minimum 0.078 < 2.6 8.7 < 5 9 40 CFR 414 Subpart I Parameters - Monitoring was waved based on a demonstration made by the Permittee in accordance to 40 CFR 122.44(a)(2)(i). The permit application includes a pollutant analysis for these parameters. No parameters were detected. Notices of Violation - The facility received two NOVs: March 2005 for BOD monthly average and daily max and March 2006 for BOD daily max. Outfall 002 Combined cooling waters, stormwater and process WWTP effluent Data reviewed: 1//1 /2004 - 9/30/2006 r -Flow I BOD I COD I Fluoride I TP I TN ,I Average 12.61 57.5 52.0 834 16.2 2.7 Maximum 22.24 212 1 102.0 1 5030 302.0 26.5 Minimum 1 2.96 1 <2 1 < 25 1 19 _1 < 0.1 0.5 Whole Effluent Toxicity - The permit requires a quarterly chronic test at 3.3 %. The facility passed all the tests for the period of Feb 2002 to Aug 2006. Notices of Violation - There were no NOVs for this outfall. Priority Pollutant Analysis - No parameters were detected in the PPA above the allowable concentrations. Fact Sheet NPDES NC0003573 Page 3 A v& N &X 1'4 IN Instream data review: There are monitoring stations in the Cape Fear River upstream (88301000) and downstream (68302000) of the discharge. Data from the monitoring stations don't show water quality concerns. RRRM nno - Upstream station at Lock & Dam #3 RRRn9000 - Dnwnstream station near Tolarsville to W " 10 N m -O z Z co o 0 o �i :3 Q fl 2 Y NF- Z Z Q -0 �LL O 0 O `) D Z F-0 - N O U � U) E3 0 Z Z T mg/I SU Wmhos/cm /100 ml mg/I NTU mg/I mg/I mg/I mg/I fatter 8.3 6.9 154.2 43.9 21.1 15.2 0.1 0.7 0.7 0.2 Mtrijm= 12.8 7.7 261.0 3000.0 124.0 33.0 0.5 1.2 1.4 0. jAyefage 5.7 5.9 81.0 6.0 3.9 4.5 0.0 0.1 0.4 0.1 RRRn9000 - Dnwnstream station near Tolarsville to C.) m -O Y Z 0 o �i Cao c co Z Z t1 D D La) O a. O - N O 0 (n Z T mg/I SU umhos/cm /100 m1 mg/I NTU mg/I mg/I mg/1 mgA 8.1 6.8 132.8 38.0 14.3 14.3 0.1 0.8 0.7 0.1 13.2 7.41 304.0 2400.01 76.01 77.41 0.3 5.3 1.4 0.5 2.8 5.91 52.0 1.01 5.01 5.01 0.01 0.2 0.4 0.0 SUMMARY OF PROPOSED CHANGES: • Outfall 006 was eliminated from the permit. This outfall authorized the discharge of wastewaters from the Nafion® manufacturing process but current procedure is to send the wastewater to the WWTP for treatment. DuPont requested to eliminate the outfall from the permit as they will continue to send the wastewater to the WWTP. • The Supplement to Cover Sheet includes authorization to discharge treated wastewater from the PVF process. The process will start up in late 2007. Fact Sheet NPDES NC0003573 Page 4 Draft Permit to Public Notice: Permit Scheduled to Issue: December 20, 2006 February 12, 2007 NPDES DIVISION CONTACT If you have questions regarding any of the above information or on the attached permit, please contact Teresa Rodriguez at (919) 733-5083 ext. 553. DATE: REGIONAL OFFICE COMMENTS NAME:DATE: SUPERVISOR: * DATE: 1-3-0-7 1fi3,'N$ ,SAN 200 �t 1' 1.3 ti Y a Fact Sheet mmnFc T\rC0nn1s71 FACILITY DuPont -Fayetteville 242 96 2.191 0.869 Federal no stdrd 0.25 no stdrd 457.99 no stdrd 7.633 OCPSF OCPSF Flow 1.08566 MGD Outfall 001: flow is based on processes only Anthracene 59 22 0.534 0.199 Federal no sidrd 40000:00 ' 7Q10S 791 cis no stdrd 170774.194 OCPSF 0.534 #/day 0.199 Benzene (c) 136 37 1.231 0.335 State Qavg 5676 cis no stdrd 130802.50 no stdrd 2180.042 OCPSF 1.231 If/day 0.335 Benzo(a)anthracene (c, P, 59 22 0.534 Permitted Flow 2 MGD no stdrd 0:018 no stdrd 32.98 Human Hith 0.550 Human Hlth Allowable Allowable 0.199 3,4-Benzofluoranthene (c, 61 23 0.552 Limit Limit Federal or Standard Standard Allowable Allowable Aquatic Life Human Hith Limit Daily Monthly Daily Monthly Daily Monthly State Aquatic Organisms conc. Aquatic conc 32.98 Organisms Based Max Avg. Max avg max avg 23 Life 0.208 Life Organisms 0.0311 no stdrd on: no stdrd 0.950 Parameter ug/1 ugli #/d #/d stdrd /1g/I Vg/I /1911 /1g/I #/day #/day 2.20 no stdrd #/day Acenaphthene 59 22 0.534 0.199 Federal no stdrd 990.00 no stdrd 253599.68 no stdrd 4226.661 OCPSF 0.534 #/day 0.199 n r.,r„4- so 22 05'14 0.199 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.534 #/day 0.199 Acrylon!trile(c) 242 96 2.191 0.869 Federal no stdrd 0.25 no stdrd 457.99 no stdrd 7.633 OCPSF 2.191 #/day 0.869 Anthracene 59 22 0.534 0.199 Federal no sidrd 40000:00 no sidrd 10246451.61 no stdrd 170774.194 OCPSF 0.534 #/day 0.199 Benzene (c) 136 37 1.231 0.335 State no stdrd 71.40 no stdrd 130802.50 no stdrd 2180.042 OCPSF 1.231 If/day 0.335 Benzo(a)anthracene (c, P, 59 22 0.534 0.199 Federal no stdrd 0:018 no stdrd 32.98 no stdrd 0.550 OCPSF 0.534 If/day 0.199 3,4-Benzofluoranthene (c, 61 23 0.552 0.208 Federal no stdrd 0:0311 no stdrd 56.97 no stdrd 0.950 OCPSF 0.552 If/day 0.208 Benzo(k)fluoranthene (c,P 59 22 0.534 0.199 Federal no stdrd 0.0180 no stdrd 32.98 no stdrd 0.550 OCPSF 0.534 #/day 0.199 Benzo(a)pyrene (c, PAH) 61 23 0.552 0.208 Federal no stdrd 0.0311 no stdrd 56.97 no stdrd 0.950 OCPSF 0.552 #/day 0.208 Bis(2-ethylhexyl) phthalatE 279 103 2.526 0.933 Federal no stdrd 2.20 no stdrd 4030.33 no stdrd 67.172 OCPSF 2.526 If/day 0.933 Carbon Tetrachloride (c) 38 18 0.344 0.163 State no stdrd 4.42 no stdrd 8097.30 no stdrd 134.955 OCPSF 0.344 #/day 0.163 Chlorobenzene 28 15 0.254 0.136 Federal no stdrd 21000.00 no stdrd 5379387.10 no stdrd 89656.452 OCPSF 0.254 #/day 0.136 Chloroethane 268 104 2.427 0.942 Federal no stdrd no stdrd no sttlrd no sttlrd no sttlrd no stdrd OCPSF 2,427 #/day 0.942 Chloroform (c) 46 21 0.417 0.190 Federal no sttlrd 470.00 no stdrd 861024.84 no stdrd 14350.414 OCPSF 0.417 #/day 0.190 2 -Chlorophenol 98 31 0.887 0.261 Federal no stdrd 1'.50.00 no stdrd #REF! no stdrd #REFI #REF! #REF! #REF! #REF! Chrysene (c, PAH) 59 22 0.534 0.199 Federal no stdrd 0.0180 no stdrd 32.98 no stdrd 0.550 OCPSF 0.534 #/day 0.199 Di -n -butyl phthalate 57 27 0.516 0.244 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.516 #/day 0.244 1,2 -Dichlorobenzene 163 77 1A76 0.697 Federal no stdrd 17000.00 no stdrd 4354741.94 no stdrd 72579.032 OCPSF 1.476 #/day 0.697 1,3 -Dichlorobenzene 44 31 0.396 0.281 Federal no stdrd 960.00 no stdrd 245914.64 no stdrd 4098.581 OCPSF 0.398 #/day 0.281 1,4 -Dichlorobenzene 28 15 0.254 0.136 Federal no stdrd 2600:00 no stdrd 666019.35 no stdrd 11100.323 OCPSF 0.254 #/day 0.136 1,1-Dichloroethane (c) 59 22 0.534 0.199 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.534 #/day 0.199 1,2-Dichloroethane (c) 211 68 1.910 0.616 Federal no stdrd 3.70 no stdrd 6778.28 no stdrd 112.971 OCPSF 1.910 #/day 0.616 1,1-Dichloroethylene(c) 25 16 0.226 0.145 Federal no stdrd 3.20 no stdrd 5862.30 no stdrd 97705 OCPSF 0.226 #/day 0.145 1,2-trans-DichloroethylerlE 54 21 0.489 0.190 Federal no stdrd 140000.00 no stdrd 35862580.65 no stdrd 597709.677 OCPSF 0.489 II/day 0.190 2,4-Dichlorophenol 112 39 1.014 0.353 Federal no stdrd 29000 no stdrd #REF! no sttlrd #REF! #REF! #REF! #REF! #REF! 1,2-Dichloropropane 230 153 2.083 1.385 Federal no stdrd 15.00 no stdrd 3842.42 no stdrd 64.040 OCPSF 2.083 #/day 1.385 1,3-D!chloropropylene (c) 44 29 0.398 0.263 Federal no stdrd 1700.00 no stdrd 3114345.16 no sidrd 51905.753 OCPSF 0.398 #/day 0.263 Diethyl phthalate 203 81 1.838 0.733 Federal no stdrd 4400000 no stdrd 11271096.77 no stdrd 187851.613 OCPSF 1.838 #Iday 0.733 2,4 -Dimethylphenol 36 18 0.326 0.163 Federal no sttlrd 850.00 no sttlrd 217737.10 no sidrd 3628.952 OCPSF 0.326 #/day 0.163 Dimethyl phthalate 47 19 0.426 0.172 Federal no sidrd 1100000.00 no stdrd 281777419.35 no stdrd 4696290.323 OCPSF 0.426 #/day 0.172 4,6-Dinitro-o-cresol (2 -Mel 277 78 2.508 0.706 Federal no stdrd 280.00 no stdrd 71725.16 no stdrd 1195.419 OCPSF 2.508 #Iday 0.706 2,4-Umtrophenol 123 71 1.114 0.643 Federal no stdrd '5300.00 no stdrd 1357654.84 no stdrd 22627.581 OCPSF 1.114 #/day 0.643 2,4-Dinitrotoluene(c) 285 113 2.581 1.023 Federal no sidrd 3.40 no stdrd #REF! no stdrd #REF! #REF! #REF! #REF! #REF! 2,6-Dinitrotoluene (c) 641 255 5.804 2.309 Federal no sfdrd no sidrd no stdrd no stdrd no stdrd no stdrd OCPSF 5.804 #/day 2.309 Ethylbenzene 108 32 0.978 0.290 AQ/NOEC 325.000 29000.00 83252.42 7428677.42 1387.540 123811.290 OCPSF 0.978 #/day 0.290 Flouranthene 68 25 0.616 0.226 Federal no stdrd 140.00 no stdrd 35862.58 no stdrd 597.710 OCPSF 0.616 #/day 0.226 Fluorene 59 22 0.534 0.199 Federal no stdrd 5300:00 no stdrd 1357654.84 no stdrd 22627.581 OCPSF 0.534 #/day 0.199 Hexachlombenzene (c) 28 15 0.254 0.136 Federal no stdrd 2.90E-.04 no stdrd 0.53 no stdrd 8.85E-03 CHRONIC 0.531 /1g/I Hexachlorobutadiene(c) 49 20 0.444 0.181 Federal no stdrd 18.00 no stdrd 32975.42 no stdrd 549.590 OCPSF 0.444 #/day 0.181 Hexachloroethane (c) 54 21 0.489 0.190 Federal no stdrd 3.30 no stdrd 6045.49 no stdrd 100.758 OCPSF 0.489 #/day 0.190 Methyl Chloride 190 86 1.720 0.779 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 1.720 #/day 0.779 Methylene Chloride (c) 89 40 0.806 0.362 Federal no stdrd 590.00 no stdrd 1080860.97 no stdrd 18014.349 OCPSF 0.806 If/day 0.362 Naphthalene 59 22 0.534 0.199 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.534 May 0.199 Nitrobenzene 68 27 0.616 0.244 Federal no stdrd 690.00 no stdrd 176751.29 no stdrd 2945.855 OCPSF 0.616 #/day 0.244 2-Nitrophenol 69 41 0.625 0.371 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.625 #/day 0.371 4-Nitrophenol 124 72 1.123 0.652 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 1.123 #/day 0.652 Phenanthrene 59 22 0.534 0.199 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.534 If/day 0.199 Phenol 26 15 0.235 0.136 Federal no stdrd 1700000.00 no stdrd 435474193.55 no stdrd 7257903.226 OCPSF 0.235 #/day 0.136 Pyrene 67 25 0.607 0.226 Federal no stdrd 4000.00 no stdrd 1024645.16 no stdrd 17077.419 OCPSF 0.607 #/day 0.226 Tetrachloroethylene (c) 56 22 0.507 0.199 Federal no stdrd 3.30 no sfdrd 6045.49 no stdrd 100.758 OCPSF 0.507 #/day 0.199 Toluene 80 26 0.724 0.235 State/AQ 11.000 200000x00 2817.77 51232258.06 46.963 853870.968 OCPSF 0.724 #/day 0.235 1,2,4-Tdchlorobenzene 140 68 1.268 0.616 Federal no stdrd 940.00 no stdrd 240791.61 no stdrd 4013.194 OCPSF 1.268 #/day 0.616 1,1,1 -Trichloroethane 54 21 0489 0.190 Federal no stdrd no stdrd no stdrd no stdrd no stdrd no sidrd OCPSF 0.489 #(day 0.190 1,1,2 -trichloroethane (c) 54 21 0.489 0.190 Federal no stdrd 16.00 no stdrd 29311.48 no stdrd 488.525 OCPSF 0.489 #/day 0.190 Trichlororethylene (c) 54 21 0.489 0.190 State no stdrd 30:00 no stdrd 54959.03 no stdrd 915.984 OCPSF 0.489 #/day 0.190 Vinyl Chloride (c) 268 104 2.427 0.942 State no stdrd 530.00 no stdrd 970942.90 no stdrd 16182.382 OCPSF 2.427 #/day 0.942 Total Chromium 2770 1110 0.000 0.000 State 50.000 no stdrd 12808.06 no stdrd 213.468 no stdrd OCPSF 0.000 #/day 0.000 " Total Copper 3380 1450 0.000 0.000 Action level 7.000 no stdrd 1793.13 no stdrd 29.885 no stdrd OCPSF 0.000 #/day 0.000 " Total Cyanide 1200 420 0.000 0.000 State 5.000 no stdrd 1280.81 no stdrd 21.347 no stdrd OCPSF 0.000 #/day 0.000 " Total Lead 690 320 0.000 0.000 State 25.000 no stdrd 6404.03 no stdrd 106.734 no stdrd OCPSF 0.000 #/day 0.000 " Total Nickel 3980 1690 0.000 0.000 State 88.000 no stdrd 22542.19 no stdrd 375.703 no stdrd OCPSF 0.000 #/day 0.000 " Total Zinc' 2610 1050 0.000 0.000 Action level 50.000 50.00 12808.06 12808.06 213.468 213.468 OCPSF 0.000 #/day 0.000 'Total Zinc for Rayon Fiber Manufacture " Metals should only be limited if Total metal bearing wastefloi 0.00 that uses the viscose process and Acrylic process contains metal bearing wasteflow. Fiber Manufacture that uses zinc Cyanide should only be limited if Total cyanide bearing wastef 0.00 chloride/solvent process is 6,796 ug/L and process contains cyanide bearing wasteflow. 3,325 ug1L for maximum for any one day and maximum for monthly average, respectively. 12/12/2006 1 [Fwd: [Fwd: PFOA]] 1 Subject: [Fwd: [Fwd: PFOA]] From: Kent Wiggins <kent.wiggins@ncmail.net> Date: Wed, 16 May 2007 11:51:26 -0400 To: Teresa Rodriguez <teresa.rodriguez@ncmail.net> CC: Pat Donnelly <Pat.Donnelly@NCMail.Net> Teresa, We have done a fair amount of research on the PFOA issue. There is currently no officially recognized method for this analysis. We discussed the analysis with our auditors and were able to find one lab that advertises the capability. Please see Pat Donnelly's attached email. Please let me know if you need anything else. Kent Subject: [Fwd: PFOA] From: Pat Donnelly <pat.donnelly@ncmail.net> Date: Wed, 16 May 2007 10:37:56 -0400 To: Kent Wiggins <Kent.Wiggins@ncmail.net> CC: Dana Satterwhite <dana.satterwhite@ncmail.net>, Gary Francies <Gary.Francies@ncmail.net> Kent, I believe this is where this issue stands. NC certified Lab 0158, STL Denver advertises PFOA analysis on their WEB site. They also hold NELAP cert fication. I'm suretHerearare other labs that also do PFOA analysis. There's no currently promulgated EPA method for PFOA. Pat Subject: PFOA From: Teresa Rodriguez <teresa.rodriguez@ncmail.net> Date: Wed, 16 May 2007 10:13:23 -0400 To: kent.wiggins@ncmail.net CC: pat.donnelly@ncmail.net, Gil Vinzani <gil.vinzani@ncmail.net> Kent, we talked a couple of weeks ago about the situation with the DuPont permit and the monitoring of PFOA but I'm not sure we determined what they need to do regarding lab certification. We are ready to issue the DuPont permit which will include monitoring for PFOA. Is there anything we can include as a footnote or in the letter to DuPont regarding the analytical method or requirements for lab certification? Thanks, Teresa Teresa Rodriguez, P.E. Division of Water Quality EAST NPDES Program 919-733-5083 ext. 553 ij Content -Type: message/rfc822 j J�JFwd: PFOA] Content -Encoding: 7bit E Content -Type: message/rfc822 1PFOA1 Content -Encoding: 7bit -T i s "jam o� ti ra, wt - o, (On q b _ 0 =,- pr -OA- - - rts 1 of 1 5/16/2007 12:59 PM Ja,IED S7%, 2 � e s 4 PRO��`O UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 4 ATLANTA FEDERAL CENTER 61 FORSYTH STREET ATLANTA, GEORGIA 30303-8960 2007 Ms. Teresa Rodriguez North Carolina Department of Environment and Natural Resources Division of Water Quality NPDES Unit 1617 Mail Service Center Raleigh, NC 27699-1617 SUBJ: Draft NPDES Permit DuPont Fayetteville Works - NPDES No. NC0003573 Dear Ms. Rodriguez: In accordance with the EPA/NCDENR MOA, we have completed review of the draft permit referenced above and have no comments. We request that we be afforded an additional review opportunity only if significant changes are made to the draft permit prior to issuance, or if significant comments objecting to the draft permit are received. Otherwise, please send us one copy of the final permit when issued. If you have any questions, please call me at (404) 562-9304. Sincerely, yk--k'IW Marshall Hyatt, Environmental Scientist Permits, Grants, and Technical Assistance Branch Water Management Division Internet Address (URL) • http://www.epa.gov Recycled/Recyclable • Printed with Vegetable Oil Based Inks on Recycled Paper (Minimum 30% Postconsumer) Draft NPDE'S Permit NC0003573 Subject: Draft NPDES Permit NC0003573 From: Michael E Johnson <Michael.E.Johnson@USA.dupont.com> Date: Tue, 2 Jan 2007 10:29:22 -0500 To: teresa.rodriguez@ncmail.net Teresa: I received the draft NPDES permit you sent me. I have two questions for you: Question 1: I noticed that on the Outfall 002 page, the frequency of instream monitoring of conductivity changed from weekly to monthly, yet all the other instream parameters stayed at the weekly frequency. Was the conductivity frequency inadvertently changed to monthly and should have remained as weekly? Question 2: We are members of the Middle Cape Fear River Basin Association (MCFRBA) which is a coalition of dischargers in the middle section of the Cape Fear River basin. Through the MCFRBA we contract a commercial / laboratory to perform instream monitoring of the river at various locations as dictated by an MOA between DWQ and MCFRBA. As such, under our existing NPDES permit, the instream monitoring requirement is waived as long as we remain members of the MCFRBA. That waiver was specified in Note 1 in condition A(5). In the draft you sent me, I cannot find this waiver. Was this an advertent omission, or has DWQ changed their policy to allow coalition monitoring to satisfy the instream monitoring requirement? Let me know the answers to these questions and whether or not I need to formally send these as official comments to your office. Regards, Mike Michael E. Johnson Environmental Manager DuPont Company Fayetteville Works (910) 678-1155 This communication is for use by the intended recipient and contains information that may be Privileged, confidential or copyrighted under applicable law. If you are not the intended recipient, you are hereby formally notified that any use, copying or distribution of this e-mail, in whole or in part, is strictly prohibited. Please notify the sender by return e-mail and delete this e-mail from your system. Unless explicitly and conspicuously designated as "E -Contract Intended", this e-mail does not constitute a contract offer, a contract amendment, or an acceptance of a contract offer. This e-mail does not constitute a consent to the use of sender's contact information for direct marketing purposes or for transfers of data to third parties. Francais Deutsch Italiano Espanol Portugues Japanese Chinese Korean http://www.DuPont.com/corp/email_disclaimer.html 1/4/2007 3:01 PM NORTH CAROLINA Cumberland County Public Notice STATE OF NOR111 CAROLINA ENVIRONMENTAL MANAORNIENf COMMISSION/NPDF.-S UNIT 1617 MAIL SERVICE CENTER RALE LOT -1, NC 27699-1617 NOTIFICATION OF INTENT TO ISSUE A NPDES WASTEWATER PERMIT On the basis of thorough staff review and application of NC General Statute 143.21., Public law 92-500 and other lawful standards and regulations, the North Carolina Environmental Management Commission rropose§ to issue a National f ,,Cant Discharge Elimina - hon Svstem (NPDES) waste - water discharge permit to the person(s) listed below effective 45 days from the publish date of this notice. Written comments regarding the propt�sed. permit will f, accepted until 30 days after the publish date of this no- tice. All comments received prior to that date are con.sid - Bred in the final deteraina - tions regarding the pro - posed permit. The Director of the NC Division of Water Quality may decide to hold a public meeting for the pro - posed permit should the Di- vision rvision receive a significant degree ofpubhc interest. Copies of the draft permit and other supporting infor- mation on .file used to deter - mine conditions present in the draft permit are available upp'cn request anis 'payment of the .costs of reproduction. Mail comments and/or re- ques[s for information to the NC Division of Water Quality at the above address or call the Point Source Branch at (919) 733-5083, extension 363. Comments can also be e-mailed to: Carolyii.Bryant@ncmail.net Please include the .NPDES permit number (attach d in any communication. Inter- ested persons may also visit the Division of Water .Quality at 512 N. Salisbury Street, Raleigh, NC 27604-1148 be- tween the hours of 8:00 a.m. and 5:00 p.m to review in- formation on file. D out Fayetteville Works, 22828 Highway 87 W., Fayetteville. NC 28306. Bladen County, has air lied for renewal of its NPD dis - ,bar permit (number NC0003573)- discharging into the Ca{)e Fear River in the Cape Fear River Basin.I1115 facday op rates one internal outfall, 001, that combines with non -contact cooling water, boiler blowdown, end stormwater and discharge through outfall 002 to die Cape. Fear River. hitemal outfall 0(11 discharges a maximum of 2.0 MGD of treated process wastewater. No parameters are currently water quality limited. This discharge may impact future allocation of the receiving stream 12/27 829200 AFFIDAVIT OF PUBLICATION uetore the unaersignea, a Notary ruonc or Sala Uounty an(J state, (Jury commissioned and authorized to administer oaths, affirmations, etc., personally appeared. CINDY L. OROZCO Who, being duly sworn or affirmed, according to law, doth depose and say that he/she is LEGAL SECRETARY of THE FAYETTEVILLE PUBLISHING COMPANY, a corporation organized and doing business under the Laws of the State of North Carolina, and publishing a newspaper known as the FAYETTEVILLE OBSERVER, in the City of Fayetteville, County and State aforesaid,' and that as such he/she makes this affidavit; that he/she is familiar with the books, files and business of said Corporation and by reference to the files of said publication the attached advertisement of CL Legal Line DUPONT/NC0003573 of NCDENR/DWQ/NPDES was inserted in the aforesaid newspaper in space, and on dates as follows: 12/27/2006 and at the time of such publication The Fayetteville Observer was a newspaper meeting all the requirements and qualifications prescribed by Sec. No. 1-597 G.S. of N.C. The above is correctly copied from the books and files of the aforesaid corporation and publication. A LEGAL SECRETARY Title Sworn or affirmed to, and subscribed before me, this 4 day of January, A.D., 2007. In Testimony Whereof, I have hereunto set my hand and affixed my ial seal, the day and year aforesaid. My commission expires 9th day of March, 2009. MAIL TO: NCDENR/DWQ/NPDES 1617 MAIL SERVICE CENTER, , RALEIGH, NC 27699 0000829200 u" on' Fluoroproducts 228 NC Highway 87 W 270 DEC 1 1 I Fa�retteville, NC 28306-7332 � - DENR • WATER QUALITY I'JIPT SOURCr 3p,1fjCH December 7, 2006 Ms. Teresa Rodriguez NCDENR Division of Water Quality NPDES Unit 1617 Mail Service Center Raleigh, North Carolina 27699 - 1617 SUBJECT: NPDES Permit Renewal Application Addendum Revised Supplemental Information NPDES Permit No. NC0003573 Dear Ms. Rodriguez: Enclosed you will find a revised Supplemental Information document that describes the proposed changes with the construction of a new manufacturing unit that will produce Polyvinyl Fluoride (PVF) polymer resins. It has been determined that the preferred means of controlling solids from the PVF unit is via the site's central wastewater treatment plant. Accordingly, treated wastewater from this new unit will, be discharged through and monitored at Outfall 001. A revised water balance sheet is enclosed which reflects the above treatment change. Should you have any questions, please feel free to call me �* Ml AN ti72_1 > sc Enclosures EI. du Pont de Nemours and Company Michael E. Johnson Environmental Manager $ ,DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information (Revised) Revised Supplemental Information — Permit Renewal Application — December 7, 2006 Proposed Changes in Operations PVF Manufacturing Facility: The DuPont Company — Fayetteville Works has been selected as the location for the DuPontTM Polyvinyl Fluoride (PVF) manufacturing process. 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 TedlarO 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. This new facility construction will be completed in August 2007 and begin start up in October 2007. The manufacturing facility will be located near the existing Teflon® FEP resin manufacturing area. This process will produce polyvinyl fluoride (PVF) resin (CAS No. 24981-14-4). The process wastewater from the PVF Manufacturing Facility will be conveyed to the site's central wastewater treatment plant, which will properly control any solids that are discharged from the process. The treated wastewater from the PVF Manufacturing Facility will be discharged through and monitored at Outfall 001. A suggested change to the language of the current permit's narrative in the "Supplement To Permit Cover Sheet" that would accommodate the new PVF Manufacturing Facility follows: 1. Continue to operate existing wastewater treatment facilities consisting of: • equalization; (etc) 2. Discharge treated process wastewater from Butacite®, NafionO, PVF, and Teflon® PMDF, process stormwater, sanitary wastewater, and co -neutralized regenerate from said treated facilities through internal outfall 001; The process wastewater is expected to contain unreacted vinyl fluoride (CAS No. 00075-02-5). The anticipated quantity of vinyl fluoride from the PVF_ Manufacturing Facility is 0.312 pounds per day. This quantity would equate to approximately 0.04 mg/L vinyl fluoride at Outfall 001 and 0.0035 mg/L vinyl fluoride at Outfall 002. Finally, non -contact cooling, condensate, and stormwater from the PVF Manufacturing Facility will be discharged directly to Outfall 002 via the site's Woodlined Ditch. Date: November 27, 2006 To: Teresa Rodriguez Environmental Engineer, Central Office Thru: Belinda Henson AG-tp,- *0 Regional Supervisor, Fayetteville Regional Office Michael F. Easley, Governor William G. Ross Jr., Secretary North Carolina Department of Environment and Natural Resources From: Mark Brantley Environmental Chemist, Fayettille Regional Office Alan W. Klimek, P.E. Director Division of Water Quality oa U DEC 1 2006 MIR Subject: Amendment to the Dupont Staff report for the NPDES Permit Renewal Dupont's Fayetteville Works will be adding a new manufacturing process in the fall of 2007. The manufacturing unit will produce Polyvinyl Fluoride (PVF) polymer resins. Dupont has determined that the preferred means of controlling solids from the PVF unit is a new clarifier, which will be dedicated to the PVF wastewater. The discharge from this clarifier will be to the existing Outfall 001. This design replaces the original submittal's description of the PVF treated wastewater being discharged through and monitored at Outfall 006. It is the recommendation of the Fayetteville Regional Office that NPDES Permit No. NCO021636 be issued for the wastewater treatment plant. The subject application for permit renewal should be processed in keeping with basinwide strategy. NoithCarolina )WAM Illy North Carolina Division of Water Quality 225 Green Street -Suite 714 Fayetteville, NC 28301 Phone (910) 486-1541 Customer Service Internet: www.ncwaterquality.org Fax (910)486-0707 1-877-623-6748 An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper Form 2C. Part III B: NPDES PERMITAPPLICATION WATER BALANCE (Revised 12/07/06) DuPont Company - Fayetteville Works Flows Unit: Gallons per Day Basis: All Production Manufacturing, using Maximum 30 day average of measured flows Ca a Fear River 16,577,194 NaOCI it-------------- 3,532,320 i i FILTERED Filtered Water WATER 2,407,680 - SYSTEM i i 1,124,640 t i Demineralized Water - WATER SYSTEM ED 1,049,640 NON.CONTACT WATER SYSTEM RAW RNER WATER COOLING WATER to/from each unit Neutralized r Regenerate 325,0001,000,000 3,600 100,800 100,800 r 13,044,874 1,000 639,360_ 1,500 _ 72.600 PURCHASED POTABLE Evap. WATER BUTACITE"' PMDF SENTRY GLASIRI PLUS NAFIDNIRt Sancta POLYVINYL BUTYRAL TEFLONtRI RESIN LAMINATE FLUOROPRODUCT Fad Itles,, BOILERS MANUFACTURING MANUFACTURING MANUFACTURING MANUFACTURING PROCESS PROCE.4'S PROCESS PROCESSES STORMWATER 8,000 _o 890 560 5100 _/rY 90IS 000 ' 3Wrmxaler ham 7- Nmaauu Area Naa: 75,000 748 B00�100 800 182 800 i 12,000 (y u I 1 180 660 1 Non -process Smrmwater t i NPDES PERMITTED Biosolids I Evap. -► Dewater/ � i BIOLOGICAL WNR'P Drying m �i 64,000 $1:7 i324,000 102,700 OuHa11001 10,000 Et �t 1,067,960 Land011 Disposal POLYVINYL FLUORIDE (PVF) MANUFACTURING PROCESS 100 000 �/ U X51,go I 177 000 v (AS F 8 DIVISION OF WATER QUALITY May 30, 2006 MEMORANDUM TO: GGinzani, Supervisor NPDES Unit 1617 Mail Service Center Raleigh, NC 27699-1617 FROM: Mark Brantley, Environmental Chemist Fayetteville Regional Office THRU: Belinda S. Henson, Water Quality Supervisor ��V.. x,,., Fayetteville Regional Office SUBJECT: NPDES Staff Report and Recommendations NPDES Permit No. NC0003573 DuPont WWTP Bladen County Please find attached the staff report and recommendations ofthe Fayetteville Regional Office concerning the renewal of subject NPDES Permit. If you have any questions or require any further information, please addv1' Attachment a F_. SOC PRIORITY PROJECT: YES_ NO -X If Yes, SOC No. To: Permits and Engineering Unit Surface Water Protection Section Y1?y; Attention: Gil Vinzani Date: May 30, 2006_ �POO NPDES STAFF REPORT AND RECOMMENDATION COUNTY: Bladen"'. Permit No. NC 0003573 PART I - GENERAL INFORMATION TO� 1. Facility and Address: DuPont Fayetteville Works 22828 NC Hwy 87 W� Fayetteville, NC 28306 ,<� Q�s ` 2. Date of Investigation: May 18, 2006 3. Report Prepared by: Mark Brantley, Environmental Chemist 4. Persons Contacted and Telephone Number: Robert Geddie, ORC 910-678-1219 Michael Johnson, Environmental Manager Fayetteville Works 910-678-1155 5. Directions to Site: This facility is located at the Bladen -Cumberland County line, between Highway 87 and the Cape Fear River. 6. Discharge Point(s), List for all discharge points: Latitude: 340 49'52" Longitude: 780 49'00" Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on map. U.S.G.S. Quad No. H23 -SE U.S.G.S. Quad Name: Duart, NC 7. Site: Land available for expansion and upgrading: YES, DuPont owns approximately 2,600 acres at this site. 8. Topography and relationship to flood plain: Relatively flat. 9. Location of nearest dwelling: None within 1,000 ft. 10. Receiving stream or affected surface waters: Cape Fear River t PART I -GENERAL INFORMATION -(continued) ` , a. Classification: Class C b. River Basin and Subbasin No.: Cape Fear River Basin 03 - 06 - 17 C. Describe receiving stream features and pertinent downstream uses: The flow from the combined waste discharge from this facility flows through a wood lined channel installed as an effluent and storm water conveyance. This combined flow discharges over a fabricated formed concrete lined ditch until velocities are diminished and from there to the remainder of the effluent channel. Under normal (dry) conditions, this facility produces the flow in the effluent channel. The Cape Fear River is located approximately 2,500 feet downstream. (The discharge point has historically been indicated as the main stem of the Cape Fear River.) PART H - DESCRIPTION OF WASTES AND TREATMENT WORKS a. Volume of wastewater to be permitted: 2.0 MGD b. What is the current permitted capacity of the Wastewater Treatment facility? 2.0 MGD C. Actual treatment capacity of the current facility (current design capacity). 2.0 MGD d. Date(s) and construction activities allowed by previous Authorizations to Construct issued in the previous two (2) years. NIA e. Please provide a description of existing or substantially constructed wastewater treatment facilities: Process wastewater and storm water 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 flow rate of the WWTP is 2.0 MGD, with an actual average flow rate 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 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 the 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. (However this system is currently broken and has been removed from the aeration tank. Portable blowers have been brought in to aerate the tank.) PART II - DESCRIPTION OF WASTES AND TREATMENT WORKS -(continued) The biologically treated wastewater is then sent to two in -ground clarifiers (119,000 gallons and 168,000 gallons respectively) 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 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 and/or dried sludge is transported off-site to a commercial Subtitle D landfill. Non -contact process cooling water and non process storm water are conveyed via surface . ditches to the site's Woodlined Ditch. In addition, excess river water flow and Outfall 001 effluent are discharged directly to the Woodlined Ditch. The combined, total flow of water from the site is discharged and monitored at Outfall 002. The Outfall 002 maximum 30 -day average flow was 16.3 MGD during the period from 2005-2006. Flow variability at Outfall 002 is from 3.0 to 18.6 MGD, however, flow can consistently be in the 16.3 MGD range. f. Please provide a description of proposed wastewater treatment facilities: Please see Attachment A for a detailed description for "Prosed Changes in Operations" g. Possible toxic impacts to surface waters: N/A h. Pretreatment Program (POTWs only): In development Approved Should be required Not needed X 2. Residuals handling and utilizing/disposal scheme: a. If residuals are being land applied, please specify DWQ Permit No. Permit Number Residual Contractor: Telephone: b. Residuals stabilization: PSRP PFRP Other C. Landfill: The dewatered and/or dried 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. d. Other disposal/utilization scheme (specify): 3. Treatment plant classification (attach completed rating sheet): Grade III 4. SIC Code(s): PrimarySecondary Main Treatment Unit Code: PART III- OTHER PERTINENT INFORMATION 0 5. Is this facility being constructed with Construction Grant Funds or are any public monies involved (municipals only)? Special monitoring or limitations (including toxicity) requests: Monitoring and limits should be in keeping with basinwide strategy. Important SOC, JOC, or Compliance Schedule Dates (please attach): N/A Date Submission of Plans and Specifications.................................................... N/A BeginConstruction.................................................................................... N/A Complete Construction.............................................................................. N/A Alternative Analysis Evaluation: Has the facility evaluated all of the nondischarge options available? Please provide regional perspective for each option evaluated. Spray Irrigation: Not practical. Connection to Regional Sewer System: None Available. Subsurface: Not practical. Other disposal options: None known. Other Special Items: There are 2 items of interest the Fayetteville Regional Office would like address. 1. The compound commonly known as "C8" (ammonium perfluorooctanoate.) has been in the media quite frequently in the recent past. This compound is currently manufactured only at the Fayetteville Dupont Works. It is noted in Dupont's application that the APFO Manufacturing site is where this chemical is made. It is also noted in the application (Attachment B) that all 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. Due to C8 being detected in some of the monitoring wells on Dupont's site and the general public's concern over the health effects of C8, the Fayetteville Regional Office of the Division of Water Quality recommends a monitoring requirement only for C8 on the effluent for data collection and information purposes. 2. All discharges form this site ultimately go into the Woodlined Ditch, which collectively discharges into an effluent channel that discharges to the Cape Fear River. Over the years the flow of the effluent through the channel has significantly eroded the banks and has carried and deposited the sediment in the Cape Fear River forming a Delta like structure. It is apparent from a meeting on March 10, 2006 with Mike Johnson, Environmental Manager for Dupont's Fayetteville Works, that Dupont acknowledges that their effluent channel has and continues to cause sediment to be deposited into the Cape Fear River and is willing to address this issue. This is a very significant matter as the Company has benefited from this PART III- OTHER PERTINENT INFORMATION -(continued) effluent channel for some years and needs to address this issue soon. As per a phone conversation with Mike Johnson it was understood that stream studies were about to begin to determine the best place to relocate the outfall line. This office requests that DuPont provide to Fayetteville Regional Office of the Division of Water Quality a definite plan of action (to be incorporated into this permit or other administrative mechanism) to address this issue. PART IV - EVALUATION AND RECOMMENDATIONS It is the recommendation of the Fayetteville Regional Office that NPDES Permit No. NCO021636 be issued for the wastewater treatment plant. The subject application for permit renewal should be processed in keeping with basinwide strategy. Signature Report epar Water Quality Regional Supervisor Date 5-31-0(, DuPont Company – Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Proposed Changes in Operations PVF Manufacturing Facility: The DuPont Company – Fayetteville Works has been selected as the location for the DuPontTM Polyvinyl Fluoride (PVF) manufacturing 'process. 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. This new facility construction will be completed in August 2007 and begin start up in October 2007. The manufacturing facility will be located near the existing Teflon® FEP resin manufacturing area. This process will produce polyvinyl fluoride (PVF) resin (CAS No. 24981-14-4). As with most fluorochemical processes, the wastewater from the PVF manufacturing process is expected to have very little or no biological oxygen demand (BODS) value. Treatability tests have been performed on samples from another DuPont site which currently manufactures PVF. These studies have indicated use of non -biological treatment will meet effluent limitation of OCPSF NSPS guidelines of Subpart D—Thermoplastic Resins (40 CFR 414.40). DuPont proposes to discharge the treated wastewaters from this new facility through a currently permitted outfall, designated as Outfall 006. The contact process wastewater and stormwater will be treated with solids separation technology prior to discharging to the outfall. A suggested change to the language of the current permit's narrative for Outfall 006 that would accommodate the new PVF Manufacturing Facility follows: r "Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is authorized to discharge from Outfall 006 (Polyvinyl fluoride Manufacturing Facility low -biodegradable process wastewaters). Such discharges shall be limited and monitored by the Permittee as specified below:" The process wastewater is expected to contain unreacted vinyl fluoride (CAS No. 00075-02-5). The anticipated quantity of vinyl fluoride from the PVF Manufacturing Facility is 0.312 pounds per day. This quantity would equate to 0.9 mg/L vinyl fluoride at Outfall 006 and 0.0035 mg/L vinyl fluoride at Outfall 002. Finally, non -contact cooling, condensate, and stormwater from the PVF Manufacturing Facility will be discharged directly to Outfall 002 via the site's Woodlined Ditch. DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Current Operating Conditions ButaciteO Manufacturing: The DuPont Company — Fayetteville Works' Butacite@ manufacturing area produces two final products. DuPontTM ButaciteO 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). NafionO Manufacturing: The DuPont Company — Fayetteville Works' Nafion@ manufacturing area produces five final products. DuPontTM NafionO Membrane is a plastic film used in the chloroalkah industry and in electrochemical fuel cells. Nafion0 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. _Teflon@ Manufacturing: The DuPont Company — Fayetteville Works' PMDF Teflon@ manufacturing area produces DuPontTM Teflon@ FEP resin. Teflon@ FEP resin is used in the electronics industry as a coating for wire, as well as many other uses. This facility was constructed in 1999-2000 and was started up in December 2000. Wastewater generated from this manufacturing facility is treated in the'WWTP. APFO Manufacturing: The DuPont Company — Fayetteville Works' APFO manufacturing area produces ammonium perfluorooctanoate. The APFO produced in this unit is used to produce fluoropolymers and fluorinated telomers, but none of the produced APFO is used at the Fayetteville Works site. This facility was started up in November 2002. All 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® Plus Manufacturing: The DuPont Company — Fayetteville Works' SentryGlasO Plus manufacturing area produces DuPontTM SentryGlas@ Plus ionoplast interlayer laminate. SentryGlasO Plus 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 the woodlined ditch and ultimately to Outfall 002. Ms. Teresa Rodriguez NCDENR Division of Water Quality NPDES Unit 1617 Mail Service Center Raleigh, North Carolina 27699 - 1617 SUBJECT: NPDES Permit Renewal Applican Addendum Revised Form 2C and Supplemental orma ion NPDES Permit No. NC0003573 Dear Ms. Rodriguez: DuPont Fluoroproducts 22828 NC Highway 87 W Fayetteville, NC 28306-7332 August 2, 2006 AUG 4 2006 u DEN ER QUALITY POINT SOURCE BRANCH Enclosed are the revised Form 2C submittals for the subject renewal application. These forms include the omitted analytical data. Outfall 002 sampling showed unexpected positive results for cyanide, chloroform, dichlorobromomethane, and bis(2-ethylhexyl)phthalate; none of which are used or produced at this site. Also, you will find a revised Supplemental Information document that describes the proposed changes with the construction of a new manufacturing unit that will produce Polyvinyl Fluoride (PVF) polymer resins. It has been determined that the preferred means of controling solids from the PVF unit is a new clarifier which will be dedicated to the PVF wastewater. The discharge from this clarifier will be to the existing Outfall 001. Therefore, please ignore the original submittal's description of the PVF treated wastewater being discharged through and monitored at Outfall 006. A revised water balance sheet is enclosed which reflects the above treatment change. Should you have any questions, please feel free to call mP ar �At nl h7R_1155_ Enclosures E.I. du Pont de Nemours and Company Michael E. Johnson Environmental Manager , DuPont Company – Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information (Revised) Revised Supplemental Information – Permit Renewal Application – August 1, 2006 Proposed Changes in Operations PVF Manufacturing Facility: The DuPont Company – Fayetteville Works has been selected as the location for the DuPontTM Polyvinyl Fluoride (PVF) manufacturing process. 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. This new facility 3 construction will be completed in August 2007 and begin start up in October 2007. �� The manufacturing facility will be located near the existing Teflon® FEP resin manufacturing area. This process will produce polyvinyl fluoride (PVF) resin (CAS No. 24981-14-4). As with most fluorochemical processes, the wastewater from the PVF manufacturing process is expected to have very little or no biological oxygen demand (BODS) value. Treatability tests have been performed on samples from another DuPont site which currently manufactures PVF. These studies have indicated use of non -biological treatment will meet effluent limitation of OCPSF NSPS guidelines of Subpart D—Thermoplastic Resins (40 CFR 414.40). DuPont will control solids in the wastewater from this new facility via a new dedicated clarifier whose discharge will go directly to Outfall 001. A suggested change to the language of the current permit's narrative in the "Supplement To Permit Cover Sheet" that would accommodate the new PVF Manufacturing Facility follows: 1. Continue to operate existing wastewater treatment facilities consisting of: • equalization; (etc) 2. To operate new wastewater treatment facilities consisting of - * f• clarifier for PVF process wastewater; 3. Discharge treated process wastewater from Butacite, Nafion, PVF, and Teflon® PMDF, process stormwater, sanitary wastewater, and co -neutralized regenerate form said treated facilities through internal outfall 001; The process wastewater is expected to contain unreacted vinyl fluoride (CAS No. 00075-02-5). The anticipated quantity of vinyl fluoride from the PVF Manufacturing Facility is 0.312 pounds per day. This quantity would equate to approximately 0.04 mg/L vinyl fluoride at Outfall 001 and 0.0035 mg/L vinyl fluoride at Outfall 002. Finally, non -contact cooling, condensate, and stormwater from the PVF Manufacturing Facility will be discharged directly to Outfall 002 via the site's Woodlined Ditch. Form 2C. Part III B: NPDES PERMIT APPLICATION WATER BALANCE (Revised 4115106) DuPont - Fayetteville, NC Flows Unit: GPD Basis: All Production Manufacturing, using Maximum 30 day—ge of measured Bows Chbnna NON,OONTACT L'% urAt ____y 13043755 COOI&1Oaet Cooling Water _----________________________________________________________________________________► 15 755----------------"" i FlRered Water Supply DEMINERALQERS Potable Water Supply Plant I Spa—water I StomrxaW from Pr— A— Pada Nongrowee Starmvater 10,000 ' 10,000 45000 1 1 1 10,000 10,000 1 45,000 e 65,000 FLAKE E Stologtoal WWTP NAFION EPS TAPE TRXQUENCH F1.1R. & CU'E. ypype WASH SCRUBBERS 1 1 1 10,000 10,000 1 45,000 e 65,000 FLAKE E Stologtoal WWTP rT—O Glandml Die mal LSIOSOUDS SOLID WASTE PVF Byraelaeem Tr�eabin�m 8 8 PmtluQteaa uen Evaporetlen 67 700 NAFION CAUSTIC ACID TREATERS 8 FP% ypype GRUBBERS &GRUBBERS PROCESS PROCESS 8 SCRUBBERS 2� rT—O Glandml Die mal LSIOSOUDS SOLID WASTE PVF Byraelaeem Tr�eabin�m 8 8 PmtluQteaa uen Evaporetlen 67 700 [Fwd: DupwAl Subject: [Fwd: Dupont] From: Belinda Henson <Belinda.Henson@nc mail.net> Date: Thu, 18 May 2006 08:20:56 -0400 To: Paul Rawls <paul.rawls(ancznail.net> Paul, We wanted to give you an update on where Dupont was on relocation of the discharge pipe. Thanks. Belinda S. Henson Regional Supervisor NC DENR-Division of Water Quality Surface Water Protection Section Fayetteville Regional Office (910)486-1541 Subject: Dupont From: Mark Brantley <Mark.Brantley@ncmwl.net> Date: Wed, 17 May 200615:07:38 -0400 To: Belinda Henson <Belinda.Henson a3ncmail.net> Belinda I talked with Mike Jonhson just a few minutes ago about thier outfall line being relocated. He told me they are in the process of drawing up a contact with Ch2m (or is it C2hm?) about doing the environmental modeling. They are having some problems doing it but he feels they should have a contract in about 2 weeks. Then the modeling work can begin. He told then he will try and provide us with a timeline for their project. Chad was the lock and dam yesterday and he said the efflent was very turbid from the erosin. Will the outfall issue need to be in the staff report for the permit renewal? Mark Mark Brantley Environmental Chemist NC DENR-Division of Water Quality surface water Protection Section Fayetteville Regional Office (910) 486-1541 Content -Type: messagelr&822 Dupont. Content -Encoding: 7bit I of 1 5/18/2006 8:47 AM Mr. Gil Vinzani NCDENR Division of Water Quality NPDES Unit Archdale Building — 90' Floor 512 N. Salisbury Street Raleigh, North Carolina 27604 SUBJECT: NPDES Permit Renew 1 Apllicati NPDES Permit No. N 0003573 Dear Mr. Vinzani: DuPont Fluoroproducts 22828 NC Highway 87 W Fayetteville, NC 28306-7332 _ May 1. 20Q6 ..,,; MAY - 2 2006 CIJ,w1i�t 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 implementing a project to construct and operate a new manufacturing unit. This unit will produce Polyvinyl Fluoride (PVF) polymer resins. The PVF resins which will be manufactured at the Fayetteville Works plant are used in the DuPontTM Tedlar® fluoropolymer film business. Tedlar® film is manufactured at another DuPont site (not the Fayetteville Works site). The application is being submitted without some of the testing results as these results were not available at the time of submittal. These absent results are indicated by an asterisk (*) on Pages V-2 throughV-9 of Form 2C. This data will be submitted as an addendum when the analytical reports are 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. Enclosures EI. du Pont de Nemours and Company Michael E. Johnson Environmental Manager DuPont Company — Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Supplemental Information — Permit Renewal Application — May 1, 2006 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 two in -ground clarifiers (119,000 gallons and 168,000 gallons respectively) 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 and/or 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 to the site's Woodlined Ditch. In addition, excess riverwater flow and Outfall 001 effluent are discharged directly to the Woodlined Ditch. The combined, total flow of water from the site is discharged and monitored at Outfall 002. The Outfall 002 maximum 30 -day average flow was 16.3 MGD during the period from 2005 to 2006. Flow variability at Outfall 002 is from 3.0 to 18.6 MGD, however, flow can consistently be in the 16.3 MGD range. ' , DuPont Company - Fayetteville Works NPDES Permit No. NC0003573 Supplemental Information Proposed Changes in Operations PVF Manufacturing Facility: The DuPont Company - Fayetteville Works has been selected as the location for the DuPontTM Polyvinyl Fluoride (PVF) manufacturing process. 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. This new facility construction will be completed in August 2007 and begin start up in October 2007. The manufacturing facility will be located near the existing Teflon® FEP resin manufacturing area. This process will produce polyvinyl fluoride (PVF) resin (CAS No. 24981-14-4). As with most fluorochemical processes, the wastewater from the PVF manufacturing process is expected to have very little or no biological oxygen demand (BODS) value. Treatability tests have been performed on samples from another DuPont site whic curren ly manufactures PVF., These studies have indicated use of non- io ogical treatment will m- eet—ee went limltahori of OCPSF NSPS guidelines of Subpart D—Thermoplastic Resins (40 CFR 414.40). DuPont proposes to discharge the treated wastewaters from this new facility through a currently permitted outfall, designated as Outfall 006. The contact process wastewater and stormwater will be treated with solids separation technology prior to discharging to the outfall. A suggested change to the language of the current permit's narrative for Outfall 006 that would accommodate the new PVF Manufacturing Facility follows: "Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is authorized to discharge from Outfall 006 (Polyvinyl fluoride Manufacturing Facility low -biodegradable process wastewaters). Such discharges shall be limited and monitored by the Permittee as specified below:" The process wastewater is expected to contain unreacted vinyl fluoride (CAS No. 00075-02-5). The anticipated quantity of vinyl fluoride from the PVF Manufacturing Facility is 0.312 pounds ep r day. This quantity would equate to 0.9 mg/L vinyl fluoride `at Outfall 006 and 0.0035 mg/L_ vinyl fluoride at Outfall 002. Finally, non -contact cooling, condensate, and stormwater from the PVF Manufacturing Facility will be discharged directly to Outfall 002 via the site's Woodlined Ditch. ' , DuPont Company – Fayetteville Works Current Operating Conditions NPDES Permit No. NC0003573 Supplemental Information 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 treatmen p ant MWTP). Nafion® Manufacturing: The DuPont Company – Fayetteville Works' Nafion® manufacturing area produces five final products. DuPontTM Nafion® Membrane is a plastic fihn used in the chloroalkali industry and in electrochemical fuel cells. Nafion® Resins are ultimately extruded- into a finished film. The FLPR Vinyl Ether and BFPO monomers are shipped to other DuPont locations to produce various u.or�cffemrcadl products such as DuPontTM Teflon& Wastewater generated from this manufacturing facility is neutralized and discha d�s� the WWTP. — v - Teflon® Manufacturing: The DuPont Company – Fayetteville Works' PMDF Teflon® manufacturing area produces DuPontTM Teflon® FEP resin. Teflon® FEP resin is used in the electronics industry as a coating for wire, as -well as many other uses. This facility was constructed in 1999-2000 and was started up in December 2000. Wastewater generated from this manufacturing facility is treated in the WWTP. APFO Manufacturing: The DuPont Company – Fayetteville Works' APFO manufacturing area produces _ onium perfluorooctanoate. The APFO produced in this unit is used to produce fluoropolymers and fluorinated telomers, but none of the produced APFO is used at the �00 Fayetteville Works site. This facility was started up in November 2002. All wastewater' gen erated from this manufacturing facility is co ected and shipped off-site for disposal. -� .�-- No process wastewater from this manufacturing facility is discharged–ro th to s -biological WWTP or to the Cape Fear River. I SentryGlas® Plus Manufacturing: The DuPont Company – Fayetteville Works' SentryGlas® Plus manufacturing area produces DuPontTM SentryGlas® Plus ionoplast interlayer laminate. SentryGlas® Plus 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 20005 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_-conta_c_ t cooling water to the woodlined ditch and ultimately to Outfall 002. ' . DuPont Company — Fayetteville Works Form 2C Permit Application Data Unavailable NPDES Permit No. NC0003573 Supplemental Information Priority Pollutants, special conventional and non -conventional analysis required testing results we not available at the time of Permit Application submittal. This data will be submitted when lab reports are received and input into the Form 2C as an appendum. These absent analytical results are indicated with an asterisk (*) on the Form 2C, Pages V-1 through V-9. Data Abnormalities When compiling the Outfall analytical database to perform the statistical analysis required in Form 2C, there were several apparent data abnormalities reported in the DMRs. These abnormalities, whether analytical or sampling event derived, are worth noting and or correcting in the Form 2C as they are misleading of representing the discharge from the site. Data Noted: On 11/08/05 a COD value of 102 mg/L was reported for Outfall 002 at a high flow rate of 13.3 MGD resulting in a calculated mass of 11,29.2 lb/day. Upon review of Outfall 001 data and_site's operating conditions, this value appears in error and the corresponding mass discharge is believed to be incorrect. As with all analytical results when retains are not available for retest, one must apply logic based on available information. This value was still reported in the 2C data, but noted here as to the possible error. Data Revised: Total Phosphorus is monitored at Outfall 002 once a month. On site there is only one potential source of phosphorus. The Butacite® operation uses phosphoric acid in the batch operation. During the months of December and March 2005, the maximum number of batches in a given day was twenty (20) batches. The quantity of phosphoric acid "as Phosphorus" in each batch is 4.7 lb/batch or a maximum of 94.5 _ lb/day "Total Phosphorus" potentially being discharged. This value is in line with what is normally reported 15 to 50 lbs per day which will vary as biological uptake will occur as well as equalization within the biological treatment system. Any value grossly in excess of 95 lb/day Phosphorus is highly probable in error, either analytical or sampling, and not representative of operations, therefore misleading. In March 2005, a concentration of 307 ppm was reported and a respective 14,092 lb Total P/day in the discharge. In December 2005, a concentration of 10.7 ppm was reported and a respective 1,040 lb Total P/day in the discharge. In both cases these values are orders of magnitude greater than what can physically be used and processed through manufacturing much less through biotreatment and are evidently grossly in error. The likely scenario is either typographic or analytical dilution calculation errors, in which both cases would be decimal place transposing errors. Rather than just not include these two data points, for purposes of the Form 2C reporting we chose to revise the numbers from 307 ppm to 0.307 ppm and 10.7 ppm to 0.107 ppm, and respective mass discharge of 14.092 and 10.4 lbs P/day. 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