NCG500609_Permit (Issuance)_20070723

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NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Coleen H. Sullins, Director
July 23, 2007
Terry Bishop
New South Companies, Inc.
4408 Mt. Hermon -Rock Creek Road
Graham, NC 27253-8909
Subject: Renewal of coverage / General Permit NCG500000
New South Lumber Company
Certificate of Coverage NCG500609
Alamance County
Dear Permittee:
In accordance with your renewal application [received on December 14, 2006], the Division is renewing
Certificate of Coverage (CoC) NCG500609 to discharge under NCG500000. This CoC is issued pursuant to the
requirements of North Carolina General Statue 143-215.1 and the Memorandum of Agreement between North
Carolina and the US Environmental Protection agency dated May 9, 1994 [or as subsequently amended].
If any parts, measurement frequencies or sampling requirements contained in this General Permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, the certificate of coverage shall be final and binding.
Please take notice that this Certificate of Coverage is not transferable except after notice to the
Division. The Division may require modification or revocation and reissuance of the certificate of coverage.
Contact the Winston-Salem Regional Office prior to any sale or transfer of the permitted facility.
Regional Office staff will assist you in documenting the transfer of this CoC.
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, Coastal Area
Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning the requirements of the General Permit, please contact Jim
McKay [919 733-5083, extension 595 or [e-mail]].
Sincerely,
for Coleen H. Sullins
cc: Central Files
Winston-Salem Regional Office / Surface Water Protection
NPDES file
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
512 North Salisbury Street, Raleigh, North Carolina 27604
Phone: [phone] / FAX [phone] / Internet: www.ncwaterquality.org
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper
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orthCarolina
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STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NCG500000
CERTIFICATE OF COVERAGE NCG500609
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SIMILAR WASTEWATERS UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision 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,
New South Companies, Inc.
is hereby authorized to discharge from a facility located at
New South Lumber Company
4408 Mt. Hermon -Rock Creek Road
Graham
Alamance County
to receiving waters designated as an unnamed tributary to Varnals Creek in subbasin
30602 of the Cape Fear River Basin in accordance with the effluent limitations, monitoring
requirements, and other conditions set forth in Parts I, II, III and IV hereof.
This certificate of coverage shall become effective August 1, 2007.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 23, 2007.
for Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

ItNEW SOUTII
LUMBER COMPANY INC.
Graham Plan(
December 14, 2006
Mr. Charles H. Weaver
NC DENR/DWQ/NPDES
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: Notice of Renewal Intent
NPDES Permit NCG5OOOOO
Certificate of Coverage (CoC) NCG5OO6O9
New South Lumber Co., Inc. — Graham Plant
Alamance County
Dear Mr. Weaver:
Attached you will find an original and two copies of our Notice of Renewal Intent for
NPDES Permit NCG5OOOOO, Certificate of Coverage NCG5OO6O9. Although we
propose to add an additional boiler and the discharge from the boiler's water treatment
unit to the permit, the Engineering Alternatives Analysis submitted with our original
Notice of Intent dated July 29, 2002 remains unchanged.
Please contact me at (336) 3130 Ext. 35 if you have any questions regarding the Notice of
Renewal Intent.
Sincerely yours,
&Nis?
Terry Bishop
General Manager
Attachments
4408 Mt. Hermon -Rock Creek Road • Graham, NC 27253
[phone] • Fax: [phone]

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NCDENR ! QUALITY
North Carolina Department of Environment and Natural Res itil CE BRA"CH--�
Division of Water Quality
Michael F. Easley, Govemor William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
NOTICE OF RENEWAL INTENT
Application for renewal of existing coverage under General Permit NCG500000
Existing Certificate of Coverage (CoC): NCG500609
(Please print or type)
1) Mailing address* of facility owner/operator:
Company Name New South Companies, Inc.
Owner Name Terry Bishop
Street Address 4408 Mt. Hermon -Rock Creek Road
City Graham State NC ZIP Code 27253-8909
Telephone Number [phone] Ext. 35 Fax: [phone]
Email address [e-mail]
* Address to which all permit correspondence should be mailed
2) Location of facility producing discharge:
Facility Name New South Lumber Co., Inc. — Graham Plant
Facility Contact Terry Bishop
Street Address 4408 Mt. Hermon -Rock Creek Road
City Graham State NC ZIP Code 27253-8909
County Alamance
Telephone Number [phone] Ext. 30 Fax: [phone]
Email address [e-mail]
3) Description of Discharge:
a) Is the discharge directly to the receiving stream? ❑ Yes ® No
(If no, submit a site map with the pathway to the potential receiving waters clearly marked. This includes tracing the pathway of the
storm sewer to the discharge point, if the storm sewer is the only viable means of discharge.)
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
1
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
❑ Non -contact cooling water
Outfall(s) #:
® Boiler Blowdown Outfall (s) #: 002
Page 1 of 3

NCG500000 renewal application
❑ Cooling Tower Blowdown Outfall (s) #:
❑ Condensate Outfall (s) #:
® Other Outfall (s) #: 002
(Please describe "Other") Backwash from boiler water treatment unit
d) Volume of discharge per each discharge point (in GPD):
#001: #002: 1,792 #003: #004
4) Please check the type of chemical [s] added to the wastewater for treatment, per each separate discharge
point (if applicable, use separate sheet):
❑ Chlorine
® None
❑ Biocides ❑ Corrosion inhibitors
0 Algaecide 0 Other
5) If any box in item (4) above [other than None] was checked, a completed Biocide 101 Form and
manufacturers' information on the additive must be submitted to the following address for approval:
NC DENR / DWQ / Environmental Sciences Section
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
6) Is there any type of treatment being provided to the wastewater before discharge (i.e., retention ponds,
settling ponds, etc.)? ❑ Yes ® No
(If yes, please include design specifics (i.e., design volume, retention time, surface area, etc.) with submittal package. Existing
treatment facilities should be described in detail. )
7) Discharge Frequency:
a) The discharge is: ® Continuous
❑ Intermittent 0 Seasonal*
i) If the discharge is intermittent, describe when the discharge will occur:
ii) *Check the month(s) the discharge occurs: 0 Jan 0 Feb ❑ Mar 0 Apr ❑ May ❑ Jun 0 Jul
❑ Aug. ❑ Sept. 0 Oct. 0 Nov. ❑ Dec.
b) How many days per week is there a discharge? 7
c) Please check the days discharge occurs: ® Sat. ® Sun. ® Mon. ® Tue. ® Wed. ® Thu. El
Fri.
8) Receiving stream[s]:
a) To what body or bodies of water (creek, stream, river, lake, etc.) does the facility discharge
wastewater? If the site discharges wastewater to a separate storm sewer system (4S), name the
operator of the 4S (e.g. City of Raleigh). unnamed tributary to Varnals Creek in Haw River Basin
b) Stream Classification: C, NSW
Page 2 of 3

NCG500000 renewal application
Additional Application Requirements:
The following information must be included in triplicate [original + 2 copies] with this application or it will
be returned as incomplete.
> Site map. If the discharge is not directly to a stream, the pathway to the receiving stream must
be clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
> Authorization for representatives. If this application will be submitted by a consulting
engineer (or engineering firm), include documentation from the Permittee showing that the
consultant submitting the application has been designated an Authorized Representative of the
applicant.
Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: Terry Bishop
Title: General Manager
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( g f Applicant) 1 (Date Signed)
North Carolina General Statute 143-215.6 b (i) provides that:
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan or other document
filed or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who
falsifies, tampers with or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under
Article 21 or regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by
a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine
of not more than $25,000 or imprisonment not more than 5 years, or both, for a similar offense.)
This Notice of Renewal Intent does NOT require a separate fee.
The permitted facility already pays an annual fee for coverage under NCG500000.
Mail the original and two copies of the entire package to:
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 3 of 3

NOTICE OF RENEWAL INTENT
New South Lumber Co., Inc. — Graham Plant
CoC: NCG500609
DISCUSSION
1.0 Description of Discharge
As originally described in the application for General Permit NCG500000, the facility
uses three wood -fired boilers to generate steam required for lumber drying operations.
The existing boilers are rated at 400 hp (Boiler #1), 600 hp (Boiler #2), and 600-hp
(Boiler #3); the boilers were installed in 1989, 1995, and 1998 , respectively. The boilers
normally operate 24 hr/day, 7 day/wk, and 52 wk/yr except for down times during routine
maintenance. Twice a year during the July 4th Week and Christmas Week, the boilers
are shutdown for maintenance.
The three existing boilers combined produce approximately 600 gal/day of boiler
blowdown water which is discharged from the boilers at a temperature in the range from
100 to 110 °F. The discharged water drains on a concrete spillway as shown in Figure 1
for approximately 360 ft where it enters a stormwater discharge drain. After entering the
stormwater drain, the boiler blowdown discharge travels approximately 450 ft to a
stormwater discharge settling pond constructed to prevent discharge of pine bark from the
site. By the time the blowdown water reaches the stormwater retention pond, its
temperature is approximately equivalent to the prevailing air temperature. The volume of
the retention pond is variable because of the bark collected therein; bark must be
manually removed from the retention pond several times a year.
Figure 1. Boiler blowdown discharge spillway.
The installation dates of these boilers were incorrectly listed on the original NPDES application as 1986,
1992 and 1997, respectively.
1

NOTICE OF RENEWAL INTENT
New South Lumber Co., Inc. — Graham Plant
CoC: NCG500609
A site map is attached to this Notice of Renewal Intent to show the flow of the boiler
blowdown discharge across the property to its discharge point at stormwater Outfall
#002.
2.0 Addition of a New Boiler
The New South Lumber Co., Inc. — Graham Plant has plans to expand their production
capacity. To accomplish this expansion, the site hopes to add a new 1,200-hp boiler, an
85.0 X 106 bdft/yr steam -heated dry kiln, and a log wet deck. The facility has obtained
Air Quality Permit No. 06740T10, effective September 13, 2006, to install the new boiler
and dry kiln; a permit Application No. WQ0030800 for the construction of the wet deck
is under review by the NCDWQ. Addition of the new boiler will approximately double
the total boiler blowdown discharge to 1,200 gal/day.
3.0 New Boiler Water Treatment System
Part of the project to install a new boiler will include the installation of an improved
boiler water treatment system. The new water treatment system produced by ANCO will
include components that adjust the well water composition to make it more compatible
for use in the boilers. Components of the treatment system include a resin -based water
softener, a resin -based dealkalizer, and an iron removal filter. Each of these components
requires regeneration on a regular basis depending on the concentration of impurities in
their feed water, i.e., well water, and the volume of water treated. The regeneration
processes require backwash of the resin beds or filter and will result in additional
wastewater discharges that we propose combining with the boiler blowdown discharge.
3.1 Dealkalizer Discharge
The discharge from regeneration, i.e., backwash, brine draw and slow rinse, fast rinse, of
the dealkalizer resin is estimated by ANCO to be 320 gal/regeneration and will contain
1.50% NaC1 and 0.09% NaOH/KOH in the discharge water. ANCO estimates that the
resin will need to be regenerated every 1.75 to 2.00 days to purify 1,200 gal/day of boiler
water. Thus the discharge from dealkalizer regeneration will amount to 183 gal/day, i.e.,
320 gal/regeneration - 1.75 day.
3.2 Water Softener Discharge
The discharge from regeneration, i.e., backwash, brine draw and slow rinse, fast rinse, of
the water softener resin is estimated by ANCO to be 660 gal/regeneration and will
contain 2.73% NaC1 in the discharge water. ANCO estimates that the resin will need to
be regenerated every 1.75 to 2.00 days to purify 1,200 gal/day of boiler water. Thus the
discharge from water softener regeneration will amount to 377 gal/day, i.e., 660
gal/regeneration - 1.75 day.
3.3 Iron Filter Backwash Discharge
The discharge from the backwash of the iron filter to remove particulate matter is
estimated by ANCO to be 32 gal/day; the filter is actually backwashed once a week for 8
min at 28 GPM. No chemicals are used in the backwash water.
2

NOTICE OF RENEWAL INTENT
New South Lumber Co., Inc. — Graham Plant
CoC: NCG500609
4.0 Total Rate of Boiler Blowdown and Treatment Water Discharge
The total rate of boiler blowdown discharge is the sum of actual boiler discharge, i.e., see
§ 1.0 and §2.0, plus the volume of water used to regenerate the boiler water treatment
system, i.e., see §3.0. The total rate of discharge from the three existing boilers is 600
gal/day and the estimated amount from the proposed new 1,200-hp boiler is 600 gal/day.
The total rate of discharge from the boiler water treatment system is estimated to be 592
gal/day. If the water treatment system discharge is added to the boiler blowdown water
discharge, the total rate of discharge will be approximately 1,792 gal/day.
5.0 Types of Chemicals Added
5.1 Boiler Water Treatment Chemicals
In a letter addressed to Mr. Gil Vinzani of the NC DWQ dated November 2. 2006, we
have previously noted the Department of the chemicals used to treat our boiler water.
These chemicals are supplied by ANCO, a division of Chem -Aqua, Inc. and are ANCO-
OX 1040, ANCOTREAT 1154, ANCOTREAT 1290, and ANCOSTEAM 2060. The
MSDSs for these chemicals are attached to this Notice of Renewal Intent.
When we requested that ANCO provide us a completed Biocide Worksheet Form 101 for
each of these chemicals, they replied in the attached letter that the subject boiler chemical
additives are not biocides and "...the completion of Biocide Worksheet Form 101 is not
applicable in this case."
5.2 Dealkalizer Treatment Chemicals
The regeneration of the chloride cycle dealkalizer is a three -step process: 1) backwash of
the resin with fresh water to remove suspended solids that accumulate on the resin bed
during the service cycle; 2) brine draw backwash of the resin bed with a solution of salt
(NaC1) and NaOH/KOH (see MSDS for ANCOTREAT 1154) removes the undesirable
anions and replaces them with chloride ions; and 3) rinse of the resin bed with softened
water to remove excess chloride and hydroxide ions. A more detailed explanation of the
process may be found in the attached ANCO Technical Bulletin 4-012, "Alkalinity
Removal Using A Chloride Cycle Dealkalizer."
5.3 Water Softener Chemicals
The removal of undesirable cations from the well water is accomplished with a sodium
cycle softener where the sodium cations on an ionic resin are replaced by calcium,
magnesium, etc. cations. The regeneration of this resin is accomplished by backwashing
with a brine (NaC1) solution that replaces the trapped undesirable cations. A more
detailed explanation of the process may be found in the attached ANCO Technical
Bulletin 4-001, "Basic Softener Operation." Additionally, ANCO has provided the
attached letter which states that "...the liquid brine and caustic solutions used to
regenerate your water softener and dealkalizer are not a biocide."
3

NOTICE OF RENEWAL INTENT
New South Lumber Co., Inc. — Graham Plant
CoC: NCG500609
5.4 Iron Removal Chemicals
There are no chemicals used in the treatment of the iron removal filter. Backwash of the
filter on a routine basis with fresh water is necessary to remove particulate materials
trapped on the filter material. The iron filter must be replaced when its removal
efficiency drops. The need for replacement depends on the results of regular water
analysis for iron.
4

BELMONT - MT. HERMON RD. S.R. 1136
UNDEVELOPED
LAND
•
1 �\
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60' B/,
KEYSTONE ROAD ':N
y
LOCATIONS
1 - Fuel Storage
2 - Parts Warehouse
3 - Motor Shop
4 - Sawmill Bulk Storage
5 - Sawmill
6 - Debarker
i 7 - Crane
8 - Planer Mill
9 - Sorter
10 - Stacker
WILSON A. ROB ERTSON k
WIFE REBECCA ROBERTSON
D.B. 461 P. 89
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60' B/yam
ELECTRIC POWER ENTRY _ _f
1Ir W.ODW ri. 6QCK MEEK R1L SR. 391r-
Fence
MT. HERMAN UNITED
METHODIST CHURCH
D.B. 152 P 58
Outfall #4
RALPH EDWARD WOOD
D9.457 P.421
Boiler Blowdown Outfall
SECTION N0. 1
PROPERTY 0E
DDLPH COBLE HEIRS
P8.50 P.181
Outfall #2
To Vamals Creek
DE1D NORTH
h3
D.B. 143 P. 318
MT. HERMAN UNITED METHODIST CHURCH
DB.265 P.301
3
a
To Varnals Creek
9g
l 2/
ESTELLE COBLE ESTATE
P9.48 P.58
Outfall #3
Master Layout Plan
for
New South Lumber Co., Inc.
Graham Plant
ALBRIGHT TOWNSHIP ALAMANCE COUNTY NORTH CAROLINA
DATE 11-11-97 SCALE 1"— 200' '
Boiler Blowdown Flow
GRAPHIC 9.1LE
200