NC0022934_Wasteload Allocation_19950327

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0022934
PERMII'1BE NAME:
FACILITY NAME:
Sonoco Products Company
Sonoco Products Company
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.: 001
Design Capacity: 0.0053 MGD
Domestic (% of Flow): 81 %
Industrial (% of Flow): 19 %
Comments:
Based on 1991 Staff Report
STREAM INDEX: 11-129
RECEIVING STREAM: South Fork Catawba River
Class: WS-IV CA
Sub -Basin: 03-08-35
Reference USGS Quad: F14NW, Lincolnton E. (please attach)
County: Gaston
Regional Office: Mooresville Regional Office
Previous Exp. Date: 01/31/95 Treatment Plant Class:
Classification changes within three miles:
WS-IV at Town of High Shoals water supply intake
Requested by:
Prepared by:
Reviewed
/3S
Jeanette Briggs
Date: 07/20/94
Date: 3 f a2 95
ri Date. �.3 qS
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3 tz7 9 5
Modeler
Date Rec.
#
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7/z, /4/_
7937
Drainage Area (mil ) Co/ Avg. Streamflow (cfs): S90
7Q10 (cfs) 77 Winter 7Q10 (cfs) /&s" 30Q2 (cfs) /97. s'
Toxicity Limits: IWC % Acute/Chronic
Instrcam Monitoring: N•C.
Parameters
Upstream Location
Downstream Location
Effluent
Characteristics
Summer
Winter
BOD5 (mg/1)
36
NH3-N (mg/1);
D.O. (mg/I)
nl
TSS (mg/1)
30
F. Col. (/100 ml)
Zoo
pH (SU)
C -f
6, 4,*l Gll v,„,io
,11 -/-jr.y.„,
r-ht
Comments:

Facility Name:
NPDES No.:
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:
County:
Regional Office:
Requestor:
Date of Request:
Topo Quad:
FACT SHEET FOR WASTELOAD ALLOCATION
SONOCO PRODUCTS CO.
NC0022934
Domestic - 81% / Industrial - 19%
Existing
Renewal
South Fork Catawba River
WS-IV CA
030835
Gaston
MRO ( '!
Briggs
7/21/94
F14NW
Request # 7937
Stream Characteristic:
USGS #
Date:
Drainage Area (mi2):
Summer 7Q10 (cfs):
Winter 7Q10 (cfs):
Average Flow (cfs):
30Q2 (cfs):
IWC (%):
501
79 (est.from yields
155 (" " ")
590 ( " " ")
197.5 (" " ")
0.01
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Tech Support recommends renewal of existing secondary limits. However, facility should pursue
the replacement of the lagoon with a package treatment plant. The absence of a discharge for
several years indicates some problem in the lagoon system.
Special Schedule Requirements and additional comments from Reviewers:
Recommended by:
Reviewed by
Instream Assessment:
Regional Supervisor:
Permits & Engineering:
/2..„cte
Date:
Date: 431 I
Date: rii/tr
Date: 3/1V/ei&
11
RETURN TO TECHNICAL SERVICES BY: WAY 0 1 1995
N.C. DEPT. OF
ENVIRONMENT, HEALTH,
& NATURAL RESOURCES
MAR 8 1995
DIVISION OF ENVIRONMENTMANAGEMENT
MOORESVILLE REGIONAL OFFICE

2
CONVENTIONAL PARAMETERS
Existing Limits:
Monthly Average
Summer Winter
Wasteflow (MGD): 0.0053
BOD5 (mg/1): 30
NH3N (mg/1): monitor
DO (mg/1): nr
TSS (mg/1): 30
Fecal Col. (/100 ml): 200
pH (SU): 6-9
Residual Chlorine (14/1): monitor
Temperature (C): monitor
Recommended Limits:
Monthly Average
Summer Winter WQ or EL
Wasteflow (MGD): 0.0053
BOD5 (mg/1): 30 EL
NH3N (mg/1): monitor
DO (mg/1): nr
TSS (mg/1): 30
Fecal Col. (/100 ml): 200
pH (SU): 6-9
Residual Chlorine (14/1): monitor
Temperature (C): monitor
Limits Changes Due To: Parameters) Affected
Change in 7Q10 data
Change in stream classification
Relocation of discharge
Change in wasteflow
Other (onsite toxicity study, interaction, etc.)
Instream data
New regulations/standards/procedures
New facility information
Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
_X_ No parameters are water quality limited, but this discharge may affect future allocations.

3
INSTREAM MONITORING REQUIREMENTS
Upstream Location:
Downstream Location:
Parameters:
Special instream monitoring locations or monitoring frequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility demonstrated the ability to meet the proposed new limits with existing treatment
facilities? Yes No
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached? (Y or N) If yes, explain with attachments.

SONOCO PRODUCTS CO. JMN
SOUTH FORK CATAWBA RIVER
WS-IV CA 12/21/94
030835
Facility is up for renewal of NPDES permit. Company makes paperboard and
connverts it to paper tubes and cores. Design flow of 0.0053 MGD, with secondary limits
and fecal and pH limits. Type of wastewater is reported as 60% Domestic and 40%
Industrial in staff reported. The industrial component is non -contact air compressor cooling
water. No biocides are added.
Review of compliance data shows no discharge from the plant since June '88. Staff
report completed in 1986 stated that Sonoco's lagoon system and the effluent weir structure
were overgrown with vegetation. The weir also had a leak below it and the effluent
bypassed the weir. An accurate measurement of flow could not be gotten because of this.
An unusual amount of algae and suspended solids were observed in the stabilization basin.
The stabilization basin seems to be made of earthen material with no liner observed. An
investigation for possible GW contamination was recommended. A staff report in 1991
again addressed possible GW impacts. Sonoco still had no discharge and claimed that
"evaporation exceeded influent plus rainfall". MRO suspects percolation through the
lagoon bottom. 1994 staff report states that facility is planning on replacing the existing
stabilization lagoon with a package treatment plant.
RECOMMENDATION: Since there has been no discharge recorded
for so many years, the renewal of existing limits for BOD5=30, TSS=30,
Fecal = 200, pH = 6-9 is appropriate.

Residual Chlorine
7010 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (UG/L)
IWC (%)
Allowable Concentration (ug/I)
Fecal Limit
Ratio of 9616.6 :1
79
0.0053
0.008215
17.0
0
0.01
163498.44
Ammonia as NH3
(summer)
7010 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL (MG/L)
IWC (%)
Allowable Concentration (mg/I)
Ammonia as NH3
(winter)
7010 (CFS)
200/loom1 DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL (MG/L)
IWC (%)
Allowable Concentration (mg/I)
79
0.0053
0.008215
1.0
0.22
0.01
7501.91
155
0.0053
0.008215
1.8
0.22
0.01
29813.12
NC0022934
12/27/94

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SOC PRIORITY PROJECT: Yes No X
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Jeanette Briggs
Date: August 3, 1994
NPDES STAFF REPORT AND RECOMMENDATION
County: Gaston
Permit No. NC0022934
PART I - GENERAL INFORMATION
1. Facility and Address: Sonoco Products Company
Post Office Box 717
Lincolnton, North Carolina 28092
2. Date of Investigation: 08-03-94
3. Report Prepared By: G. T. Chen
4. Persons Contacted and Telephone Number: Mr. H. Walter Harvey,
III, Plant Manager and Mr. Micah Boyles, Maintenance
Supervisor; [phone].
5. Directions to Site: From the junction of Highway 321 and
Hoffman Road (SR 1562) in southern Lincoln County, travel
southwest on SR 1562 approximately 0.8 mile. Sonoco Products
Company is located on the left (south) side of SR 1562.
6. Discharge Point(s). List for all discharge points:
Latitude: 35° 24' 27" Longitude: 81° 13' 51"
Attach a U.S.G.S. map extract and indicate treatment facility
site and discharge point on map.
USGS Quad No.: F 14 NW USGS Name: Lincolnton East, NC
7. Site size and expansion are consistent with application?
Yes X No If No, explain:
8. Topography (relationship to flood plain included): Relatively
flat with slopes less than 3%. The site is in the 100 year
flood plain, however, the facilities are elevated to prevent
flooding.
9. Location of nearest dwelling: None within 1,000 feet.

10. Receiving stream or affected surface waters: South Fork
Cataba River
a. Classification: WS-IV
b. River Basin and Subbasin No.: Catawba and 03-08-35
c. Describe receiving stream features and pertinent
downstream uses: The receiving stream which appeared to
be very muddy on the day of the investigation, contains
a good flow at all times. There are many discharges
located above and below this facility.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted: 0.0053 MGD
(Ultimate Design Capacity).
b. What is the current permitted capacity of the wastewater
treatment facility? 0.0053 MGD.
c. Actual treatment capacity of the current facility
(current design capacity)? 0.0053 MGD.
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years: None.
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: The
existing facilities consist of a 0.30 acre stabilization
lagoon followed by chlorine (gas) disinfection.
f. Please provide a description of proposed wastewater
treatment facilities: N/A.
g. Possible toxic impacts to surface waters: None.
h. Pretreatment Program (POTWs only): N/A.
in development: approved:
should be required: not needed:
2. Residuals handling and utilization/disposal scheme: Sludge
has not been removed from the stabilization lagoon since its
operation. A sludge disposal scheme needs to be developed and
submitted to DEM for approval.
a. If residuals are being land applied, please specify DEM
Permit No.:
NPDES Permit Staff Report
Version 10/92
Page 2

Residuals Contractor:
Telephone No.:
b. Residuals stabilization: PSRP:
RFRP:
Other:
c. Landfill:
d. Other disposal/utilization scheme (specify):
3. Treatment plant classification (attach completed rating
sheet): Class I, see attached rating sheet
4. SIC Code(s): 2655
Wastewater Code(s) of actual wastewater, not particular
facilities, i.e., non -contact cooling water discharge from a
metal plating company would be 14, not 56.
Primary: 02 Secondary: 14, 16
Main Treatment Unit Code: 30000
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved (municipals only)?
N/A.
2. Special monitoring or limitations (including toxicity)
requests: N/A.
3. Important SOC, JOC or Compliance Schedule dates: (please
indicate) N/A.
Date
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Alternative Analysis Evaluation: Has the facility evaluated
all of the non -discharge options available. Please provide
regional perspective for each option evaluated.
Spray Irrigation: Not evaluated.
Connection to Regional Sewer System: No area -wide sewer
NPDES Permit Staff Report
Version 10/92
Page 3

system available in the near future.
Subsurface: Not evaluated.
Other Disposal Options: The Company is planning to install a
package treatment plant to replace the existing stabilization
lagoon.
5. Air Quality and/or Groundwater concerns or hazardous materials
utilized at this facility that may impact water quality, air
quality or groundwater? The existing discharge consists of
mainly domestic wastewater, plus a small amount of non -contact
cooling water and boiler blowdown. No hazardous materials are
used at this facility. Adverse impacts on the environment, if
any, will be minimal.
6. Other Special Items: None.
PART IV - EVALUATION AND RECOMMENDATIONS
It is recommended that the subject Permit be renewed as
requested.
G�-
Signature Report Preparer
/(a.
Water Quality Regi1 Supervisor
Date
NPDES Permit Staff Report
Version 10/92
Page 4