NC0083038_Wasteload Allocation_19930426

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NCO083038
PERMITTEE NAME: Ball-InCon Glass Packaging Corporation
FACILITY NAME: Ball-InCon Glass Packaging Corp.
Facility Status: Existing
Permit Status: New
Major
Pipe No.: 001
Design Capacity:
_ Minor �1
0.24 MGD
Domestic (% of Flow):
Industrial (% of Flow):
Comments:
0 %
1 ' UT I/'1
RECEIVING STREAM:M� Cr�k lNT To 'Vo-TWl CPI
Class: WS-III NSW
Sub -Basin: )3 :4 01 03-o3-oz
Reference USGS Quad: B25SW (please attach)
County: Vance
Regional Office: Raleigh Regional Office
Previous Exp. Date: 00/00/00 Treatment Plant Class: unknown
Classification changes within three miles:
No change within three miles PLOTTED
Requested by: Randy E{ 1er (w, Date: 1/6/93
Prepared by: wo�q• Date: .4-4ZA3
Reviewed by: a -L a/I t! Date:
&D, 19A c� 7 o/Q•5
Modeler
Date Rec.
#
SAVJ
1
�7-47
Drainage Area (mil ) ^ 0.1 Avg. Streamflow (cfs): - U. 09
7Q10 (cfs) O Winter 7Q10 (cfs) 0 30Q2 (cfs) 0
Toxicity Limits: IWC % Acute/Chronic
ddaNCrGKtnf4 EPtSo�tC
Instream Monitoring:
Parameters
Upstream Location
Downstream Location
Effluent
Characteristics
Summer
Winter
BOD5 (mg/1)
NH3-N (mg/1)
D.O. (mg/1)
F. Col. (/100 ml)
PH (SU)
ott L#
3t.y
i .(o
/pty
15.6
t
5 �D Nl'k
MAa
T txiRA aG
1-t16 Di5aAe4e wAit.Nat'
(pose -tub
F"-QVtntc, wR'fi3Rs
Z-Ffc Amve EA
6uF"A-fkaC- To
i"Np mj> w tic
IT- 'fb wzerop W *c,.
�4
CCED
15F CAusc
Comments:-fPcirf iFflftNy %wutD Bs rea*be tcb bu24NG 79E
fig-5T PISC9AE46 6fgNTS CT1115 MAY Wr oCsufL. G T1nnL-S PuetN4
iKe FIfzST yEAR)

Ball-InCon Glass Packaging Corp.
1509 South Macedonia Avenue. Muncie, IN 47302-3664 [phone]
ReoIV to: P.O. Box 4200. Muncie, IN 47307-4200
November 23, 1992
Mr. Don Safrit
Supervisor Permits and Engineering
Division of Environmental Management
P.O. Box 29535
Raleigh, NC 27626
Re: Permit #WQ 0000 221
Ball-InCon Glass Packaging Corp. :>>
Vance County
Dear Mr. Safrit:
Ball-InCon Glass Packaging Corp. owns and operates a glass container
manufacturing facility located at U.S. Highway #1 Bypass in Henderson, NC.
This plant is presently operating under a Recycle System Permit
#WQ 000 221 which does not permit discharge of wastewater to surface
water. Ball-InCon would like to amend,this permit to allow us to discharge
Process Water to nearby Martin Creek during glass furnace drains.
Attached is a completed Application For Permit to Discharge - Short Form C.
Ball-InCon would like to provide a more detailed explanation of the
information provided on this form.
Item #9 requests information on the frequency of this discharge. The
discharge that we are requesting to permit occurs only when the glass in the
glass furnace is being drained or removed. During these furnace drains, a
large amount of water is needed to cool the molten glass as it exits or is
being drained from the furnace. The furnace is drained on a very
intermittent basis and only for the following reasons and frequencies:
1) Furnace Rebuilds - The glass must be drained from the furnace prior
to the furnace being torn down and rebuilt. On an industry average,
this occurs approximately every seven (7) years.
wwn va.. A subsidiary of Ball Corporation

November 23, 1992
Page 2
2) Emergency Repairs - A hole may develop in the furnace or needed
repairs may require a total or partial drain of the glass in the furnace.
This is NOT a regular maintenance item and only occurs in an
emergency situation.
3) Color Change - Customer demands may require that we produce both
green glass and flint or clear glass at this plant. Since this plant
presently operates one furnace, when a different color glass is
needed, the glass color of all the glass in the furnace must be
changed. When going from flint to green, a furnace drain is not
usually required because the glass can be darkened to green by
adding green cullet (i.e. recycled glass) and altering the raw material
batch mix. However, when changing the color of the glass in the
furnace from green to flint, the entire contents of the green glass in
the furnace must be drained and replaced with flint cullet, as well as
changing the raw material mix. When this color change occurs, in an
attempt to remove all of the green glass from the furnace, it is
actually drained once, partially refilled with cullet, and then drained
again. This is all done within a two (2) day time frame. We
anticipate having to change the color in the furnace from 0-3 times
per year.
This should help to clarify our response to Item #9 which is an intermittent
discharge to occur only during furnace drains which may occur from zero to
three times a year for 1 or 2 days intervals.
Item #10 requests information on the type of wastewater to be discharged.
Large amounts of water are used during a furnace drain to help cool the
molten glass as it exits the furnace. The operating temperature of the glass
in the furnace is approximately 28000 F. Chutes are set-up for the glass to
drain from the furnace. Water is used to cool and "lubricate" the chutes and
quench the glass as it exits the furnace. The cooling effects of the water
also breaks up the glass and keeps it from forming one solid glass block.
Since the water does come in contact with the molten glass, it must be
considered by definition "process water", with quenching being its primary
purpose. This water and the glass during a furnace drain does not come in
contact with oils or any other substances at the plant.

,J�;..
November 23, 1992
Page 3
Analytical results to sampling that was conducted during a recent furnace
drain that was discharged to the treatment works at the City of Henderson
are attached for your review. We performed a grab sample after 2 hours
into the first furnace drain and had this analyzed for Oil and Grease,
Biochemical Oxygen Demand, and Total Suspended Solids. We also took an
hourly temperature and pH reading during both of the furnace drains.
We also monitored a total flow for both of these furnace drains. This
information is also attached. The "process water, daily average" number in
column (5) is an average of both flows, while the "Maximum per operating
day for total discharge" in column (5) is the flow of the first furnace drain.
The temperature reading for these furnace drains were taken at a sump near
the furnace building prior to this material being pumped into a manhole for
discharge to the city. However, the flow of this wastewater to Martin Creek
would actually follow a very different route. The attached map shows the
route the furnace drain wastewater would take to reach Martin Creek.
Significant cooling of this wastewater would occur in the small holding pond
and in the 2500 feet of drainage ditch and branch leading to Martins Creek.
It is unknown what the actual temperature of this water would be by the
time it were to reach Martin Creek.
It should also be noted that the City of Henderson requested that we not
discharge this waste water to them again. Typically, these furnace drains
are done over a weekend and with such a large volume of water, we could
overflow their plant. They also see no reason why we should have to treat
this one pass cooling water.
We have enclosed a significant amount of information on this permit change
application. If you have any questions on the contents of this letter or the
attachments, please do not hesitate to contact me at 317/741-7117.
Respectfully,
Robert J. Cappiello
Environmental Project Engineer
jw

November 23, 1992
Page 2
Attach. Short Form C Application
Furnace Drain Analytical Data
Furnace Drain Flow, Temperature and pH
Map - Discharge Route
Permit Processing Fee - $400
Four Complete Copies
cc:
Tom Spain, City of Henderson

NORTH CAROLINA DEPT. OF NATURAL RESOURCES AND COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT, P.O. BOX 276870 RALEIGH, NC 27611
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM APPLICATION NUMBER
APPLICATION FOR PERMIT TO DISCHARGE - SHORT FORM C FOR
AGENCY p 0 3 8'
USE DATE RECEIVED
To be filed only by persons engaged in manufacturing and mining F
�—IV
YEAR MO. DAY
415
CO- 44w oo. �
00 not attempt to complete this form before reading accompanying instructions
Please print or type V U
I. Name, address, location, and telephone number of facility producing discharge
A. Name Ball -InCnn _Gl ass Packaging Corp.
B. Mailing address
1. Street address U.S. Highway #1 Bypass
2. City -- NAnrlArcnn 3. State NC
4. County Vance S. ZIP 27536
C. Location:
1. Street Same
2. City
4. State _
D. Telephone No.
919 492-1131
Area
Code
2. SIC
(Leave blank)
3. Number of employees
300
3. County
If all your waste is discharged into a publicly owned waste treatment facility
and to the best of your knowledge you are not required to obtain a discharge
permit, proceed to item 4. Otherwise proceed directly to item 5.
4. if you meet the condition stated above, check here O and supply the information
asked for below. After completing these items, please complete the date, title,
and signature blocks below and return this form to the proper reviewing office
without completing the remainder of the form.
A. Name of organization responsible for receiving waste
B. facility receiving waste:
1. Name
2. Street address
3. City
4. County
S. State 6. ZIP
�. )(Principal product, Draw material (Check one)
'�. Principal process Gas fired industrial furnace
Y. Maximum amount of principal product produced or raw material consumed nor fthoek heal
Basis
Amount
1-99
(1)
100-199
(2)
200-499
(3)
500-999
(4)
1000-
4999
(5)
5000-109000- 509000
9999 49.999 or more
(6) (7) (B)
A. Uay
260
1
B. Month
C. Year
4
P"ZVIOUS EDITION MAY 69 USED UNTIL SUPPLY IS CKMAUSTED

ft, Mix In. im A1111111rt1 of print, Lila 1 pr•tlfi111 1 ilrtxile( 1-11 I)r
in t ten; / , aaovr . Is xwesurv(l In ( f-het k one):
A.0 pounds B.)(tons C.0 barrels
raw 11IA 11•► 1.11 1 /N I'. elrtll•41, 1•1•i if It 11.11
0.0 bushels f . O square feet
f .O gallons G.O p1eces or units H. O other, specify
9. (a) Check here if discharge occurs all year O , or Occasional discharge during furnace drains,
;b) check the rnonth(s) discharge occurs: 0-3 times a year for 1-2 days duration for each furnac
1.0 January 2.0 February 3.0 March 4.0 Apri 1 5.0 May 6.0 June drain.
` 7.0 Ju I 8.0 August 9.0 Septemher 10.0 October 11.0 November 12.0 Decemner
(c) Check how marry days per week: 1.01 2.X2-3 3.04-5 4.06-7 1-2 days per furnace drain
10. Types of waste water discharged to surface waters only (check as applicable)
F low, gallons per operating day
Volume treated beforedischarging (percent)
Discharge per
operating day
0.1-999
1000-4999
5000-9999
10,000-
50,000-
done
0.1-
30-
65-
95-
49,999
or more
29.9
64.9
94.9
100
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
A. Sanit3ry, daily
average
B. Cooling water, etc.
' --
daily average
C. Process water,
daily averaoe
240,000
X
1. Maximurr per ooprat-
ing day for total
360,000
discharge (ail types►
11, If an% c•f trip three types of waste iden t i f ied in Item 10. either treated or untreated.
are di scraroed to places other than surface water., rfieck below as applicable.
waste water is
dischar"d to:
Average flow, gallons per operating day
0.1-999
(1)
1000-4999
(2)
5000-9999 109000-499999
(3) (4)
50,000 or more
(5}
A. Municipal sewer system
4500
B. Underground well
C. Septic tang
D. Evaporation lacio n or pond
E. Other, specify -
12. Number of separate di scharae points: A.)(1 8.0 2-3 C.a 4-5 D.0 6 or more
13. Name of receiving water or waters Martin Creek
14. Does your discharge contain or is it possible for your discharge to contain
one or more of the following substances added as a result of your operations,
activities, or processes: ammonia, cyanide, aluminum, beryllium, cadmium,
chromium, copper, lead, mercury, nickel, selenium, Zinc. phenols, oil and
.grease, and chlorine (residual). A.0 yes 8.X3 no
i certify that I am familiar with the information contained in the application and
that to the best of my knowledge and belief such information is true, compietP, and
accurate.
Robert J. Cappiello Environmental Project Engineer
Printed Ka of P rson Signing Title
Date App icat on Signed _ Signature of Applit nt "
North Carolina General Statute 143-215.6(b)(2) provides that: Any person who knowingly makes
any false statement representation, or certification in any application, record, report, plan,
or other document files or required to be maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, or who falsifies, tampers with,
or knowly renders inaccurate any recording or monitoring device or method required to be
operated or maintained under Article 21 or regulations of the Environmental Management Commissif:
implementing that Article, shall be guilty of a misdemeanor pumishable by a fine not to exceed
$10,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001.provic
a punishment by a fine of not more than $10,000 or imprisonment not more than 5 years, or both,
for a similar offense.)

`+ 11
SEC DONOHUE
Environment & Infrastructure
October 13, 1992
Ball-InCon Glass Packaging Corp.
P. O. Box 4200
Muncie, Indiana 47307-4200
Attention: Mr. Robert Cappiello
Reference: Furnace Water Analytical Results
SEC Donohue Project No. RE411.30
Dear Mr. Cappiello,
Enclosed are the analytical test results of the water discharged from the glass furnace
at Ball-InCon's Henderson, North Carolina Facility.
If you have any questions concerning the results, please let me know.
Sincerely,
SEC DONOHUE
1
John G. Funk
Project Manager
3500-B Regency Parkway - P.Q. Box 1308 - Cary, NC 27511 - [phone] • Fax: [phone] #0

•
1EA
An Aquarlon Companv
October 13, 1992
John Funk
Sirrine
3500 B Regency Park
Cary, NC 27512
An Environmental Testing Companv Phone [phone]
Post Office Box 12846 Fax [phone]
Fiesearcn Triangle Bark. NC 27709
IEA Project No.: 115917
TEA Reference No.: W9209014
Client Project I.D.: RE411.30 Ball-Incon
Dear Mr. Funk,
Transmitted herewith are the results of analyses on one sample submitted
to our laboratory.
The sample(s) were received intact.
Analyses were performed according to approved methodologies and meet
the requirements of the IEA Quality Assurance Program except where noted.
Please see the enclosed reports for your results and a copy of the Chain
of Custody documentation.
Please do not hesitate to call your Client Account Representative should
you have any questions regarding this report.
Very truly yours,
IEA, Inc.
d'T?a 4 & X 4 (-Ile. 1r4 4 2w
Linda Amitchell
Director, Technical Support Services
State Certification:
Georgia - #816
New Jersey - #67719
California - #1768
Massachusetts - NC039
Tennessee - #00296 Alabama - #40210
Virginia - #00179 South Carolina - #99021
West Virginia - #50 North Carolina - #37720/#84
Kentucky - #90049 Kansas - E-158/E-1189
Monroe, Sunrise. Schaumburg, N. Billerica, Whippany, Essex Junction,
Connecticut Florida Illinois Massachusetts New Jersey Vermont
203.261.4458 305.846.1730 708.705-0740 617-272.5212 201.428.8181 802.878.5138

An Aquanoany
n Coma
IEA LABORATORY RESULTS
IEA Project #: 115-917
Client Name: Sirrine
Date
Sample # Client ID Parameter Results Analyzed
1 S-1 Biochemical Oxygen Demand <2.0 mg/L 09/04/92
1 S-1 Total Suspended Solids <4 mg/L 09/10/92

IEA
An Aouanon Company
IEA LABORATORY RESULTS
IEA Project #: 115-917
Client Name: Sirrine
Date
Client ID Parameter Results Analyzed
QC Blank Biochemical Oxygen Demand <2.0 mg/L 09/04/92
QC Blank Total Suspended Solids <4 mg/L 09/10/92

IEA
An Acmanon Comoany
IEA Sample #: 115-917-1
Client Name: Sirrine
Client Project I.D.:RE411.30 Ball-Incon
Sample I.D.: S-1
Matrix: Water
Date Received: 09/04/92
Date Sampled: 09/04/92
Date Prepared: 09/10/92
Detection Date
Parameter Method Limits Results Analyzed Analyst
Oil & Grease(Gray.) SW-846 9070 5 mg/L BQL 09/11/92 LG
Comments:
BQL= Below Quantitation Limit
FORM RES-P Rev. 071991

IEA
An Aquanon ComDany
IEA Sample #: 115-917
Client Name: Sirrine
Client Project I.D.:RE411.30 Ball-Incon
Sample I.D.: QC Blank
Matrix: Water
Date Received: N/A
Date Sampled: N/A
Date Prepared: 09/10/92
Detection Date
Parameter Method Limits Results Analyzed Analyst
-----------------------------------------------------------------------------------
Oil & Grease(Gray.) SW-846 9070 5 mg/L SQL 09/11/92 LG
Comments:
N/A = Not Applicable
BQL= Below Quantitation Limit
Corresponding Samples: 115-917-1
FORM RES-P Rev. 071991

INFORMATION ON TANK DRAINS
TANFr DATE TIME GLASS TIME
DRAINED STARTED PLUGED
c 9 -4 -92 8 : 3()AM $ : (15PM
WATER USED
NO. OF
GALLON TOTAL PER
HOSES
PER MEN. MINUTE
7 HOSES
44.4
310.8
K I CKER
130.4
130.4
HEADER
235.2
235.2
TOTAL PER__________
MINUTE
626.4
TOTAL PER__________
HOUR
37584
TOTAL FOR
DRAIN
451008
LESS EST.
VOLUME
LOSS DUE
TO
REDUCED PRESSURE
EST. 20%
LOSS
90201.6
ESTMATED
TOTAL
TEMPERTURE OF WATER AND PH
TIME
TEMP.
PH
8 : 20
77.00
9:20
150.40
8.69
10:20
153.60
8.51
1 1 :20
155.00
8.81
12 : 26
155. C)�)
8.78
1:20
152.60
9.79
2:26
156.40
8.99
3:22
155.40
9.34
4:20
145.40
9.14
5:20
137.80
8.94
. c
P VERASE
-_2 t-.,-
-
TANf,.: DATE TIME GLASS TIME
DRAINED STARTED PLUGE
#2 9-5-92- 7: 51 All
WATER USED
NO. OF
GALLON
TOTAL PER
HOSES
PER MIN.
MINUTE
7 HOSES
44.4
310.8
K I Ci� ER
80.4
80.4
HEADER
235.2
235.2
TOTAL PER
MINUTE
626.4
TOTAL PER__________
HOUR
37584
TOTAL FOR
-
DRA I N
150336
LESS EST.
VOLUME
LOSS DUE
TO
REDUCED PRESSURE
EST. 20%
LOSS
30067.2
ES TMA TE D
TOTAL
120268.8
TEMPERTURE OF WATER AND PH
TIME
TEMP.
PH
7:45
76
7.06
8:45
160.4
9.47
9:44
151.4
9.29
10:41
129.8
8.96
AVERAGE
147. `Q*
---------
9.24

November 22, 1994
TO: Permits & Engineering Unit
Raleigh Regional Office
Environmental Sciences Branch
Central Files
FROM: Marcia Toler-McCullen 'N'4��
SUBJECT: Ball-InCon Glass Packaging Corporation
NC0083038
Vance County
In plotting this facility, I have discovered the subbasin for this WLA was
indicated incorrectly on the NPDES Wasteload Allocation Form. The receiving stream
is UT Martin Creek which is not in subbasin 03-03-01, but it is located in subbasin
03-03-02. The staff report had the location correct; however, when the WLA was
completed everything was indicated as W-03-01.
Please make all the necessary changes which are needed in correcting the
subbasin to 03-03-02. If there are any questions, please feel free to give me a call.
Thanks.

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
Ball InCon Glass Pkg. Corp.
NCO083038
Industrial - 100%
Existing
New
UT Martins Creek
WS-III, NSW
030301 o3d30Z
Vance
RRO
R. Kepler
1/6/93
B25SW
Request # 7297 qg
APR 0 1 19S
DEHNR-RAL RO
Stream Characteristic:
USGS #
estimated
Date:
Drainage Area (mi2)
= 0.1
Summer 7Q10 (cfs):
0.0
Winter 7Q10 (cfs):
0.0
Average Flow (cfs):
=0.09
30Q2 (cfs):
0.0
IWC (%):
100.0
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Ball InCon currently recycles wastewater. The facility is seeking a permit to discharge large
amounts of contact cooling water during 1) furnace rebuilds 2) emergency repairs 3) color change
(when changing from green to clear glass). These events are expected to occur 0-3 times per year
at 1 to 2 day intervals. The City of Henderson will not take this water. Since this is considered
"process" water, effluent guidelines 426.82 BPT are applicable. High temperature from this
discharge will be a problem, so the standard temperature language for cooling water discharges
will be recommended. TSB recommends that a clause be placed in the permit stating that the
facility must make efforts to release the flow slowly in order to decrease the chance for excessive
channelization of Martins Creek due to the high velocity of the discharge slug. P&E should review
staff report comments.
Although this is a new permit to NSW class stream, TP and TN will not be limited - not expected
to be in the discharge.
Special Schedule Requirements and additional comments from Reviewers:
Recommended by:
Reviewed by
Instream Assessment:
Regional Supervisor: _
Permits & Engineering:
RETURN TO TECHNICAL SERVICES BY:
3 k-
APR 2 8 1993

3
TOMCS/CONVENTIONAL PARAMETERS
Type of Toxicity Test: Acute Full range episodic
Existing Limit:
Recommended Limit: Monitoring only
Monitoring Schedule: first five events, then annually
Recommended Limits
Monthly Average Daily Max. Mon. Freq. WQ or EL
Flow monitor
pH (Si): 6-9
Oil & Grease (#/day): 15.6 31.2 el
TSS (#/day): 36.4 72.8 el
Turbidity (NTU): 50
Temperature The discharge shall not cause the receiving
water's temp. to exceed 2.8°C above
background and in no case cause it to
exceed 3rC.
(See page three for special monitoring requirements.)
Limits Changes Due To: Parameteds) Affected
Change in 7Q10 data
Change in stream classification
Relocation of discharge
Change in wasteflow
New pretreatment information
Failing toxicity test
Other (onsite toxicity study, interaction, etc.)
Instream data
New regulations/standards/procedures 426.82 subpart H
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.
AA
X No parameters are water quality limited, but this discharge may affect future allocations.

l
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
AdQuacy 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?
Wasteload sent to EPA? (Major) N (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? N (Y or N) If yes, explain with attachments.

FacilityName Eft t, INCOYJ Permit # 1_0083030 Pipe #
ACUTE TOXICITY MONITORING (EPISODIC)
The permittee shall conduct FIVE acute toxicity tests using protocols defined as definitive in
E.P.A. Document 600/4-85/013 entitled "The Acute Toxicity of Effluents to Freshwater and
Marine Organisms." The monitoring shall be performed as a Fathead Minnow (Pimephales
promelas) 24 hour static test, using effluent collected as a single grab sample. Effluent samples
for self -monitoring purposes must be obtained below all waste treatment. Sampling and
subsequent testing will occur during the first five discrete discharge events after the effective date
of this permit. After monitoring of the first five toxicity tests, the permittee will conduct one test
annually, with the annual period beginning in January of the next calendar year. The annual test
requirement must be performed and reported by June 30. If no discharge occurs by June 30,
notification will be made to the Division by this date. Toxicity testing will be performed on the
next discharge event for the annual test requirement.
The parameter code for this test is TAE6C. All toxicity testing results required as part of this
permit condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it
was performed, using the appropriate parameter code. Additionally, DEM Form AT-1 (original) is
to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Rd.
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all doselresponse data. Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should any test data from either these monitoring requirements or tests performed by the North
Carolina Division of Environmental Management 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 and appropriate environmental controls, shall constitute an invalid test.
Failure to submit suitable test results will constitute noncompliance with monitoring requirements.
7Q10 0
cfs
Permitted Flow Vk2,
MGD
lWC l00
%
Basin & Sub -basin o3o
-r
Receiving Stream u T An AR
i n15 (REEI-
County VANCt
Recommended by:
Date 3 2 3
aAl i N Con) s �tsc�laluc Ev NTs mAy oNLy occu(Z 0--3 TtmeS
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FOR APPROPRIATE DISCHARGERS, LIST COMPLETE GUIDELINE LIMITATIONS BELOW
Effluent Characteristics
Monthly
Average
Daily
Maximum
Comments
361
-72. $
2(o 2 8 r'T
TSS
albs/day
albs/da ./y
40CFR
Oil
15.6lbs/da .o3
31.2 lbs/da o(,
Same as above
H
6.0-9.0 SU
6.0-9.0 SU
Same as above
The watewater is contact cooling water used to cool
the lass when the furnace is beingchanged over
therefore should be considered process waters.
Randy Kepler ,.K
3-u - v
Type of Product Produced
s/Day Produced
Effluent Guideline Reference
Glass Containers
520,000
40 CFR 426 Glass Manufacturin
Subpart H, Glass Container Manufacturing

Ball-InCon Glass Packaging Corp.
1509 South Macedonia Avenue, Muncie, IN 47302-3664 [phone]
Reply to: PO. Box 4200, Muncie, IN 47307-4200
March 10, 1993
Mr. Randy Kepler
North Carolina Department of
Environment, Health and Natural Resources
512 North Salisbury Street
Raleigh, NC 27604
RE: NPDES Permit #NC 0083038
Ball-InCon Glass Packaging Corp.
Vance County
Dear Mr. Kepler:
Ball-InCon Glass Packaging Corp. would like to acknowledge receipt of your
notice dated January 6, 1993 with the request for the Delegation of
Authority and an Engineering Economics Alternatives Analysis. We would
also like to reference our conversation on January 29, 1993, when Ball-
InCon requested and was verbally granted a 30 day extension to supply the
information requested in your notice.
Attached to this letter is a copy of the original "Short Form C" application
signed by the plant manager, who is authorized under state regulation to
sign such documents. Also attached to this letter is the "Evaluation of
Wastewater Disposal Alternatives" as prepared to Rust Environmental for
the Ball-InCon Glass Packaging Corp.
Ball-InCon would also like to enclose additional information for your review.
Since our original submittal, the plant's glass furnace has been drained and
the cullet quench water was again discharged to the City of Henderson.
Equipment problems at the pump station for the City and rainfall in the area
nearly caused us to delay the draining of the furnace. These problems are
discussed in the attached "Evaluation of Wastewater Disposal Alternatives".
With this latest furnace drain, we were able to more accurately determine
our flow. Taking into account the quench water used in the initial furnace
drain and the followup flush and drain, we have estimated a total quench
water usage of 600,000 gallons in a 24 hour period. However, during this
furnace drain, we did alter our furnace drain procedure by using a 500,000
cmu Ra as A subsidiary of Ball Corporation

March 9, 193
Page 2
gallon aboveground storage tank at the plant. The cullet quench water was
first pumped into this aboveground tank and was then metered into the city
sewer system. This allowed us to both better determine our flow and it
gave the cullet quench water some time to cool down prior to discharge.
Also, attached is information on the flow, temperature and pH readings of
the water during the last furnace drain.
We are proposing to discharge to Martin Creek by using this same method.
We feel in this way we can better control our flow to the creek and we can
reduce the temperature of some of the quench water prior to discharge. It
should be noted that we estimate our furnace drain quench water discharge
at 600,000 gallons, while the aboveground tank will hold only 500,000
gallons. This means that approximately 100,000 gallons will definitely need
to be discharged over a 24 hour period with minimal residence time for
cooling.
Upon review of our previously submitted Short Form C submittal letter,
application and attachments; and, review of this submittal letter, alternatives
analysis and other attachments, if you have any questions, please call me at
317/741-71 17.
Respectfully,
rl- ewe
Robert J. Cappiello
Environmental Project Engineer
jw
Attach: Amended Short Form C
Evaluation of Wastewater Disposal Alternatives
Furnace Drain Quench Water Data
4 Complete Copies
cc:
W. A. Jones, Plant Manager
Rust Environment

NORTH CAROLINA DEPT. OF NATURAL RESOURCES AND COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT, P.O. BOX 27687, RALEIGH, NC 27611
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
• APPLICATION FOR PERMIT TO DISCHARGE - SHORT FORM C APPLICATION NUMBER
' FOR
AGENCY
USE DATE RECEIVED
To be filed only by persons engaged in manufacturing and mining
YEAR MD. DAY
Oo not attempt to coapiete this form before reading accompanying instructions
Please print or type
1. Name, addresso locationg and telephone number of facility producing discharge
A. Name _ Ball-Tn .nn Glass Packaging Corp.
B. Mailing address
1. Street address U.S. Highway #1 Bypass
2. City 14pndarcnn 3. State PVC
4. County Vance S. ZIP 27536
C. Location:
1. Street Same
2. City 3. County
4. State D. Telephone No. _
919 492-1131
,00-�
• Area
Code
2. SIC " I 'n
(Leave blank)
3. Number of empioyees 300
If all your waste is discharged into a publicly owned waste treatment facility
and to the best of your knowledge you are not required to obtain a discharge
ptrai t, proceed to item 4. Otherwise proceed directly to item y.
4. If you meet the condition stated above, Check here p and supply the information
asked for below. After completing these items, please complete the date,, title,
and signature blocks below and return this fora to the proper reviewing office
without completing the remainder of the form.
A. Nape of organisation responsible for receiving waste
B. Facility receiving waste:
1. Nam*
2. Street address
3. City 4. County
S. State 6. 2IP
�. )(Principal product. Oraw material
Check one)- Glass rnntainers
t. Principal process Gas fired industrial furnace
7. Maxim= amount of principal product produced or raw material enns�A nor irk&&& .�.►
Basis
Amount
1-99
(tj
1004 99
(2)
200-499
(3)
500-999
1000•
4999
5000-10.000- 50.000
9999 49.999 or more
(6) (7) (8)
A. uay
260
B. Month
C. Year
Pwty+OYs EDITION "AV 89 USED UNTIL SUPPLY 18 txwausstp

MAE rn. frr+ Ar11f111h1 11t ortnt 1118 1 got 111im t for foam 0-11 11♦
tf1 1 (.M. J , 4,)ove , IS waeasureu Ir. (Liset p. (11 e ! :
A.a pounds B.kftons C.p barreis
rAw QIAt t•r I., 1 f IHI•.rolowoi , t t•1111r i /•/1
u.0 bushel s :. 0 square feet
F.0 ga i ions G.O pieces or units H.0 other, specs fy _
y. (a) Check here if discharge occurs all year p , or Occasionai
,b) Check the month(s) di scharae occurs - 0-3 times a vear
1.0 January
7.0 July
discharge during furnace drains,,
for 1-2 days duration for each fdrn
`-.O MaY 6.0 June drain.
11. 0 November 12.0 v, c emoe r
(c) Check how many days per week: 1.01 -.x2-3 3.04-5 4.06.7 1-2 days ,2r `urnace drai
10. Types of waste water discharged to surface waters only (check as applicable)
2.0 February ;, 0 March 4.0 Apr i
8.0 August 9.0 Septem er 10.0 Octoher
F low. gallons per operating day
>
Yolume 7 _ated before
dischar:,ng 1percent)
Discharqe per
operating day
0.1-999
1000-4999
5000-9999
10,000-
50,000-
None
0.1. 30-
65-
95-
49,999
or more
29.9 64,9
94.9
100
(1)
(2)
(3)
(4)
(5)
(6)
(7) (8)
(9)
(10)
A. Santt3ry, daily
average
B. Cooling water, etc.
daily average
C. ProCP.SS water,
daily averaae
2409000
X
). Maxtmutr per oot►rat-
ing day for total
3609000
discharge (a)1 t yes l
ll. If any 0 tt,O three types of waste identified in rtet" 10.e1ther treated or untreated.
are discrar?ed to v'.aces other than surface water., oteck below as applicable.
Waste water is
diSchorgrfd to:
Average flow, gallons per operating day
0.1-999
(1)
1000-4999
(2)
SOCO-9999
(3)
101,000-49,999
(4)
509000 or more
(S)
A. Municipal sewer system
4500
B. Underground ►c-o l
C. Septic tan, .
D. Evaporation l aonfon or pond
E. Other, spectt)
12. Number of separate di scharae points: A.)(1 8.0 2-3 C.O 4-5 D.O 6 or more
13. Name of receiving water or waters Martin Creek
14. Does your discharge contain or is it possible for your discharge to contain
one or more of the following substances -added as a result of your operations,
activities, or processes: ammonia, cyanide, aluminum, beryllium, cadmium,
chromium, copper, lead, mercury, nickel, selenium, zinc, phenols, oil and
.grease, and chlorine (residual). A.a yes B X no
1 certify that I am familiar with the information contained in the application and
that to the best of my knowledge and belief such information is true, compietP, and
accurate. I
.W_: A. Jones .. Plant Manager
Printed Natee of, Person Sionino Title
ebruary 1, 1993 v4 ' ► ,'y
Date Application Signed _ Signature of Appl tint
North Carolina General Statute 143-215.6(b)(2) provides t: Any person who knowingly makes
any false statement representation, or certification in any application, record, report; plan,
or other document files or required to be maintained under Article 21 or regulations of -the
Environmental Management Commission implementing that Article, or who falsifies, tampers with,
or knowly renders inaccurate any recording or monitoring device or method required to be
operated or maintained under Article 21 or regulations of the Environmental management Commiss
implementing that Article, shall be guilty of a misdemeanor pumishable by a fine not'to exceed
$10,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001.proN
a punishment by a fine of not more than $10,000 or imprisonment n:ot more than 5 years, or both
for a similar offense.)

EVALUATION OF WASTEWATER DISPOSAL ALTERNATIVES
BALL-INCON GLASS PACKAGING CORPORATION
HENDERSON, NORTH CAROLINA
prepared for:
Ball-InCon Glass Packaging Corporation
P.Q. Box 4200
Muncie, Indiana 47307-4200
John G. Funk, P.E.
Date:
Prepared by:
Rust Environment & Infrastructure
P.O. Box 1308
Cary, North Carolina 27511
[phone]
3�319�
CA A,
Sa
w�b 0,Yoo
101
ea
• u SEAL s
O
14799 .9
R�Jf ��IN

1.0 GENERAL INFORMATION
1.1 DESCRIPTION
Ball-InCon Glass Packaging. Corporation operates a glass bottle manufacturing facility
in Henderson, North Carolina. Periodically, the Facility changes the color of the glass in
the furnace, and water is used to cool the glass when it drains from the furnace. This
operation results in a discharge of approximately 600,000 gallons of furnace drain quench
water over a 24-hour period. Ball InCon has submitted an application for a NPDES permit
(NPDES Permit No. NC0083038) to discharge the 600,000 gallons per day to a tributary of
Martin Creek. The location of the Facility is shown on Figure 1 which was prepared from
the U.S. Geological Survey Henderson Quadrangle. A site map of the Ball-InCon Facility
is provided in Figure 2. This report describes and evaluates three disposal alternatives to
discharge to surface waters via a NPDES permit. The alternatives consist of: Connection
to Sewerage System, Subsurface Disposal System, and Spray Irrigation System.
1.2 REFERENCES
1. Soil Survey of Vance County. North Carolina, United States Department of
Agriculture, Soil Conservation Service, 1977.
2. Salvato, Joseph A. Jr., Environmental Eneineering and Sanita_tiQn. Wiley-
Interscience, 2 ed.91972.
2.0 EVALUATION OF THE FEASIBILITY OF DISCHARGE ALTERNATIVES
This section evaluates the environmental feasibility of the three non -discharge
alternatives to NPDES discharge. Information contained in this report concerning the origin
and nature of the wastewater discharge and the description of the Ball-InCon Henderson
Facility was provided to Rust Environment & Infrastructure by Ball-InCon Glass Packaging
Corporation for the preparation of this report. The alternatives evaluated in this report
consist of Connection to Sewerage System, Subsurface Disposal System, and Spray Irrigation
System
2.1 CONNECTION TO SEWERAGE SYSTEM
The Henderson Facility currently discharges its sanitary wastewater stream to the City
of Henderson sewer system through a sewer line located on the Facility. The City has
expressed a willingness to also accept the furnace drain quench water but the flow rate is
restricted to approximately 20 gallons per minute (gpm) and the City does not wish to take
the water during a storm event when storm water evidently enters the sewer system. The
Facility has available a 500,000 gallon above ground storage tank which could be used
... 1RB ILBOURDESALTAM

during the furnace drain. Utilization of the tank as temporary storage would still require
the discharge of 100,000 gallons during a 24-hour period. Due to the two discharge
restrictions of flow rate and uncertain availability imposed by the sewer authority, the
alternative of discharge to the sewer system cannot always be available to support the
Facility operational requirements. Furnace drains are firmly scheduled weeks to months in
advance and are critical to facility operation. Delays in draining glass from a furnace can
result in financial loss of over $100,000/day in lost sales. For these reasons, Ball-InCon
must have a more reliable means of discharge for its furnace drain quench water and has
applied for an NPDES permit for that discharge.
2.2 SUBSURFACE DISPOSAL SYSTEM
The Soil Survey of Vance County' for the location of the Ball-InCon Facility
identifies the soils as Appling Sandy Loam. The Survey provides an evaluation of the
degree and the kind of soil limitations that affect septic tank absorption fields. For Appling
soils the evaluation for use as absorption field is listed in the Survey as "moderate" which
indicates that the soil properties or site features are not favorable for the that use and
special planning, design, or maintenance is needed to overcome or minimize the limitations.
The Survey also provides general physical and chemical properties of soils. For Appling
soils, the Survey indicates the permeability of the soil to ranges from 0.6 to 2.0 inches per
hour at a soil depth of 10 to 35 inches. Using the upper end of the permeability range of
2 inch per hour, or 1 inch in 30 minutes, results in a recommended application rate of 0.9
gallon per day per square feet. If the required volume of water to be discharged to the
system is 100,000 gpd, the resultant application area is
1009000 gpd / 0.9gpd/ftZ = 111,111 ft
If the trench for the system are 3 feet wide and the spacing between trench is 9 feet,
the require application area is
1119111 ft / 3 ff = 37,037 linear feet of trench
Assuming that the length of each trench is 500 feet results in 74 trenches. If the
center to center spacing between trenches is 12 feet, the resultant area of the drain field is
500 ft x 12 ft x 73 = 438,000 ftz
At 43,560 fe per acre, the required area is approximately 10 acres.
As shown in Figure 2, two-thirds of the approximately 60 acre Facility are under roof
or paved. Over half the remaining area is wooded, marshy or otherwise unsuitable. The
northwest corner may appear suitable, but applying the required 50 foot property line buffer
requirement to that section of the property results in a total area of approximately 8 acres
which is less than the 10 acres required. The application rate of 0.9 gpd/ft used in the
...1 M11.B01 MESALT.002

above calculations was based upon the high end of the permeability range given for the
Appling soils. Using a mid -point permeability of 1 inch per hour results in a recommended
application rate of 0.6 gpd/ft. That application rate would result in a application area of
10 acres x 0.9/0.6 = 15 acres
It is clear from the above analysis that subsurface disposal system is not a feasible
alternative for disposal of the furnace drain quench water at the Ball-InCon Facility. The
Ball-InCon Facility is bounded on the north and south by other industrial facilities and on
the east by US Route 1 and its adjacent service road. Industrial plants also are located west
of the Facility. Due to the uses of the adjoining properties, acquisition of adjoining property
for use as a disposal system may not be feasible.
2.3 SPRAY IRRIGATION SYSTEM
Spray irrigation shares the same limitation as a subsurface disposal system. The low
recommended application rate results in extensive land area being devoted to the disposal
of the furnace drain quench water. Permit conditions for spray irrigation system require a
100 foot property line buffer area between the property line and the spray irrigation system.
This buffer requirement further reduces the area available for spray irrigation and renders
the alternative unfeasible. Permit conditions for spray irrigation systems also require 30 day
storage capacity. This requirement is designed to provide storage of the wastewater during
conditions where the ground is frozen on the application site. The limitation of discharge
places an operating constraint on the Ball-InCon Facility which also could render the
alternative as not being feasible.
3.0 NPDES DISCHARGE
The conclusion of the above evaluation is that none of the three discharge
alternatives are environmentally feasible considering the volume of the flow and the
operational constraints present during a furnace drain.
Ball-InCon has applied for a NPDES permit to discharge its furnace drain quench
water to a tributary of Martin Creek. The tributary borders the Facility on the south side
and the plant presently discharges storm water to this tributary and it is intended to
discharge the furnace drain quench water through the same existing system. To BallInCon's
knowledge, the tributary stream has not been gauged, and 7Q10 30Q2 flow information is
not available at this time. BallIncon has available a 500,000 gallon above ground storage
tank which could be used to temporarily store the furnace drain quench water, and permit
discharge to the tributary at a lower rate after the initial discharge of 100,000 gallons in 24
hours.
...UM i.BOTME8ALTAM

off 0
IT
seem
VA ce
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SCALE
1'0000 0 11000' 2.000' 3.000' 4,000' 5,0000
VICINITY MAP
1C?ATBTtT1�,ft� Q' BALL--INCON PACKAGING CORP.
��sN VI Wd & HENDERSON, NORTH CAROLINA
Bleb" UcTm SCAM. PROJaCT NUYBIR FICr1RS:
1" = 2000' R5347.00
Cary, North Carolina DATE: CADFIM. 1
10-2-93

x
�c
MW-1
FENCE
x rK�RTM�E
x
k
WAREHOUSES
NO. 5
WAREHOUSES
N0. 1, 2, 3 & 4
'^ k
b
ANUFACTURING
.• , d
•d +
• k
OFFICE
L rtK TRACK" v WASTE WATER r` r , . • , . • `
BASIN �n a d
d r • /
' R � x d + r • + �
DERn'
1 x 1 ^
LINE x
�~1xr FENCE
500,000 GALLON 1 J•
FUEL OIL TANK
(ABANDONED).WATER FILLED
r
PROPERTY UNE •�`
j
r'
x_
NAMES DATE �T �y1l� �r
DRAWN: HWV 2/26/93 E�y1Y 1�� RONMEd�Y 6 .
DESIGN: SITE MAP MRAMU
CHECKED:
PE: Tcy F 12/26/93
APP'D: BALL-INCON PROJECT NUMBER R5347.00
APP'D: GLASS PACKAGING CORP.
NO. REVISIONS MADE 'CHK DATE APP'D. I HENDERSON NORTH CAROLINA SCALE 1" = 200'
The drawings, specifications and other documents prepared by the Engineer for this project are instruments of the Engineer's service for use solely with respect to this project and,
unless otherwise provided, the Engineer shall be deemed the author of these documents and shall retain all common law, statutory and other reserved rights, including the copyright.
DATE 2/26/9
FIGURE 2
PLOT DATE: 3/26/9

TANK DAZE 1TME GAS; ITME REASON FOR DRAIN
ti
44M MAMEG P'L%SGEEi CCL OR t'r M4GE
#2 12-26-92 8:40AM 8:f GM CHANGE FROM GREEN TO FLfNT.
NO. OF
t3 UON TOTAL PER
"OSES
PER MRA. MMITE
7 ' HOSES
44A • 310.8
IKICKEfR
M.4 ZOD.4
"EMER
226.2 20.B.2
TOTAL PER
MNUTE 626.4
343PL PEP,
HOUR 376M
TOTAL FOR
MIA%4 4?,22i 6
Vw_ k3sm A 4' "M. PIMP TO PkMp ` ilk TER
NT 0 LARGE OIL TANK. ALSO
UPMAEB M&M 0T Pu"K 11,14 Q S IER
WHILE PLUMNO TnTr O OIL TANK. WE RAN
MITER 1111434 m'iEP, AT V'lo OF ZR
SEWER CAPACITY. AT COMPLETION
OF {'� MN VIE "AD RQX. 2MOM 3O
,UM GAL.. IN TANK.
PLUGEG TMK NT 3:i OPM.
LESS E81. VCLUM ES7MATED AP"P'RO'A. I a,DM QMZ DRAINED
EST . W�4 LOSS 1642-42.1
F-IMIA 'EMIDT& 267973.9 'LESr3 DMINVIr INTO ZEMER AA- MMT.
HAD ASO UT 24010M GIAL.S . IN TAN. WM
EMPERTURE OF WATEER AND FH
VIE STARTED FLUE" NEXT f o"Ifft G.
THE
TEMP.
PH
9:44AM
131.8
8.9
i 045r.M%h
i 33.4
9.05
1 i :4W&A
A44.9
9.04
1:15m
146 B
9AS
2-16F i
146.6
9.17
3: 15mf
f 43.4
9.1
4:15MI
143
918
6:ti5
M
9.04
7153M
iOi
897

CANE T'W E aA : i %sy E REASON FOR PiPAIN
DRAINED. STARTED R! IJ(3EG Ca._Gl. GN.A.N.(a"'F
xxxxxxxxxxxxxxxxxxxxxx�xxxxxxxxxxxxxxxxxxxxx�rxxxxxxx�xxxxxxxxxxxxxxxxxxxxxxxxxxxx*
1 f .JVAkvf CLVSILT ACTLR LRR1WV &N { G-LV-9
E HAD APPROX. 20'OF GLASS WHEN
V
WATER �iSE
IWESTAR D7naAIN. 4=t- 7tE1V Ct'vRiiCT
a
NO. OF
C ALLON
rO rAL PER
FROM 8::30PM UNTf. 7:20AM.
HOSES
PER &ffiV.
&fflVU i E
7 HOBS
44.4
310.B
PLUCED .AhK AT 11:3aAM. .
KI QT-R
80.4
SSA
HEADER
2352
2352
SViUT OFF WATEfi AT i 1:35AM.
TOTAL PEPI
w"JTE
626 4
EST TED 2%jam GALS. to TAW
TOT FIEFIER
Vfrrm3v Fl-mli COMPI E i r �.
"Gulp,
'037594
TEUP. GE WATER, GaOtN. G tKTG SEWER
rO TAL FOR
+14
112752
'NAB 112 DEGFIEES.
LESS EST .
VOLUME
LOSS DUE TO
REDUCEZ7
PRESSURE
ESA': 3996 LOSS
42845.76
ESTUArED TOTAL a i 24
TEMPERTL1RE OF 1r4t.ATEB .AND PH
ThfE
?EAV.
PH
900Ahl
1136
sob
0.-3"
111.4
BL.97
11:25AM
91.2
8.96

WA
r
&j.q re it 7-6 e .. Tr X E cat . 0% /r4
r
7'm e.
rt= P, A
rld w Wore
-017- 9 Z.
/i: 3d A.M.
//0? °
�s
- �g- 9A
- 3 0 - 90?
3 : 3 4 4.1"0
y.
S3
8:33NOW
.`A
r
3 - 93
S'uti��r
�/� Qom_
� M
d ' f
7— 93
1.37two
76'
J
• q� 9 3
fvrim d
y ma
3
NO

r� .� t. - ..._ �.� P g _ A,la ma Pitre
1- 13- 93
9!3q Am
5a, 6 0
47
/-1+-
8 " 318 Q m
50,0
44
/9- 93*
9: LJO. orl%
14
1
so 9
/7- 93