WQ0006594_Final Permit_20050826

OF WA7-E9 Michael F. Easley, Governor
O= QG William G. Ross Jr., Secretary
y North Carolina Department of Environment and Natural Resources
j r
—1 Alan W. Klimek, P.6., Director
5 r Division of Water Quality
August 26, 2005
Ms. LISA HAYNES, ENVIRONMENTAL BIOLOGIST
UNIFI, INCORPORATED
POST OFFICE Box 737
MADISON, NC 27027
Subject: Permit No. WQ0006594
Unifi, Incorporated
Unifi, Inc. Plants 2 and 15 Distribution
of Residual Solids
Distribution/Land Application of Residuals from
the Treatment of Other Wastewater
Rockingham County
Dear Ms. Haynes:
In accordance with your permit renewal application package received on March 25, 2002 as well
as the additional information received on October 29, 2003, we are forwarding herewith a renewed Permit
No. WQ0006594, dated August 26, 2005, to Unifi, Incorporated for the operation of a program to
distribute residuals from the treatment of other wastewater. The product is a residual that is generated
from the treatment of industrial wastewaters at the Unifi, Inc. Plant #2 at Reidsville, North Carolina under
pre-treatment program permit R-0002 and at the Unifi Inc. Plant #15 at Mayodan, North Carolina under
pre-treatment program permit M-0104.
This permit shall be effective from the date of issuance until July 31, 2010; shall void Permit No.
WQ0006594, issued on April 22, 1997; and shall be subject to the conditions and limitations as specified
therein. Make note of this permit's expiration date and the fact that a permit renewal application is due to
the Division of Water Quality (Division) no later than six months prior to that date (i.e., see Condition VI.
7.), as the Division does not send reminders to apply for permit renewal.
This permit approves the continued operation of the residuals land application program for
another five-year cycle. As always, remember to take the time to review this permit thoroughly, as
sonic of the conditions contained therein may have been added, changed, or deleted since the last
issuance. Pay particular attention to the monitoring requirements in this permit. Failure to establish an
adequate system for collecting and maintaining the required operational information will result in future
compliance problems.
Please note that all domestic wastewater shall be kept separated from the subject industrial
wastewaters at both Unifi Plants. A permit modification is required if domestic wastewater is ever mixed
with the subject industrial residuals_ Additional treatment facilities may be necessary to meet the
requirements for Processes to Further Reduce Pathogens (PFRP) with domestic wastewater residuals.
Non -Discharge Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
SM
P06EM
Internet http:/th2o.enr,slate.nc.us/ndpu
Telephone [phone] Fax [phone]
DENR Customer Service Center
An Equal Opportunity Action Employer
Telephone [phone]
50% recycled/10% post -consumer paper

Ms. Lisa Haynes
Page 2
August 26, 2005
If any parts, requirements, and/or Iimitations contained in this permit are unacceptable, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request shall be in the from of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes and filed with the Office of Administrative Hearings at 6714 Mail Service
Center, Raleigh, North Carolina 27699-6714. Unless such demands are made, this permit shall he final
and binding.
If you need any additional information concerning this matter, please contact Mr. Duane Leith by
telephone at [phone], or via e-mail at duane,[e-mail]. /f
Sincerely %
for Alan W. Klimek, P.E.
cc: Mr. Chris Alexander, Precision Land Application, Inc.
Rockingham County Health Department
Winston-Salem Regional Office -Aquifer Protection Section
Technical Assistance and Certification Unit
APS Central Files
LAU Files
LAU Residuals Program Coordinator

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
PERMIT FOR THE DISTRIBUTIONILAND APPLICATION OF RESIDUALS FROM THE
TREATMENT OF OTHER WASTEWATER
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Unifi, Incorporated
Rockingham County
FOR THE
continued operation of a wastewater residuals facility for the distribution and marketing of residuals which
meet exceptional quality standards throughout the State of North Carolina, consisting of the distribution of
200 dry tons per year of residuals from the sources Iisted in Condition II 2, with no discharge of wastes to
surface waters, pursuant to the permit renewal application package received on March 25, 2002 as well as
the additional information received on October 29, 2003 and in conformity with the project plan,
specifications, and other supporting data subsequently filed and approved by the Department of
Environment and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until July 31, 2010; shall void Permit No.
WQ0006594, issued on April 22, 1997; and shall be subject to the following specified conditions and
limitations:
I. PERFORMANCE STANDARDS
L The program for the distribution/land application of the residual product shall be effectively
maintained and operated as a non -discharge system to prevent the discharge of any wastes to
waters of the state resulting from the operation of this program.
2. This permit shall become voidable in the event of failure of the distribution/land application
program to protect the assigned water quality standards of the surface waters and groundwater
adequately.
3. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to
surface or groundwater resulting from the operation of the distribution/land application
program.

4. In the event that the residuals distribution/land application program is not operated
satisfactorily, including the creation of nuisance conditions, the Permittee shall cease
distributing/land applying residuals to the site, contact the Aquifer Protection Section of the
appropriate Division of Water Quality's (Division) regional office, and take any immediate
corrective actions as maybe required by the Division.
Diversion or bypassing of untreated residuals or leachate from the wastewater and/or residuals
treatment facilities shall be prohibited.
6. No residuals shall be stored at any location other than at the wastewater treatment facility at
any time, unless approval has been requested and obtained from the Division.
7. All leachate must be reused as a wetting agent for the processing of residuals or routed to the
head of the treatment plant.
II. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities and program shall be properly maintained and operated at all times.
2. No residuals other than the following are hereby approved for distribution in accordance with
this permit: Permit Volume
Source County Number (Dry Tons/Year)
Unifi, Inc. Plant No. 2 Reidsville Rockingham M-0104 100
City of Reidsville
Unif, Inc. Plant No, 15 Mayodan Rockingham R-0002 100
Town of Mayodan
Upon classification of the facilities by the Water Pollution Control System Operators
Certification Commission (WPCSOCC), the Penmittee shall employ a certified operator to be
in responsible charge (ORC) of the residuals distribution/land application program. The
operator shall hold a certificate of the type classification assigned to the residuals
distribution/land application program by the WPCSOCC. The Permittee shall also employ a
certified back-up operator of the appropriate type to comply with the conditions of 15A NCAC
8G .0202.
4. For The residuals of exceptional quality to be distributed/land applied, the following shall be
satisfied:
2

The Ceiling Concentrations (i.e., on a dry weight basis) and the Pollutant Monthly Average
Concentrations (i.e., on a dry weight basis) shall be maintained:
Ceiling
Monthly Average
Concentrations
Concentrations
Parameters
(mg/kg)
(Mg/kg)
Arsenic
75
41
Cadmium
85
39
Copper
4,300
1,500
Lead
840
300
Mercury
57
17
Molybdenum
75
----
Nickel
420
420
Selenium
100
100
Zinc
7,500
2,800
5. All residuals shall be adequately stored to prevent leachate runoff prior to and following
treatment. The residuals may be stored in an elevated silo, placed on a concrete pad, kept
under shelter, or covered until such time as it is distributed/land applied. If an alternative
storage site is to be used, approval shall first be obtained from the Division.
6. Adequate provisions shall be taken to prevent wind erosion and surface runoff from conveying
pollutants from the residuals treatment, storage, and/or distribution/land application fields onto
adjacent property or into any surface waters.
7. A label shall be affixed to the bag or other container in which residuals that are sold or given
away for application to the land, or an information sheet shall be provided to the person who
receives the residuals sold or given away in an other container for application to the land. The
label or information sheet shall contain the following information:
a. The name and address of the person who prepared the residuals that is sold or given
away in a bag or other container for application to the land.
b. A statement that application of the residuals to the land is prohibited except in
accordance with the instructions on the label or information sheet.
C. A statement which identifies that this material shall be prevented from entering any
public or private water supply source (including wells) and any stream, lake, or river.
d. Residuals shall not be applied to any site that is flooded, frozen or snow-covered.
e. Adequate procedures shall be provided to prevent surface runoff from carrying any
disposed or stored residuals into any surface waters.
III. MONITORING AND REPORTING REQUIREMENTS
Any monitoring (i.e., including groundwater, surface water, residuals, soil, or plant tissue
analyses) deemed necessary by the Division to ensure protection of the environment shall be
established and an acceptable sampling and reporting schedule shall be followed.
3

2. Proper records shall be maintained by the Permittee tracking all distribution/land application
activities. The Permittee shall be responsible for developing and maintaining a consistent field
numbering/identification system. Records shall contain, but shall not be necessarily limited
to, the following information:
a. Source, volume and analysis of each residuals, and
b. Name of residuals' recipient, volume received and intended use
A residuals analysis shall be conducted annually from the date of permit issuance and any time
that a change in the manufacturing process occurs. The results of all residuals analyses shall
be maintained on file by the Permittee for a minimum of five years. If distribution/land
application occurs at a frequency less than annually, a residuals analysis will be required for
each instance of distribution/land application. The residuals analysis shall include, but shall
not necessarily be limited to, the following parameters:
Aluminum
Ammonia -Nitrogen
Arsenic
Cadmium
Calcium
Copper
Lead
Magnesium
Mercury
Molybdenum
Nickel
Nitrate -Nitrite Nitrogen
Percent Total Solids
pH
Phosphorus
Potassium
Selenium
Sodium
Total Kjeldahl Nitrogen
Zinc
Plant Available Nitrogen
(by calculation)
4, A Toxicity Characteristics Leaching Procedure (TCLP) analysis shall be conducted by the
Permittee annually. The TCLP analysis shall include the following parameters (i.e., note the
regulatory level in milligrams per liter in parentheses):
Arsenic (5.0)
Barium (100.0)
Benzene (0.5)
Cadmium (1.0)
Carbon tetrachloride (0.5)
Chlordane (0.03)
Chlorobenzene (100.0)
Chloroform (6.0)
Chromium (5.0)
m-Cresol (200.0)
o-Cresol (200.0)
p-Cresol (200.0)
Cresol (200.0)
2,4-D (10.0)
1,4-Dichlorobenzene (7.5)
Nitrobenzene (2.0)
1,2-Dichloroethane (0.5)
Pentachlorophenol (100.0)
1,1-Dichloroethylene (0.7)
Pyridine (5.0)
2,4-DinitrotoIucne (0.13)
Selenium (1.0)
Endrin (0.02)
Silver (5.0)
Hexachlorobenzene (0.13)
TetrachloroethyIene (0.7)
Heptachlor (and its hydroxide) (0.008) Toxaphene (0.5)
Hexachloro-1,3-butadiene (0.5)
Trichloroethylene (0.5)
Hexachloroethane (3.0)
2,4,5-Trichlorophenol (400.0)
Lead (5.0)
2,4,6-Trichlorophenol (2.0)
Lindane (0.4)
2,4,5-TP (Silvex) (1.0)
Mercury (0.2)
Vinyl chloride (0.2)
Methoxychlor (10.0)
Methyl ethyl ketone (200.0)
After the residuals have been monitored annually for two years, the Permittee may submit a
request to the Division for a permit modification to reduce the frequency of the TCLP
analysis. In no case, however, shall the frequency of TCLP monitoring be less than once per
permit cycle when residuals are distributed/land applied.
5. Three copies of all required monitoring and reporting. requirements as specified in Condition
III. I., Condition III. 2., Condition 111. 3., and Condition III. 4. shall be submitted annually on
or before March I' of the year following the distribution/land application event to the
following address:
rd

Division of Water Quality
Information ProcessingUnit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
6. Noncompliance Notification:
The Permittee shall report by telephone to the Aquifer Protection Section of the Division's
Winston-Salem Regional Office at telephone number (336) 7714600, as soon as possible, but
in no case more than 24 hours or on the next working day following the occurrence or first
knowledge of the occurrence of any of the following:
a. Any occurrence with the residuals land application program that results in the land
application of significant amounts of residuals that are abnormal in quantity or
characteristic.
b. Any failure of the residuals land application program resulting in a release of material to
receiving waters.
c. Any time that self -monitoring information indicates that the residuals land application
program has gone out of compliance with the conditions and limitations of this permit or
the parameters on which the program system was designed.
d. Any process unit failure, due to known or unknown reasons, that render the residuals land
application program incapable of adequate residuals treatment.
e. Any spillage or discharge from a vehicle or piping system transporting residuals to the
application site.
Persons reporting such occurrences by telephone shall also file a written report in letter form
within five days following first knowledge of the occurrence. This report shall outline the
actions taken or proposed to be taken to ensure that the problem does not recur.
IV. GROUNDWATER REQUIREMENTS
Any groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
V. INSPECTIONS
1. The Permittee or his designee shall inspect the residuals storage, transport, and treatment
facilities to prevent malfunctions and deterioration, operator errors and discharges which may
cause or lead to the release of wastes to the environment, a threat to human health, or a
nuisance. The Permittee shall maintain an inspection log or summary including at least the
date and time of inspection, observations made, and any maintenance, repairs, or corrective
actions taken by the Permittee. This Iog of inspections shall be maintained by the Permittee
for a period of five years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
5

Any duly authorized officer, employee, or representative of the Division may, upon
presentation of credentials, enter and inspect any property, premises or place on or related to
the treatment site or facility at any reasonable time for the purpose of determining compliance
with this permit; may inspect or copy any records that must be kept under the terms and
conditions of this permit; and may obtain samples of groundwater, surface water, or leachate.
VI. GENERAL CONDITIONS
This permit shall become voidable unless the residuals land application events are carried out
in accordance with the conditions of this permit, the supporting materials, and in the manner
approved by the Division.
2. This permit shall be effective only with respect to the nature and volume of residuals described
in the application and other supporting data.
Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division in accordance with North Carolina General
Statutes § 143-215.6A through § 143-215.6C.
4. The annual administering and compliance fee shall be paid by the Permittee within 30 days
after being billed by the Division. Failure to pay the fee accordingly may cause the Division
to initiate action to revoke this permit, as specified by 15 NCAC 2H .0205 (c)(4).
The issuance of this permit does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances that may be imposed by other government agencies
(i.e., local, state, and federal) which have jurisdiction, including, but not limited to, applicable
river buffer rules in 15A NCAC 2B .0200, soil erosion and sedimentation control
requirements in 15A NCAC Chapter 4 and under the Division's General Permit NCGO 10000,
and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 15A NCAC
.0500.
6. This permit may be modified, revoked, and/or reissued to incorporate any conditions,
limitations and monitoring requirements the Division deems necessary in order to protect the
environment and public health adequately.
The Permittee, at least six months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Division shall review the adequacy of the facilities
and residuals land application program described therein, and if warranted, shall extend the
permit for such period of time and under such conditions and limitations as it may deem
appropriate.
8. This permit shall not be automatically transferable. In the event that there is a desire for the
residuals land application program to change ownership or to change the name of the
Permittee, a formal permit request shall be submitted to the Division documentation from the
parties involved and other supporting materials as may be appropriate. The approval of this
request shall be considered on its merits and may or may not be approved.
A

Permit issued this the 26th day of August 2005.
NORTH CAR W77
AL MANAGEMENT COMMISSION
for Alan W. Klimek, 15'.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0006594
7