NC0006190_RENEWAL APPLICATION_19970625

WDES DOCUWEMT SCAMMIM& COVER SMEET
NPDES Permit:
NC0006190
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Renewal Application
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
June 25, 1997
MMIS docxxxlmelmt is primted oxx reuse paper - igpmore any
coxxtent oa the re-srerse side

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3uaf 417
NPDES Permit
Modification Application
Delta Apparel, Inc.
Nco00619 0
June 1997
Prepared for:
Delta Apparel, Inc.
(Delta Mills, Maiden Plant)
100 West Pine Street
Maiden, North Carolina 28650
Catawba County
[phone]
Prepared by:
Applied Water Technology
621 Hutton Street
Suite 107
Raleigh, North Carolina 27606
[phone]
3 rn ,
W:
rf,� �T�M+-+r:��-wit.• -_
APPLIED WATER TECHNOLOGY AWT

FOR AGF=NUY
r '
NORTH CAROLINA DEPT. OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
ENVIRONMENTAL MANAGEMENT COMMISSION
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER
STANDARD FORM C - MANUFACTURING AND COMMERCIAL
I
I
I
I
I
1
1
1
1
SECTION I.
APPLICATION AND FACILITY DESCRIPTION
Unless otherwise Wocifled on this form all Rome are to be
completed. 9 an Rom Is not applicable Indicate 7-W.
So
X rn
ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED. REFER TO BO3WET
:M
�:Ir- rn
BEFORE FILLING OUT THESE ITEMS.
p
morn
Plea so Afnif or Type"P.
rn <
1. Legal Name of Applicant
101
Delta Mills, Inc.
(see instructions)
Maiden Plant
2. Mailing Address of Applicant
(see Instructions)
100 1.7 D4 C
Number & Street
City
State
Zip Code
Applicant's Authorized Agent
(see Instructions)
Name and Tite
Number& Street
City
State
Zip Code
Telephone
4. Previous Application
It a previous f plication for a
permit under e National
Pollutant Discharge Elimination
System has been made, give
of application.
the date
N
103C
103d
1030
103f
'104
�- Q1 L. ne treel-
Maiden
North Carolina
28650
Charles BI
Applied Water Technn]lngy
621 Hutton Street
Suite 107
Raleigh
North Carolina
27606
919 835-8688
Area Number
Code
YF1 M0 DAY
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.
Charles D. Blackwell 102e Authorized A-ent-
Printed Name of Person Signi 1 Title
1021
Signature of Applicant or Authorized Agent YR M0 DAY
Date Application Signed
North Carolina General Statue 143-216.6 (b)(2) provides that Any person who knowingly makes any false statement representation, or certification in any
record, report plan, or other document files or required to be maintained under Article 21 or regulations of the Environmental Management
rrl��M`snsn implementing that Article, or who falsifies, tampers with, or knowing�_ 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 $10,000. or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a
punishment by a fine or not more than $ 10,000 or imprisonment not more than 5 years, or both, for a similar offense.)

y
5 Facility (see instructions)
Give the name, ownership, and
physical location of the plant or
other operating facility where
discharge(s) presently omugs)
or wiU occur.
Name
6.
7
8.
Ownership (Public. Private
or both Public and Private)
Check block if a Federal
facility
and give GSA Inventory
Control Number
Looation:
Number tf Stmet
City
County
State
Nature of Business State the nature
of the business conducted at the
plant or operating facility.
Facility Intake Water (see
instructions) Indicate water intake
volume per day by sources.
Estimate average volume per day
in thousand gallons per day.
Municipal or private water system
Surface water
Groundwater
Othef
Total Item 7
' If there is intake water from 'other,
specify thq source.
Facility Water Use Estimate average
volume per day in thousand gallons
per day for the followingg types of
water usage at the fact ity.
(See instructions)
Noncontact cooling water
Boiler feed water
Process water Including contact
cooling water}
Sanitary water
Other'
Total Item 8
' If there are discharges to'other,
specify
Et there is'Sanitary' water use,
give the numborof people served.
106a
105b
105c
105d
lose
105f
105g
loch
106a
106b
107a
107b
107c
107d
107e
107f
108a
108b
108C
108d
108e
108f
108g
108h
Delta Apparel Co.
Maiden Plant
® PUS 0 PFIv 0 OPP
❑ FM
100 West Pine Street
Maiden
North Carolina
Textiles
Manufacture Knit Fabric
AGENCY USE
I-
2000 thousand gallons per day
thousand gallons per day
thousand gationtis per day
thousand gallons per day
thousand gallons per day
thousand gallons per day
90
thousand gallons per day
1500 -
thousand gallons per day
NA
Thousand gallons per day
400
Thousand gallons per day
2000
thousand gallons per day
le se rved

TOR AGENUY Ubb
J'-
0. All Facility Discharges and other Losses. Number
and Discharge (See lnshictions)Vclume Specify the
number of discharge points and ft volume of water
discharged lostirom the facility to the
'
or according
- categones below. Estimate average volume per day in
Thousand gallons per day
Numberof
Total Volume Discharged,
Discharge Points
Million Gallons Per DR
Surface Water
109al
1
10&2
1 - U with e intent t?.kabrease to
Sanitary wastewater transport systen
109bl
NA
iogm
'0.4
Storm water transport system
109c1
5
109c2
NA
Combined sanitery and storm water
incidl
-NA
1n-QrV
I
I
I
I
0
transport system
Surface impoundment with no
10901
10902
effluent
Underground percolation
1091
lom
Well injection
_109gl
109g2
Waste acceptance firm
109h1
1109112
Evaporation
101 NA
low 0.1
Consumption
109j1
10912
Other
109k1
109k2
Facility dischargers and volume
Total item 9
10911
1092
'If there are discharges to 'other.
1109m1
specify.
Permits. Licenses and Applications
List all existing, pending or denied permits, licenses and applications related to discharges from this facility (see
Issuing
For
z-Typo of
Date
Data
I Date
Expiration
Agency
Agency
Permit or
Filed
Issued
I Denied
Date
use
License
10 Number
YRIMO/DA
YRIMOIDA
I YRrMO/DA
YR/M01DA
h)
ICDEM
'N'
b v-.k o.,r
W- pop to i ci
94/11/1835/9/1
)0/9/30
N&-EM
OQ0op 8122/9/8
93/212
NMEM
A 4f
Fio t I a
.3 4 7, L R. I L
9 6-15 16
()6/7Z99
01/3/31
11. Maps and Drawings
Attach all requited maps and drawings to the back of this application. (see instructions)
12. Additional Information
r
instructions)

OR AGENCYUSE
-7
STANDARD FORM
C MANUFACTURING AND COMMERCIAL
SECTION It. BASIC DISCHARGE DESCRIPTION
complete this section for each discharge indicated in section 1, Items 9. that Is to This Includes discharges to sewerage systems in
surface waters. munkipal
which the waste water does not go through a treatment works prior to being discharged to surface waters. Discharges to wells must be described where there are
discharges to
also surface waters imm tt" facility. SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE REQUIRED EVEN IF SEVERAL DISCHARGES
ORIGINATE IN THE SAME FACILITY. All values for an exiAkV discharge should be repmentallve of the twelve previous months of operation. If this Is a proposed
discharge, values should reflect bad engineering ealknales.
ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLETAS INDICATED. REFER TO BOOKLET
BEFORE FILLING OUT THESE ITEMS.
7. Discharge Serial No. and Name
001
a Discharge Seriat No. 201a
(we instructions)
b. Discharge Name 201b
Give the name of discharge, it
NA
any (see instructions)
c. Previous Discharge Serial No 201c.
NA
If a previous permit
for this dis.r"
application was made
I
'
charge (item 4, Section provide
previous discharge sN
number.
z Discha rating Dates
DM%p %legan Date 202a
70 2
If the discharge described below
is in operation, give the date
(within best estimate) the
discharge began
b. Discharge to Begin Date 202b
NA
It the dscha7 has never
YR MO
occurred but is planned for some
future date, give the date to
discharge vAll begin.
c. Discharge to End Date If the 202c
NA
c2schar is scheduled to 6;9,
YR MO
discontinued within the next 5
years, give the date (within best
estimate) the discharge will and.
3. Engineering Report Available
Check it an engneering report Is
available to reviewing agency
upon request (we instructions) '203
R3
4. Discharge Location Name the
polidcal boundaries within which
the point of discharge Is bcated:
Agency Use
State 204a
County 204,
North Carolina 2111d
Catawba 2D40
(it applicable) City or Town 204c
Maiden 2W
5. Discharge Point Description
8 siee instructions)
scharge into (check one)
Stream (includes ditches, arroyos, 205a
k]STR
and other watercourses
Lake
[] LKE
008arl
C]OCE
Municipal S ' anitary Wastewater
[]MTS
Transport System
Municipal Combined Sanitary
and Storm Transport System
E] MCS
I
I

FUR-AUENUY U5i--
DISCHARGE SET 6 NUMBER
Municipal storm Water Transport [3 STS
System
Well (injection) ❑ WE L
Other ❑ OTH
if -athee is &&*od, specify type msb
6. Discharge Point- Lal/Lon.
Give the precise location of the
point
discharge to the nearest
Latitude 206a _15—DEG. _L4-MIN. _-L—sEc
Lcongftudo 206b. 81 DEG. _14_M I N. 2 5_sE c
7. Discharge Receiving Water Name
Name Me waterway at the point of 207a Clark Creek
discharge. (see instructions)
If the disdiame is through an outfall that extends 2=
beyond the shoreline or is below the mean low
water line, complete hem 8.
' Fa A Use
I S.
207c
FwAoentv Use
8. Offshore Discharge
a. Discharge Distance from Shore 206a feet
b. Discharge Depth Below Water 20eb feet
9 Discharge Typo and Occurrence
a. Type of Discharge Check
whether the discharge is M (oon) Continuous
continuous or intermittent D (int) Intermittent
(See instructions)
b. Discharge Occurrence Days
per Week- Enter the average
number of days per week M Z_days per week
(during periods of discharge)
this discharge oemrs.
c. Discharge Occurrence- Months 209c JAN FEB MAR
If this discharge normally oper- APR MAY J U N
ates (either intermittently or JUL AUG SEP
continuously) on less than aye OCT NOV DEC
around basis (excluding shut-
downs for routine maintenance),
check the months during the yea
when the discha. is operating
(see in-structionsr
Complete Items 10 and 11 K *intermittent' is
chocked in Item 9.a. Otherwise, proceed to
Item 12.
110. Intermittent Discharge Quantity
State the average volume per clis- 210 NA thousand gallons per day
charge occurnanoe in thousands of
gallons
11. Intermittent Discharge Duration
and Frequency
a Intermittent Discharge Duration
Per Day State the average 211a NA hours per day
numberof hours perday the
discharge Is operating
b, Intermittent. Discharge
Frequency State the average 211b discharge occurrences per day
number of discharge occurrenoi s
r day during days when
discharging
12, Maximum Flow Period Give the
time period in which the maximum 212 From Jan to Dpc--
flow of this discharge occurs month month
I

PUH AGENCY USE
DISCHARGE SERIAL NUMBER
001
13. Activity Description Give a 213a Manufacture of cotton and synthetic
narrative description of activity fabric on circU ai riitting machines
producing this discharge (we Process also includes .bleachi.n.g, _d eeing
instructions) finishing fabric using all dyes and
c emica s associated with this process
generally falling under Standard _
Industrial.Qgdg (SM—No. 2257.
14.
2
N
Activity Causing Discharge For each SIC Code which
describes the activity causing this discharge, supply the
type and maximum amount of either the raw matenal
consumed (Item 14a) or the product produced (Itom 14b)
In the units specified in Table I of the Instruction Booidet.
For SIC Codes not Osted in Table I, use raw material or
production units nomlafly used for measuring production
(see instructions) r'
a Raw Materials
b. Products
Maximum Unit Shared Discharges
SIC Code Name Amount/D See Table Serial Number)
t a
2257 extile --Mi:ll 80 H-2 001
Products
mYL, -,VU ffw 7f t 0�
/Q c.'fv� t,
jtIA.,-5 -W
41A
wv 14 -
Pro -\,—r
0ry CtL1` J �
Qvt
VAIty
'7)1)4) S k b Ilt
r
b4j, �
P,,ku� lb,
su�y rR6 - Uvpt-r,�G�
do

'�NOY U81z� FOR Al2
T.
DISCHARGE SERIAL NUMBER
001
is Waste Abatement
a Waste Abatement Practices 215a
Wastewater from dyehouse goes to
Narrative- - --
Describe to waste abatement
heat reclaimer buildinp, whereheatis
prac6oas used on this dis-
recovered from hot wastewater, -Hot & rold
charge with a brief narrative
wastewater is screened, then discharge ggU
(s" instrudons)
to wastewater treatment facility consisting
of bar screen-, dual aeration basins, dual
secondary clarifiers with sludge return,__
chlorine contact basin and Post aeration
basin.
b. Waste Abatement Codes 215b
(IfSCREE _(2) RHEATR -_(3) BACTIV
Using the codes listed in Table r
(4ESEPAR -(s) MPOSTA .—(6) QMON11
11 of the instruction Booklet,
(7ELAGOO s)SLANDD (9)
closaibc the waste abatement
(10) (11) (12)
p rooesses for this discharge in
(13) --- (14)--- -- -0s)—
the order in which they occur
(16) --- (17)_(18)_
if possible.
(19) _(20)(21)_
(22) (2 (24)
(25)
I
I
I
I
I

s
FOR AGENCY U 5dE
s;
DISCHARGE SERIAL NUMBER '
001
16. Wastewater Characteristics '
Check the box beside each constituent which is present in the effluent (discharge wateo. This determination is to be
based on actual anatysis or best estimate,(see instructions) '
Parameter
emsent
Parameter
Present
216
216
Color
00080
X
Cop
01 per
X
Xm—monia
Iron
00610
X
01045
tganic tutrogen
o0E05
Y
01051
X
Nitrate
agnesium
OOG20
X
OO9Z7
itnte
00615
01�
Phosphorus
r
Mercury
03565
X
71900
Sulfate
Moi m
00945
x
1 010 2
00745
X
01067
Witite
Selenium
00740
01147
romi a
5fiver
71870
01077
Chionde
Potassium
00940
X
00937
X
anOO
wm
03720
00929
X
Huonde
I hallIUM
00951
01059
Aluminum
I iLanium
01105
01152"
AnbmGny
I in
01097
01102
Arsenic
Zinc
01002
01092
X
ryhum
gtu s
x
01012
74051
num
Crilonnated organic oompou
01037
74052
s
01022
74053
X
Cadmium
i and grease
01027
00550
Calcium
PneFM
00916 .
X
3Z73:)
X
Coball
buflaclanb
01037
38M
X
Chromium
C londe
01034
X
50060
X
ecal co arm bacteria
HaoicactivIty
74055
1
74050
- 1
1
1
1
1
1
1
Specify substances, compounds and/or elements in Item 26. '
Pesticides (insecticides, fungicides, and rodenticides) must be reported in terms of the acceptable common names specified in Acceptable Common Names
and Chemicalnames for the In mcf'ant statement on Pesticide Labels, 2nd Edition, Environmental Protection Agency, Washington, D.C. 20250, June 197Z as
required by Subsection 1623(b) of the Regutations for f}18 Enfowrient of the Federal Insecticide, Fungicide, and Rodenticide Act. '
1
1
1

DISCHARGE SERIAL NUMBER
' 17. Description of Intake and Discharge
For each of the parameters listed below, enter in the appropriate box the value or code letter answercailed for (see instructions)
In addition, enter the parameter name and code and all required values for any of the following parameters if (hey ere checked in Item 16:
ammonia, cyanide, aluminum, arsenic, beryllium, cadmium, chromium, copper, lead, mercury, rocket, selenium, zinc, phenols, oil and grease, and
' chlorine (residual).
1
1
1
1
1
1
n uent
tmuant
Parameter and Code
ntmaled
Intake
ln-P n
Treated
Uaily
Average
Minimum
Value
aximum
Value
Frequency
of Analysis
Numbero
Analyses
bmple
Type
Water
Intake
Observed or
Observed or
217
(Daily
Water
F)gmbd
Expected
average)
(Daily
During
During
average)
Discharge
Discharge
Activity
Activity
(9
2
(31(4)5
6
(7)
1 (8
Flow'
MGD
Gallons per day
50050
.789
NA
.007
1.112
Daily
I
I
P
Units
0=
10.3
NA
8.1
8.5
5/7
1
G.
emperature (winter)
cc
74026
38
NA
22.3
9
28
5/7
1
G
emperature summer
°C
74025
1 43
NA
26.7
1 22
30
1 5/7
1
1 G
• ioc emcra xygen
Demand
(BOD 5-Day)
mgA
t>310 LBS
NA
I NA
21.1
7.4
82 1
3/7
1
C
Mmical Oxygen
Demand (COD)
12647.2
mg/I LBS
flosao
NA'
NA
961.4
359.8
1/7
1
C
otal buspenoed
(nonfi tenable) Solids
mgA LBS
00=
NA
NA
126.0
5.7
1557.5
3/7
1
C
G cuctance
micromhoslcm at 25'C
ODOG,
NA
NA
54.2
486
1/7
1
C .
SiMeabie Panet
(residue)
mIA
ODSa5
1.4
NA
0.0
0.0
0.0
5/7
1
G
' ' Other discharges sharing intake flow (serial numbers) (see instructions)

Y
O��L'It[�Y�►ty��b'1�
Attmloni
Chroms
Copper
Lead
Zinc
Phenol
Residt
DISCHARGE SERIAL NUMBER
001
17. (Cont'd)
Innuent
en
Parameter and Code
n
Intake
n
Treated
at y
Average
Minimum
Value
Maximum
Value
Frequency
of Analysts
Number
of
Samp,e
Type
Water
Make
Observed or
Observed or
Analyses
217
(Daily
Water
Expected
Expected
average)
(Daily
During
During
average)
Discharge
Discharge
Activity
Activity '.
1
2)
IM
a
5
6
8
a 00610 Mg/1
NA
0.8
0
um 01034 Lbs.ug
1 NA
2.93
0.7
01042 u /1
NA
2
01051 a/1
NA
J
4
4
4
1 365
01092 u 1
NA
35.1
10
s 32730 Lbs
N
al Chlorine Mg/l
NA
0.77
0.29
60.4
1/7
1
G
50060
18. Plant Controls Check if the following
plant controls are available for this
discharge
Attemate powersource for major
pumping facility
Alarm or emergency procedure for
power or equipment failure
Complete Item 19 if discharge is Iron
cooling andror steam water
generation and water treatment
addWyes are used
19. Water Treatment Additives 1f the
discharge is treated with any
conditioner, inhibitor, or algtcide,
answer the following:
a Name of Material(s)
b. Name and address of
manufacturer
218
219a
2M
c, Quanbty (pounds added per # 219c
million gallons of water treated) {
APS
[] ALM
NA

d Chemical composition of these 219d
additives (s" instruction I
Complete Hems 20-25 H them is a thermal discharge
(e.g., associated with a stoam and/or power generation
plant steel mill, petroleum refinery, or any other
manufacturing process) and the total discharge flow is
10 million gallons per day or more. (see Instructions)
20.. Thermal Discharge Source. Check 220
the appropriate hem(s) indcating
the souroe of the discharge (see
instructions)
Boiler Slowdown
Boiler Chemical Clewing
Ash Pond Overflow
Boiler Water Treatment -
Evaporator. Slowdown -
Oil and Coal Fired Plants -Effluent
from Air Pollution Control Devices
Condense Cooling Water
Cooling Tower Blowdown
Manufacturing Process
Other
1. Discharge/Receiving Water
Temperature Difference
Give the maximum temperature
difference between the discharge
and receiving waters for summer
and winter operating oonditions,
instnictons)
Summer 221a
Winter 221b
22. Discharge Temperature, Rate of
Change Per Hour 222
Give the rnaximum posstUe rate of
m
change per hour of
disc
harge
23. WaterTempemture, Percentile
Rcgrt(Frequency of Occurrence)
In table below, enter the
temperature which is exceeded 1019
of the year, 5% of the year. I% of
the year and not at all (maximum
yearty temperature). (we
instructions)
Frequency of occurrence
a. Intake Water Temperature 223a
(subject to natural changes
b. Discharge Water Temperature 223b
DISCHARGE SERIAL NUMBER
001
NA
C] BLBD
❑ BCCL
❑ APOF
❑ EPSD
0 OCFP
NA
F1 COND
❑ CTBD
❑ MFPR
❑ OTHR
NA OF
NA OF
NA__ FJhour
yCr/-
NA
511/0
NA
1%
NA
M1A1mum
NA OF
NA OF
NA OF
NA OF
NA *F
NA OF
I NA OF
I NA OF
24. Water Intake Velocity 224 _HA _feet/sec.
(see instructions) -
25. Retention Time Give the length of 225 NA minutes
time, in minutes, from start of
water temperature rise to discharge
of cooling water. (see instructions)
E
rd

DISCHARGE SERIAL NUMBER
001
26. Adcri6onal Inlomiation

FQH A5ENL;Y =1
'' STANDARD FORM C MANUFACTURING AND COMMERCIAL
SECTION Ill. WASTE ABATEMENT REQUIREMENTS & IMPLEMENTATION (CONSTRUCTION) SCHEDULE
This section requires information on any uncompleted implementation schedule which may have been imposed for construction of waste treatment facilities.
Such requirements and implementation schedules may have been established by local, State. or Federal agerxoes or by court action. In addition to cornplating
the lollowirq Rents, a copy of an official Implementation sdwduie should be attached to this application. IF YOU ARE SUBJECT TO SEVERAL DIFFERENT
IMPLEMENTATION SCHEDULES. EITHER BECAUSE OF DIFFERENT LEVELS OF AUTHORITY IMPOSING DIFFERENT SCHEDULES (DIFFERENT
AND/OR STAGED CONSTRUCTION OF SEPARATE OPERATIONAL UNtTS (ITEM 1c), SUBMIT A SEPARATE SECTION Ill FOR EACH ONE.
1.
FUH ALi,:NL;Y U51:
Improvements
EL Discharge Serial Numbers 300
Affected List the discharge
serial numbers, assigned in
Section 11, that are covered by
this implementation schedule
b. Authon Imposing Require- 30ia
ment Aack the appropriate
item indicating the authority
for the implementation schedule
It the identical implementation
schedule has been ordered by
more than one authority, check
the appropriate items. (see
instructions)
Locally developed plan 301b ❑ LOC
Amawide Plan ❑ AR E
Basin Plan ❑ BAS
State approved implementation E)SQS
schedule
Federal approved water quality f3was
standards implementation plan
Federal enforcement procedure (DENF
or action
State court order OCRT
Federal court order r-1 FED
c. Facility Requirement Specify
the 3-charactercode of those 3-character
listed below ftat best describes
,n general terms therequire-
ment of301C
the implementation
schedule and the applicable six -
character abatement oodes(s)
from Table 11 of the instruction
booklet If more than one 301d 6-character
schedule applies to the facility specific)
because of a staged constructior �soo Table 11)
schedule, state to stage of con-
struction being described here
with the appropriate genera)
action code. Submit a separate
Section Ill for each stage of
construction planned.
Now Facility NEW
Modification (no increase in capacity or treatment) MOD
increase in Capacity INC
Increase in Treatment Level INT
Both Increase in Treatment Level and Capacity ICT
Process Change PRO
Elimination of Discharge ELI
I

- "MM
HIM
2' hnFMementatson Schedule and 3. Actual Completion Dates
Provide dates imposed by schedule and any actua! dates of completion for implementation steps listed below.
Implementation Steps 2- Schedule
(yr/Mo/Day)
3. Actual Completion (Yr/Mo/Day)
a. Pfefirninary plan complete 302a
303a
t I
b. Final plan submission 302b
303b
c. Final plan complete 302c
303c;
d Fina=g complete & contract 3X!d
3Md
LJ
awarded
e. Site acquired 302e
303e
f. Begin construction
3=
g, End construction 30
3M9
h Begin discharge 302h
303h
i. OperaWnal favat attained 3W
I
303i
9

' N. C. DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
ENVIRONMENTAL MANAGEMENT COMMISSION
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
APPLICATION FOR PERMIT TO DISCHARGE
' ADDITIONAL REQUIRED INFORMATION
' APPLICATION NUMBER
DISCHARGE SERIAL. NUMBER, 001
' REFER TO DIRECTIONS ON REVERSE SIDE BEFORE ATTEMPTING TO COMPLETE THIS FORM
1
.1
Untreated
' REMARKS:
I certify that I am familiar with the information oontained In this report and that to fh'e
best of my knowledge and belief such information is true, complete and exurate.
are corm mateleo Name ol Aulnonzmn r a re

Direcsbns - For each parameter listed, complete the information
requested in each column in the units 4 oified according to the htstructions
given below.
Column f - Enter the daily average value of the intake water at the
point it enters the facility. If intake water d from more than one source, and
enters the facility at separate entry points, the value Oven In column 1 should
be waVited proportional to the quantity of flow contributed Iran each source.
If water is treated before use, completion of this column is not required (see
Instructions for column 2). Values of intake are not required for n9ning
activities.
Cokrrnn 2 -'If all or part of intake water is treated before use,
provide values for total intake here instead on in Column t, Also describe
briefly in item 26'additional information,' the type of treatment performed on
lntake water (e.g., rapid sand filtration, coagulation, flocculation, ion
exchange, etc.) and the percent of intake water contributing to this discharge
that has been tmated.
Column 3 - Supply daily average value for the days when
discharge is actually operating or is expected to be operating (anew
discharge). Daitf average values ate to be computed by weighing the daily
value in proportion to the daily flow. H a discharge occur; irregularly, the
value supplied in the oolumn marked'Dally Average' should represent an
average for the average for the days the discharge actually occurs. Average
values are not to be supplied for pia, specific conductance, and
bacteriological parameters e.g., colifotm bacteria).
Columns 4 and 5 - Supply minimum and maximum value
obse rved (or expected for new discharge) over any one day when the
discharge is operating.
Column 6 - Specify the averraaggee freque �f is for each
parameter as number analyses per numberof dayss e.g.W isequNalent
to three analyses performed every 7 days). lfcontinuous, enter'CONT.'
When analyses are conducted on more than one indvidual grab sample
coliectod during the same day, the analysis frequency should reflect one
analysis whose value is the average of the individual grab sample
measurements. Average frequency should be based on an operating month.
Ca/umn 7- Specify the number of analyses performed at the
average frequency specified in column 6, up to 365.
Column a - Specify sample type as follows:
G For grab sample (individual sample collected in less tan 15
minutes).
4C For composite sample # is to be replaced by the average
numberof hours over which the composite sample was collected.
Composite samples are combinations of individual samples
obtained at intervals overa time period, either the volume of
each individual sample is directly proportional to discharge flow
rates or the sampling interval (for constant volume samples) is
inversely proportional to the flow rates over the time period
used to produce the composite.
NA If 'CONT' was entered in column 6.
Analytical moViods - Appendix A contains all parameters with
their reporting levels, test descriptions, and references. The parameter
values can be determined either by use of the standard analytical methods as
described in table A or by methods previously ap raved by time EPA Regional
Administrator or Director of a federally approv State program (or their
authorized representative) who has jurisdiction over the State in which the
discharge occurs. If the test used is not one shown in table A, the test
procedure should be referenced'n'Remarks' cr on a separate sheet.. H
values are determined to be less than the detectable limits (as determined by
referenced standard analytical techniques and/or instrument manufacturer's
literature), specify 'LT(Value of detectable limit)' In the appropriate space.
For example, It the detectable Gmft Is .005 mgA and quantities of less than
this are determined, spp�9*'LT.005.' Do not enterdescriptors such as
'NIL, "TRACE,' 'NE G,' etc. for this purpose. If It Is your reasoned
judgment that one or more of the required parameters is not present in the
initial untreated or treated process water and/or tho discharge, enter an 'A'
(meaning 'absent') in the appropriate space.
In order for values reported to be representative, It is
recommended that they be based on from at least five to seven analyses of
composite samples(if applicable). Each of the composite samples should be
obtained by compositing frequent samples in proportion to flow over an
operating day. SamFles should be taken during period of maximum
production, if possible. ff samples are taken at perlods of less than
maximum production, state in 'Remarks* the percent of maximum
production that was obtained during the sampling period. .
1

I
1
1
1
1
1
1
1
1
1
1
1
1
1
SLUDGE MANAGEMENT PLAN
Delta Mills, Inc. (Maiden Plant)
Solids that settle and thicken in the clarifiers are wasted at a rate of approximately 50,000
gallons per week. This waste rate can vary with the amount of mix liquor total solids,
flow and sludge blanket depth in clarifiers. Sludge is wasted into a lagoon with a holding
capacity of approximately 2 million gallons. The decant is pumped back into the
treatment works at aeration basins #1 and #2. This sludge thickens to about 4% solids.
Once the lagoon is full or near full, we have a professional contractor empty it on an
annual or as needed basis.
Sludge from the lagoon is hauled to parts of a 240 acre pasture for land application. Land
application takes place under the regulations listed in our permit WQ00069834.
APPLIED WATER TECHNOLOGY A w'I`

Engineering Alternatives Analysis
Delta Apparel, Inc.
June1997
Prepared for:
Delta Apparel, Inc.
(Delta Mills, Maiden Plant)
100 West Pine Street
Maiden, North Carolina 28650
Catawba County
[phone]
Prepared by:
Applied Water Technology
621 Hutton Street
Suite 107
Raleigh (9 9) 836-8688 North Carolina 27606
APPLIED WATER TECHNOLOGY AW T

TABLE OF CONTENTS
PAGE N-0.
SUMMARY i
BACKGROUND INFORMATION 2
PROJECT DESCRIPTION 2
EVALUATION OF DISPOSAL ALTERNATIVES 4
A. Connection to a Sewer Collection System 4
1. Existing Sewerage System 4
2. Planned Sewerage System 4
B. Land Based Disposal 4
1. On -Site Land Based Disposal 4
2. Off -Site Land Based Disposal
C. Wastewater Reuse 5
D. Surface Water Discharge
7
E. Disposal Combinations 7
Surface Water Discharge and Wastewater Reuse Combination 7
Option 1 8
Option 2 9
Attachments
• Flow Schematic for Surface Water/Wastewater Reuse Options
• Land Availability for Land Based Disposal Alternative Letter
• Land Area Required for 0.5 MGD Flow
• Land Area required for 1.5 MGD Flow
• Calculations of Wastewater Flow:
Current Production and Existing Facilities
Higher Production and Existing Facilities
• Wastewater Treatment Plant Schematic
• Proposed Wastewater Flow Schematic
• Delta Mills WWTP Characteristics
• Estimation of WWTP Effluent Limit Characteristics at 1.5 MGD
• EPA Cost Curves
- IV 3.3 - 15, IV 3.3 - 16 Secondary Clarifier with Polymer
- IV 3.6 - 3, IV 3.6 - 4 Dual Media Filtration
- IV 5.1 - 2, IV 5.1 - 3 Activated Carbon Adsorption
- IV 5.9 - 3, IV 5.9 - 4 Reverse Osmosis
- IV 4.1 - 6, IV 4.1 - 7 Aeration Basin
• Analytical Report of Wastewater Influent
• Additional Calculations - Aeration Basin and Reaeration Basin
• Crocker & Associates, Inc. Quotation for Aerators
Man Pocket
• Catawba County Tap Map
• To -Scale Facility Site Map
APPLIED WATER TECH NOLOGY AWT

Delta Apparel, Inc.
June 1997
Page 1
SUMMARY
Delta Apparel, Inc. would like to increase production at their Maiden Plant as soon as
possible to continue to be competitive and to meet consumer demand. The current
amount of wastewater generated by this facility is approximately 1.0 MGD. However,
this production increase will ultimately result in an increase in the amount of wastewater
generated of approximately 500,000 gpd. _.
To comply with both state and federal requirements for requesting a NPDES permit
modification due to an increase in flow, an engineering alternatives analysis has been
completed. This engineering alternatives analysis is an evaluation of the available
disposal alternatives, their costs, and applicability to determine the most cost effective
alternative. The results of this analysis indicate that the most cost effective alternative
available to Delta is to continue surface water discharge of their wastewater.
The only costs associated with continuing to discharge to surface waters results from
expanding the existing on -site wastewater treatment plant to handle the additional flow
increase. The WWTP expansion includes the addition of both an aeration basin and a
clarifier and the modification of the existing sludge lagoon. The other applicable disposal
alternatives require not only expanding the WWTP to handle the additional flow, but also
require additional treatment of the wastewater.
Most of the costs provided in this analysis represent the Total Capital Investment as
indicated in the appropriate EPA cost curves enclosed. These costs have been used to
determine the total cost of each disposal alternative on a relative basis and are not
necessarily represent4tive of actual construction costs. However, the costs provided were
obtained from the same source of EPA cost curves and should provide a good relative
cost comparison. There are three equipment costs, the 0.5 MGD bar screen, the 0.5 MGD
aeration basin,and the 0.5 MGD reaeration basin, that were not available in the EPA cost
curves and were provided either by quotes from vendors or determined based on best
engineering judgment. Even though these costs were not obtained from the EPA cost
curves as the other costs were, these costs are only used to determine the cost for
additional wastewater treatment and will not affect the determination of the most cost
effective alternative.
This NPDES permit modification request is to continue to discharge to surface waters at
an increased discharge flow. The estimated flow at an increased production rate will be
approximately 1.5 MGD, not considering flow restricting devices. The use of flow
restricting devices have not be investigated for this analysis; however, Delta intends to
implement flow restricting devices some time in the future. When these flow restricting
devices are used at this facility, the water requirements and wastewater generated will be
reduced. This reduction would then allow a future production increase to be possible at
this facility.
APPLIED WATER TECHNOLOGY AWT

Delta Apparel, Inc.
June 1997
Page 2
BACKGROUND INFORMATION
Delta Apparel, Inc. (listed as Delta Mills, Inc., Maiden Plant, on the NPDES Permit
NC0006190) is a manufacturer of cotton and synthetic fabrics using circular knitting
machines. The manufacturing process includes bleaching, dyeing, and finishing these
fabrics using a variety of chemicals and dyes.
There are two separate wastewater streams generated at this facility, sanitary and
manufacturing wastewater. The sanitary wastewater is discharged to the Town of
Maiden's sewer system and treated by their wastewater treatment plant. The
manufacturing wastewater includes wastewater from the boiler, cooling tower, and the
dyehouse which is discharged to Delta's on -site wastewater treatment plant.
This on -site wastewater treatment plant has been used by Delta for the past thirty (30)
years to treat the industrial wastewater generated at this facility. The performance of this
treatment plant has been very good thus far. The treatment plant has consistently
discharged an effluent meets their NPDES discharge permit limits, even during the times
that the treatment plant has been operating at or above its design capacity of 1.0 MGD.
As indicated on the attached wastewater treatment plant schematic, the plant consists of a
bar screen, two aeration basins, two clarifiers, a chlorine contact chamber, a reaeration
basin, a waste sludge holding tank, and a 1.2 MGD sludge lagoon.
Each aeration basin has a volume of 1.2 MG and is equipped with two 50 h.p. floating
aerators. Each clarifier is 38 feet in diameter with a 10 foot sidewater depth. The surface
loading rate is calculated to be 441 gallons per day per square foot at the design flow of
1.0 MGD. The chlorine contact chamber is inactive since there is no sanitary waste
discharged to the WWTP. The reaeration basin contains two 10 h.p. floating aerators.
Currently, all of the treated wastewater flows from the reaeration basin through a parshall
flume for effluent flow measurement, and then is discharged into Clark Creek which is
the receiving water designated under DeIta's NPDES permit, NC0006190. Sludge is
wasted to a 1.2 MGD sludge lagoon.
PROJECT DESCRIPTION
Delta Apparel would like to increase their production rates at this facility as soon -as
possible., Orders received by Delta for the first four to six (4-6) months of 1997 indicate
that sales have increased and will continue increasing. By not being able to increase the
production rate at this facility, the amount of additional business that can be accepted by
this facility.will be limited.
Currently, Delta is operating at an average production rate of approximately 700,000
pounds of cloth per week. The goal of this facility is to increase the production rate to an
estimated maximum and average production rate per week of 1,000,000 and 900,000
pounds per week of cloth respectively. Production at this rate will enable Delta to be
more cost competitive and enable them to produce a sufficient amount of their products
to meet customer demand.
This production increase will ultimately result in an increase in the amount of wastewater
generated at this facility of approximately 500,000 gallons per day. Since this facility is
already treating the maximum amount of wastewater that the WWTP is designed to
APPLIED WATER TECHNOLOGY AWT

Delta Apparel, Inc.
June 1997
Page 3
handle, Delta Apparel is reviewing all of the options available to determine which
solution will be the most cost effective.
This alternatives evaluation reveals that of the options available to be considered, the
only applicable options are surface water discharge, wastewater reuse, and a combination
of the surface water discharge and reuse; however, the most cost effective choice would
be for_Delta to continue discharging to surface water, namely Clark Creek. All:three of
these potential alternatives will require upgrading the on -site WWTP to handle the
increased flow, but for wastewater reuse to be workable, the wastewater will require
additional treatment. Delta must be able to have treated wastewater that is free of color
and chlorides if this treated water is to be reused in the dyehouse. Since this facility relies
on the quality of their product, Delta must be able to depend on the treated water to be
consistent with their quality standards. Not only will Delta have to treat the wastewater
more thoroughly for reuse, pilot studies will need to performed to determine if enough
treatment is being applied.
The size of flow, L5 MGD, is the major factor limiting the options available for
treatment of this wastewater. An evaluation of the available disposal alternatives, their
costs, and applicability are discussed in the following sections.
APPLIED WATER TECHNOLOGY
AWT

Delta Apparel, Inc.
June 1997
Page 4
EVALUATION OF DISPOSAL ALTERNATIVES
A. Connection to a Sewer Collection System
1. Existing Sewerage SyaMmm
There is an existing sewer line and manhole located on Delta Apparel's property. Delta is
currently discharging the facility's sanitary waste to this sewer system which discharges
into the Town of Maiden's wastewater treatment plant. The maximum capacity that the
Town of Maiden's WWTP can handle is LO MGD.
The volume of wastewater currently generated by Delta Apparel's facility is
approximately 1.0 MGD, which is very near to the maximum capacity of wastewater that
the Town's WWTP is designed to treat. When production is increased at Delta, the
volume of wastewater generated will be approximately 1.5 MGD. This 1.5 MGD flow is
more than the Town's WWTP was designed to handle; therefore, discharging this entire
wastewater flow to this WWTP is not an option that is available to Delta Apparel.
Currently, the Town of Maiden's WWTP is only receiving approximately 400,000 gallons
per day of wastewater. It is possible that Delta could discharge on a temporary basis the
500,000 gallons per day increase to the Town's WWTP. Unfortunately, this could only
be on a temporary basis because the Town has already allotted most of the remaining
WWTP capacity. When the flow from these other sources is received, there will not be
enough capacity available for Delta to use for the increased flow amount. In addition, the
Town is also experiencing infiltration problems and if the Town agreed to accept this
additional flow on either a temporary or permanent basis, Delta would not be able to
discharge to the Town on any rainy days, otherwise the Town's effluent would not meet
the permit's effluent flow limits.
2. Planned Sewerage Sy tem
There is no planned sewerage system in this area that would be available to Delta Apparel
at this time, nor is it likely that any system will be planned for this area in the near future.
Therefore, this alternative is not an option that is available to Delta.
B. Land Based Disposal
There are a number of options listed under the land based disposal alternative that could
be considered: nitrification systems, low pressure pipe systems, drip irrigation systems,
mound systems, and spray irrigation systems. However, the only land based option that
is even remotely feasible to consider for this large wastewater flow, 1.5 MGD, is a spray
irrigation system. Spray irrigation could be used for this amount of flow; however, there
is not enough land available on -site (See Site Diagram in Map Pocket) for Delta to use
this system to dispose of their wastewater. The land requirement for the 1.5 MGD flow is
approximately 105 acres. In fact, it is not possible for any reasonable portion of this
wastewater to be land applied on -site. The land requirement for only the additional
500,000 gpd flow is approximately 35 acres.
APPLIED WATER TECHNOLOGY AWT

Delta Apparel, Inc.
June 1997
Page 5
• . I � :. $I i .we
There is no adjacent land available for Delta Apparel to acquire for use in this disposal
system (See Catawba County Tax Map in Map Pocket). Delta Apparel is almost
completely surrounded by other developed properties. These properties are either
commercial or industrial and currently have buildings located on these lots. Based on
AWT's review of the Catawba County tax map there is insufficient open land available or
a farm nearby to land apply all or a portion of this wastewater. A letter from Delta
Apparel confirming this lack of available adjacent land is attached.
C. Wastewater Reuse
Wastewater reuse at this facility is a possible alternative to consider for the 1.5 MGD
wastewater stream. However, the cost of reusing the wastewater will be quite expensive.
Delta must not only upgrade the existing WWTP to handle the flow increase, but also
provide additional treatment to the wastewater so that the effluent quality will be
acceptable for use in the manufacturing operations. The two main parameters of concern
for treatment and reuse are color and chlorides removal.
For the existing WWTP to handIe the additional 500,000 gpd flow increase, Delta will
need to modify the existing sludge lagoon and add an additional clarifier to the WWTP.
Modification of the sludge lagoon will require partitioning a portion of the lagoon and
with the addition of aerators, convert this portion of the lagoon from anaerobic digestion
to aerobic digestion. This modification should not only reduce the odor resulting from
the anaerobic digestion, but should also increase the sludge handling capacity. In
addition to modifying the sludge lagoon, an additional aeration basin and a secondary
clarifier will be necessary. A 0.5 MGD aeration basin and a 0.5 MGD secondary clarifier
with polymer addition were selected for use in handling this flow increase. The polymer
addition should be able to contribute to the removal of color in the wastewater; however,
to reuse this wastewater in the dyehouse even more treatment of this wastewater will be
necessary.
To reuse the wastewater at this facility, this wastewater will need to be treated for not
only color removal, but also for the presence of chlorides. Since the current treatment
operations do not address either of these two issues, additional treatment systems will be
needed if an acceptable level of effluent quality is to be achieved. The technology
available to address the removal of color and chlorides is very expensive. The reuse of
this wastewater would not be cost effective when compared to continuing to discharge to
surface waters.
Reverse osmosis would be the treatment system necessary to remove chlorides. The cost
provided in this analysis is the Total Cost Investment from the EPA cost curve 5.9-4 (see
attached). To remove color, carbon adsorption was evaluated. This cost is the Total Cost
Investment from the EPA cost curve 5.1-3, this cost does not include disposal of the spent
carbon which would need to be considered. Other possible alternatives for removing
color are the addition of polymers or bleach.
To consider using polymers or bleach for color removal, maintenance and operating costs
must be considered. The wastewater from the facility varies continuously with consumer
APPLIED WATER TECHNOLOGY AWT

Delta Apparel, Inc.
June 1997
Page b
demand; therefore, there would be a lot of time invested in operating and maintaining the
quality of effluent required for reuse.
The costs associated with handling the additional flow of 500,000 gpd and for additional
treatment for the removal of chlorides and color are provided below.
Wastewater Reuse,
Handling low Increase
EQuipmpu
(Total it
Comments
Lagoon Modification
250,000
Aeration Basin
750,000
0.5 MGD
Secondary Clarifier w/ Polymer Addition
350,000
0.5 MGD
Total cost for handling additional flow
1,350,000
0.5 MGD
Additional Treatment
Equipment
CD2
(Total
Comments
Reverse Osmosis
$1,300,000
1.5 MGD
(chlorides)
Activated Carbon Adsorption
$2,000,000
1.5 MGD (color)
Total Cost for Additional Treatment =
3,300,000
otal Cost for Wastewater Reuse
1$4,650,000
i 1.5 MGD
It is quite possible that even with additional treatment, the wastewater quality will not be
acceptable for reuse at this facility. Pilot studies will inevitabIy need to be performed to
determine the exact treatment scenario that will be needed to provide an acceptable
effluent quality. The costs associated with implementing pilot studies have not been
included in this analysis.
APPLIED WATER TECHNOLOGY AWT

' Delta Apparel, Inc.
June 1997
' Page 7
I D. Surface Water Discharge
g
' This is the current disposal method being used at Delta Apparel for the wastewater
discharge of 1.0 MGD. The facility's on -site wastewater treatment system is operating
very near its maximum design capacity; therefore, the on -site wastewater treatment
' system will need to be expanded to accommodate the increased flow resulting from the
production, increase.
The WWTP facilities which will require modifications include the existing sludge lagoon
' and the capacity of the clarifiers and the aeration basins. The sludge lagoon modification
includes partitioning off a portion (one-fourth) of the lagoon and adding aerators to
convert this portion of the lagoon from anaerobic to aerobic digestion. This modification
' should not only result in controlling the odor, but will also increase the sludge handling
capacity of the lagoon. The cost presented in this alternatives analysis to modify the
lagoon does not include installation or engineering costs.
1
1
An aeration basin and a secondary clarifier will also. be required to handle this flow
increase. To be conservative and in the event of future production increase, an aeration
basin and a secondary clarifier capable of handling up to 1.0 MGD flow were selected.
The costs provided in this analysis for the 1.0 MGD aeration basin and 1.0 MGD
secondary clarifier represent the Total Capital Investment from the EPA cost curve IV
4.1-7 and 3.3-16 respectively. The cost below represents a secondary clarifier with
polymer addition.'UP `was considere a"s theconserva ive app IT .
"Polymer addition should be able .to help control color; however, additional treatment
could be necessary if the addition of polymer is not as effective as anticipated in meeting
NPDES permit limits.
Surface Water Discharge
EquipmentComments
(Total Ca an tall
Lagoon Modification
250,000
Aeration Basin
1,200,000
1.0 MGD
Secondary Clarifiers
450,000
1 1.0 MGD
Total Cost for Surrace Water Discharge -
1, O,U00
11.5
E. Disposal Combinations
Surface Water Discharge and Wastewater Reuse Combin
The only disposal combination that is available for Delta to consider is the combination
of surface water discharge and wastewater reuse. There are two options which will need
to be considered when evaluating this disposal combination. The first option for surface
water discharge and wastewater reuse is to add a separate smaller version of the existing
WWTP and treat the additional 500,000 gpd for reuse and continue to discharge the
remaining 1.0 MGD to surface water. The second option is to upgrade the existing
APPLIED WATER TECHNOLOGY AWT

1
Delta Apparel, Inc.
June 1997
Page 8
' WWTP to handle the additional 500,000 gP d and add additional treatment to the end of
the treatment process for reuse of the additional 500,000 gpd and continue to discharge
' the remaining flow to surface water. The following is a description of both of these
options and the associated costs.
1 Option 1
' This alternative consists of adding a small treatment plant that would treat only the
additional 0.5 MGD flow for reuse purposes. The treatment would consist of a bar
screen, an aeration basin, a clarifier with polymer addition, and a reaeration basin.
Reverse osmosis and activated carbon would also be required for chloride and color
' removal respectively. Furthermore, the increased flowrate would necessitate the existing
lagoon to be modified to handle the additional sludge loading.
' An extensive pilot study would be needed to determine all necessary wastewater
treatment for reuse. Additional treatment operations may be required such as sand or
dual media filtration. Other treatment operations may also be considered such as the use
of bleach or highly concentrated peroxide to maintain a color free wastewater for reuse.
tThe equipment costs associated with this option are presented in the following table.
1
Wastewater Reuse and ur ace Water Discharge - Option
Handling tional Flow
Equipment
(Total apitall
Comments
Bar Screen
45,000
0.5 MGD*
Aeration Basin
750,000
0.5 MGD
Secondary Clarifier wl 1 mer
350,000
0.5 MGD
Reaeration
30,000
0.5 MGD
Lagoon Modification
250,000
Total cost for handling additional flow
$1,425,000
0.5 MGD
Additional Treatment
Equipmen
!=
1 it
Comments
Activated Carbon
$1,200,000
0.5 MGD
Reverse Osmosis
T 6 00,000
0.5 MGD
Total cost for additional treatment
$1,800,000
0.5 MGD
Total Cost ror OpPion. 1-$3,225,0)0
Sand/Dual Media Filter
800,000
optional, 0.5
MGD
*Quote by phone from Emory L. Wilson Associates.
><D;
APPLIED WATER TECHNOLOGY AWT

Delta Apparel, Inc.
June 1997
Page 9
Option 2
This alternative consists of treating the entire 1.5 MGD flow in one plant, with additional
treatment for reuse of 0.5 MGD of the wastewater. The additional treatment would
consist of reverse osmosis and activated carbon for chloride and color removal
respectively. Sand or dual media filtration may also be necessary to meet reuse water
standards. Furthermore, the existing lagoon would have to be modified to handle the
additional sludge production. Again, an extensive pilot study would be needed to
determine which treatment operations would consistently provide an effluent suitable for
production reuse. The total capital equipment costs associated with this option are
presented in the table below.
Wastewater Reuse and Surface Water Discharge - Option
Handling Additional Flow
Fume t
. C-=
(Total Capital)
Comments
Aeration Basin
750,000
0.5 MGD
Second Clarifier w/ polymer addition
350,000
0.5 MGD
Lagoon Modification
250,000
Total cost for handling additional flow =
1,350,00
0.5 MGD
Additional Treatment
i�
C=
(Iota] i
Comments
Activated Carbon
$1,200,000
0.5 MGD
Reverse Osmosis
b00,0 Q
0.5 MGD
Total cost for additional treatment
$1,800,000
0.5 MGD
Total Cost for OFtion 2
$3,150,060
an Media Filter
$00,0 0
optional, 0.5
MGD
1\1
APPLIED WATER TECHNOLOGY AWT

Plow Schematic for Surface Water Discharge/Wastewater Reuse Options
'Option 1
Treat and Reuse 0.5 MGD
in separate WWTP.
tContinue to treat current
1.0 MGD in existing WWTP
and discharge to Clark Creek.
1
Clark
Option 2
Upgrade existing WWTP.
Treat entire 1.5 MGD in
existing WWTP.
Provide additional treatment
for 0.5 MGD and reuse.
Discharge remaining 1.0 MGD
treated wastewater into
Clark Creek.
APPLIED WATER TECHNOLOGY AWT

4- DELTA
' A.P-P-A.R-E-L
' Mr. Mark McIntire
NCDEE-INR
' Division of Water Quality
Post Office Box 29535
' Raleigh, North Carolina 27626-os3s
June 5,1997
1 '"Z
JUN 10 1997
APID WXrER
TECHNOLOGY
RE: Engineering Analysis Alternatives
Land Availability for Land Based Disposal Alternative
' Delta Mill, Inc., Maiden Plant
NPDES Permit - NCO006190
' Dear Mr. McIntire:
' Our consultant, Applied Water Technology, is preparing the wastewater permit
application for the proposed increased flow from our facility. During the
' evaluation the land based disposal alternative, the option of a acquiring land
adjacent to our facility was reviewed. Unfortunately, there is not any land
' adjacent to our facility that could be acquired for this use.
If there are any questions regarding this issue; please contact either Dena Pittman
' with Applied Water Technology at [phone] or Allen McRee of our
facility at [phone] Extension 266.
' Coye Kidd
Acting Plant Manager
' CKlrc
' P. O. Box 37.408 S. Main Avenue - Maiden, North Carolina 28650
[phone] - FAX [phone] & 428-8312
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Land Area Required for 0.5 MGD Flow
Water losses inches
Water apetied, inches
Month
Eva otrans 1
Percolation 2
Total 3
Preci 4
WW Lw 5
Total 6
Jan
0.1
18.144
18.244
3.87
14.374
18.244
Feb
0.1
18.144
18.244
4.58
13.664
18.244
Mar
1.2
18.144
19.3441
5.05
14.294
19.344
Apr
1.8
18.144
19.944
3.96
15.984
19.944
Ma
3
18.144
21.144
4.67
16.474
21.144
Jun
4
18.144
22.144
5
17.144
22.144
Jul
4.5
18.144
22.644
4.03
18.614
22.644
Aug4.1
18.144
22.244
4.87
17.374
22.244
Sep
2.9
18.144
21.044
3.91
17.134
21.044
Oct
1.8
18.144
19.944
3.31
16.634
19.944
Nov
0.6
18.144
18.744
2.98
15.764
18.744
Dec
0.1
18.144
18.244
4.18
14.064
18.244
Total
24.2
217.7281
241.928
50.41
191.5
241.928
percolation(Wp)= (O.t3 in/h)'(24 hNd)•(0.04)•(30 d/mon)
Wp - 18.144
Area Needed (Aw)- 0'365/Lwp
Aw- (0.5MGD'O.134 cu ft/gal'365 d/yr)/(191.5 in/yr'1ft/12 in'43560 sq ft/acre)
Aw. 35.2 acres
Column explanations:
1 - data for Brevard, NO. Reference Metcalf & Eddy.
2 - data for Maiden, NO. Reference Soil Survey
3 - column 1 + column 2
4 - data for Hickory, NC. Reference NO Office of Climatology Report No. 185
5 - column 3 - column 4
6 - column 4 + column 5
Notes: Calculation procedure from Metcalf & Eddy 3rd ed, p. 960
APPLIED WATER TECHNOLOGY AWT

1
1
1
1
1
1
1
1
Land Area Required for 1.5 MGD Flow
Water losses, inches
Water applied, inches
Month
Eva otrans 1
Percolation 2
Total 3
Precl 4
WW,Lw 5
Total 6
Jan
0.1
18.144
18.244
3.87
14.374
18.244
Feb
0.1
18.144
18.244
4.58
13.664
18.244
Mar
1.2
18.144
19.344
5.05
14.294
19.344
Apr
1.8
18.144
19.944
3.96
15.984
19.944
May
3
18.144
21.144
4.67
16.474
21.144
Jun
4
16.144
22.144
5
17.144
22.144
Jul
4.5
18.144
22.644
4.03
18.614
22.644
Auq
4.1
18.144
22.244
4.87
17.374
22.244
Sep
2.9
18.144
21.044
3.91
17.134
21.044
Oct
1.8
18.144
19.944
3.31
16.634
19.944
Nov
0.6
18.144
18.744
2.98
15.764
18.744
Dec
0.1
18.144
18.244
4.18
14.064
18.244
Total
24.21
217.7281
241.9281
50.41
191.5
241.928
peroolation(Wp)n (0.63 in/h)'(24 hr/d)'(0.04)'(30 dlmon)
Wp a 18.144
Area Needed (Aw)a 0'36511-wp
Aw- (1.5MGD'0.134 cu ft/gal'365 d/yr)/(191.5 in/yr'1ft/12 in'43560 sq it/acre)
Awa 105.5 acres
Column explanations:
f - data for Brevard, NC. Reference Metcalf & Eddy.
2 - data for Maiden, NC. Reference Soil Survey
3 - column 1 + column 2
4 - data for Hickory, NC. Reference NC Office of Climatology Report No. 185
5 - column 3 - column 4
6 - column 4 + column 5
Notes: Calculation procedure from Metcalf-& Eddy 3rd ed, p. 960
APPLIED WATER TECHNOLOGY A`�rrAr
T

Delta Apparel - CURRENT PRODUCTION AND EXISTING FACILITIES
1
1
1
1
1
1
1
DELTA APPAREL - PRODUCTION & WATER USAGE
CURRENT
PRODUCTION AND
EXISTING FACILITIES
DYE
MACHINES
Gal. per
lb. of
Product
Number
of
Machines
Number
of Ports
per
Machine
Ports
Extended
Total
Prod. Lbs.
per Batch
per
Machine
Prod.
Lbs. per
Batch
Prod. Lbs.
per Day
Gals. per Day
(All
Machines)
Gals per
Lb. of
Product
Estimated turnsper daV4.25
15 to 1
30
5
Dbl. cure
800
4,000
15 to 1
30
1
Sn le cure
400
400
4,400
5,500
165,000
30.00
4
Estimated turnpe!_Layd.25
10 to 1
16
1
6
6
2,400
2,400
10 to' 1
16
3
4
12
1,600
4,800
18
7,200
9,000
144,000
16.00
Estimated turnsper da
.56
6 to 1
8
1
1
1
420
420
6 to 1
8
1
2
2 1
840
840
6 to 1
8
3
4
12
2,000
6,000
6 to 1
8
1
6
6
3 000
3,000
6 to 1
8
1
12
12
6,000
6,000
33
16,260
25,366
202,925
8.00
Total Ports::-51
DYE OPERATION SUMMARY
Total Lbs er Da
39,866
Total Gallonsper Day=
511,925
12.84
BLEACH
MACHINES
Gal. per
lb. of
Product
No. of
Machines
Lbs of
Product
per Hour
Prod. Lbs.
per Day
15
1
400
15
1
400
800
19,200
288,000
Gal. per
lb. of
Product
Number
of
Machines
Number
of Ports
per
Machine
Ports
Extended
Total
Prod. Lbs.
per Batch
per
Machine
Prod.
Lbs, per
Batch
Prod. Lbs.
per Day
Estimated turns
per da W
5.0
6 to 1
6
1
12
12
6,000
6,000
6 to 1
6
1
6
6
3,000
3,000
Total Ports
18
9,000
45,000
270,000
BLEACH OPERATION SUMMARY
Total Lbs per Day=
64,200
Total Gallons per Da
558,000
8.69
TOTAL PRODUCTION SUMMARY
% D e=
38.3%
% Bleachin
61.7%
Lbs. per day::'
104,066
Pounds per 7 day week
728 459
Gallons er da
1,0691925
10.28
APPLIED WATER TECHNOLOGY AWT

Delta Apparel - HIGHER PRODUCTION AND EXISTING FACILITIES
1
1
1
1
DELTA APPAREL - PRODUCTION & WATER USAGE
HIGHER PRODUCTION
AND EXISTING FAI ILITIE
DYE
MACHINES
Gal. per
lb. of
Product
Number
of
Machines
Number
of Ports
per
Machine
Ports
Extended
Total
Prod. Lbs.
per Batch
per
Machine
Prod.
Lbs. per
Batch
Prod. Lbs.
per Day
Gals. per Day
(Ail
Machines)
Gals per
Lb. of
Product
Estimated turnsper da
.00
15 to 1
30
5
Dbi. cure
800
4,000
15 to 1
30
1
Sn le cure
400
400
4,400
8,800
264,000
30.00
Estimated turns per da
2.00
10 to 1
1 16
1
6
6
2,400
1 2,400
10 to 1
16
3
4
12
1,600
4,800
18
7,200 1
14,400
230,400
16.00
Estimated turns per do
.00
6 to 1
8
1
1
1
420
420
6 to 1
1 8
1
2
2
B40
840
6 to 1
8
3
4
12
2,000
6,000
6 to 1
8
1
6
6
3.000
3.000
6 to 1
8
1
12
12
6,000
1 6,000
33
16,260
32,520
260,160
8.00
Total Ports
51
DYE OPERATION SUMMARY
Total Lbs per Day
55,720
Total Gallons per Dayn
754,560
13.54
BLEACH
MACHINES
Gal. per
lb. of
Product
No. of
Machines
Lbs of
Product
per Hour
Prod. Lbs.
per Day
i5
1`
525
15
1
525
1050
25,200
378,000
Gal. per
lb. of
Product
Number
of
Machines
Number
of Ports
per
Machine
Ports
Extended
Total
I
Prod. Lbs
per Batch
per
Machine
Prod.
Lbs. per
Batch
Prod. Lbs.
per Day
Estimated turns per da =
7.00
6 to 1
6
1
12
12
6,000
6,000
6 to 1
6
1
6
6
3,000
3,000
Total Ports
18
9,000
63,000
378,000
BLEACH OPERATION SUMMARY
Total Lbs per Da
88,200
Total Gallons per Da
756,000
6.57
TOTAL PRODUCTION SUMMARY
% D e=
38.7%
% Bleachin
61.3%
Lbs. per do
143,920
Pounds per 7 day week
1,007,440
Gallons per da
11510,560
10.50
APPLIED WATER TECHNOLOGY AWT

WASTEWATER TREATMENT PLANT SCHEMATIC
AERATION BASIN #2
' VOLUME . 1,222, 000 gallons
(2) 50 h.p. floating aerators
L—SAMPLING LOCATION
,1
1
1
1
'r
' BASIN
1
r�
1
1
BAR SCREEN
AERATION BASIN #1
VOLUME . 1,222,000 gallons
(2) 50 h.p. floating aerators
SLUDGE RETURN
SLU1DGE CLARIFIER #138' diameter
RETURN 10' sidewater depth
CLARIFIER #2 SLUDGE
PUMP STATION
SLUDGE PUMP
CHLORINE CONTACT
WASTE & 2.0 MGD FLOW
POST
SLUDGE MEASUREMENT
EQUALIZATION
BASIN
REAERATION
BASIN
WASTE SLUDGE DISPOSAL
SLUDGE BY LAND APPLICATION
(2) 10 h.p. floating
HOLDING T TO AGRICULTURAL SITE
aerators
TANK 45,000 gallons
1.2 MGJJL1.0 MGD
holding capacityFi.UlTiR_OYNASUREMENT
111C
CLARK CREEK
APPLIED WATER TECHNOLOGY AWT

S1
h,
land disposed.
Proposed Wastewater Flow Schematic
APPLIED WATER TECHNOLOGY A rY T

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Estimation of WWTP Effluent Limit Characteristics at 1.5 MGD
BOD5 (Avg Flow & Jan 97 lbs (worst casell
X 1.5 = ((35.6 lbs/d) / (0.797 MGD)) * 1.5 MGD = 67 lbs/d
COD (Avg Flow & Apr 97 lbs (worst case))
X 1.5 = ((1545.1 ibs/d) / (0.797 MGD)) * 1.5 MGD = 2908 lbs/d
= (Avg Flow & Mar 97 lbs (worst case))
X 1.5 = ((254 lbs/d) / (0.797 MGD)) * 1.5 MGD = 478 lbs/d
Ammonia (Avg Concentration)
X 1.5 = 0.8 mg/L
Chromium (&_vg Concentration)
X 1.5 = 2.93 µg/L .,-
Sulfides (Avew
X1.5 = ((0.74 lbs/d) / (0.797 MGD)) * 1.5 MGD = 1.4 lbs/d
Phengls (Ave Flow & lbs)
X1.5 = ((0.08 lbs/d) I (0.797 MGD)) * 1.5 MGD = 0.151bs/d
APPLIED WATER TECHNOLOGY AWT

Della Mills VAVTP Characteristic
M2LI& Averages
Ma 96
Jun•95
Jtd-95
Au -96
ftoe
Oct-96
NOv96
Dea96
Jart97
Fob-97
Mar-97
r-97
Average
Est 1.5M
Commvres
•0.96055
Row
0.694
0.66a
0.6$6
0.769
0.75
0.734
0.912
0.654
0.823
0.91
0.94947
0.727
PH
xxx
XXXI
xxx
xxx
xxxi
xxx
xxx
XXXI
xxx
xxx
MI
xxx
xxx
t C
25
26.51
29.1
29
25.6
25
22
21
22
21.4
241
23.6
24.5
BOD 5 bs
20.3
24.9
11,95
16.2
17.6
19
23.5
32.6
35.6
16.4
15.7
t6.7
21.1
67.03
Avg Flow 6 Jan 97 Ibs fforg Case)
COD
763
741
772.5
1047.9
675.9
803.8
9a6.3
812.5
057.6
1179.2
1249.3
1545.1
951.4
2909.1E
Avg Flow E Apr 97 tba Drat Case)
TSS s
103.7
191.5
t ri.4
t45.6
62
61.1
144.4
115.1
t06.4
81.8
254
113.5
126.0
476.24
Avg Row d Mar 9710s Mrst Case
C-orKWwxs
227
205
354
279
275
267
205
229
302
374
404
236.6
2E7.2
Sate. Maser rrmLlL
4
0
0
0
0
0
0
0
0
0
0
0
0.0
Ammonia
1.9
0.73
O.S.0.53
0.77
0.$
0.5
0.5
1.9
0.5
0.5
0.5
0.5
1.90
Avotago Concantra6on
Chromium
6.9
1.5
1.4
2,3
1.E
11
0,675
4.1
51
3.4
4
2.E4
2.93
6.90
Avers Concerara5an
Coeper
30
35.3
45.4
31.3
24
26.4
26
26.5
21.4
23.3
27.5
19.2
26.2
SUTA66
0.59
0.5
0.51
0.65
0.64
0.59
0.69
0.75
0,7t
0.7E
0.7E
1.65
0.7
1.39
Average Flow B lbs
zinc
40
611.3
39.6
45.5
32
27.6
29.5
25.E
33.4
25
37.5
16.6
35.t
PMnds bs
0.042
0.033
0.026
0.500
0.03
0.05
0.04
0,04
0.0E
0.04
0.04
0.05
0.0E
0,15
Aywage Row # Ws
Residual Chlorkw
0.73
0.69
O.a
0.43
0.64
0.6E
0.72
0.95
0.26
0.94
0.914
0.23
0.77
1,46
Avwage Raw d the
!Twmeralum 1s dvided klto tr o s: vdnter V20v - 6M and nmsner fuffy

Typical design criteria. Typical design criteria for pri-
mary circular clarification re described in Section 2V.3.2.1.2.
Typical design criteria for polymer addition are shown below.
Design criteria value
Dosage
Materials contacting
polymer solutions
Storage conditions
Viscosity
Determined by jar testing
Type 316 stainless steel,
FRP or plastic
Cool and dry; storage period
should be minimized
Must be considered in feed-
ing system design
Costs. Purchased equipment and installation cost for esti-
mation of the total capital investment includes primary sludge
pumps; clarifier; chemical storage, chemical feeding, and rapid
mixing tanks; piping and building -to house the feeding equipment;
and bag storage. Cost varies according to the plant size as
shown below.
Plant size
Factors affecting costs
0.1 Mgpd
Manual operation offeeder, mix tank, solu-
tion feeder, and holding tank are included
in cost estimation; no separate building is
required.
1 Mgpd and smaller
Manual procedures are applied; two systems of
tanks and feeders are included in cost
estimation.
10 Mgpd
Cost estimate includes feeders and mixing
tanks, one day tank, and two solution
feeders.
100 Mgpd
Cost estimate includes four feeders and mix-
ing tanks, two holding tanks, and 10 solu-
tion feeders; rapid mix tank is concrete
and equipped with stainless steel mixer and
handrails.
This cost assumption is based on primary circular clarification
with polymer addition at a dosage of 1.0 mg/L and a cost of
$1.50/lb.
References.
1. innovative and Alternative Technology Assessment Manual,
EPA-430/9-78-009 (draft), U.S. Environmental Protection
Agency, Cincinnati, Ohio, 1978.
Date: 6/23/80• 1V.3.3-15

E�
1G
4
0.
0.
0 01
h
TOTAL CAPITAL INVESTMENT
A5
35
1
ENR INDS(3119
0.1 a 1.0 10 100
FLOW, Mga IId
Date: 6/23/80
IV.3.3-16

IV.3.6.3 Costs
Purchased equipment and installation cost for estimation of the
total capital -investment includes facilities for backwash stor-
age, all feed and backwash pumps, piping, and building. The
following operating characteristics were assumed for cost estima-
tion of a dual -media filtration system:
'Operatin9 characteristic Assumedvalue
Gravity filters
TDH for backwash and feed pumps
Run length
Pump, efficiency
Motor efficiency
Centrifugal pumps
Backwash holding tank
IV.3.6.4 References
4 gpm/ft2
14 ft
12 hr; 15 min backwash at
15 gpm/ft2
70%
93%
Capacity of two backwash
cycles
1. innovative and Alternative Technology Assesszient Manual,
EPA-430/9-78-009 (draft), U.S. Environmental Protection
Agency, Cincinnati, Ohio, 1978. 252 pp.
2. Physical, Chemical, and Biological Treatment Techniques for
Industrial Wastes, PB 275 287, U.S. Environmental Protection
Agency, Washington, D.C.., November 1976. pp. 22-1-22-25.
Date: 6/23/80
iv.3_6-3

10
10
0
0
L"
0
0.1 L-
0.1
Date: 6/23/80
TOTAL CAPITAL' INVESTMENT
O, s 1, '0 ► ,S
Flow, Mga 11d
IV.3.6-4
ENR INDEX - 3119
10 100

IV.5.1.2 Typical.Design Criteria
Typical design criteria for an granular activated carbon adsorp-
tion process are -shown below.
Design criterion ^Value
Vessel size
Arba loading
Organic Loading
Backwash
Air scour
Bed depth
Contact time.
Land area
2 - 12 ft diameter commonly used
2 -- 10 gpm/f tz
0.1 - 0.3 lb BODS(or
12 - 20 gpm/ftx
3 - 5 ft3/min/ft
5 - 30 £t
10--50min
Minimal
COD)/lb carbon
t
IV.5.1.3 Costs
Purchased equipment and installation cost for estimation of 'the
total capital investment includes vessels, media, pumps, carbon
{ storage tanks, controls, and operations building. Disposal, costs
f; are not included. No regeneration is included; therefore, above
`• 3 Mgal/d cost curves are extrapolated. The following operating
characteristics were assumed for cost estimation.
Operating characteristic Assumed value
Loading rate 30 lb/Mgal
1'
Contact time 30 min
IV.5.1.4 References
{
1. Innovative and Alternative Technology Assessment Manual,
EPA-430/9-78--009 (draft), U.S. Environmental Protection
Agency, Cincinnati, Ohio, 1978. '252 pp.
Date: 6/23/80 IV.5.1--2

Ac.� ► J a �� �. csl �,.ca..+ to � � � ,� S � r �'�� � �� n,
TOTAL CAPITAL INVESTMENT
Phi
0.1
FLOW, Mgalld
1
1
1
)ate: 6/23/80 IV. 5.1-3
1
eO%
10
ENR INDEX - 3119 1

The design basis for reverse osmosis included 24-hr/d, 330-d/yr
' operation; pumps and filter, and cellulose acetate membranes in
a spiral configuration.
Fixed capital costs based on an ENR index of 3119 are estimated
' to be $16,000. Similarly, total capital cost is estimated to be
$17,000. Estimation of annual operating cost is presented in
the following table based on a flowrate of 3,300 gal/d.
1 Cost item. Annual cost,.$
1
Direct operating cost
Labor
Membrane replacement
Power
Total
Annual operating cost
1,320 (1/4-hr/d @$16/hr)
436 (replaced @2.5 yr)
375 ($0.035/kWh)
2,131
5,491
Cost curves were developed for total capital investment and
' annual operating cost using the cost data shown above and the
following exponential scaling factors, which were used to deter-
mine costs at varying flowrates:
' Exponential
Cost item factor
`Total capital investment 0.7
Labor 0.3
' Power and chemicals 1.0
IV.5.9.4 References
1. Physical, Chemical, and Biological Treatment Techniques for
t Industrial Wastes, PB 275 287, U.S. Environmental Protection
Agency, Washington, D.C., November 1976. pp. 39-1 to 39-19.
Date: 6/23/80 IV.5.9-3

1.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
m
100
10
0
0
0
cn
z
0
.5 I.5
1.0
a•b
0.1
0.01
0.1
Date: 6/23/80
TOTAL CAPITAL INVESTMENT
Pam/
ENR INDEK---3119
o.s 1.01'S 10
FLOW, Mgasld
IV. 5.9--4
100

Typical design criteria. A partial listing of typical de-
sign criteria for the conventional activated sludge process is
summarized below.
Design criteria Value
' Mixed liquor suspended solids (MLSS) 1,500-3,000 mg/L
Food -to -microorganism (F/M) ratio 0.25-0.5 lb BOD5/d/lb MLSS
Sludge age 5-10 d
The mixing equipment for aeration or oxygen transfer must be
sized to keep the solids in uniform suspension at all times. De-
pending on basin shape and depth, 4,000 mg/L of MLSS require about
0.75 to 1.0 hp/1,000 ft3 (0.02 to 0.03 kW/m3) of basin volume to
prevent settling if mechanical aerators are employed. However,
the power required to transfer the necessary oxygen will usually
equal or exceed this value.
Costs. Purchased equipment and installation cost for esti-
mation of the total capital investment includes aeration basins.
Clarifier and recycle pumps are not included. The following op-
erating characteristics were assumed for cost estimation:
Operating characteristic Assumed value
Organic loading 1,200 mg/L BOD5
Oxygen requirement 1.1 lb 02 supplies/lb BOD5 removed
MLSS 2,000 mg/L
F/M 0.25 lb BODs/d/lb MLSS
References.
1. innovative and Alternative Technology Assessment Manual,
' EPA-430/9-78-009 (draft), U.S. Environmentdl Protection
Agency, Cincinnati, Ohio, 1978. 252 pp.
Date: 6/23/80 IV.4.1-6

Ki
0.1
A O EI-XI-S Y►..
TOTAL CAPITAL INVESTMENT
i
ENR INDEX - 3119
i
102 103 104 105
LOAD i NG, lb/day BOD5
IV.4.1-7

BURLINGTON
HF.SBARCH
V
CUSTOMER:
IIEPORTTO:
Aquatic aloassay Testing a Aquatic Toxicity Reduction Evaluations
Chemical Product Environmental Assessments • NPOES 7estirlg
Reporting a Data Handling Services
1302 Belmont Street a Burlington, NC 27215-6935 * [phone] • Fax [phone] �T_ ►-
ANALYTICAL REPORT
Delta Apparel, Inc. WORK ORDER #: 7M86-002
Mr. Alien Mcl; ee RECEIVED: 05/23/97
REPORTED: 06105/97
SAMPLE DESC: PERMIT MONITOR
MAMPLE TYPE: - WASTEWATER, INFLUENT COMP
OLI_ECTED: 05/21/9712:00 to 05/22/97 12:00
PO NUMBER: DA07301
Tlow ^�— I.pMvk�
' PARAMETER DATEMME/ANALYST ML RESULT
Ammonia Nitrogen
Started 05/31/97 12:38
0.1
1.8
mg/L
'
EPA 350.1
Analyzed 05/31/97 by BMM
BOD. 5-Day -
Started 05/23/9713:05
1.0
237
mg/L z so
'
EPA 405.1
Analyzed 05/28/97 by-RAw
Chrmic4 Oxygen Demand
Started 05/27/97 09:00
20.0
774
mg1L .SSA
EPA 410.4
Analyzed 05/2-7/97 by LMB
'
Chloride
Started 05/27/9714:20
1.0
525
mg/L
EPA 325.2
Analyzed 05/27/97 by BMM
'Solids.
Total. Suspended
Started 05/27/9710:35
1.0
10.0
mg/L
EPA 160.2
Analyzed 05/27/97 by D1D
Sulfate
Started 05/27/9710:25
3.0
419
mg/L
EPA 375.3
Analyzed 05/27/97 by DID
Sulfide
Started 05/27/97 08:30
-0.10
C 0.10- Mg/L
'
EPA 376.2
Analyzed 05/27/97 by BCC
Chromium, Total by ICPMS
Started 05/27197 10:00 .
0.0007
0.0080
tME/L
'
EPA 200.8
Analyzed 05/28/97 by RTW
Copper, ToM1 by ICPMS
Started 05/27/97 10:00
0.002
0.055
mg/L 0.06
EPA 2004
Analyzed 05/28/97 by RTW
Zinc, Total by ICPMS
Started 05/27/97 10:00
0.005
0.053
mg/L
EPA 200.8
Analyzed 05/28/97 by RTW
'
MQL r Minimum Quantitation Limit
BOD5: 500 mg of Sodium Sulfite were added to .1000 ml of
sample to remove Peroxide.
,�, r., r� t� C7G?C7 k_;:�
.fliN 111997 L ��
Page z "APPLIED
ATER
Tm
1
% t .. go (aam) L6 . t t Hns
v

IAdditional Calculations - Aeration Basin and Reaeration Basin
' Aeration Basin
Influent BOD5 concentration: 237 mg1l @ 1.0 MGD
Convert mg/1 to lbs/day
(237 mg/l)(1 MGD)(8.34 lbs/gal) = 1,977 lbs/day
For 0.5 MGD
' (1,977 lbs/day)(0.5 MGD) = 989 lbslday
Dimensions of existing reaeration basin designed for 1.0 MGD flow: 2Y x50, x4'
Volume: 5000 cf
Convert cf to gal
(5000 cf)(7.481 gal/cf) = 37,403 gallons
' Assume $1.001gallon
' Cost of 0.5 MGD Reaeration Basin = (37,403 gal)($1.00/gal)(0.5 MGD/1.0 MGD) = $
18,700
t Cost of Aerator (10 Hp) provided in quote from Crocker and Associates = $ 9,390.00
Total Cost of Adding 0.5 MGD Reaeration Basin = $ 28,090.00
1
APPLIED WATER TECHNOLOGY AWT

V.,
{r
1
1
1
1
CROCKER & ASSOCIATES, INC.
Manufacturer's Representative
1131 Mt. Gallant Road - Rock Hill, SC 29732.803/329-5384 - Fax: [phone]
May 13, 1997
Mr. Larry Horton, P.E.
Applied Water Technology
Raleigh, NC
Fax #[phone]
Re: Western North Carolina Textile Industry -- Revised Quotation
Dear Mr. Horton:
Per the request of our associate, Mr. Bob Ward, we are pleased to present the following
budget pricing for your review and consideration:
Option_ 1 (8) 20HP Aqua -Jet II Covered Aerators
Model CSS, 575 volt $12,3130.00 each x 8 units = $99,120.00
OR
-pN- (16) 10HP Aqua -Jet II Covered Aerators
Model CSS, 575 volt $9,390.00 each x 16 units = $150,240.00
Option 2 (6) 3HP Aqua -Jet (I Covered Aerators
Model CSS, 575 volt $7,370.00 each x 6 units = $44,220.00
Accessories:
Anti -Erosion Assembly for 10HP unit $260.00 each
Anti -Erosion Assembly for 20HP unit $440.00-each
7 x 19 x 3/16" Mooring Cable .40/foot
3116" Mooring Clip $2.75 each
3116" Mooring Thimble $1.35 each
#12-4 Electrical Cable for 3HP and 10HP units .851foot
#10-4 Electrical Cable for 20HP units $1.10lfoot
Delivery for any of the options is 10 to 12 weeks after receipt of purchase order or
receipt of approved drawings.
Should you have any questions or require additional information, please feel free to
contact us. We appreciate your interest in Crocker and Associates, Inc.
Best Regards,
Crocker and Associates, Inc.
A0_t1__
Kelly eater
Sales Assistant
M. A.Y t 1997
APPL"I"; --i' WA 4 t-
1ECHM)LOGY
cc: Mr. Bob Ward, Crocker and Associates, Inc.
919/870-1927 phone [phone] fax