NCS000106_Renewal Application_20131219

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KAPSTONE
December 12, 2013
Stormwater Permitting Program
Individual Permit Renewal
1612 Mail Service Center
Raleigh, North Carolina 27699-1612
KAPSTONE
KRAFT PAPER CORPORATION
A Division ofKAPSTONE PAPER AND PACKAGING CORPORATION
100 0apton nod Rennoke- nnridl,, NC 27470
252.533.6000 fax:[phone] KAPSTONEPAPER.com
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WETODS AND SjOR
Re: Stormwater Discharge Permit Renewal, KapStone Kraft Paper Corporation, Roanoke
Rapids NC, NCS000106.
Mr. Bradley Bennett;
KapStone Kraft Paper Corporation in Roanoke Rapids, NC is requesting renewal of their
NPDES stormwater permit NCS 000106. Enclosed you will find three copies of the
Renewal Application and the Supplemental Information that was requested for renewal.
If there are any questions or concerns. I can be reached by phone at 252-533-6295.
Sincerely,
4
Ne 1 R. Davis
Environmental Engineer
KapStone Kraft Paper Corporation
Roanoke Rapids, NC
Enclosures

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KapStone Kraft Paper Corporation
100 Gaston Road
Roanoke Rapids, NC 27870
NPDES Stormwater Permit Coverage Renewal Request
Roanoke Rapids Mill
Permit Number
NCS000106
Halifax County

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Preventive Maintenance and Good Housekeeping Program
The KapStone Kraft Paper Corporation facility (KapStone) is located at 100 Gaston Road,
Roanoke Rapids, North Carolina approximately 1 mile west of Interstate 95. Approximate
facility coordinates are 36-28-30 N and 77-38-30 W. The site is located directly along the
Roanoke River and functions under NPDES Stormwater Permit NCS000106. KapStone
produces bulk rolls of unbleached paper from pine round wood and purchased chips.
The mill is adjacent to, and generally drains to the Roanoke River through three major sub -
basins.
The largest sub -basin contains about 155.8 acres, and includes: the pulp mill, paper
mill, the wood yard, supporting facilities, and the north portion of a gravel trailer yard.
The entire sub -basin drains to the mill's wastewater treatment facility. Petroleum
products and chemicals are stored in this area. Petroleum products on site include tall
oil, diesel fuel, #6 fuel oil, hydraulic oil, and lubricants. Chemicals include, but are
not limited to, sulfuric acid, caustic, defoamers, and sodium hypochlorite. Storage
tanks are surrounded by containment.
2. An area of appproximately 0.97 acres known as the "Storeroom" Sub -Basin located
north of the storeroom drains directly into the Roanoke River. There are no
manufacturing processes in this area. Best Management Practice activities in
December 2010, installed block and gravel at this discharge to the river.
3. The third sub -basin drainage area consists of the mill's employee parking, main office,
maintenance shop, shipping building, the south gravel trailer yard and truck scales.
This area contains about 12.75 acres and drains generally south to a series of
stormwater conveyance pipes and ditches and is known as the "Tent" Sub -Basin.
Run-off from this system was untreated until December 2010, when the Tent Sub -
Basin received additional Best Management Practices. These were submitted and
approved by the state and include block and gravel at two inlets, and check dams and
silt fences along the open ditches. This discharge area combines with a larger
stormwater drainage area of approximately 770 acres from the City of Roanoke
Rapids.
Based on observations, the areas within the Tent Sub -Basin that would be most likely
to contribute to any water quality issues would be the south gravel trailer yard and the
roads running through and around the basin.
Loading and Unloading Activities
Oil and chemicals are located in storage tanks within the mill. A map of their locations is
contained within the Stormwater Plan and the Emergency Action Plan. The chemical tanks
are filled from rail -cars or tractor -trailers. The unloading points are on concrete pads that
drain to our process sewer in case of any spills. All chemical tanks are on concrete pads that
drain to the process sewer or within concrete containment areas. These containment areas
have locked valves that also drain to the process sewer. They are inspected once a week and
after a rain event. Records of these inspections are kept in the Containment Log and are part

of the Spill Prevention Control and Countermeasure Plan. An electronic copy of the log
location: S: drive\Groups\EOHS\EOHS\2013 Containment Log SPCC & Stormwater
Tote bins of chemicals are stored at the Paper mill Spra White slab. Empty tote bins are also
stored on the cement slab West side of the Paper mill, directly south of the Spra White slab.
All of these locations drain to the wastewater treatment plant.
Outdoor Process Areas
Logs, Bark, Chips, and Sawdust are brought into the mill through the Scale house and stored
on the mill site and transported around the mill pneumatically or on conveyor belts. Logs are
debarked in the debarking drum and cut into chips. The chips are transported to the Pulp Mill
or Chip Storage by conveyor belts to be processed. The sawdust is burned in the boiler. Log
and chip holding areas have drains and ditches around them that carry any run-off to the
Stormwater Holding Pond, which is then pumped to the emergency pond and later returned to
the head of the wastewater plant.
Dust Control Process
A large portion of the Tent Sub -Basin is gravel and dust is controlled by spraying the roads
with river water. The Environmental Programs Department hires a contractor to provide this
service. During dry weather, the roads are sprayed three days a week.
A Spill Prevention Control and Countermeasure Plan is contained in the Emergency Action
Plan. It contains procedural and contact information in case of spills and what response is
recommended. These can be found in the Emergency Management System on the mills
intranet and the EHS trailer.
On Site Vehicle Maintenance Monitoring
Vehicle maintenance is performed on site in what is known as the Truck shop and the
Woodyard Maintenance shop. These areas are enclosed from the weather. Spills are cleaned
up with sawdust. Drains in the buildings go to the process sewer. Waste oil is collected in
drums that are hauled away by a contractor.
General spills from the vehicles and heavy equipment in the mill are cleaned up with sawdust.
The sawdust is then burned in the boiler.
Waste Disposal Practices
The mill has a lined landfill that is permitted for primary clarifier residuals, flyash, and lime
mud. This landfill has two of four phases complete with a footprint of 25 acres. The two
additional phases will be constructed when the current cells near capacity. Leachate from the
landfill is gravity fed to the Aeration Basin of the wastewater treatment facility.
All trash is put into dumpsters located throughout the mill and hauled away by a Contractor.

Best Management Plan
In July of 2010, a Stormwater Best Management Plan was submitted to the North Carolina
Division of Water Quality. The Study was conducted by Eco Engineering a Division of John
McAdams Company, Durham, NC. Approval from the NCDENR was received on August
26, 2010.
A copy of the manual as submitted is maintained in Neal Davis' EHS Office.
Erosion Control devices were installed December of 2010
Stormwater Erosion Control Devices Installed
• Check Dams were put in the large ditches surrounding the Scale House.
• A 6-inch layer of 57-stone was placed around the parameter of the ditches. The stone
is cleaned and/or replaced as needed.
• Grass was allowed to grow lining the ditches.
• Erosion Control measures were constructed in the Trailer Yard.
o The existing drain was raised 16 inches using concrete block. The block was
surrounded with 57-stone. The stone is cleaned and/or replaced as needed.
o A chain was also installed to keep vehicles out of the area.
• A check dam of Railroad blast was installed at the Storeroom discharge along with 57-
stone for better filtration. The stone is cleaned and/or replaced as needed.
Environmental Awareness Training is conducted annually for each employee of KapStone
Kraft Paper Corporation, Roanoke Rapids.. A signed copy of the Check for Understanding is
kept on file in the EHS trailer. The Environmental training slides are in a tab in the
Stormwater Plan.
KapStone Roanoke Rapids has a Hazardous Materials Team that receives 32 hours of training
annually. Eight hours are Technician Level Training.
As part of the mill's Spill Prevention Control and Countermeasure Plan and the Facility
Response Plan, two boats are maintained on -site with outboard motors and 1,000 feet of
boom.
In Case of Spill:
Mill Personnel are trained to immediately attempt to stop or control the source of a spill. The
mill's Emergency Response Team will take measures to contain and clean up any spilled
materials utilizing the adsorbent materials stored in the hazmat truck. Since bulk storage
containers are located outside, particular attention is paid to protecting the drainage pathways
in the direction of the spill. Use of material to dike, dam or divert the spill may also be used if
necessary to prevent the spill from entering the storm drain. Incident and response activities
are documented.
All but 13.7 acres of the Roanoke Rapids Mill Facility drains to the mill's Wastewater
Treatment Plant. The mill has also deployed erosion control devices in the 13.7 acres that
could be exposed to stormwater.

KAPSTONE
KRAFT PAPER CORPORATION
A Division of KAPSTONE PAPER AND PACKAGING CORPORATION
100 Gaston Road Roanoke Rapids, NC 27870
kapstonepaper.com
To Whom It May Concern;
Kapstone Kraft Paper Corporation has not made any significant changes in the industrial activities
at the Roanoke Rapids facility. The only exposure to stormwater runoff is the 12.5 acres listed in
the permit. Any other areas of the mill that are exposed to stormwater are piped to our Wastewater
Treatment Plant. Permit Number NC0000752.
Sincerely,
z
Ne Davis
Environmental Engineer
KapStone Kraft Paper Corporation

Permit Coverage Permit Number
AA Renewal Application Farm NCS000106
NCDENR National Pollutant Discharge Elimination System
Stormwater Discharge Permit
The following is the information currently in our database for your facility. Please review this information carefully and make all
corrections/additions as necessary in the space provided to the right of the current information.
Owner Affiliation Information
Owner / Organization Name:
Owner Contact:
Mailing Address:
Phone Number:
Fax Number:
E-mail address:
* Reissued Permit will be mailed to the owner address
Kapstone Kraft Paper Corporation
Anitra Collins
100 Gaston Rd
Roanoke Rapid, NC 27870
F.aciftlPermit Contact Information
Facility Name: Roanoke Rapids Mill
Facility Physical Address: 100 Gaston Rd
Roanoke Rapids, NC 27870
Facility Contact:
Mailing Address:
Phone Number:
Fax Number:
E-mail address:
Discharge Information
Receiving Stream
Stream Class:
Basin:
Sub -Basin:
Number of Outfalls:
ROANOKE RIVER
WSAV
Roanoke River Basin
03-02-08
Wilbur G. Kessinger, Jr.
252-533-6000
[e-mail]
Neal R. Davis
100 Gaston Road
Roanoke Rapids, NC 27870
252-533-629S
[e-mail]
Impaired Waters,JIMDL
Does this facility discharge to waters listed as impaired or waters with a finalized TMDL? 0 Yes ❑ No a Don't Know
( for information on these waters refer to http://h2o.enrstate.nc.us/su/Impaired Waters TMDL/ )
CERTIFICATION
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, complete and accurate.
z
Signature ""`` Date
Print or type name of person signing above Title
Please return this completed renewal application form Stormwater Permitting Program
Individual Permit Renewal
and other required supplemental information to: 1612 Mail Service Center
Raleigh, North Carolina 27699-1612

STORMWATER POLLUTION PREVENTION PLAN
DEVELOPMENT AND IMPLEMENTATION
CERTIFICATION
North Carolina Division of Energy, Mineral, and Land Resources - Stormwater Permitting
Facility Name: Roanoke Rapids Mill
Permit Number: NCS000106
Location Address: 100 Gaston Rd
Roanoke Rapids, NC 27870
County: Halifax
"i certify, under penalty of law, that the Stormwater Pollution Prevention Plan (SPPP) document and all attachments were developed and
implemented under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather
and evaluate the information required by the SPPP. Based on my inquiry of the person or persons who manage the system, or those persons
directly responsible for gathering the information, the information gathered is, to the best of my knowledge and belief, true, accurate and
complete."
And
9 certify that the SPPP has been developed, signed and retained at the named facility location, and the SPPP has been fully implemented at
this facility location in accordance with the terms and conditions of the stormwater. discharge permit"
And
"1 am aware that there are significant penalties for falsifying information, including the possibility of fines and imprisonment for knowing
violations."
Sign (according to permit signatory requirements) and return this Certification. DO NOT SEND
STORMWATER POLLUTION PREVENTION PLAN WITH THIS CERTIFICATION.
Signature <N� � w� Date
GK: Ut:
Print or type name of person signing above Title
SPPP Certification 10113

SUPPLEMENTAL INFORMATION REQUIRED FOR RENEWAL OF INDIVIDUAL NPDET
STORMWATER PERMIT i
k Two CCI of each of the following shall accompany this submittal in order for the application be to
considered complete:
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iilrlzi�qri lig ieii��',
IBM. M
NRD 1. A current Site Map from the Stormwater Pollution Prevention Plan. The location of
industrial activities (including storage of materials, disposal areas, process areas ani,
loading and unloading areas), drainage structures, drainage areas for each outfall,
building locations and impervious surfaces should be clearly noted.
-NRD 2. A summary of Analytical Monitoring results during the term of the existing pen -nit (if your
permit required analytical sampling). Do not submit individual lab reports. The summary
can consist of a table including such items as outfall number, parameters sampled, lab
results, date sampled, and storm event data. H
NRD 3. A summary of the Visual Monitoring results. Do not submit individual monitoring reports.
The summary can consist of a table including such items as outfall number, parameters
surveyed, observations, and date monitoring conducted.
5. A short narrative describing any significant changes in industrial activities at the permi
cilitySignificant changes could include the addition or deltion of work progesy1`J
NPD- 6. Certcation of the development and implementation of a Stormwater Pollution Prevention Plan
for the pennitted facility (Sign and return attached form).
If the final year analytical monitoring of the existing permit term has not been completed prior
to filing the renewal submittal, then the last years monitoring results should be submitted within 30
days of receipt of the laboratory reports. (i.e. do not withhold renewal submittal waiting on lab results)