NC0025135_PERMIT ISSUANCE_20100208

NPDE!i DOCYNEMT SCAHNINL COVER SHEET
NPDES Permit:
NC0025135
Huffman Finishing WWTP
Document Type: r'
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Report
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
February 8, 2010
This document ig Printed oa reuse paper - ignore aRly
coateat oa tlxe w evterec Bide

Beverly Eaves Perdue
Governor
NCDENR
North Carolina Department of Environment and
Division of Water Quality
Coleen H. Sullins
Director
February 8, 2010
Mr. Lee Huffman, Manager
Huffman Finishing
P.O. Box 170
Granite Falls, North Carolina 28630
Subject:
Dear Mr. Huffman:
Natural Resources
Dee Freeman
Secretary
Issuance of NPDES Permit NCO025135
Huffman Finishing WWTP
Caldwell County
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant to the
requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North
Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as subsequently amended).
This final permit includes no major changes from the draft sent to you on October 21, 2009.
If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable
to you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt
of this letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh,
North Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
1617 Mail Service Center, Ralegh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604 T�rOnet 1, �'+ 1
Phone: [phone] FAX: 919$07-64921 Customer Service: 1-877-623-6748 1�O,/r��`rlll.,arg0r111$
Internet:www.unity lerqualtweAg N"tim lly
An Equal OpporlurulylAKrmalive Action Employer � '

The Division has reviewed your request to remove the limits for Nickel. This request cannot be granted.
The limits are based on the statistical analysis of the effluent data. The sample that was taken during October 2008
indicated that concentration of Nickel in the effluent is 130 µg/L. This sample had a significant impact on the
statistical analysis of the data. Based on the EPA guidance, this result can only be removed from the analysis if it
was the result of the laboratory error.
Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the legal requirements
to obtain other permits which may be required by the Division of Water Quality or permits required by the
Division of Land Resources, the Coastal Area Management Act or any other Federal or Local governmental permit
that may be required. If you have any questions concerning this permit, please contact Sergei Chernikov at
telephone number [phone].
Sincerely, h�
yU�/
'N Coleen H. Sullins
cc: NPDES Files
Central Files
Asheville Regional Office -Surface Water Protection
Aquatic Toxicology Unit (e-copy)
Marshall Hyatt, EPA Region IV (e-copy)
Shankar E. Mistry, Ph.D., P.E. (e-copy)
1617 Mail Service Center, Ralegh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Ralegh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet: w .ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
ne
NorthCarolina
Naturally

• Permit # NCO025135
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1,
other lawful standards and regulations promulgated and adopted by the North Carolina
Environmental Management Commission, and the Federal Water Pollution Control Act, as
amended,
Huffman Finishing Company, Inc.
is hereby authorized to discharge wastewater from a facility located at
4919 Hickory Boulevard
southeast of Granite Falls
Caldwell County
to receiving waters designated as the Catawba River (Lake Hickory) in the Catawba River
Basin in accordance with effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective March 1, 2010.
This permit and authorization to discharge shall expire at midnight on January 31, 2015.
Signed this day February 8, 2010.
�,. 'Eoleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit # NCO025135
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this
permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive
authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and
provisions included herein.
Huffman Finishing Company, Inc. is hereby authorized to:
1. Continue to operate an existing 0.250 MGD wastewater treatment facility
consisting of the following components:
➢ Manual lint screen
➢ Manual trash screen
➢ Flow equalization basin with four floating aerators
➢ Lift pumps
➢ Oxidation ditch
➢ Circular clarifier
➢ Sludge recirculation pumps
➢ Chlorine contact tank
➢ Ultrasonic flow measurement
➢ Chemical dechlorination
➢ Cascade post aeration
➢ Aerobic sludge digester
➢ Sludge holding lagoon
➢ Sludge thickener
➢ Sludge drying beds
➢ Auxiliary power
The facility is located at Huffman Finishing Company Wastewater Treatment
Plant, at 4919 Hickory Boulevard, southeast of Granite Falls, Caldwell County.
2. Discharge from said treatment works at the location specified on the attached map
into the Catawba River (Lake Hickory), which are classified WS-IV B CA waters in
the Catawba River Basin.

'I L
ex Y 7 . t
7
Discharge location
n
DIMON
MOM�'4
LIS
360
Huffman Finishing - NCO025135
Facility
USGS Quad Name: Hickory Lat.: 35 48'49" Location
Receiving Stream: Catawba River (Lake Long.: 81'23'47"
Hickory)
Stream Class: WS-IV B CA North Not to SCALE
Subbasin: Catawba - 03 08 32 1 1

Permit NC0025135
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning upon the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001. Such discharges shall be limited and monitored by the Permittee as
specified below:
PARAMETER
LIMITS
MONITORING REQUIREMENTS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample
Type
Sample
Location
Flow
0.250 MGD
Continuous
Recorder
Influent or
Effluent
BOD, 5 day, 20°C V
65.9 pounds/day
131.8 pounds/day
y 3/Week �/
jl
Composite
Effluent
Total Suspended Solids
287.4 pounds/day
574.7 pounds/day
03/Week �/
Grab
Effluent
COD V
790.9 pounds/day
1581.8 pounds/day
(F)3/Week V
Composite
Effluent
Fecal Coliform (geometric _ /
mean)V
200/100 mL
400I100mL
3lWeek-: R
`y, . .
Grab
Effluent
pH
> 6.0 and < 9.0 standard units
: , 3/Week J
Grab
Effluent
Temperature
� vPeek V
Grab
Effluent
Total Chromium
1.3 pounds/day
2.6 pounds/day
Weekly
Composite
Effluent
Sulfides _ ✓
2.6 pounds/day
5.3 pounds/day
Weekly
Grab
Effluent
Phenols V
104 Ng/L
104 Ng/L
Weekly
Grab
Effluent
Total Residual Chlorine' �1/
28 Ng/L
Weekly
Grab
Effluent
NH3 as N
Monthly
Composite
Effluent
Total Nickel
261 NgIL
261 pg/L
Monthly
Composite
Effluent'
Total Silver
Monthly
Composite
Effluent
Total NiUogen
NO2 + NO3 + TKN
Monthly
Composite
Effluent
Total Phosphorus
Monthly
Composite
Effluent
Total Antimony
Quarterly
Composite
Effluent
Chronic Toxicityz
Quarterly
Composite
Effluent
Notes:
1.. The TRC limit and monitoring requirements apply only if chlorine is used for disinfection. The facility shall report all
effluent TRC values reported by a NC certified laboratory including field certified. However, effluent values below 50
µg/L will be treated as zero for compliance purposes.
2. Chronic toxicity (Ceriodaphnia) P/F® 0.96%; March, June, September, and December. See Special Conditions A (2) of the
Supplement to Effluent Limitations.
There shall be no discharge of floating solids or foam in other than trace amounts.

Permit NCD025135
A (2). CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 0.96 %.
The permit holder shall perform at a minimum, uag rterl y monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase
11 Chronic Whole Effluent Toxicity Test Procedure' (Revised -February 1998) or subsequent versions. The tests will be
performed during the months of March, June, September, and December. Effluent sampling for this testing shall be
performed at the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then
multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North
Carolina Phase 11 Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable
impairment of reproduction or survival. The definition of"detectable impairment," collection methods, exposure regimes,
and further statistical methods are specified in the "North Carolina Phase 11 Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form
(MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/ fail results and THP3B
for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the
end of the reporting period for which the report is made. Test data shall be complete, accurate, include all supporting
chemical/physical measurements and all concentration/response data, and be certified by laboratory supervisor and ORC or
approved designate signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee
will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit
number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the
form. The report shall be submitted to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required
during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water Quality
indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring
requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be
included in the calculation & reporting of the data submitted on the DMR & all AT Forms submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival,
minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will
require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial
monitoring.

ZQ►Q
NCDENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
Huffman Finishing Company, Inc.
NCO025135
Facility Information
(1.) Facility Name_ — —
Huffman Finishing Company, Inc.w------------------ -
(2.) Permitted Flow (MGD)
-
i 0.25 Co (6) unty I Caldwell
---- - - -
(3.) Facility Class
, II (7) Regional Office
Asheville
(4.) Pretreatment Program:
N/A 1 (8) USGS Topo Quad
D13SW
(5.) Permit Status:
Renewal (9.) USGS Quad Name:
Granite Falls
Stream Characteristics
(1.) Receiving Stream:
Catawba River
f
(7.) Drainage Area (miz):
1090 _
(2.) Sub -basin:
03-08-32
(8.) Summer 7Q10 (cfs):
40 min. inst. release)
(3) Stream Index Number
(9.) Winter 7Q10 (cfs):N/A
(4) Stream Classification:
WS-IV B CA
(10.) 30Q2 (cfs):
N/A
(5.) 303(d) Status: _ -__— _
N
_ot listed
_ 1.) Average
(1erage Flow (cfs):
N/A
(6.) 305(b) Status:
(12.) IWC °U:
0.96
1.0 Proposed Changes Incorporated Into Permit Renewal
• Add the nickel limit.
Update effluent guidelines based limits to reflect recent production data.
Phenol limit will be increased to 104 µg/L to account for dilution at the new discharge
location.
2.0 Summary
Huffman Finishing, Inc. is a textile plant that manufactures hosiery and has requested renewal of
their existing NPDES permit. Applicable effluent guidelines are 40 CFR 410.52 (Subpart E, Knit
Fabric). The facility has a design flow of 0.25 MGD and its wastewater is 95% textile dye and
bleach process and 5% domestic. The plant discharges into the Catawba River (Lake Hickory)
approximately 2.5 miles below Rhodhiss Dam. This segment of the Catawba River is a class WS-
IV B CA waterbody in CTB32 subbasin. The outfall is approximately one mile downstream of the
water supply intake for the City of Hickory.
Development of Effluent Guidelines
Applicable effluent guidelines are listed in 40 CPR 410.52 Subpart E, Knit Fabric. Huffman
Finishing was able to provide long term average daily production data. New effluent guidelines
based limits have been calculated (please see attached table).
The phenol limit proposed by the effluent guidelines would be equivalent to a daily maximum
discharge of 1247 µg/L. The WQ based limit at the current location is calculated to be 104 µg/L.
Since WQ based limit is more stringent, it will be included in the permit.
3.0 Compliance Summary

The facility has a goo compliance record. During the period from 01/2006 through 09/2009 the
facility violated the permit limits on 3 occasions (2 times for phenols and one time for Cu). The
latest compliance evaluation inspection conducted on 03/18/09 concluded that the facility is in
compliance.
4.0 RPA
RPA was performed for Cr, Ni, Ag, and Sb. Please see attached.
5.0 WET
The facility has an excellent compliance history with the chronic toxicity limit during the
previous permit cycle. Please see attached.
6.0 Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: October 28, 2009 (est).
Permit Scheduled to Issue: December 21, 2009 (est.).
7.0 State Contact Information
If you have any questions on any of the above information or on the attached permit, please
contact Sergei Chernikov at [phone] or [e-mail].
Regional Office Comments

Production Data (provided by facility)
daily production volume 26,363 lb
Revised Effluent Limits
40 CFR 410.52 (a)
BPT limitations Ibs/1000 Ibs
Pollutant
Daily max Monthly avg
Daily Max limit M.
Avg limit
BOD5
5.0 2.5
131.8
65.9
COD
60.0 30.0
1581.8
790.9
TSS
21.8 10.9
574.7
287.4
Sulfide
0.20 0.10
5.3
2.6
Phenols
0.10 0.05
2.6
1.3
Total Chromium
0.10 0.05
2.6
1.3
pH
between 6.0 and 9.0 s.u.

October 21, 2009
MEMORANDUM
To: Jun Adams, Regional Engineer
NC DENR / DEH / Public Water Supply Section
Asheville Regional Office
From: Sergei Chernikov, Environmental Engineer II, NPDES-West,
Division of Water Quality (fax-919-807-6495)
Subject: Review of the discharge locations for the following:
Hufman Finishing
NC0025135
Caldwell County
Please indicate below by November 23, 2009 your agency's position or viewpoint on the
facility listed above. We cannot issue the permit without your concurrence. Please return
this format your earliest convcmence.
REESPONSE:
This agency has reviewed the draft permit and determined that the proposed
discharge will not. he sufficiently close to any existing or known proposed
public water supply intake so as to create an adverse effect on water quality.
We concur with the issuance of this permit provided the facility is operated
and maintained properly, the stated effluent limits are met prior to discharge,
and the discharge does not contravene the designated water quality standards.
Concurs with issuance of the above permit, provided the following conditions
are met
Opposes the issuance of the above permit, based on reasons stated below, or
attached:
Signed Date: �� ✓�� O
cc: fi

THE
WOOTEN
COMPANY
ENGINEERING
PLANNING
ARCHITECTURE
120 North Boylan Avenue
Raleigh NC 27603-1423
919.828.0531
fax [phone]
October 26, 2009
Mr. Sergei Chernikov, Ph.D
NCDENR/DWQ/point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1677
Subject: DRAFT NPDES Permit
Permit NCO025135
Huffman Finishing WWTP
Caldwell County
Dear Dr. Chemikov:
RECEIVED
OCT 2 8 2009
DENR - WATER QUALITY
POINT SOURCE BRANCH
We have reviewed the subject Draft Permit and noticed that a Monthly
Average Limit and a Daily Maximum Limit on Nickel of 261 µg/L has
been added in the Permit, based on a statistical analysis of effluent data.
The reported effluent Nickel concentrations in the EPA Form 2C, included
in the Permit renewal application, are listed as follows:
Maximum Daily
Maximum 30
Long Term
Number of
Value
Day Value
Average Value
Analysis
µg/L
µg/L
µg/L
<10
<10
<4.58
11
The Nickel concentration reported in priority pollutants scan by Research
& Analytical Laboratories, Inc. was also BQL (Below Quantitation Limit
of 0.005 mg/L). The reported Maximum Daly Nickel concentration in the
plant effluent is always <10 µg/L. Accordingly, it requested that the
effluent limits on Nickel be removed and the monitoring requirements
should be kept same in the NPDES Permit.
We appreciate your assistance provided in this matter.
Sincerely,
Shankar R. Mistry, Ph.D., P.E.
C: Mr. Lee Huffman, Huffman Finishing Company
Mr. Schuford Wise, WWTP Superintendent

Chernikov, Sergei
From: [e-mail]
Sent: Monday, October 26, 2009 2:24 PM
To: Chernikov, Sergei
Subject: re NC0025135, Huffman Finishing
EPA has no comments on this draft permit.

The Charlotte Observer Publishing Co.
Charlotte, NC
North Carolina ) ss Affidavit of Publication
Mecklenburg County)
THE CHARLOTTE OBSERVER
__________________________________________________t______________._________
DINA SPRINKLE I -
NCDENR/DWO/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6401010 NPDES Wastewater Per
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of Mecklenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and Publication.
PUBLISHED ON: 10/23
AD SPACE: 70 LINE
FILED ON: 10/30/09
NAME: Z-Cl-. le O/Cf� TITLE:
DATE: Gin
In Testimony Whereof I have hereunto set my ha nd affixed my seal, the
day and year aforesaid. My Commission Expires May 17, 2011
Nota y Commission Expires: _/_/_

Chernikov, Sergei
From: Price, Don
Sent: Friday, October 23, 2009 1:46 PM
To: Edwards, Roger; Menzel, Jeff
Cc: Chernikov, Sergei / C
Subject: RE: permit for your review /V
Roger, Jeff, and Sergei,
I believe the facility should be classified as a Grade 2 Biological based upon their permitted flow of 0.250 MGD. Class 3
facility classification doesn't start until the facility is permitted at 0.500 MGD or higher. Thanks, Don.
Don Price, CET - [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax:[phone]
Notice: E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and
therefore may be disclosed to third parties.
From: Edwards, Roger
Sent: Monday, October 19, 2009 3:34 PM
To: Menzel, Jeff; Price, Don
Subject: FW: permit for your review
Please review the attached permit and facts sheet. Nothing jumped out at me at a quick look. Let me know if we need
to comment too Sergei and James.
Thanks,
Roger Edwards - Roger. [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Surface Water Protection
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Notice: E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and
therefore may be disclosed to third parties.
From: Chernikov, Sergei
Sent: Monday, October 19, 2009 2:44 PM
To: Edwards, Roger; Pugh, James L.; Meadows, Susan
Subject: permit for your review

Sergei Chernikov, Ph.D.
Environmental Engineer II
NPDES-West
Phone: [phone], fax [phone]
1617 Mail Service Center
Raleigh, NC 27699-1617
Express mail: 512 North Salisbury St.
Raleigh, NC 27606
E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and may be
disclosed to third parties.

July 21, 2009
Mrs. Dina Sprinkle
THE NC DENR/DWQ/Point Source Branch
y p� 1617 Mail Service Center
�p�
HH 0O I EN Raleigh, NC 27699-1617
COMPANY Subject: Renewal of the NPDES Permit NCO025135
E N G I N E E R I N G Huffman Finishing WWTP
Granite Falls, Caldwell County
PLANNING
ARCHITECTURE Dear Mrs. Sprinkle:
Reference is made to the application for renewal of the NPDES Permit
NC0025135, mailed to your office on July 20, 2009. Please include the
following items in the three (3) copies of the Permit renewal application
package.
1. Three (3) copies of the Priority Pollutants Analysis by Research and
Analytical Laboratories, Inc.
2. Three (3) copies of Mercury Analysis by Gel Laboratories LLC.
3. Three (3) copies of the current NPDES Permit No. NCO025315
We appreciate your assistance in this matter. If you have any questions
concerning the application package or need additional information, please
call me at 919-828-0531.
Sincerely,
Shankar R. Mistry, Ph.D., P.E.
C: Mr. Lee Huffman, Huffman Finishing Company
Mr. Schuford Wise, WWTP Superintendent
t.�
120North Boylan Avenoe JUL 2 2 2009
Raleigh NC 27603-1423
919.828.0531 DENR - WATER QUALITY
fax[phone] POINT SOURCE BRANCH

Huffman finishing Company
Post Office Box 170
Granite falls, North Carolina; 28630
Huffman Finishing Company
Wastewater Treatment Plant
NPDES # NC0025135
Statement to Delegate Authority to Authorized Representative:
Authority is hereby given to Shankar R. Mistry, Ph.D., P.E. to act as the authorized
representative for all matters that directly effect the operational, reporting, and permitting
requirements of the Huffman Finishing Company Wastewater Treatment Plant NPDES
Permit Number NC0025135.
Given This Day July 15, 2009
By Lee T. Huffman, Manager/Owner Huffman Finishing Company
i4rv*�

Sludge Management Plan
Wastewater Treatment System Improvements
Huffman Finishing Company
Granite Falls, North Carolina
NPDES Permit No. NC0025135
The Huffman Finishing Company operates the 0.25 mgd extended aeration (Oxidation
Ditch) type activated sludge plant which discharges its effluent into Catawba River (Lake
Hickory) in accordance with the requirements set forth in the NPDES Permit
NC0025135. The plant includes screening, flow equalization, extended aeration type
activated sludge system, chlorine disinfection, pre and post dechlorination, post aeration,
influent and effluent flow metering and sampling facilities, aerobic sludge
stabilization/storage facilities, and disposal of stabilized sludge by land application in
accordance with the requirements set forth in the land application of residuals (Non-503)
Permit No. WQ002431. The settled sludge from the clarifier is periodically wasted to two
(2) aerobic stabilization/storage basins for stabilization, settling and supernatant
withdrawal operations. The supernatant withdrawn is recycled back at the headwork for
reprocessing. The process of sludge wasting, stabilization, settling, and supernatant
withdrawal is repeated and the stabilized sludge is disposed of once a year by land
application at agronomic rates.
The estimated waste activated sludge quantity of 325 lbs/day (4,775 gallons/day at
specific gravity of 1.02 and 0.8 percent solids), at design conditions, will be aerobically
stabilized to comply with the Class B pathogen reduction requirement, included in item
no I.7 of the land application of residual solids Permit No. WQ002431. The Permit does
not require Vector Attraction Reduction requirements. However, the existing aerobic
sludge stabilization/storage facilities are adequately designed to comply with the Vector
Attraction Reduction requirements. The 227 lbs/day (890 gallons/day at specific gravity
of 1.02 and 3.0 percent solids) aerobically stabilized sludge will be disposed of by land
application at agronomic rates on the permitted sites, using a private contractor engaged
in sludge or residual disposal service. For disposal of the stabilized sludge by land
application, the Huffman Finishing Company will comply with the pathogen reduction
requirement and vector attraction reduction requirement as follows:
Class B Pathogen Reduction: Compliance with the Class B pathogen reduction will be
achieved by using one of the following alternatives:
Alternative 1: Monitoring of Fecal Coliform (EPA 563.32 (b) (2)).
Alternative 2: Use of PSRP Aerobic Digestion and Lime Stabilization (EPA
503.32 (b) (3))
Vector Attraction Reduction: Compliance with the vector attraction reduction will be
achieved by using one of the following options:
Option 1: Reduction of volatile solids content (EPA 503.33 (b) (1))

Option 4: Specific Oxygen Uptake Rate for aerobically digested sludge (EPA
503.33 (b) (4))
Option 6: Addition of alkali (EPA 503.33 (b) (6))
Option 9: Injection below ground (EPA 503.33 (b) (9))
Option 10: Incorporation of sludge into the soil (EPA 503.33 (b) (10))

WATER SUPPLY
0.25 MGD
0.0125 MGD 1 0.1425 MGD 1 0.095 MGD
SANITARY SOCKS SOCKS
FACILITIES BLEACHING DYEING
OPERATIONS OPERATIONS
0.0125 MGD T 0.1425 MGD T 0.095 MGD
0.25 MGD
WASTEWATER
TREATMENT
PLANT
EFFLUENT
wl
OUTFALL 001
0.25 MGD THE
WOOTEN
WATER AND WASTEWATER FLOWS SCHEMATIC COMPANY
HUFFMAN FINISHING COMPANY EN G I N E EN I NG
PLANNING
GRANITE FALLS, NC ARC N I T E C T U NE

DECHLORINATION
FAG LI TI ES
--------------------------------- ►---------------I
I �
1
I ,
SCREEN
EQUALIZATION 0.25 MGD AERATION TANK 0.25 MGD 0.25 MGD CHLORINE I CASCADE
INFLUENT I TANK EFFLUEI\
(OXIDATION DITCH) CLARIFIER CONTACT POST
0.25 MGD TANK AERATION 0.25 MGD
SLUDGE RECIRCULATION SLUDGE RECIRCULATION/
L - - - - - 4 - - - - WASTE PUMP STATION
0.25 MGD
i WASTE SLUDGE
0.005 MGD
I I
ALTERNATE
SLUDGE
HANDLING
I I _
0.0041 MGD
AEROBIC
SLUDGE
DIGESTION
FACI LI TI ES
AEROBIC
SLUDGE
DI GESTI ON
FACILITIES
STABILIZED
SLUDGE TO
LAND
APPLICATION
SITES
0.0009 MOD
HUFFMAN FINISHING COMPANY VVVVfP PROCESS SCHEMATIC
CASCADE O
AERATOR
0.25 MGD
EFFLUENT
0.25 MGD
LAKE
HICKORY -
THE
WOOTEN
COMPANY
EN GI N EE PI NG
PLANNING
A H C N I T E C T U PE