NC0034860_Regional Office Historical File Pre 2018 (10)

VSt
e of North Carolina
Department of Environment
nd _Natural Resources
Division of Water Quality
G
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
May 11, 2005
Gary Elder, Plant Engineer
Schneider Mills
P.O. Box 519
Taylorsville, North Carolina 28681
Dear Mr. Elder:
BRAY 12 2005
VIATI
Subject: Draft NPDES Permit
Permit NCO034860
Schneider Mills 'VM P
Alexander County
Enclosed with this letter is a copy of the draft permit for your facility. Please review the draft very carefully . .
to ensure thorough understanding of the conditions and requirements it contains.
The draft permit contains the following significant changes from your current permit:
Limits for BOD, COD, TSS, Sulfide, Chromium and Phenols have been recalculated based on the
provided production data. Limits for COD, Chromium, and TSS remain unchanged, limits for BOD,
Sulfide and Phenols have been reduced due to the reduction in the production volume.
A daily maximum limit for ammonia nitrogen has been added to the permit. Due to the Federal Guideline
requirements the daily maximum value is five times the monthly average value.
A monthly monitoring for Total Residual Chlorine (MC) for Outfall 002 has been added to the permit.
State of North Carolina has recently adopted a TRC standard and this monitoring is necessary to evaluate
potential TRC discharges by Schneider Mills.
Please submit any comments to me no later than thirty days following your receipt of the draft. Comments
should be sent to the address listed at the bottom of the previous page. If no adverse comments are received
from the public or from you, this permit will likely be issued in early July, with an effective date of August 1,
2005.
If you have any questions or comments concerning this draft permit, contact me at the telephone number or
e-mail address listed at the bottom of this page.
Sergei Chernikov, Ph.D.
NPDES-West
cc: _NPDES Files
Mooresville / Surface Wat_e_f Pr6_te_ction'
Aquatic Toxicology Unit_
Mr. Roosevelt Childress, EPA Region IV
NPDES Unit,1617 Mail Service Center, Raleigh, North Carolina 27699 919 733-5083, extension 594 (fax) 919 733-0719
An Equal Opportunity Affirmative Action Employer sergei.chemikov@ ncmail.net

Permit NC0034860
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
Draft 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,
Schneider Mills, Inc.
is hereby authorized to discharge wastewater from a facility located at
Schneider Mills
NC Highway 16 North
Alexander County
to receiving waters designated as Muddy Fork Creek within the Catawba River Basin, in accordance
with effluent limitations, monitoring requirements, and other conditions set forth in Parts I,1I,111 and IV
hereof.
This permit shall become effective
This permit and authorization to discharge shall expire at midnight on July 31, 2010.
Signed this day
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NCO034860
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.
Schneider Mills, Inc. is hereby authorized to:
1. Continue discharging 0.780 MGD of treated process -contact and domestic
wastewater via outfall 001 from a treatment facility with the following components:
• Bar screen
• Instrumented flow metering device
• Aeration basin with two mechanical aerators
• Clarifier
• Sludge return pumps
• Aerobic digester
• Cascade aeration and
• Sludge drying beds
2. Continue discharging non -contact wastewater from two (2) settling ponds connected
in series via outfall 002 (flow not limited). The discharge consists of:
• Air conditioning condensate
• Water treatment plant (WTP) filter backwash
• Boiler blowdown
• Stormwater runoff
This facility is located at Schneider Mills. Inc. off NC Highway 16 North in Alexander County.
3. Discharge from said wastewater treatment works through Outfall 001 and Outfall 002 to Muddy
Fork Creek (see attached map), classified C waters within the Catawba River Basin.

2
4" -'-K, Sln
4
Vi" A
r4ik-,
A-6
Z14—J
9
Schneider Mills, Inc.
StaleGrid,Qua& D 14 NW / TaylorsyiHe, NC
Lafflude: 35'56! 13" N
i&pgppde 81* 11' 28" W PernittedFlovr 0.780 MGD
Repqv Stream Muddy Fork Creek DrainageRmdn- Catawba River Basin
fteamClasm C Sub -Basin: 03-08-32
7
'7 0
Facility
A.
Location
not to scale
FDES Peii�o- �NCO�03486�0
North N
I Catawba Cormtv

PAPermit NCO034860
. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (001)
During the period beginning on the effective date of the permit and lasting until expiration, the permittee is authorized to
discharge treated wastewater through Outfall 001. Such discharges shall be limited and monitored by the permittee as
specified below:
r7
PARAMETERS
x EFFLUENT LIMITS '•
MONITORING
REQUIREMENTS
r
Monthly
Weekly`
- Daily
4 Measurement
Sample
Sample
a Average,
Frequency_'_
TyP_e,Locat�on'
xri ._Average.'
,'a_
.YMawmum,` ,
..
Flow
0.780 MGD
Continuous
Recording
Influent or
Effluent
BOD, 5 day, 20°C
20.3 mg/L
40.6 mg/L
Weekly
Composite
Effluent
132 lbs/day
264 Ibs/da
Total Suspended Solids (TSS)
125 lbs/day
275 lbs/day
Weekly
composite
Effluent_
COD
685 lbs/day
1,065 lbs/day
Weekly
Composite
Effluent
NH3 as N (April 1 through
1.9 mg/L
9.5 mg/L
Weekly
Composite
Effluent
October 31) 2
NH3 as N (November 1 through
4.7 mg/L
23.5 mg/L
Weekly
Composite
Effluent
March 31) 2
Dissolved Oxygen3
Weekly
Grab
Effluent
Total Nitrogen (NO2 + NO3 +
Quarterly
Composite
Effluent
TKN
Total Phosphorus
Quarterly
Composite
I Effluent
Chronic Toxicity4
Quarterly
Composite
Effluent
Temperature (°C)
Weekly
Grab
Effluent
H5
Weekly
Grab
Effluent
Sulfide
4.0 lbs/day
8.0lbs/da
2/Month
Composite
Effluent
Phenols
2.0lbs/day
4.0lbs/da
2/Month
Composite
Effluent
Total Chromium
109 /L
1022 /L
2/Month
Composite
Effluent
Silver
Quarterly
Composite
Effluent
Conductivity
Weekly
Grab
Upstream &
Downstream
Temperature, °C
Weekly
Grab
Upstream &
Downstream
Dissolved Oxygen
Weekly
Grab
Upstream &
Downstream
Table Footnotes:
1. Upstream = at least50 feet upstream from the outfall. Downstream = at or near NCSR 1313.
2. NH3 as N — See Special Condition A. (4).
3. Daily average effluent concentration of dissolved oxygen shall not fall below 5.0 mg/L.
4. Chronic Toxicity (Ceriodaphnia) at 46 %; quarterly during March, June, September, December; See Special
Condition A. (3.)
5. pH shall not fall below 6.0 nor exceed 9.0 standard units.
Effluent shall contain no floating solids or foam visible in other than trace amounts.
Cj
IA,41 IQ
�c , �Ar�
'�--- P��

Permit NC003486
A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized
to discharge treated wastewater through Outfall 002. Such discharges shall. be limited and monitored by the Permittee
as specified below:
P`TERSr y
IJFFI:UENT x ` E,
.: , r MONK YOKING REQUIIEME N TS
LIMITS
x
is
R _
#Monthly
Daily
1VIeasuremen
#
Sample Locations'
1 ;
Average
Maimu
t Frequency
,S`ample
Flow
Continuous
Recording
Influent or Effluent
Total Suspended
30 mg/L
45 mg/L
2/Month
Composite
Effluent
Solids (TSS)
Settable Solids
0.1 mg/L
0.2 mg/L
Weekly
Grab
Effluent
Iron
Weekly
Composite
Effluent
H2
Weekly
Grab
Effluent
Total Residual
Monthly
Grab
Effluent
Chlorine
Turbidity3
Weekly
Grab
Upstream &
Downstream
Table Footnotes:
1. Upstream = at. least50 feet upstream from the outfall. Downstream = at or near NCSR 1313.
2: pH shall not fall below 6.0 nor exceed 9.0 standard units.
3. Discharge shall not cause stream turbidity to exceed 50 NTU. If natural background turbidity
exceeds 50 NTU, discharge shall not increase receiving -stream turbidity.
Effluent shall contain no floating solids or foam visible in other than trace amounts.

pp,
Permit NCO034860
SUPPLEMENT OT EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A. (3.) 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 46%.
The permit holder shall perform at a minimum, quarterly 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 II 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
TBT3B 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 Branch 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.
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.

pp,
DENR / DWQ / NPDES Unit
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES Permit No. NCO034860
Facility Information d z ",
.. rr _ �,.G' _ �. _ a,.t, � �s"c s .E _.Sa _r, J„-, _ w .. E; te§F`„' 3✓_; . �' ��_ _.. � _,_i7
Qpphcant/Facihty Name r
Schneider Mills, Inc.
AppltcantAddress_`` �Y_„
P.O. Box 519, Taylorsville, North Carolina 28610
Facility Address '.3 r' ' -
1170 Hwy 16 North
�P,emutted Flow (lVIGD) r
0.780 (Outfall 001); Outfall 002 not limited
Type btf Waste �r`� ;Industrial
process wastewater. Primary SIC Codes 2221; 4941
WW Code Prim 55, 21, 02; Treatment Unit Code 02003
Fac hty/Per rut,Status
Class H, Major / Renewal
�Drainage.Basm/ County :. <'
Catawba Basin / Alexander County
-
�. = tn-.t f
Reci rvtng Stream ",
Muddy Fork Creek
Rdgiorial;'Office y '-
Mooresville
,,.,
,k,
Stream Classtfication r
C
State Crud'°/ '
D 14 NW /
x r
USGS,Topo Quad, ,
Taylorsville, NC
a r
Not listed
Permit Winter. "
Sergei Chernikov
Subliasina >
03-08-32
D,`ale f_ y
March 31, 2005
Drama e Area s , mi) '.
8.0
r
'
-
1.4,
Winter 7Q00(cfsS 1¢1 '#
2.2
Q( ) T,;
=30 cfs d
3.0
Average Flow (cfs); N> 5.
8.8
IWG (%fi{ ys4 4
46%
Lat. 35° 56' 10" Long. 81° 11' 29"
` hV 0
Lat. 350 56' 11" Long. 81° 11' 29"
INTRODUCTION
Schneider Mills, Inc. (also herein referred to as Schneider Mills or the permittee) requires a National
Pollutant Discharge Elimination System (NPDES) permit to dispose treated wastewater to the surface
waters of the state. The permittee's 5-year NPDES permit has expired and they have requested
renewal from the Division of Water Quality (the Division). This Fact Sheet summarizes background
information and rationale used by the Division's NPDES Unit to determine permit limits and
conditions. This document also contains references to information sources relevant to this permit
renewal (superscripted numbers in order of appearance, See References).
Facility Description. Schneider Mills is a synthetic textile weaving facility discharging process -
contact wastes and non -process wastes through two separate outfalls. Influent to the onsite
wastewater treatment plant (WWTP) includes waste from "water jet weavers" (roughly 85%) and
fiber coating or "sizing" waste (about 15 %). Sanitary sewer (-1,200 gallon per day) comprises only
0.03 % of the WWTP influent. The WWTP discharges through Outfall 001 with a permitted flow of
0.780 MGD. Non -contact wastewater (Outfall 002; flow not limited) includes air-conditioning
condensate, boiler blowdown, Water Treatment Plant (WTP) filter backwash, and stormwater.
Schneider Mills has been in business in North Carolina since 1951. At this location Division records
date from 1972.
Fact Sheet
Renewal -- NPDES Pen -nit NCO034860
Page 1

MR
PERMITTING APPROACH
Limits for parameters regulated under 40CFR 410 Subpart D have been recalculated to reflect new
production level. Based on data provide by the permittee, limit calculations assume 40,000 lbs/day as
the average production rate over three years (2001, 2002 and 2003). Parameters required under
40CFR are summarized in Table 2.
Table 1. Parameter Limits Calculation
40CFR
410.42 (a)
Monthly
Average
40CFR
410.42 (a)
Daily
Maximum
per 1000 lbs.
Per 1000 lbs.
Sulfide
0.1
x 40
4.0 lbs/day
0.2
x 40
8.0 lbs/day
Phenols
0.05
x 40
2.0 lbs/day
0.1
x 40
4.0 lbs/day
Total Chromium
0.05
x 40
2.0 lbs/day
0.1
x 40
4.0 lbs/day
Table 2. ADDlicable 40CFR Part D Permit Limits Summary
Monthly Average
Daily Maximum
BOD, 5-day
132 lbs/day
20.3 mg/L
2641bs/day
40.6 mg/L
COD
685 lbs/day
1065 lbs/day
TSS
125 lbs/day
2751bs/day
Sulfide
4.0 lbs/day
8.0 lbs/day
Phenols
2.0 lbs/day
4.0 lbs/day
Total Chromium
2.0 lbs/day
4.0 lbs/day
Further Consideration of Total Chromium. Technology -based calculations for chromium
(40CFR) were compared to the acute and chronic NC State Standards (Chronic = 50 µg/L; Acute =
1022 µg/L — %z FAV for freshwater) to evaluate which permit limits are more stringent, i.e. more
environmentally conservative.
Chronic Chromium -- Weekly Average Limit
Considering dilution (IWC 46 %): 50 = 109 µg/L
0.46
compared to technology -based: 2.0 lbs/day = 0.780 MGD (flow) x 8.34 x (y) mg/L
y = 0.307 mg/L or 307 µg/L
Therefore: because 109 µg/L is less than the technology -based limit of 307 µg/L, the more
environmentally conservative 109 µg/L will be implemented to protect against the
chronic affects of chromium as a Weekly Average.
Acute Chromium -- Daily Maximum Limit
Considering: 1,022 µg/L (freshwater % FAV, intentionally not accounting for dilution)
Fact Sheet
Renewal -- NPD1 S NCO034860
Page 2

PW
compared to Technology -based: 8.0 lbs/day = 0.780 MGD (permitted flow) x 8.34 x (y) 1 mg/L
y= 1.230 mg/L or 1,230 µg/L
Therefore: because the %Z FAV of 1,022 µg/L is less than the technology -based limit of 1,230
µg/L, 1,022 µg/L is more environmentally conservative and will be implemented as a
Daily Maximum to protect against acute toxic affects.
Reasonable Potential Analysis
Reasonable potential analysis was conducted for: Cd, Cr, Ni, Pb, Ag and Zn. (see attached).
Toxicity Testing
Current Requirement: Quarterly Chronic Toxicity @ 46% MAR, JUN, SEP, DEC
Recommended Requirement: Quarterly Chronic Toxicity @ 46% MAR, JUN, SEP, DEC
The facility has been consistently passing its WET tests (see attached).
Compliance Summary
DMRs have been reviewed for the period January 2002 through March 2005. Facility has a good
compliance record. During the review period, the following NOVs (notices of violation) have been
issued: 01/08/04 — Sulfide; 07/15/03 — Sulfide.
A compliance evaluation inspection conducted on January 11, 2005 determined that the facility is in
compliance.
Instream Monitoring
Instream monitoring is required for Conductivity, Temperature, and Dissolved Oxygen.
Analysis of the instream monitoring data indicates that facility has insignificant negative
effect on the stream water quality (see attached).
Proposed Changes
• Monitoring Frequencies: TRC monitoring has been added to the outfall 002.
Limits: Based on the application flow data, calculations were conducted in accordance with
federal guidelines. Based on the calculation results, limits were reduced for most parameters.
Calculated COD limit exceeded current limit, but since the permittee has been able to consistently
meet the current limit, the decision has been made to leave it unchanged. Similar decision has
been made regarding TSS limit. A daily maximum limit for ammonia nitrogen has been added to
the permit. A daily maximum value is five times the monthly average value.
State Contact
If you have any questions on any of the above information or on the attached permit, please
contact Sergei Chernikov at [phone] ext. 594.
Fact Sheet
Renewal -- NPDES NCO034860
Page 3

Nq
REGIONAL OFFICE COMMENTS:
EPA COMMENTS:
NAME:
TE:
TE:
Fact Sheet
Renewal -- NPDES NCO034860
Page 4