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HomeMy WebLinkAboutNC0000272_Meeting Notes_20050519 I ,J k Blue Ridge Paper Products Inc . Canton Mill Mill Information and Wastewater Permit Reference NPDES No. NC 0000272 DWQ Mill Visit and Permit Discussion 5/19/2005 BLUE RIDGE PAPER PRODUCTS 4NG., Mill Tour - Basic Process Flow CHIPS F"' iProduction LIME SCREENING KILNS V p� N NaOH NaCO3 White Liquor DIGESTERS CAUSTIZING Green Liquor FIBERLINES Black Liquor t Washing —► EVAPORATORS --pp- RECOVERYFURNACES Bleaching Chemical Recovery PAPER MACHINES Cycle k GF i .'l � S Q�' -1 . �� �_ '�_ 1 _ - }. >: ']. _. .._.�._ f J ^-�-_ y�: :� _ .. � • � - - _ ,. �:. :. _ .. . -,� _ ,j_... __._ _L_ __.____. � -t . . ... ,. i.. ,r_,.[yip .a::'�M..:V.o_..;P_-.�ai .u:.��:��. � � �.� ;tt* ..} , Color Loadings to Mill Sewer Areas 11-May-05 "Good Color" Upper Limit Sewer Area Daily Color Units Average Xbar UNPLx ---------- ----------- ----- ------------ ----------- Primary Influent 35929 Lbs/day 42, 720 71,095 Pri.Infl.New NCASI* 33505 Lbs/day Pri Inf Turbidity 7 10 .5 23. 9 PI BMP LAL 70,322** Lbs/day PI BMP UAL 78, 609** Lbs/day Secondary Effluent 27774 Lbs/day 37,260 50, 175 #1 Sewer( ll & 12 MC) 1400 Lbs/day 1690 4335 #2 Sewer 177 PPM 2B Sewer (Digesters) 980 Lbs/day 3955 8970 3A Sewer (EO Filtr) 6360 Lbs/day 9180 18,250 3A Calculated Sewer 3730 Lbs/day #4 Sewer 144 PPM 204 390 Contaminated Condensate Sewer Values Concentration 415 mg/L Flow 596 GPM Color 2968 Lbs/day 4420 7695 Combined Condensate Sewer Values Concentration 182 mg/L Flow 194 GPM Color 424 Lbs/day 1510 4840 5B Sewer (Recovery) 7760 Lbs/day 6885 16, 070 CRP Color 980 Lbs/day 3630 7470 6A Sewer 6300 Lbs/day 6760 10, 600 6A Calculated Sewer 5630 Lbs/day 6A Sewer pH 6 . 5 Pine Bleach 3090 Lbs/day 4365 9660 4 . 9 Lbs/ton pulp Pine D1 1780 Lbs/day 2650 5230 Pine Eo 650 Lbs/day 1700 6125 Pine D2 660 Lbs/day 135 233 Hardwood Bleach 6270 Lbs/day 8510 13, 045 7 .4 Lbs/ton pulp Hardwood Dl 3190 Lbs/day 5635 10, 150 Hardwood Eo 3080 Lbs/day 2925 5130 BFR Closure 89 . 6 % >85 <75 Unaccounted Color 9737 Lbs/day Sewer Total 26192 Lbs/day * New NCASI color test method which accounts for turbidity. **The Primary Influent Lower Action Level (LAL) and Upper Action Level (UAL) must be exceeded for two consecutive days before investigative or corrective action is mandatory. Blue Ridge Paper Products Inc. Canton Mill Mill Information and Wastewater Permit Reference NPDES No. NC 0000272 DWQ Mill Visit and Permit Discussion 5/19/2005 BLUE RIDGE PAPER PRODUCTS -INC. DWQ Wastewater Visit & Permit Discussion 5/19/2005 Blue Ridge Paper Products Inc. Canton Mill • Wastewater plant tour — Control room, lab and computer room — Process flow walk thru — Flood impacts & recovery • Mill overview tour • Permit discussion (aEHS Offices) — Brief Permit history — Color performance & challenges — Re-permitting in 2006 — Acid sewer and flood strengthening projects Y/ Wastewater Tour • Wastewater process diagram and sewer schematics are attached • Canton Mill — Fully integrated ECF bleached kraft mill — 1420 tons per day annual average capacity — Both hardwood and pine fiber lines — 1 paper board machine and 3 paper machines — 1000 employees — $90 million per year payroll — $500 million per year in sales including DairyPak Gantom Mill Environmental Investment Over $526 million invested over last 15 years in environmental process improvement Both fiber lines exceed Cluster Rules requirements Is a minimum impact mill with world class environmental performance through a combination of; ➢ Oxygen delignification with 100% substitution of chlorine dioxide for elemental chlorine (OD100TM) ➢ Bleach Filtrate Recycle (BFRTM) ➢ State-of-the-Art BMPs Secondary effluent contains very low BOD, TSS, COD, AOX and color levels Bleach plant effluent non-detect for 2,3,7,8 TCDD and chlorophenolics Extensive Sump and Spill Recovery Systems Secondary Effluent Performance Blue Ridge Paper Products Canton Mill Parameter 2004 Pre-Flood 2005 Jan-Apr Limits Flow, mgd 25.08 24.97 29.9 mon avg BOD, mg/I 7.4 9.3 Ibs/day 1547 1966 3205 mon avg TSS, mg/I 14 17.2 Ibs/day 2919 3633 12,549 mon avg True Color, ppm 190 188 Ibs/day 3%737 399134 42,000 annual avg Canton Mill Secondary Effluent Color Performance Annual Averages: 1988-2006 400000 Including Permit Limitations Permit Limitations 350000 1 -258,945#/d Monthly Ave. eff. 4/14/94 2 - 172,368#/d Annual Ave. eff. 4/14/94 ^> 3 - 125,434#/d Monthly Ave. eff. 12/12/96 300000 4-98,168#/d Annual Ave eff. 12/12/96 J2 5 -95,000#/d Monthly Ave eff. 1/1/98 ZVI 6-69,000#/d Monthly Ave. eff. 1211/98 `0 250000 S 7-60,000#/d Annual Axe. eff. 12/1/98 U 8-48,000#/d Annual Ave. eff. 5/1/01 200000 ❑2 9-40,000-42,000#/d Annual Ave eff. 1211/03 10-32,000-39,000#/d Annual Axe eff. 3/1/06 w 150000 0 100000 50000 0 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Annual Permit Limitations tSE Color Annual Flood Impacts and Recovery Canton Mill wastewater Plant • Back-to-back historic floods - Frances 9/8/04 & Ivan 9/17/04 — topped mill dikes and flooded the wastewater plant — Lost lab and control room — Motors, controls and power feeds wet • Restored secondary treatment within 4 days of Frances and within 5 days of Ivan — Contracted out lab analysis for temporary period — Restored permit-required monitoring and records and in stages while pre-flood systems were restored. • Restored full wastewater lab within 90 days Wastewater Treatment Process Diagram H2 SOq Ph Confiol PE NH4 H POq Po Addllbn Intemrllterlt Addll of CaCO3 bn t #4 Chiller 20D' Diameter Dewatered Sludge 12' Deep To la1dN 2.62 Moron GalanAeralbn BasksPorynser M c Szbm hew v11A MaDn eebn Prhrsaty Shrdgef0ln 12 Atilt pro 6z belt Pf95ses Recycle SludgeRecycle CksNler 14,75' Deep 200' Dkameter 3A7 Won Sludge 12' Deep Milloon Galora Pumps 2.62 Moon Flow Gown Press Station Fate #2 #1 Waft Sludge Re%,cb Pff Cladler Polymer #d 126' Diameter CO2 pH CAW 11' Deep Corltm1 150' Dkameter 1.01 M1on 11189 Do Gallons Gallons LAW Corlfaat Lift BQ G1B Chamber Sample Collection Pumps screen Charlber Sites Oxygen Denotes Site City Sewer Aeratbn PI - Ptlrnary Influent Mill Wastewater Pf Cascade PE -Primary Effluent as SE n. SE -Secondary Effluent Final Effluent Q� �! N0. 1S PM CAMPGROUND MAW FOLEY BARK BOOK TOIL LIMM AND CAUSTIC MflT BOILER N0. 12 PH ODRRS STORIIT TANKS CLF11 PM ERGO COOL4IIim NO. 11 FM STORAGE NMI FL BLEACH F$OWATBt 07 OEMMIER PLANT CF$1 HILL WFREF N4 20 PM ACID FILTRATE BROKE TANK COO!ER .Y ACTH S�TG RECI AII1 EO COOLER [--o- OVERFLOW 1 LINE vw BLOW TALK � SEWER COM310 TOWER WATER TANKS STRIPPER gFEED TAIX DIGESTERS BL04 TALK E� BFECOVERY LOWDOWN COAL d MANUFACTUiE Ba0)ELS a EVAPORATORS STORA¢ N0. 3 SEWER N4 2 AREA SEWER COMBINED MUD COWB�SATE � COKERSATE SAMPLE STATIONS OVe(ffSHE CAUSTICIZINO PCC PLAPTT LII1E � 10 BLO 6 HEAVY 3A SEWER LIOUOR STG NO. 11 RE0. 1B toPUMPS m BOILER N0. 10 REC NEW 58 SEWER BOILER MILL SEWER SYSTEM POST CW iz7 ERCO CLO2 GENERATOR N01 FILTER PLANT BLEACH CFEMICAL PREPARATION N4 19 WW CHEST NO. 18 PM FRESH WATER NO, 19 MACI ENE BOOSTER PUMPS NO. 19 HOTWELL ` r �-------------i FINISFBNC RWM Na 20 PAPER MACHINE 3 i CENTRAL WHITE WATER CHEST N0. 20 WW CHEST MAIN COOLING TOWBi � t� i i � d GENERATOR COOLING BODSTHi PUMPS N0. 9 TURBINE GONENSER N0. 12 MACHINE BOILER FEEOWA7ER PUMPS NO. 11 MACHINE i -------------- '-- i i � N0. 11 TURBBNE CONOEI ------------ ----------------- FOWER BOILER BEARING COOLING PAPER CHEM PREP i j LOWER END i ----------------------------------------------------------------------------------------- PRESSURE CONTROL VALVES PAPER MILL WATER SYSTEM HILL FILTEi PLANT MAIN COOLING TOWER NO.1 FIBERLUE Nall TURBINE NO. 19 PM HOTWELL CONDENSER PINE BLOWHEA7 N0.1 FL Rx"j, ffARY WHEATSEC. CONOHNSEft HO TT�+ ONOENSERHANGERS HWO BLOWHEAT COOLING TOWER COOLING TOWEL SEC. CONDENSER WARM WATER HO TMWIAK ER CONDENSATE SWENSON EVAPORATOR \ STRIPPER SURFACE CONDENSERS WEST GB EVAPORATOR I NO. 11 & 12 PMS NOB TURBINE SURFACE CONDENSER F®WATER DOWENSER PINE TURPENTINE CONDENSER NO2 FL PINE BLOWHEAT HOTMWAATER PRIMARY CONDENSER HWD NRPENI7NE HEAT EXCHANGERS CONOBNSER 0 AND�OOLF�ILS7RATE EIoc MILL COOLING WATER SYSTA COOLERS F N�� ICC COOLING RIVER TOWER PUMP HOUSE OE'OLY CONTAMINATED BARK BOILER CONDENSATE ::]7 SEAL WATER NAKEIP SCHEMATIC OF HEAT RECOVERY SSYSTEMS LNW 11/15M ATTACHMENT II - A PAN FOVER 4 Fj2U EYAP fly NT PLANT PLW t GUSE 20 RAW WATER 28 MARKETS FILTER PLANT SLUDGE 03 MILL COOLING u BI W� 115E Os EVAP V PAPER K L.L N(L 11 PM L0 Na 12 PM L3 NO. 20 PM 20 NO. 19 PM 27 CMER PREP 0 FCC PLANT 03 PUP GIST. LS 2.0 WHITE WATER PUP MILL 111 �q PREP OB 131 COOOZiG L4 BLEACWNG 45 REMVERY 34 EVAP LI 49 � 38 GENERATION 8.9 KSCEI_�ANOM 89 TOWN OF a CANTOR Bffi CITY WATER CANTON MILL WATER BALANCE FLOWS IN MGO 047E MAR. U MH 1-40 Station 5 RM 19.0 5 Bluffton TN (19.3j Hartford,TN .•�7�,TENNESSEE T) — — NORTH • CAROLINA 19G1�R 4 m 6 Hydro Plant f( A (26.0) 2 11 ii / 1 A Ij 5tit' Walters Dam B� Station 48 Station 4A RM 39.0 RM 41.5 4A Waterville Lake Fines Creek New Hepco Bridge � FLOW Jonathan Creek Old Rt.209 3 Station 3 Station 2 Mill Outfall RM 52.3 RM 59.0 RM 63.3 Waynesville STP 2 Outfa 54 l acJ Canton,NC r� e� f��a6le Clyde Station 1 1 RM 64.5 (Control) IFigure 2-1. Fish tissue sampling station locations on the Pigeon River. 2-3 Mill Tour — Basic Process Flow CHIPS Pulp Production LIME SCREENING KILNS NaCO3 NaOH White Liquor t DIGESTERS CADS TIZING Green Liquor t FIBERLINES Black Liquor Washing EVAPORATORS --*- RECOVERYFURNACES Bleaching 1 Chemical Recovery PAPER MACHINES Cycle Fro M' Forest to Paper dhlp BN CmMp Twer Chemical Additives "ap°°" N t per and Reactions �� cope Ste" mom ✓�Me�,�" ape t �' h A.White liquor added to wood b„rsed chips—starts to dissolve Ilgnin. mrluel i°roNB B.Black liquor(white liquor+Ilgnin Pub sae.ne o°"O1°r°` Cau , residue)washed out. 61eom6 P..,Plant q,'Y°0d01ti I nlll' RepowryeeMr C.Oxygen Reactor for further M... p1tW4VT dellgnification. C.Pulp bleached to Increase eveperetor - whiteness. M°tlJno Cheat V Pap wwrnp GeMul RemnryCrde E.Pulp extracted with caustic soda I j - to further remove tignin. Ranters 1 F.Pulp bleached to increase whiteness. ' Heed Me Cleaners—+ F°uNMler G.Bleached pulp slurry. Paper pre'.sea. additives(such as pH adjusted f �—oryerseCpn dyes,rosin,alum,clay,titanium dioxide)added to enhance �� r Uyersaerim1 paper properties. 1 H.Paper sheet formed here through dewatering. sMer I. Black liquor concentrated. R°wvorsa�.ter , ✓ °` J.Black liquor converted to green liquor. `p er'"e° K.preen liquor manufactured. St.Prsae L.Green liquor converted to while liquor. w.�wersua M.Calcium carbonate settled out Reel and sent to time kiln, Clarified White liquor goes back into new cooking cycle at Point A. N.The temperature of non-contact process water is reduced by the cooling towers for reuse In the mill. 'Making( ; ur mark for you. x LUR RIneR PAPRR p.nn,,,,. INf. Canton Mill 2002 Statistics (per calendar day) (per operating day) Wood 5,080 tons Pulp 1,355 tons Wood (chips) $69,155,433 Employees: Coal 1,127 tons Pine 579 tons Freight $12,208,565 Canton Mill Fuel Oil 099 18,748 gal. Hardwood 776 tons Purchased electricity1,238 Fresh Lime 98 tons Paper and Board 1,596 tons Telephone $9,190,028 Waynesville Plant 238 Starch 80 tons paper $590,317 Total 1,337 P P 801 tons Coal, oil, gas, bark fuel $21,231,534 PCC's 117 tons board 795 tons _ Caustic 56 tons Tall Oil 26 tons Taxes: Turpentine 1,010 gal Canton $1,006,631 Haywood County $1,196,212 Total $2,202,843 All numbers,with the exception of Taxes and Employees,reflect Canton Mill only MILL OVERVIEW e Built in 1908 to produce pulp for the Champion International Hamilton, Ohio Mill • 3 uncoated paper machines, Nos. 11, 12, and 20 producing 280,000 tons per year • 1 paperboard machine,No. 19, producing 254,000 tons per year • $526 million invested over the last 15 years plus another$29 million invested by Blue Ridge • Significant improvements to mill operations • Improved environmental performance • Pulp bleaching system replaced • Improved quality/productivity • All machines converted to alkaline • Causticizing Project to improve reliability of lime kilns and slaking equipment • No. 19 PM upgraded technology to improve board strength, surface quality, and yield , • The J. E. Edwards/Optivision Computer System for the Company. r The Canton Manufacturing Process Overview: Blue Ridge Paper Products' Canton, North Carolina, facility is,a pulp and paper mill that makes uncoated paper and bleached paperboard. The mill occupies some 200 acres through which the Pigeon River flows, and it is readily accessible to the network of roads and rail necessary to bring raw materials in and ship products out. Two million tons of wood arrive at the mill each year; approximately two-thirds are purchased from private landowners, and the remaining third comes from residual sources such as chip mills, etc. The mill's four machines -- three paper and one board—produce close to 1,500 packed tons each day, adding up to approximately 535,000 packed tons annually. The uncoated paper, most of which goes directly from the mill to our customers in large sheets or rolls, is used for a variety of end products, including letterhead, envelopes, notepads, and endpapers in books. Some of that paper, in turn, is used in copiers and printers and for the commercial printing of brochures, catalogs, annual reports, and school supplies. Recycled fiber also is included in some envelope papers. Paperboard from the mill is sold for use in a variety of packaging applications. The Canton mill has been upgraded to meet new or changing market demands and to integrate the latest pulp, papermaking, and environmental technologies. The Canton Modernization Program(CMP), completed in June of 1994,represents'a$330 million investment and features pioneering methods for reducing emissions. The Canton mill is currently operating a full-scale demonstration of ,a patented Bleach Filtrate Recycle (BFRTm) technology. BFR is designed to close the loop on the bleaching process, and further reduce the mill's impact on the environment. BFR and the CMP underscore Blue Ridge's dual commitment to the regional economy and the environment. The Woodyard: The woodyard is the first step in the papermaking process at Canton. Wood chips come in by truck and railcar from forestlands in North Carolina, South ' Carolina, and Tennessee. The chips are made from two kinds of wqod: softwood, such as pine, and hardwood, such as oak. Softwood fibers are long and tough and help give paper its strength. Hardwood fibers are shorter and provide paper its smoothness. All of Canton's paper and paperboard contain both kinds of wood in varying proportions to achieve different paper characteristics based on end use. Envelope grades, for instance, have-more softwood for strength. Offset printing grades, on the other hand, contain more hardwood fibers for smoothness. Pulp Manufacturing: This process, during which wood chips are turned into the pulp used to make paper and paperboard,'involves cooking or pulping the chips. A mixture of chips and a cooking solution called white liquor, which consists of sodium carbonate and sodium hydroxide, is heated in a digester, which essentially is a large pressure cooker. Canton has 18 digesters: 10 for softwoods and eight for hardwoods. In the digester, lignin, the natural binder that holds wood fibers together, is dissolved and yields cellulose fiber called brown kraft pulp. Next, the pulp is thoroughly washed, screened, and then bleached to a bright white, using a combination of oxygen and chlorine dioxide in a process we call ODIOOT . The OD1oo process was designed to improve the quality of the mill's wastewater. The bleaching time for pulp vanes depending on the brightness required, but the process from chips to bleached pulp takes about 18 hours, after which the pulp is held in high-density storage tanks until it is needed on the paper machines. Paper and Paperboard Manufacturing: Canton's three paper machines, Nos. 11, 12, and 20, produce more than 765 packed tons of uncoated paper each day, while No. 19 makes approximately 700 packed tons of paperboard a day for a combined total of nearly 535,000 packed tons annually. The pulp,refined and mixed with large amounts of water and various additives, is pumped to the four paper machines. Also at this stage, hardwood pulp and softwood pulp are mixed together in various proportions to enhance the paper's smoothness,printability, and strength. The pulp solution, about 99.5 percent water, flows horizontally onto a rapidly moving, fine mesh screen called the wire. A uniform sheet is formed as excess water is drained away. Depending on the machine and the grade of paper being made, the continuous web of paper is formed and dried at speeds ranging from 750 to 2,000 feet per minute. At the end of the dryer, about 95 percent of the water has been removed, with the remaining moisture left in the sheet to prevent cracking. The calender stack, a set of rolls stacked one above the other,irons the paper to reduce its thickness and increase smoothness. Then, as it leaves the calenders, the paper is wound onto large reels. When the reel is full, it is taken to the winder where it is cut into smaller rolls to meet the needs of our customers' converting equipment. Converting and Shipping: Once the manufacturing process is complete, the priority is to ship the paper and paperboard. But depending on end uses and customers needs, most of the uncoated paper made at Canton is shipped directly to customers. Recovery and Utility: This is the stage of the manufacturing operation that recovers, recycles, and makes ready for reuse most of the spent pulping chemicals (the remainder of which is burned as fuel). After being cooked, the pulp contains both fiber and used cooking liquid, or black liquor, which is mainly composed of dissolved lignin and other natural wood chemicals. The chemicals and dissolved lignin are concentrated in the evaporators, and the resulting thick liquid is burned in recovery boilers. Further processing in the lime kiln and causticizing area recovers 90 percent to 95 percent of the original pulping chemicals, which are reused in the digesters. This part of the mill also is responsible for the steam and electrical generation that powers the entire papermaking process. The Environment: At Blue Ridge Paper Products, safeguarding the quality of air, water, and soil -- along with reducing waste and conserving resources is an integral company commitment. Canton is a model of the ongoing efforts to protect the environment by reducing, reusing, and recycling. A large share of the$330 million spent on the CMP was directed toward reducing the color of the mill's wastewater. Among other successes, the mill already has reduced the amount of water used each day by more than 35 percent. a Additionally, the color of the wastewater has been significantly reduced by more than 80 percent. Two processes at Canton are centerpieces of a program that is expected to set new industry standards for improved pollution prevention: oxygen delignification used with 100 percent substitution of chlorine with chlorine dioxide which we call OD100; and bleached filtrate recycle, or BFR. The OD100 process captures and recycles many dissolved wood chemicals that might otherwise be discharged with wastewater. The ODloo technology is what the EPA has based its new effluent standards for the industry. Canton.also is the demonstration site for BFR, which has the potential for lessening the impact of the papermaking process on the environment. This breakthrough technology opens the door to the concept of a closed bleaching process that has only a minimal impact on the environment. OD100 and BFR demonstrate a commitment to investing in the technologies that both protect the environment and make quality paper products. vm Brief NPDES Permit History Blue Ridge Paper Products Canton Mill • 1988 EPA-issued Permit — Initial color variance based on technical and economic review of color treatment technologies — 85 ppm at TN state line, color prediction model — Allowed Canton mill modernization project to proceed during 1990 — 1992 • 1994 — 1996 State-issued Permit — Set color discharge mass limits — NC / TN dispute over state line color — Meanwhile, Canton mill effluent color discharge reduced by 75% compared to 1988 levels — BFR demonstration Brief NPDES Permit History Blue Ridge Paper Products Canton Mill • 1997 Settlement Agreement — Resolved issues between NC, TN and enviro groups — Revised color & temperature variance for NC portion of Pigeon River — Set annual color mass discharge limits to meet 50 ppm at state line under 30Q2 flow conditions — Established Technology Review Workgroup (TRW) and NPDES Committee — Required implementation of BFR and certain BM[Ps — Established tiered color reduction limits based on technical, economic and operational feasibility — Established framework for interested party participation in 2001 permit Brief NPDES Permit History Blue Ridge Paper Products Canton Mill • 2001 Permit — Renewed color & temperature variance for NC portion of Pigeon River — TRW heavily involved in permit development — Continued tiered color reduction limits based on implementation / evaluation of "highest certainty", "reasonable certainty" and "lowest certainty" items. — Established schedule of technical reports and performance evaluations to support tiered color reduction limits — Canton mill effluent color discharge reduced by 85 to 90% compared to 1988 levels — Permit expires 11/30/2006 Present SE Color Limits Annual Average • December 2001 : 48,000 lbs/day • January 2004: 42,000 lbs/day • March 2006: Target 32,000 — 39,000 lbs/day To reach 32K, we'll need to run at 28 — 30! r r Brief NPDES Permit History Blue Ridge Paper Products Canton Mill g p Other milestones Canton Mill purchased by employees — May 1999 Blue Ridge Paper became Charter Member of EPA Environmental Performance Track — Dec 2000 Fishing advisories for dioxin lifted 2001 — NC portions of Pigeon River 2002 —TN portions of Pigeon River Non-game species re-introduction project coordinated by University of Tennessee Knoxville 2002 — TN portions of Pigeon River 2004 — Expanded to NC portions of Pigeon River NC DHHS release:Dioxin Posting on Pigeon River Rescinded; Page 1 of 2 Michael F. Easley Carmen Hooker Buell Governor Secretary North Carolina Department of Health and Human Services For Release: IMMEDIATE Date: August 28, 2001 Dioxin Posting on Pigeon River Rescinded; Walters Lake Advisory Partially Rescinded RALEIGH-The fish consumption advisory on the Pigeon River in Haywood County has been completely lifted and the Walters Lake advisory has been partially lifted, Interim State Health Director Leah Devlin announced today. The lifting of the Pigeon River advisory indicates that all fish from the river can now be eaten safely. The original advisory, enacted by the State Health Director in 1988, had advised the public not to eat fish from the Pigeon River below the Champion International paper mill located in Canton because of dioxin contamination. The advisory was reduced in 1994 to include only carp and catfish. Walters Lake, also known as Waterville reservoir, is located downstream from the mill. Fish tissue samples from the river and lake for the past two years show that only carp from Walters Lake are still contaminated above the recommended level for dioxin. Therefore, a limited advisory for carp in Walters Lake remains in effect. The limited advisory recommends that women of child-bearing age and children not eat any carp from Walters Lake. All other persons can consume one meal of carp per month from the lake. There are no longer any restrictions on eating gamefish such as largemouth bass, smallmouth bass, crappie,bream and trout or any species of catfish from the lake. "This is good news," said Dr. Devlin. "The environment has truly gotten cleaner in this area and the conditions continue to improve, and that's why we were able to further revise these advisories." "North Carolina has a very stringent water quality standard for dioxin," said Bill Ross, Secretary of the N.C. Department of Environment and Natural Resources. "That standard has driven improvements at the mill, which have paid off with the continued downgrading of these advisories. Eliminating the discharge of dioxin into our state's waters has created a cleaner environment." Improved pollution controls at the Canton paper mill were enacted during the late 1980s. The Canton mill, formerly owned by Champion International, was purchased by mill employees and renamed Blue Ridge Paper Products Inc. in 1999. For questions regarding fish advisories, contact the Occupational and Environmental htti)://www.dhhs.state.nc.us/pressrel/8-28-Ola.htm 5/18/2005 NC DHHS release:Dioxin Posting on Pigeon River Rescinded; Page 2 of 2 Epidemiology Branch of the N.C. Department of Health and Human Services at 919-733- 3410 or visit the NC DHHS Fish Consumption Advisory web site at http://www.schs.state.nc.us/epi/fis Public Affairs Office Debbie Crane 101 Blair Drive, Raleigh, NC 27603 Director (919)733-9190 FAX (919)733-7447 http://www.dhhs.state.nc.us/pressrel/8-28-Ola.htm 5/18/2005 RESULTS OF 2004 DIOXIN MONITORING IN FISH TISSUE I Prepared for: Blue Ridge Paper Products Inc. Canton Mill Canton, North Carolina Prepared by: EA Engineering, Science;and Technology, Inc. 444 Lake Cook Road, Suite 18 Deerfield, 1L 60015 f February 2005 _ 1920201 EXECUTIVE SUMMARY Bottom feeding species were collected in 2004 from six locations in the Pigeon River and analyzed for 2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD), 2,3,7,8-tetrachlorodibenzofuran (TCDF), and other CDD and CDF isomers. TCDD and TCDF concentrations in fillet composites from bottom feeders were very low (range=non-detected to 1.0 ppt) at the three riverine locations downstream of the mill. Bottom feeders used at these locations were common carp, black redhorse, and channel catfish. TCDD concentrations in bottom feeder fillet composites at the two Waterville Lake locations were 1.7 ppt and 1.6 ppt (Stations 4A and 4B, respectively) for carp and non-detect for flathead catfish (Station 4A) and channel catfish (Station 4B). Since 1990, TCDD concentrations in common carp fillets have declined dramatically (94-99 percent) at all downstream stations(Figure ES-1). B r f vii Figure ES-1. TCDD Concentrations in Carp Fillets Couected from the Pigeon River, 1990-2004 (Stations 2 and 3). 20 15 c 4 Station 2 0 — -©— Station 3 •L w L d Q Y 10 — Q ❑ U F 5 q\ b o - - - - -- 0 19gO 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 YEAR a) TCDD concentrations at Station 3 were not detected,therefore,the value plotted represents the detection limit for that sample. b) TCDD concentrations at Station 2 were not detected,therefore,the value plotted represents the detection!limit for that sample. c) TCDD concentrations at Stations 2 and 3 were not detected from 2000 through 2004,therefore,the values plotted represent detection limits for those samples. figure ES-1 (Cont.). TCDD Concentrations in Carp Fill,, lollected from the pigeon River, 1990-2004 (Stations 4A and 4B). 70 60 5 50 o �� 1 Station 4a 40 — ►— Station 4b a M a 30 F LI 20 10A,0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 YEAR Effluent Color Performance and Challenges Blue Ridge Paper Products Inc. Canton, NC NCASI Effluent Color Management Workshop Baltimore, MD 21 March 2005 Updated 5119105 for DWQ VisitN��� BLUERIDGE PAPER -PRO-DUCTS INC. Blue Midge Paper Products Canton Mill 1420 ton per day Kraft mill - hardwood and softwood, 55% : 45% split - free sheet paper and food grade paper board Environmental Setting - in heart of Blue Ridge Mountains - on small river 133 sq mile upstream watersheds"" 200 mgd average annual flow 35 mgd 7Q10 flow - under close scrutiny for color Wastewater Utilities Blue Ridge Paper Canton Mill 29.9 mgd permitted wastewater discharge monthly and annual average effluent color limits 25 mgd average discharge activated sludge secondary treatment in tanks mill wastewater plant • treats wastewater - 1 • mgd municipal flow n Effluent Color Management Blue Ridge Paper Canton Mill NPDES permit is driver — 2001 permit includes color reduction tiers — 48k lbs/day in 2001 -> 40 to 42k lbs/day by 2004 --> 32 to 39k lbs/day by 2006 Technical approach to achieve color limits — Bleach Filtrate Recycling TM — Water conservation and reuse — Tight mill operations — Spill collection and recovery facilities — BMP program focus on color Historical Color Performance Blue Ridge Paper Canton Mill Annual Average Secondary Color Blue Ridge Paper Canton Mill (tnru Apr 2005) c� U) 380 Canton Mill Modernization, C400 333 301 307 BFR Demonstration 300 Color Improvement Projects c 200 120 V 100 78 83 d 41 42 43 --41--45 40 39 LL 0 �/�W R1) RL (�(,�.O P� S� 5cp A� !l'J (p A` AV (�, OO O� V/ N� Nq NJ Nq Nq ),q N(>j Nq Nq N4 Nq Nq VO VO VO VO VO �� n�O A Color Improvement Projects Blue Ridge Paper Canton Mill • Color Prevention Approach - 24-hr composite sample color monitoring of in-mill sewers and 2-hr primary influent color monitoring - spare clarifier for spill diversion & treatment - numerous improvements to spill collection and storage for outages and process malfunctions - closure and internal recycling of filtrates and wash water from small color sources - double mechanical seals - BFR and washing reliability upgrades to maintain high filtrate closure - color performance is a mill KPI Color Improvement Projects Color Reduction Initiatives Under 2001 NPDES Permit-May 2005 Update Blue Ridge aper Products, Inc. - Canton Mill Color Reduction Measure Mffi-69-7=1 2oo2 INF2-05=1 2004 =2005M 2006 1 2-Hour Color Testing _ __ __ 2 liebereott Recommendations Implemented Permit- 3 Use of Off-line ClarifurforSpill Diversion 4 Hwd Brown Recovery Tank line to Pine Blow Tower 5 1-Hour colortestmg before and during maintenance outages specified 6 Installation of Mechanical Seals(clean waterse rc ation) and other 7 Improvement of equipment used for handling Pine and Hardwood Knot Rejects S $1.5MM spent on Bleach Filtrate Recycle Improvements _ 9 Installed Pine Brownstock Control Logic' rovements initiatives to Determined multiple contributors and interaction effects causing Sewer Csnemted Color II Bench-scale sewer-generated colorwork identified 12 Process Optimization/Six Sigtnt Team designated for Hardwood Fiberline color lutmovements by Blue 13 Improvements made to Pine Brownstock sumps for better recovery 14 White Rot Fungus Trial-growth efforts unsuccessful,may Ridge re-visit in future. 15 Pine Brown Recovery Tank Line to Hwd Blow Tower 16 Milk of line Trial(not successful) ___ Peal O PPY0. lit Pine and Hardwood Quaternary Screen Rejects Press 17 (eliminate quaternary screen rejects discharge to sewer, since 2�01 recover filtrate and shives) Trial to confumand size system for C102 de-coloriation of - 18 CRP/evaluate full-scale application(trials completed after Sep 04 Floods,not economically,technically or operationally feasible) 19 Cacen liquorsump at recovery furnaces(implementation delayed b Sep 04 floods) Additional Spill Tank Veto=for color material recovery 20 during outages and process upset events 21 Acid Sewer Rerouting-improved segregation of bleach plant filtrates with option to bypass primary clarifiers Completed Process Change/Evaluation Process Evaluation or Change too Continued Performance 1 rovement Expected Performance Improvem Recent Color Performance Blue Ridge Paper Canton Mill Annual Average Secondary Color a lbs per day held steady Blue Ridge Paper Canton Mill(thru Apr 2005) m 9 w 60 0 40 40 39 Production-Normalized SE Color 30 Blue Ridge Paper Canton Mill (thru April 2005) o a 0 20 m 40.0 0 10 °a 32.4 32.0 30.4 32.3 w 0 2000 2001 2002 2003 2004 2005 30.0 2�2 rn pre- YTD `o flood 0 20.0 d W 10.0 N 2000 2001 2002 2003 2004 2005 6800 lbs per day color pre- YTD flood reduction accounting for production lbs / ADTP x 0.508 = kg / tonne Current and Best Color Performance Blue Ridge Paper Canton Mill Production Normalized Avg SE Color Color, Avg SE Color Year Ibs per day Ibs per ADTP Conc, mg/I 2000 42,130 32.4 210 2001 42,676 32.0 212 2002 413166 30.4 205 2003 44,627 32.3 219 2004 pre-flood 399737 27.4 190 2005 YTD 399135 27.2 174 2004 417463 29.2 205 Best performance periods This color Dec 03 — Feb 04 25.91bs per ADTBP performance is Mar — Apr 05 23.8 lbs per ADTBP among best of best SE color concentration 160 to 180 ppm pulp mills in world Color Challenges and Issues Blue Midge Paper Canton Mill • Sewer generated color - color of bleach plant filtrates increases 20% or more across sewer system and wastewater treatment - effect of pH, sulfides, temperature and anaerobic conditions not fully understood (not all color is created equal) • washing consistency - can hurt filtrate recycling r and closure • Single events 4� - add 1500 to 3000 lbs to s, monthly avg color - add 500 lbs to annual avg color Color Challenges and Issues Blue Ridge Paper Canton Mill The last 10,000 lbs/day of color 2006 target of 32,000 lbs/day 4 22.5 lbs / ADTP or 11 .4 kg / tonne - no magic bullets - about at the limit of tight mill operations and color prevention techniques - about at the limit of BFR `� other internal recycles h Y 1 - want to achieve 2006 target with color prevention techniques if possible 2006 NPDES Permitting • 316a Thermal Variance Study — Contracted to University of Tennessee, Knoxville concurrent with non-game species reintroduction work — Work plan submitted 3/l/05 — Field work this summer • Statistical evaluation of color performance to support 32-39k lbs/day color target is due 12/1/2005 — DWQ & TRW review & recommendation - 2/1/06 — Revised color limit, if applicable - 3/1/06 • Thermal variance report and permit application are due by 1 May 2006 Current Color Improvement Projects Color Reduction Initiatives Under 2001 NPDES Permit-May 2005 Update Blue Ridge Paper Products, Inc. - Canton Mill Color Reduction Measure 2001 1 2002 INE2003 1 2004 2005 2006 1 2-Hour Color Testing 2 Uebergott Recommendations Implemented Initiatives 3 Use of Off-line Clarifier fors ill Diversion 4 Hwd Brown Recovery Tank Line to Pine BlowTower 5 1-Hour color testing before and during maintenance outages identified 6 Installation of Mechanical Seals(clean water segregation ) by Blue 7 Improvement of equipment used for handling Pine and Hardwood KnotRe'ects 8 $L5MM spent on Bleach Filtrate Recycle Improvements Ridge 9 Installed Pine Brownstock Control Logic rovements K V 10 Determined multiple contributors and interaction effects cousin Sewer lesewenem[edColor Paper to I1 Bench-scale sewer-generated color work 12 Process Optimization/Six Sigma Team designated for Hardwood Fibedine color irrprovements, achieve 13 Improverrents made to Pine Browastock sumps for better recovery 14 White Rot Fungus Trial-growth efforts unsuccessful,may March re-visit in future. I5 Pine Brown Recovery Tank Line to Hwd BlowTower 16 Milk of Lim Trial(not successful) 2006 color Pine and Hardwood Quaternary Screen Rejects Press 17 (eliminate quaternary screen rejects discharge to sewer, recover filtrate and strives) reduction Trial to cent=and size system for C102 decolorization of - 18 CRP/evaluate full-scale application(trials completed after Sep 04 floods,not economically,technically or operationally targets feasible 19 Caeen liquor sump at recovery furnaces(implementation delayed outages ge and pros) Additional Spill Tank Volume for color material recovery 20 Burin outa es and process upset events 21 Acid Sewer Returning-improved segregation of bleach plant filtrates with option to bypass primary clarifiers Completed Process Change Evaluation Process Evaluation or Change rt— Continued Performance Improvement Expected Performance Improve Color Reduction Initiatives Under 2001 NPDES Permit - May 2005 Update Blue Ridge Paper Products, Inc. - Canton Mill Color Reduction Measure 20D1 2002 2003 2004 2Q95 2006 1 2-Hour Color Testing 2 Lieber ott Recommendations Implemented 3 Use of Off-line Clarifier for Spill Diversion 4 Hwd Brown Recovery Tank Line to Pine Blow Tower 5 I-Hour color testing before and during maintenance outages 6 Installation of Mechanical Seals(clean water segregation) Improvement of equipment used for handling Pine and 7 Hardwood Knot Rejects 8 1$1.5MM spent on Bleach Filtrate Recycle Improvements 9 Installed Pine Brownstock Control Logic improvements 10 Determined multiple contributors and interaction effects causing Sewer Generated Color 11 Bench-scale sewer-generated color work 12 Process Optimization/Six Sigma Team designated for Hardwood Fiberline color improvements 13 Improvements made to Pine Brownstock sumps for better ,recovery 14 White Rot Fungus Trial-growth efforts unsuccessful,may re- visit in future. 15 Pine Brown Recovery Tank Line to Hwd Blow Tower 16 Milk of Lune Trial(not successful) Pine and Hardwood Quaternary Screen Rejects Press(eliminate OMMMMMM 17 quaternary screen rejects discharge to sewer,recover filtrate and shives Trial to confirm and size system for C102 de-colorization of 18 CRP/evaluate full-scale application(trials completed after Sep 04 floods,not economically,technically or operationally feasible .................................... ............................................................................................................ ................................... .................................... Green liquor sump at recovery furnaces(implementation 19 delayed bv Sep 04 floods) Additional Spill Tank Volume for color material recovery during 20 outages and process upset events 21 Acid Sewer Rerouting-improved segregation of bleach plant filtrates with option to bypass primary clarifiers - Completed Process Change/Evaluation Process Evaluation or Change MWOMM Continued Performance Improvement Expected Performance Improvement Colorproischd.xls, Initiatives Page 1 of 1 Printed 5/18/2005 VGBI BLUE RIDGE PAPER PRODUCTS, INC. . FOR: CANTON MILL ' AND CLEAN WATER FUND OF NORTH CAROLINA ON BEHALF OF THE ENVIRONMENTAL COALITION ON BRPP BLEACH ENVIRONMENTAL PROCESS EVALUATION AND REPORT JUNE 8, 2001 L.. �] G N i A Comparison between Selected Effluent Parameters from the Blue RidgePaper Products Inc Canton Mill Bleach Plant Effluent and Other Facilities in the U.S.A., Canada and Finland(Integrated Mills) Pulp Production BHWK BSWK AOX TSS BOD . COD Color Flow* Data From ADMT ADMT Lbs/ton Lbs/ton Lbs/ton Lbs/ton Lbs/ton Gal/ton Canton Mill 1999 765 655 0.17 2.08 0.73 13.69 31.22 15,145 Canton Mill 1995 0.33 2.81 1.34 30.80 56.20 19,547 NCASI Study Avg 2.16 6.68 4.13 76.88 200.55 20,637 Min 0.20 1.00 0.91 13.90 31.90 13,413 Max 16.78 23.00 16.06 224.00 581.00 42,000 Espanola Mill, 2000 450 550 0.36 7.2 4.00 99.02 124.20** 20,800 Boyle Alberta Mill, 2000(2) 1700 1480 0.40 4.8 0.41 15.0 51.11 22,890 CPPA Study 30HW,4SW, 38-43 mills 9 HW/SW-Avg 1.20 8.1 5.20 68.20 146.22 22,140 Min 0.32 4.3 0.41 15.90 24.20 19,800 Max 2.35 24.60 28.20 83.96 297.20 29,000 TCF Finland (mills produce TCF and ECF HW& HW& 0.10 N/A 1.6 30.02 40.3 9,000 pulps based on demand) SW SW (1) 1995 NCASI Solid Waste Survey (23 mills) - overall average of 17 to 30 mills (2) 2000 (2) Canadian Mill data (Softwood pulp bleached on different days) (3) 1996 CPPA Environmental Study (48 mills) (4) 1999 Finnish mill data - (3 mills) * Flow is Total Mill Effluent Flow *" Reported Data is Color from the effluent treatment plant; estimated color in bleach plant effluent is 175 Lbs/ton. All other data in the table is bleach plant effluent (in flow to the effluent treatment plant). CONFIDENTIAL 12 i Acid Sewer Project Blue Ridge Paper Products Canton Mill • Acid sewer replacement — Acid sewer was damaged by floods. Repairs were made, but line requires long-term replacement. — Plan - reroute acid filtrates in manifolded force main above ground across river to primary clarifier splitter box — Benefit will allow better acid filtrates segregation and reduce sewer generated color in primary clarifiers — Schedule — out for bid 5105. Construction this summer and tie-ins during Sep 05 semi-annual outage — Wastewater construction permit ? Flood Proj ects Blue Ridge Paper Products Canton Mill • Flood Strengthening — Have raised critical electrical supply and control systems at wastewater plant to above elevation of Sep 2004 floods — Evaluating options to pump flood waters to keep mill and critical systems at wastewater plant dry — Recognition that mill and wastewater operations will be disrupted by future floods of Sep 2004 magnitude. — Focus is on protection of critical systems to minimize damage and expedite future flood recovery. 2001 NPDES Permit Compliance Timeline Permit No.NC0000272 Date: Color Requirements and Limitations: December 1,2001 Monthly average effluent true color loading shall not exceed 55,000 pounds per Completed day. The average annual discharge of true color for each calendar month shall not exceed 48,000 pounds per day. October 1,2002 (internal target date) Implement all `Highest Certainty' action items by October 1,2002 or in sufficient time to generate a representative database of mill effluent color data for statistical analysis due by October 1,2003. Highest Certainty items include: • Process Optimization o See Liebergott Report for specific fiberline optimization requirements • Improved black liquor leak&spill collection and control o Continuous improvement of operating practices so more leaks and spills are recovered rather than discharged to sewer; o Improvement in preparation for planned outages to maximize capture of tank clean-out waste and routing to recovery; o Reduction of clean water that continuously runs into sewers to prevent dilution of smaller spills and facilitate recovery of highly colored wastewaters;and, o Improvement in the equipment used for handling of knot rejects to prevent black liquor leaks into the recovery sumps. • BFR reliability improvement Highest Certainty items shall reduce the annual average color discharge limit 6,000—8,000 lbs/day,based on the statistical analysis conducted for the October 1,2003 report. October 1,2003 Completed Report due to DWQ,which must include: • Statistical analysis of monthly average color since implementation of `Highest Certainty' actions and technologies • Mill performance as related to color since `Highest Certainty' actions and technologies implemented,and • All available data necessary to derive the lowest achievable annual average and monthly average color loading limits. November 1,2003 The NCDWQ,in consultation with the TRW and NPDES Committee,shall Completed recommend the lowest achievable annual average and monthly average color loading effluent limitations(based on the mill's October 1,2003 report.) December 1,2003 Limits recommended by DWQ become effective if they are within or below the Completed, got target range of 40,000—42,000 pounds per day as an annual average. extension to 12/15/03 If the DW Q's recommended limits are above the target range,the Permit shall be modified in accordance with NC's permitting process to reflect those limits. DWQ will then recommend alternate interim limits to become effective December 1,2003 and a new effective date for achieving an annual average color loading limit of 40,000—42,000 pounds per day. Report due to DWQ,TRW and the NPDES Committee on the feasibility of achieving a target annual average color reduction within the range of 3,000 and 8,000 pounds per day from the reduction achieved by implementation of the 'Highest Certainty'actions. Report shall include: • An evaluation of the use of the `Reasonable Certainty' actions identified in the EPA Tech Team Report(Ozone/Chlorine Dioxide stage for hardwood bleach line and second stage oxygen delignification for the pine line), • Any other actions that would result in additional color reductions(see last bullet), • Actions taken by the permittee to reduce color loading since permit issuance, • The technical,economic, and operational feasibility of implementing the 'Reasonable Certainty' actions on a continuous or intermittent basis in order to achieve a target annual average color reduction within the range of 3,000 and 8,000 pounds per day, • The projected additional color reduction expected for each technology J evaluated and maximum color reduction possible using the identified 1 technologies, • A proposed schedule for implementation of process improvements or installation of technologies required to achieve an additional effluent color reduction of 3,000—8,000 pounds per day and, • An updated report on the results of ongoing and additional planned color reduction activities. February 1,2004 DWQ,in consultation with the TRW,shall approve or modify the Permittee's recommended plan for achieving an additional 3,000—8,000 pounds per day reduction to the target annual average. NOTE: Permit was modified to annual average limit of 42,000 lbs/day and monthly maximum limit of 52,000 lbs/day. December 1,2004 Report Due to DWQ and TRW evaluating color reduction technologies Extension to April 1, associated with the CRP wastestream. Report must include/identify: 2005 due to Sept.2004 floods • Technical,economic,and operational feasibility of implementing the applicable technologies on all or a portion of the purge stream, • Specific economic and implementation issues associated with the improvements, • Projected additional color reduction expected for each technology evaluated and maximum color reduction possible using the identified technologies including,but not limited to: F o Analysis of the land application of the high chloride 1 wastewater, o Commercial incineration, / o Coagulant/precipitation technologies and, o Solidification for land disposal February 1,2005 DWQ,in consultation with the TRW,shall evaluate the feasibility of Extension to.Tune 1, implementing identified technologies for further color reduction and shall 2005 due to Sent. submit to the NPDES Committee their recommendations regarding color 2004 floods reductions associated with the treatment of the CRP stream. If during the course of the CRP evaluation Blue Ridge identifies a technical, economic,and operationally feasible color reduction technology that can be implemented for treatment of the CRP wastestream,the permittee may request that the TRW review this technology for implementation at the Canton Mill. If the TRW agrees such technology is suitable and that the color reductions achievable are adequate,the mill's obligation to research additional technologies will be waived after formal notification from Blue Ridge Paper. December 1,2005 Permittee shall submit,as related to 'Reasonable Certainty' items,a statistical analysis of Blue Ridge Paper's effluent quality performance including: • A statistical analysis of monthly average and annual average color discharge, • Mill performance as related to color,and • All available data necessary to derive the lowest achievable annual average and monthly average color loading limits. February 1,2006 DWQ,in consultation with the TRW,shall recommend to the NPDES Committee the lowest achievable annual average and monthly average color loading effluent limitations. March 1,2006 If the recommended limits are within or below the target range of 32,000— 39,000 pounds per day as an annual average,the limits shall become effective. If the recommended limits are above the 32,000—39,000 pounds per day target range,the Permit shall be modified in accordance with NC's permitting process to reflect those limits. Report due to DWQ the TRW and the NPDES Committee on the color reduction efforts as part of the Variance review process (Triennial Review). Report shall include: • An evaluation of Color in the Pigeon River at the Fiberville Bridge and, • An evaluation on the feasibility of complying with NC's Color Standard. The NPDES Permit shall be subject to reopening based upon the following and in association with the required triennial reviews: • Any breakthrough in color removal technologies,which shall be brought to the NPDES Committee for consideration,by BRPP and the DWQ,as soon as they are discovered. • An acceptable statistical analysis of effluent color discharge data demonstrating significantly better color removal performance than that currently prescribed in the variance and permit. • Successful application of end-of-pipe color reduction technology or in-mill color minimization effort that results in significant and measurable reduced mass color discharge. 4, The permittee shall not increase the mill's pulp production capacity during the term of this permit,unless the permittee can demonstrate that the increased production can be achieved while reducing color loading. In addition,increasing the mill's pulp production capacity may require permit revision in accordance with NC's NPDES Permitting rules. 1 MichaelState of Norrth Carolina y William G.Ross,Jr.,Secretary F" Department of Environment and Natural Resources y Alan W.Klimek,P.E.,Director Division of Water Quality February 27,2004 Robert Shanahan,Vice President and Operations Manger Blue Ridge Paper Products (,114h il P.O.Box 4000 Canton,North Carolina 28716 7 Subject: NPDESPermit Modification Color Limitations r Permit Number:NC0000272 ". Blue Ridge Paper Products Canton Mill Haywood County Dear Mr. Shanahan: Blue Ridge Paper's NPDES permit was reissued on November 15,2001. That permit included several special conditions concerning effluent color discharges from the mill. Section A. (8.) of the permit in part 5.required that Blue Ridge Paper submit "a report including a statistical analysis of the permittee's monthly average color discharge,mill performance as related to color, [and] all available data necessary to derive the lowest achievable annual average and monthly average color loading limits"by October 1,2003. Blue Ridge Paper provided the required report in accordance with that condition. The 2001 NPDES Permit also required that the Division review the October 1 report in consultation with the Technology Review Workgroup (TRW),Chaired by the Environmental Protection Agency and with members from both North Carolina and Tennessee,and determine appropriate color loading limitations for this permit. The TRW provided to DWQ its final recommendation on what it believes is the most appropriate interim color limitations for the mill for annual average color discharged and for monthly average color discharge on February 4,2004. The Division has reviewed that recommendation and is providing this written notification to Blue Ridge Paper that its annual average and monthly average limitations for effluent color are being revised. Therefore, and in accordance with condition A. ( 8.) 6. of your permit and the TRW recommendation,I am revising your annual average color limitation to the following: Effective January 1,2004,the average annual discharge of true color for each calendar year shall not exceed 42,000 pounds per day. Pounds of effluent color shall be determined in accordance with the existing conditions and monitoring requirements of Permit Number NC0000272,issued on November 15,2001. rIn addition,I am making an administrative change to your permit to reduce your monthly average color limitation from the current level of 55,000 pounds per day to 52,000 pounds per day. This F change is effective March 1,2004 and reflects the recommendation of the TRW. As indicated above, pounds of effluent color shall be determined in accordance with the existing conditions and monitoring requirements of Permit Number NC0000272,issued on November 15,2001. This change reflects a more restrictive limitation for monthly average color discharge and a monthly average North Carolina Division of Water Quality (919)733-7015 1617 Mail Service Center FAX(919)733-0719 Raleich, North Carolina 27699-1617 n...r,e.....................,,,.,___-......___.._, IA Ridge Paper Products y it No. NC000272 r hex = z, g ` tation in line with the reduction of the annual average color limitation. This change provides a s more effective regulatory control requirement for monthly average color and provides bett r_.,_o protection of the water quality of the Pigeon River. er The described changes affect only the limitations for annual and monthly average color discharge limitations in the NPDES permit in section A. (B. )2. All other conditions in this permit remain in effect as issued on November 15,2001 and effective December 1,2001. Please include a copy of this letter with all copies of the plant's permit filed with the company and used for reference at the mill site. If any parts,or requirements of this permit modification are unacceptable to you,you have the t righ eipt of this to an adjudicatory hearing upon written request within thirty(30) days following rec letter. This request must be in the form of a written petition,conforming to Chapter eipt50B of the North Carolina General Statutes,and filed with the Office of Administrative Hearings (6714 Mail Service Center,Raleigh,NC 27699-6714). Unless such demand is made, this decision shall be final and binding. The Division appreciates the continued progress of Blue Ridge Paper in improving the quality of your treated effluent and the Pigeon River. We anticipate continued improvement and pro gr toward the overall goal of this process: removal of the color variance for Blue Ridge Paper by the expiration date of the NPDES Permit. If you have any questions concerning this permit modification,please call Forrest Westall at 828/251-6208. Sincerely, Alan Klimek,PE cc Central Files Forrest Westall Sergei Chernikov Keith Haynes Don Anderson Paul Davis David McKinney Karrie-Jo Shell State of North Carolina Department of Environment and Natural Resources � Division of Water Quality Michael F. Easley, Governor NCDENR William G. Ross, Jr., Secretary Gregory J.Thorpe, Ph.D., Acting Director November 15, 2001 Mr. Robert Shanahan Vice President-Mill Manager Blue Ridge Paper Products P.O.Box 4000 Canton,North Carolina 28716 Subject: NPDES Permit Issuance Permit No.NC0000272 Blue Ridge Paper Products Inc. Haywood County Dear Mr. Shanahan: After conducting a public hearing on Blue Ridge Paper's Request for renewal of the color variance, temperature variance and the NPDES Permit, the Environmental Management Commission's NPDES Committee approved renewal of the color variance, with the color conditions contained herein, on October 10, 2001.The conditions related to color(as approved by the NPDES Committee)have been incorporated into this permit and are an enforceable part of the permit. In considering the comments presented at the September 6, 2001 public hearing, the hearing officer made several recommendations for the color variance and the NPDES permit. The recommendations made by the hearing clearly indicate the hearing officer's commitment to addressing the concerns raised at the hearing and have been incorporated into the approved color variance and this NPDES Permit. Specifically, the changes to the color variance and this permit include: ➢ The color variance and permit explicitly requires the Canton mill to implement all of the 'Highest Certainty' action items (as identified by the EPA's Tech Team). ➢ The initial color limit reduction to 42,000 pounds per day is now stipulated as a range of 40,000—42,000 pounds per day. After implementation of the 'Highest Certainty' action items, the Technology Review Workgroup will evaluate mill performance. If the limit recommended by the TRW is within or below the 40,000 to 42,000 pounds per day, that limit will become effective on December 1, 2003, after written notification from the Director of the Division of Water Quality. ➢ The color variance and permit explicitly requires the Canton mill to evaluate all of the 'Reasonable Certainty' action items. ➢ The color variance and permit explicitly states that the second 3,000 to 8,000 pounds per day color reduction is in addition to the initial 6,000 to 8,000 pounds per day color reduction. ➢ The range for the final color limit effective December 1, 2005 is now 32,000 to 39,000 pounds per day. If the limit recommended by the TRW is within or below the 32,000 to 39,000 pounds per day, that limit will became effective on March 1, 2006, after written notification from the Director of the Division of Water Quality. ➢ The report evaluating color reduction technologies for the Chloride Removal Process purge stream is due on December 1,2004, so that this waste stream can be evaluated by the 1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617-TELEPHONE 91 9-733-5083/FAX 919-733-0719 AN EQUAL OPPORTUNITY AFFIRMATIVE ACTION EMPLOYER- 50%RECYCLED/ 1 0%POST-CONSUMER PAPER VISIT US ON THE INTERNET @ http://h2o.enr.state.nc.us/NPDES Permit Number: NC0000272 Technology Review Workgroup for additional color reductions by the end of the permit cycle. ➢ The evaluation of color reduction technologies associated with the Chloride Removal Process waste stream shall include land application, commercial incineration, and solidification for land disposal. The inclusion of these technologies should not be interpreted as limiting the scope of this evaluation,rather that in addition to other technologies the report should include the technologies referenced above. ➢ The color condition has been reworded to clarify that the role of the color ranges is not permitting limits; rather they are clauses to trigger reopening of the permit. If the effluent color limit, which will be set only after implementation of the"Highest Certainty" items and the"Reasonable Certainty"(or equivalent) items, fails to fall at least within the ranges set in the condition,Blue Ridge Paper would be required to satisfactorily justify the circumstances, for not achieving the stipulated color reductions, to the Division of Water Quality, the Technology Review Workgroup and the Environmental Management Commission's NPDES Committee. If the TRW and the Division of Water Quality concur with Blue Ridge Paper's rationale for not achieving the stipulated ranges,the permit would be reopened for public comment, prior to presenting these findings to the NPDES Committee. If the performance of the mill results in a limit within or better than these two color ranges, the permit would not be reopened and the performance attained would become the limit that is effective on the date stipulated in the color condition. ➢ Finally, the color condition has been reworded to better describe that the methodology for determining the effluent color limits are based on the performance of the mill after implementation of the identified technologies.The effluent color limit implemented at the end of the permit cycle, will be set only after all the"Highest Certainty" items and "Reasonable Certainty"(or alternative technology that will achieve similar color reductions) items have been implemented. After implementation of these items, the Division(based on the recommendation of the Technology Review Workgroup)will set a final effluent color limit based on a statistical analysis of the performance of the mill. The Division of Water Quality commends Blue Ridge Paper for their initiative and leadership in fostering community involvement. The openness and willingness of Blue Ridge Paper to work with the community was evident at the public hearing and has manifested itself in a trust between the community and the company. The Division strongly recommends that Blue Ridge Paper continue their efforts to foster this relationship and maintain a leadership role on the Community Advisory Committee. The Canton mill has made incredible strides in reducing its impact on the Pigeon River, though significant work remains. The Division of Water Quality has worked together with the community,EPA, the State of Tennessee, and Blue Ridge Paper to develop a permit and color variance conditions that meets the goals of all the parties. By the end of the permit cycle,the Division expects that, for the first time since the variance was issued in 1988,the Division and the NPDES Committee will be able to evaluate whether the Canton mill's performance has achieved compliance with North Carolina's narrative color standard(15A NCAC 2B .0211(3)(f)). However, if mill performance fails to achieve the color reductions expected, the Division recommends that Blue Ridge Paper consider facilitating another independent evaluation of the Canton mill, similar to the evaluation conducted by Dr.Liebergott. In addition to the changes and recommendations regarding color above the hearing officer suggested the following changes to the permit: ➢ Clarification on the sampling location for the Fiberville Bridge instream monitoring station (refer to Special Condition A.(5.)) Permit Number: NC0000272 ➢ Monitoring of the full range of dioxin and furan isomers on the effluent from the Canton mill (refer to Special Condition A.(9.)). Division personnel have reviewed your application for renewal of the subject permit, the temperature and color variance. Accordingly,we are forwarding the attached NPDES discharge permit that incorporates the recommendations of the hearing officer and the conditions of the color variance. 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 May 9, 1994 (or as subsequently amended). 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. 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 the draft permit for your facility, please call Michael Myers at(919)733-5083, extension 508. Sincerely, Gregory J.Thorpe,Ph.D. Acting Director cc: Central Files NPDES Files Aquatic Toxicology Unit Marion Deerhake-North Carolina Environmental Management Commission,NPDES Committee Jerry Wilde-Dead Pigeon River Council 402 W.Broadway Newport,Tennessee 37821 Forrest Westall-Asheville Regional Office/Water Quality Section Dan Oakley-North Carolina Attorney General,Environmental Division Keith Haynes-Asheville Regional Office/Water Quality Section Rob Lang-Compliance and Enforcement Unit Diane Reid-Classification and Standards Unit Scott Gordon-Chief of Permits, Grants,and Technical Assistance Branch,EPA Region IV Roosevelt Childress Jr.-Environmental Protection Agency,Region IV Marshall Hyatt-Environmental Protection Agency,Region IV Karrie-Jo Shell-Environmental Protection Agency,Region IV Don Anderson-Environmental Protection Agency,Headquarters Mark Perez-Environmental Protection Agency,Headquarters Permit Number: NC0000272 Justin P.Wilson—Deputy to the Governor Tennessee State Capital,Suite G10 Nashville,Tennessee 37243 Paul Davis—Tennessee Division of Water Pollution Control 6th Floor,L&C Annex 401 Church Street Nashville,TN 37243-1534 Charles Lewis Moore—County Executive Cocke County 360 Main Street,East Newport,Tennessee 37821 David Jenkins—American Canoe Association 7432 Alban Station Boulevard,Suite B-232 Springfield,Virginia 22150-2311 Hope Taylor-Clean Water Fund of North Carolina 29'fz Page Ave Asheville,North Carolina 28801 David McKinney—Tennessee Wildlife Resources Ellington Agricultural Center P.O.Box 40747 Nashville,Tennessee 37204 Jonathon E.Burr—Tennessee Division of Water Pollution Control Regional Environmental Assistance Center 2700 Middlebrook Pike,Suite 220 Knoxville,Tennessee 37921 Robert Williams—Blue Ridge Paper 175 Main Street P.O.Box 4000 Canton,North Carolina 28716 Derric Brown—Blue Ridge Paper 175 Main Street P.O.Box 4000 Canton,North Carolina 28716 Patsy R.Williams—Chairman Newport/Cocke County Tourism Council 360 East Main Street Court House Annex,Suite 141 Newport,Tennessee 37821 Dianne Keys—Newport/Cock County Tourism Council 360 East Main Street Court House Annex,Suite 141 Newport,Tennessee 37821 Timothy L.Dockery—Director City of Newport Parks and Recreation Department 433 Prospect Avenue Newport,Tennessee 37821 A. Dean Williams—Coordinator Newport/Cocke County Economic Development Commission 433 Prospect Avenue Newport,Tennessee 37821 Ray Snader—News Director WNPC Radio AM/FM 377 Graham Street Newport,Tennessee 27821 Permit Number: NC0000272 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, Blue Ridge Paper Products Inc. is hereby authorized to discharge wastewater from a facility located at Blue Ridge Paper Products Inc. Canton Mill Wastewater Treatment Plant Off Highway 215 Canton Haywood County to receiving waters designated as the Pigeon River in the French Broad 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 December 1, 2001. This permit and authorization to discharge shall expire at midnight on November 30, 2006. Signed this day November 15,2001. Gregory J.Thorpe,Acting Director Division of Water Quality By Authority of the Environmental Management Commission Permit Number: NC0000272 SUPPLEMENT TO PERMIT COVER SHEET Blue Ridge Paper Products, Inc. is hereby authorized to: 1. Continue operation of a 29.9 MGD wastewater treatment plant for the treatment of wastewater associated with the Blue Paper Products Inc. pulp and paper mill, the Town of Canton's chlorinated domestic wastewater and landfill leachate. The treatment system consists of the following treatment units: • Grit Chamber • Bar Screen • Lift Pumps • Polymer addition pH control(COZ injection or H2SO4 backup) /• Three primary clarifiers • Nutrient Feed • Aeration basins • Three secondary clarifiers • Residual belt presses • Effluent flow measurement • Cascade post aeration with oxygen injection • Instream oxygen injection facilities The facility is located at the Blue Ridge Paper Products WWTP, off Highway 215, Canton, Haywood County, and; 2. Discharge treated wastewater from said treatment works at the location specified on the attached map through outfall 001 into the Pigeon River, which is classified C water, in the French Broad River Basin. Permit Number: NC0000272 A. (1.)EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge treated industrial,municipal,stormwater and landfill wastewater through outfall(s) 001. Such discharges shall be limited and monitored by the Permittee as specified below: Effluent Characteristics Effluent Limits Monitoring Requirements Monthly Daily Measurement -Sample;Type Sample Average Maximum Frequency I Location'] Flow 29.9 MGD Continuous Recording I or Ej BOD,5-day,20°C 3205 lb/day 108971b/day Daily Composite I,E, Total Suspended Residue 125491b/day 49560 lb/day Daily Composite 1,El NH3-N Daily Composite El AOXz 1556.9lb/day 2822.2lb/day Daily Composite El Color Daily Composite El Dissolved Oxygen Oxygen4 Daily Grab Ei Tem erature Daily Grab El PIFDaily Grab El Conductivity Daily Grab E, Fecal Coliform 200/ 100 ml 400/ 100 nil Weekly Grab E, COD Weekly Composite E, Silver Quarterly Composite El Zinc Quarterly Composite El Total Nitrogen (NO2-N+NO3-N+TKN) Monthly Composite E, Total Phosphorus Monthly Composite El Chronic Toxicity Quarterly Composite E, Cadmium Quarterly Composite E, Trichloro henol 3.0 QuarterlyComposite E, Pentachlorophenol 8.9 g/L Quarterly Composite El Selenium 10.6 /L Quarterly Composite El 2,3,7,8 Tetrachloro-dibenzo- 0.014 pg/L Quarterly Composite I,El dioxin10 Conductivity Daily Grab Pigeon River Flow I Daily Grab Pigeon River Fecal Coliform Weekly Grab Pigeon River Color Variable Grab Pigeon River Tem erature Variable Grab Pigeon River Dissolved Oxygen Variable I Grab Pigeon River Footnotes: I. Sample Location:I-Influent,E,—Effluent,Pigeon River-Instream sampling as specified in A.(5.)Instream Monitoring Special Condition. 2. AOX monitoring shall be in accordance with the Sampling Plan for Cluster Rule Parameters(dated March 19, 2001)or subsequent modifications approved by the Division. AOX data shall be submitted on a quarterly basis along with other Effluent Guideline chemical data;refer to A. (7.) Effluent Guideline Sampling Plan Special Condition. 3. See A. (8.) Color Analysis and Compliance Special Condition. 4. The daily average effluent dissolved oxygen concentration shall not be less than 6.0 mg/L. See A. (10.) Dissolved Oxygen Special Condition. 5. The monthly average instream temperature measured at a point 0.4 miles downstream of the discharge location shall not exceed 32°C during the months of July,August,and September and shall not exceed 29.0°C during Permit Number: NCOOOO272 the months of October through June. The monthly average instream temperatretemnerature measured at this location shall not exceed the monthly average instream temperature of the upstream monitoring location by more than 13.9°C [See Special Condition A.(13.)Temperature Variance Review Special Condition]. 6. The pH of the effluent shall not be less than 6.0 nor greater than 9.0(on the standard units scale). 7. Chronic Toxicity(Ceriodaphnia)at 90%Effluent Concentration:March,June,September,December(see A. (4.)Chronic Toxicity Permit Limit(Quarterly)). 8. Trichlorophenol and Pentachlorophenol limits and monitoring are provisionally waived since the facility has certified that chlorophenolic biocides are not used at this facility. If the facility changes operations to include chlorophenolic biocide,the Permittee shall notified the Division prior to use and the limits and monitoring requirements shall become immediately effective. 9. If after 18 months selenium has not been detected,the facility may request that the Division review selenium data for possible removal of the limitation. 10. See A. (9.) Dioxin Monitoring Special Condition. 11. See A. (5.) Instream Monitoring Special Condition. See A.(6.) Best Management Practices(BMP)Special Condition. See A. (11.) Town of Canton Inflow and Infiltration Special Condition. Definitions: MGD—Million gallons per day lb/day—Pounds per day ml—Milliliter BOD—Biochemical Oxygen Demand µg/L-Micrograms per liter AOX-Adsorbable Organic Halides COD-Chemical oxygen demand pg/L-picograms per liter Permit Number: NC0000272 A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning upon the effective date of the permit and lasting until expiration, the discharge of wastewater from the pine bleach plant to the wastewater treatment plant through outfall(s) 002(E21), shall be limited and monitored by the Permittee as specified below and in A. (7.) Effluent Guideline Sampling Plan Special Condition: Effluent Characteristics Limits Monitoring 'ReciuirementsZ Monthly , Daily Measurement 'Sample rType3 Sample Average, , Maximum' Frequency Location' Flow' Weekly Calculated Ez Chloroform 5.15lb/day 8.60lb/day Weekly Grab EZ 2,3,7,8 Tetrachloro-dibenzo- < 10 pg/L Monthly Composite E2 dioxin(TCDD) 2,3,7,8 Tetrachloro-dibenzo- 31.9 pg/L Monthly Composite EZ p-furan(TCDF) Trichlorosyringol < 2.5 µgII2 Monthly Composite EZ 3,4,5-Trichlorocatechol < 5.0 µg/L Monthly Composite E2 3,4,6-Trichlorocatechol < 5.0 µg/L Monthly Composite E2 3,4,5-Trichloroguaiacol < 2.5 µg/L Monthly Composite Fe 3,4,6-Trichloroguaiacol < 2.5 µg/L Monthly Composite E2 4,5,6-Trichloroguaiacol < 2.5 µg/L Monthly Composite E2 2,4,5-Trichlorophenol < 2.5 µg/1. Monthly Composite E2 2,4,6-Trichlorophenol < 2.5 µg/L Monthly Composite EZ Tetrachlorocatechol < 5.0 µg/L Monthly Composite Fa Tetrachloroguaiacol < 5.0 µg/L Monthly Composite E2 2,3,4,6-Tetrachlorophenol < 2.5 µg/L Monthly Composite F2 Pentachlorophenol < 5.0 µg/L Monthly Composite E2 Footnotes: 1. Sample Location:EZ—Effluent is composed of Bleach Plant Effluent-acid(acid sewer collected from tap installed on filtrate pump from C102 bleaching stage D-100 and from tap installed on filtrate pump from C102 bleaching stage D-2)and Bleach Plant Effluent-alkaline(alkaline sewer collected from tap installed on filtrate pump from alkaline extraction stage E.).See A. (7.)Effluent Guideline Sampling Plan Special Condition 2. Monitoring and flow calculations shall be in accordance with the"Sampling Plan for Cluster Rule Parameters" (dated March 19,2001)or subsequent modifications approved by the Division. Chemical results for Effluent Guideline parameters as prepared by the permittee(Internal Outfall 002 parameters+internal Outfall 003 parameters+AOX from Outfall 001)shall be reported on a quarterly basis or more frequently;refer to A. (7.) Effluent Guideline Sampling Plan Special Condition. 3. Sample Type: Calculated-calculate separate flows for alkaline and acid sewers by water balance or flow meters,and report total bleach plant flow(acid+alkaline wastestreams)in DMRs. Grab-collect separate grab samples every 4-hours for 24-hour period from both the acid and alkaline streams,which will then be composited separately by the lab,and analyzed as separate 24-hr composite acid and alkaline samples. Composite-collect separate grab samples every 4 hours for 24-hour period from both the acid and alkaline streams,then prepare and analyze a single flow-proportioned composite of the acid and alkaline wastestream. 4. For compliance purposes,the permittee must report the total chloroform mass loading based on addition of separate acid and alkaline chloroform mass loadings. 5. Limits are based on Minimum Levels (MI.)specified in 40 CFR 430.01. Definitions: lb/day—Pounds per day µg/L—Micrograms per liter pg/L—Picograms per liter Permit Number: NC0000272 A. (3.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning upon the effective date of the permit and lasting until expiration, the discharge of wastewater from the hardwood bleach plant to the wastewater treatment plant through outfall(s) 003 (E31), shall be limited and monitored by the Permittee as specified below and in A. (7.) Effluent Guideline Sampling Plan Special Condition: Effluent Characteristics Limits Monitoring Requirements Monthly DailyAverage Measurement Sample Type3 Sample Average Frequency Location' Flow2 Weekly Calculated E, Chloroform 7.14lb/day 11.93lb/day Weekly Grab E3 2,3,7,8 Tetrachloro-dibenzo- < 10 pg/L. Monthly Composite E3 p-dioxin(TCDD) 2,3,7,8 Tetrachloro-dibenzo- 31.9 pg/L Monthly Composite E3 p-furan(TCDF) Trichlorosyringol < 2.5 gg;112 Monthly Composite E3 3,4,5-Trichlorocatechol < 5.0 µg/L Monthly Composite E3 3,4,6-Trichlorocatechol < 5.0 µg/L Monthly Composite E3 3,4,5-Trichloroguaiacol < 2.5 µg/L Monthly Composite E3 3,4,6-Trichloroguaiacol < 2.5 µg/L Monthly Composite E3 4,5,6-Trichloroguaiacol < 2.5 µg/L Monthly Composite E3 2,4,5-Trichlorophenol < 2.5 µg/1. Monthly Composite E3 2,4,6-Trichlorophenol < 2.5 µg/L Monthly Composite E3 Tetrachlorocatechol < 5.0 µg/L Monthly Composite E3 Tetrachloroguaiacol < 5.0 µg/L Monthly Composite E3 2,3,4,6-Tetrachlorophenol < 2.5 µg/L Monthly Composite E3 Pentachlorophenol < 5.0 µg/I. Monthly Composite E3 Footnotes: 1. Sample Location:E3—Effluent is composed of Bleach Plant Effluent-acid(acid sewer collected from tap installed on filtrate pump from C102 bleaching stage D-100)and Bleach Plant Effluent-alkaline(alkaline sewer collected from tap installed on filtrate pump from alkaline extraction stage Eo).See A. (7.)Effluent Guideline Sampling Plan Special Condition. 2. Monitoring and flow calculations shall be in accordance with the"Sampling Plan for Cluster Rule Parameters" (dated March 19,2001)or subsequent modifications approved by the Division. Chemical results for Effluent Guideline parameters,as prepared by the permittee(Internal Outfall 002 parameters+internal Outfall 003 parameters+AOX from Outfall 001)shall be reported on a quarterly basis or more frequently;refer to A. (7.) Effluent Guideline Sampling Plan Special Condition. 3. Sample Type: Calculated-calculate separate flows for alkaline and acid sewers by water balance or by flow meter,and report total bleach plant flow(acid+alkaline wastestreams) in DMRs. Grab-collect separate grab samples every 4-hours for 24-hour period from both the acid and alkaline streams, which will then be composited separately by the lab,and analyzed as separate 24-hr composite acid and alkaline samples. Composite-collect separate grab samples every 4 hours for 24-hour period from both the acid and alkaline streams, then prepare and analyze a single flow-proportioned composite of the acid and alkaline wastestream. 4. For compliance purposes,the permittee must report the total chloroform mass loading based on addition of separate acid and alkaline chloroform mass loadings. 5. Limits are based on Minimum Levels (NIL)specified in 40 CFR 430.01. Definitions: lb/day—Pounds per day µg/L—Micrograms per liter pg/L—Picograms per liter Permit Number: NC0000272 A. (4.) CHRONIC TOXICITY PERMIT LIMIT(QRTRLY) The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia dubia at an effluent concentration of 90%. The permit holder shall perform at a minimum,aaarterl 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,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 II 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: North Carolina Division of Water Quality Environmental Sciences Branch 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. Permit Number: NC0000272 A. (5.) INSTREAM MONITORING SPECIAL CONDITION Stream Mile Location Description Parameter Frequency Designation Marker UP 63.8 Pigeon River upstream of the Temperature Daily waste treatment plant outfall D.O. Daily (prior to mixing with the Conductivity Daily discharge) Color 2/Week Flow Daily Fecal Coliform Weekly DNl 62.9 Pigeon River at Fiberville Bridge Temperature Daily D.O. Daily Conductivity Daily Color I 2/Week DN23 57.7 Pigeon River Above Clyde Temperature Daily D.O. Daily DN3 55.5 Pigeon River Below Clyde See Footnote 3 See Footnote 3 DN4 53.5 Pigeon River at NCSR 1625 See Footnote 3 See Footnote 3 bridge DN5 42.6 Pigeon River at Hepco Temperature Weekly D.O. Weekly Color Variables Flov2 Daily Waterville Reservoir See Footnote 4 Annually DN6 26.0 Pigeon River prior to mixing with Color Variable Big Creek BC -26.0 Mouth of Big Creek prior to Color Variable mixing with the Pigeon River DN7 24.7 Pigeon River at Browns Bridge Temperature Weekly (-NCITN State Line) D.O. Weekly Color Variables All instream samples shall be grab samples. 1. Color(See A. (8.) Color Analysis and Compliance Special Condition) All instream samples collected shall be representative of the Pigeon River and Big Creek, respectively. Both true and apparent color shall be monitored using the methods specified in A. (8.)Color Analysis and Compliance Special Condition. Samples shall be collected at stations DN6,BC, and DN7 only when at least one generator at CP&L is in operation and releasing water to the Pigeon River. Samples collected at DNl shall be collected from the middle or midpoint of the transect of the Pigeon River. 2. Flow monitoring is necessary, as specified above, for the True Color calculation stipulated in A. (8.) Color Analysis and Compliance Special Condition. 3. Dissolved Oxygen. The average daily dissolved oxygen concentration measured at River Mile 62.9 (DNl), and 57.7 (DN2), shall not be less than 5.0 mg/l and the instantaneous minimum dissdlved oxygen concentration shall not be less than 4.0 mg/1 (See A. (10.) Dissolved Oxygen Special Condition). If the dissolved oxygen drops below 5.0 mg/1-at station 57.7 then monitoring shall be required at stations 55.5 (DN3) and 53.5 (DN4). 4. See A. (12.) Waterville Reservoir Sampling Special Condition. 5. Sampling is required 2/week during the summer and once per week during the winter. Summer is defined as the period from April 1 through October 31, while winter is defined as November 1 through March 31. Permit Number: NC0000272 A. (6.) BEST MANAGEMENT PRACTICES(BMP) SPECIAL CONDITION The permittee must implement the BMPs specified in Section A below. The primary BMP objective is to prevent leaks and spills of spent pulping liquors, soap, and turpentine. A secondary objective is to contain,collect, and recover at the immediate process area, or otherwise control,those leaks, spills,and intentional diversions of spent pulping liquor,soap, and turpentine that do occur. BMPs must be developed according to best engineering practices and must be implemented in a manner that takes into account the specific circumstances at the mill. Section A. BMW Implementation Requirements 1. The permittee must return spilled or diverted spent pulping liquors, soap, and turpentine to the process to the maximum extent practicable as determined by the mill,recover such materials outside the process, or discharge spilled or diverted material at a rate that does not disrupt the receiving wastewater treatment system. 2. The permittee must establish a program to identify and repair leaking equipment items. This program must include: (i)Regular daily visual inspections of process area with equipment items in spent pulping liquor, soap, and turpentine service; (ii)Immediate repair of leaking equipment items, when possible. Leaking equipment items that cannot be repaired during normal operations must be identified, temporary means for mitigating the leaks must be provided, and the leaking equipment items repaired during the next maintenance outage; (iii)Identification of conditions under which production will be curtailed or halted to repair leaking equipment items or to prevent pulping liquor, soap, and turpentine leaks and spills; and(iv)A means for tracking repairs over time to identify those equipment items where upgrade or replacement may be warranted based on frequency and severity of leaks, spills, or failures. 3. The permittee must operate continuous, automatic monitoring systems that the mill determines are necessary to detect and control leaks, spills, and intentional diversions of spent pulping liquor, soap, and turpentine.These monitoring systems should be integrated with the mill process control system and may include, e.g., high level monitors and alarms on storage tanks; process area conductivity(or pH) monitors and alarms; and process area sewer,process wastewater, and wastewater treatment plant conductivity(or pH)monitors and alarms. 4. The permittee must establish a program of initial and refresher training of operators, maintenance personnel, and other technical and supervisory personnel who have responsibility for operating, maintaining, or supervising the operation and maintenance of equipment items in spent pulping liquor,soap, and turpentine service.The refresher training must be conducted at least annually and the training program must be documented. 5. The permittee must prepare a brief report that evaluates each spill of spent pulping liquor, soap, or turpentine that is not contained at the immediate process area and any intentional diversion of spent pulping liquor, soap, or turpentine that is not contained at the immediate process area.The report must describe the equipment items involved, the circumstances leading to the incident, the effectiveness of the corrective actions taken to contain and recover the spill or intentional diversion, and plans to develop changes to equipment and operating and maintenance practices as necessary to prevent recurrence. Discussion of the reports must be included as part of the annual refresher training. 6. The permittee must establish a program to review any planned modifications to the pulping and chemical recovery facilities and any construction activities in the pulping and chemical recovery areas before these activities commence. The purpose of such review is to prevent leaks and spills of spent pulping liquor, soap, and turpentine during the planned modifications, and to ensure that construction and supervisory personnel are aware of possible liquor diversions and of the requirement to prevent leaks and spills of spent pulping liquors, soap, and turpentine during construction. 7. The permittee must install and maintain secondary containment(i.e.,containment constructed of materials impervious to pulping liquors) for spent pulping liquor bulk storage tanks equivalent to the Permit Number: NC0000272 volume of the largest tank plus sufficient freeboard for precipitation. An annual tank integrity testing program, if coupled with other containment or diversion structures,may be substituted for secondary containment for spent pulping liquor bulk storage tanks. 8. The permittee must install and maintain secondary containment for turpentine bulk storage tanks. 9. The permittee must install and maintain curbing, diking or other means of isolating soap and turpentine processing and loading areas from the wastewater treatment facilities. 10. The permittee must conduct wastewater monitoring to detect leaks and spills, to track the effectiveness of the BMPs, and to detect trends in spent pulping liquor losses. Such monitoring must be performed in accordance with Section E. Section B. BMP Plan Requirements 1. The permittee must prepare and implement a BMP Plan.The BMP Plan must be based on a detailed engineering review as described in this section. The BMP Plan must specify the procedures and the practices required for the mill to meet the requirements of Section A, the construction the mill determines is necessary to meet those requirements including a schedule for such construction,and the monitoring program(including the statistically derived action levels)that will be used to meet the requirements of Section E.The BMP Plan also must specify the period of time that the mill determines the action levels established under Section D may be exceeded without triggering the responses specified in Section E. 2. The permittee must conduct a detailed engineering review of the pulping and chemical recovery operations--including but not limited to process equipment, storage tanks,pipelines and pumping systems, loading and unloading facilities,and other appurtenant pulping and chemical recovery equipment items in spent pulping liquor, soap, and turpentine service--for the purpose of determining the magnitude and routing of potential leaks, spills, and intentional diversions of spent pulping liquors, soap, and turpentine during the following periods of operation: (i)Process start-ups and shut downs; (ii)Maintenance; (iii)Production grade changes; (iv) Storm or other weather events; (v) Power failures; and(vi)Normal operations. 3. As part of the engineering review,the permittee must determine whether existing spent pulping liquor containment facilities are of adequate capacity for collection and storage of anticipated intentional liquor diversions with sufficient contingency for collection and containment of spills.The engineering review must also consider: (i)The need for continuous, automatic monitoring systems to detect and control leaks and spills of spent pulping liquor, soap, and turpentine; (ii)The need for process wastewater diversion facilities to protect end-of-pipe wastewater treatment facilities from adverse effects of spills and diversions of spent pulping liquors, soap, and turpentine; (iii)The potential for contamination of storm water from the immediate process areas; and(iv)The extent to which segregation and/or collection and treatment of contaminated storm water from the immediate process areas is appropriate. 4. The permittee must amend its BMP Plan whenever there is a change in mill design, construction, operation, or maintenance that materially affects the potential for leaks or spills of spent pulping liquor,turpentine, or soap from the immediate process areas. 5. The permittee must complete a review and evaluation of the BMP Plan five years after the first BMP Plan is prepared and,except as provided in Section B.4., once every five years thereafter. As a result of this review and evaluation,the permittee must amend the BMP Plan within three months of the review if the mill determines that any new or modified management practices and engineered controls are necessary to reduce significantly the likelihood of spent pulping liquor, soap, and turpentine leaks, spills, or intentional diversions from the immediate process areas, including a schedule for implementation of such practices and controls. 6. The BMP Plan, and any amendments thereto,must be reviewed by the senior technical manager at the mill and approved and signed by the mill manager. Any person signing the BMP Plan or its amendments must certify to the Division under penalty of law that the BMP Plan (or its amendments) Permit Number: NCO000272 has been prepared in accordance with good engineering practices and in accordance with this regulation. The permittee is not required to obtain approval from the Division of the BMP Plan or any amendments thereto. Section C. BMP Recordkeeoing Requirements 1. The permittee must maintain on its premises a complete copy of the current BMP Plan and the records specified in Section C.2 and must make such BMP Plan and records available to the Division for review upon request. 2. The permittee must maintain the following records for three years from the date they are created: (i) Records tracking the repairs performed in accordance with the repair program described in Section A; (ii)Records of initial and refresher training conducted in accordance with Section A; (iii)Reports prepared in accordance with Section A; and (iv)Records of monitoring required by Sections A and E. Section D. Establishment of Wastewater Treatment System Influent Action Levels 1. The permittee must conduct a monitoring program per Section D.2, for the purpose of defining wastewater treatment system influent characteristics(or action levels), described in Section D.3,that will trigger requirements to initiate investigations on BMP effectiveness and to take corrective action. 2. The permittee must employ the following procedures in order to develop the action levels required by Section D: • Monitoring parameters.The permittee must collect 24-hour composite samples and analyze the samples for a measure of organic content(e.g., Chemical Oxygen Demand(COD) or Total Organic Carbon(TOC)). Alternatively, the mill may use a measure related to spent pulping liquor losses measured continuously and averaged over 24 hours (e.g., specific conductivity or color). • Monitoring locations.The permittee must conduct monitoring at the point influent enters the wastewater treatment system. For the purposes of this requirement, the permittee may select alternate monitoring point(s) in order to isolate possible sources of spent pulping liquor, soap, or turpentine from other possible sources of organic wastewaters that are tributary to the wastewater treatment facilities(e.g., bleach plants,paper machines and secondary fiber operations). 3. By the permit effective date, the permittee must complete an initial six-month monitoring program using the procedures specified in Section D and must establish initial action levels based on the results of that program. A wastewater treatment influent action level is a statistically determined pollutant loading determined by a statistical analysis of six months of daily measurements.The action levels must consist of a lower action level,which if exceeded will trigger the investigation requirements described in Section E, and an upper action level, which if exceeded will trigger the corrective action requirements described in Section E. 4. By January 15,2002, the permittee must complete a second six-month monitoring program using the procedures specified in Section D and must establish revised action levels based on the results of that program.The initial action levels shall remain in effect until replaced by revised action levels. 5. Action levels developed under this Section must be revised using six months of monitoring data after any change in mill design,construction, operation, or maintenance that materially affects the potential for leaks or spills of spent pulping liquor,soap, or turpentine from the immediate process areas. Section E. BMP Monitoring Corrective Action and Reporting Requirements 1. The permittee must conduct daily monitoring of the influent to the wastewater treatment system in accordance with the procedures described in Section D for the purpose of detecting leaks and spills, tracking the effectiveness of the BMPs,and detecting trends in spent pulping liquor losses. Permit Number: NC0000272 2. Whenever monitoring results exceed the lower action level for the period of time specified in the BMP Plan, the permittee must conduct an investigation to determine the cause of such exceedance. Whenever monitoring results exceed the upper action level for the period of time specified in the BMP Plan, the permittee must complete corrective action to bring the wastewater treatment system influent mass loading below the lower action level as soon as practicable. 3. Although exceedances of the action levels will not constitute violations of an NPDES permit,failure to take the actions required by Section E.2 as soon as practicable will be a permit violation. 4. The permittee must report to the Division the results of the daily monitoring conducted pursuant to Section E.1. Such reports must include a summary of the monitoring results, the number and dates of exceedances of the applicable action levels, and brief descriptions of any corrective actions taken to respond to such exceedances. Submission of such reports shall be annually, by March 3 1"of the following year. Section F. BMP Compliance Deadlines 1. The permittee is subject to the following BMP deadlines: • Prepare BMP Plans and certify to the Division that the BMP Plan has been prepared in accordance with this regulation not later than the permit effective date. • Implement all BMPs specified in Section A that do not require the construction of containment or diversion structures or the installation of monitoring and alarm systems not later than the permit effective date. Establish initial action levels required by Section D not later than the permit effective date. Commence operation of any new or upgraded continuous, automatic monitoring systems that the mill determines to be necessary under Section A (other than those associated with construction of containment or diversion structures)not later than the permit effective date. Complete construction and commence operation of any spent pulping liquor, collection, containment, diversion, or other facilities, including any associated continuous monitoring systems, necessary to fully implement BMPs specified in Section A not later than the permit effective date. • Establish revised action levels required by Section D as soon as possible after fully implementing the BMPs specified in Section A,but not later than January 15, 2002. • Submit Annual Reports required by Section EA to the Division by March 31"of the following year. Section G. BMP Definitions 1. Action Level: A daily pollutant loading that when exceeded triggers investigative or corrective action. Mills determine action levels by a statistical analysis of six months of daily measurements collected at the mill.For example, the lower action level may be the 75th percentile of the running seven-day averages (that value exceeded by 25 percent of the running seven-day averages) and the upper action level may be the 90th percentile of the running seven-day averages (that value exceeded by 10 percent of the running seven-day averages). 2. Division: North Carolina DENR,Division of Water Quality, 1617 Mail Service Center,Raleigh, North Carolina 27699-1617. 3. Equipment Items in Spent Pulping Liquor,Soap, and Turpentine Service: Any process vessel, storage tank, pumping system, evaporator,heat exchanger,recovery furnace or boiler, pipeline, valve, fitting, or other device that contains, processes, transports, or comes into contact with spent pulping liquor, soap, or turpentine. Sometimes referred to as"equipment items." 4. Immediate Process Area:The location at the mill where pulping, screening,knotting, pulp washing, pulping liquor concentration, pulping liquor processing, and chemical recovery facilities are located, generally the battery limits of the aforementioned processes. "Immediate process area" includes spent Permit Number: NC0000272 pulping liquor storage and spill control tanks located at the mill, whether or not they are located in the immediate process area. 5. Intentional Diversion: The planned removal of spent pulping liquor, soap, or turpentine from equipment items in spent pulping liquor, soap, or turpentine service by the mill for any purpose including,but not limited to, maintenance, grade changes, or process shutdowns. 6. Mill: The owner or operator of a direct or indirect discharging pulp, paper, or paperboard manufacturing facility subject to this section. 7. Senior Technical Manager:The person designated by the mill manager to review the BMP Plan.The senior technical manager shall be the chief engineer at the mill, the manager of pulping and chemical recovery operations, or other such responsible person designated by the mill manager who has knowledge of and responsibility for pulping and chemical recovery operations. 8. Soap: The product of reaction between the alkali in kraft pulping liquor and fatty acid portions of the wood, which precipitate out when water is evaporated from the spent pulping liquor. 9. Spent Pulping Liquor: For kraft and soda mills"spent pulping liquor"means black liquor that is used, generated, stored, or processed at any point in the pulping and chemical recovery processes. 10.Turpentine: A mixture of terpenes, principally pinene, obtained by the steam distillation of pine gum recovered from the condensation of digester relief gases from the cooking of softwoods by the kraft pulping process. Sometimes referred to as sulfate turpentine. Permit Number: NC0000272 A. (7.) EFFLUENT GUIDELINE SAMPLING PLAN SPECIAL CONDITION The bleach plant effluent samples(Outfalls 002 and 003) shall be analyzed for 2,3,7,8-TCDD in accordance with EPA Method 1613. A single sample, from each of the bleach plant effluents, may be analyzed to determine compliance with the daily maximum effluent limitation. The bleach plant effluent samples (Outfall 002 and 003) shall be analyzed for the 12 chlorinated phenolic compounds in accordance with EPA Method 1653. A single sample, from each of the bleach plant effluents, may be analyzed to determine compliance with the daily maximum effluent limitation. The Minimum Levels for each of the 12 chlorinated compounds are the same as the Daily Maximum concentrations listed on the effluent pages for the respective outfall(s). The final wastewater treatment plant effluent sample(Outfall 001) shall be analyzed for AOX in accordance with EPA Method 1650, or subsequent test methods approved by the Division. The permittee may request future monitoring modifications to the Effluent Guideline requirements, including 1)use of ECF certification in lieu of monitoring for chloroform in the bleach plant effluents (Outfall(s)002 and 003) when this rule is promulgated by EPA; 2) demonstrating compliance using samples collected less frequently than every four hours; 3) using automated composite volatile samplers for chloroform sampling; and 4)using automated composite samplers for chlorophenolic,2,3,7,8 TCDD and 2,3,7,8 TCDF sampling. Such future requests will be evaluated in accordance with 15A NCAC 2H.0114. The flow calculations for internal Outfall(s)002 and 003 shall not be subject to accuracy requirements specified under Part II, Section D.3. This exclusion is similar to that provided for pump log flow calculations. Chemical data for Effluent Guideline parameters (Outfall(s)002 and 003 parameters+AOX from Outfall 001) shall be submitted to the Division on a quarterly basis or more frequently(January-March,April- June,July-September, October-December). Quarterly submissions shall be due 60 days following the last day of each quarter(Due dates=May 31,August 31,November 30, and February 28). Chemical data shall be submitted on Division-approved DMR forms, with a separate form provided for each month. Permit Number: NC0000272 A. (8.) REQUIREMENTS FOR COLOR ANALYSIS AND COMPLIANCE SPECIAL CONDITION 1. The color reduction requirements contained in this special condition have been derived directly from the mill's efforts to identify possible reduction measures and from the EPA Technology Review Workgroup(TRW report dated August 3, 2001)and the EPA Tech Team Report(dated July 25, 2001). These requirements are aimed at securing the highest feasible reduction of the mill's effluent color over the permit cycle and for laying the foundation for removal of the color variance by the expiration date of this permit. The EPA Tech Team Report identified three levels of possible color reduction actions (identified in the report as Highest Certainty,Reasonable Certainty and Lowest Certainty). Each of these tiers of reductions have identified specific actions or technologies that when implemented may result in additional color reductions in the mill's effluent. For example,the color reduction goals of the condition in Paragraph 6 of this special condition is premised on the implementation of all the actions of'Highest Certainty.' Paragraph 7 of this special condition requires the company to evaluate actions of'Reasonable Certainty'. Identified under Reasonable Certainty'are the technologies of Ozone/Chlorine Dioxide stage for the hardwood bleach line and second stage oxygen delignification for the pine line. This condition requires the permittee to examine the technical, economic and operational feasibility of implementing these technologies.The review of this required evaluation (Paragraph 7) will be supported by the EPA TRW. Regardless of the outcome of this feasibility analysis, the permittee is required to achieve 3,000- 8,000 pounds per day additional color reduction, except to the extent allowed by Paragraph 6. This is considered the equivalent reduction of what would be expected from the installation of the two technologies identified by the EPA TRW process. Color Treatment of the Chloride Removal Process Purge Stream is the color reduction methodology with the'Lowest Certainty'. Therefore, this condition requires the permittee to evaluate potential technologies for treatment of this wastestream and to implement those if shown technologically, economically and operationally feasible. Built into this special condition is a series of regulatory requirements that the permittee achieve reductions of the mill's effluent color consistent with each series of reduction actions. This means that following implementation of the Highest Certainty'actions the mill's annual color limit must be reduced by 6,000- 8,000 pounds per day, except to the extent allowed by Paragraph 6. If the implementation of all the actions identified under'Highest Certainty'actually result in better long term effluent quality, this in no way reduces the permittee's responsibility to achieve the color reductions measured by those actions identified as having Reasonable Certainty'of success and determined to be technically, economically and operationally feasible under paragraph 7. The mechanism for applying the overall success of the mill's efforts to reduce color is demonstrated by the actual color Performance. This performance will be the basis for limitations established following implementation of the Reasonable Certainty'category actions and the process of developing the mill's limitations for the next permit renewal. Again, it is the goal of this special condition to achieve the color reductions identified by the EPA TRW and lay the foundation for removal of the color variance by the expiration date of this permit. 2. The average annual discharge of true color for each calendar month shall not exceed 48,000 pounds per day. The monthly average effluent true color loading shall not exceed 55,000 pounds per day. For the purpose of this permit/variance only, "pounds of true color" is calculated by the following equation: Permit Number: NCO000272 Effluent Flow(frtgd) x Effluent True Color Level-(Platinum Cobalt Units)x 8.34. 3. All samples collected for color analysis and for use in the above calculation shall be measured and reported using the procedure referenced in 39 FR 430.11 (b) (May 29, 1974) -true and apparent color or as amended by the EPA. 4. Blue Ridge Paper, in accordance with activities underway at the mill and in response to the work of the EPA Technology Review Workgroup(EPA TRW),has already begun the process of identifying and implementing technically, economically and operationally feasible process optimization measures, which can be taken to further reduce color discharges from the mill. The permittee is directed to continue evaluating mill operations with the goal of fully identifying opportunities for preventing and controlling measurable black liquor leaks and spills (Best Management Practices-BMPs). Such BMPs include but are not limited to: ➢ Continuous improvement of operating practices so more leaks and spills are recovered rather than discharged to sewer; ➢ Improvement in preparation for planned outages to maximize capture of tank clean-out waste and routing to recovery; ➢ Reduction of clean water that continuously runs into sewers to prevent dilution of smaller spills and facilitate recovery of highly colored wastewaters; and ➢ Improvement in the equipment used for handling of knot rejects to prevent black liquor leaks into the recovery sumps. 5. As indicated in Paragraph 4,the permittee has already begun the process of implementing the specific actions and technologies identified by the EPA Tech Team as having the'Highest Certainty'. The permittee is directed to implement all the specific actions and technologies the EPA Tech Team Report identified as having the 'Highest Certainty'. The specific action items identified as having the 'Highest Certainty' include: Process Optimization,Improved black liquor leak&spill collection and control,and BFR reliability improvement. These 'Highest Certainty' action items and technologies shall be implemented in sufficient time to generate a sufficient database of representative mill effluent data for statistical analysis by October 1,2003. By October 1, 2003, the permittee shall submit to the North Carolina Division of Water Quality a report including a statistical analysis of the permittee's monthly average color discharge, mill performance as related to color, all available data necessary to derive the lowest achievable annual average and monthly average color loading limits. By November 1,2003, the Division of Water Quality (in consultation with the Technology Review Workgroup) shall recommend, considering the statistical analysis report submitted by the permittee and the demonstrated performance of the mill, the lowest achievable annual average and monthly average color loading effluent limitations. If the limits determined to be achievable are within or below the target range of 40,000-42,000 pounds per day as an annual average, the limits shall become effective on December 1, 2003,by written notification from the Director. If the limits determined to be achievable by the Division of Water Quality(in consultation with the Technology Review Workgroup) are above the target range, the Permit shall be modified in accordance with North Carolina's permitting process to reflect those limits. Permit Number: NCO000272 6. Implementation of the'Highest Certainty'action items or technologies shall reduce the annual average color discharge limit 6,000-8,000 lbs/day,based on the statistical analysis conducted according to Paragraph 5. Beginning December 1, 2003, upon written notification from the Division of Water Quality the annual average discharge of true color shall not exceed 40,000- 42,000 pounds per day. However, if by November 1,2003, the Division of Water Quality(DWQ), in consultation with the Technology Review Workgroup',and the NPDES Committee agree that there are overwhelming technical, economic, or operational barriers to the Permittee's ability to attain a 40,000-42,000 lbs/day annual color loading limit,DWQ shall recommend to the NPDES Committee, alternate interim limits to become effective December 1,2003. At that time, DWQ shall recommend a new effective date for achieving an annual average color loading limit of 40,000-42,000 pounds per day. These recommendations shall be based on what DWQ concludes Blue Ridge Paper can reasonably achieve, giving consideration to the actual demonstrated color levels discharged and the 'Highest Certainty'action items and technologies implemented pursuant to Paragraphs 4 and 5. Based on DWQ's recommendations, the NPDES Committee will determine an alternate interim limit to become effective on December 1, 2003, and the new effective date for achieving an annual average color loading limit of 40,000-42,000 pounds per day. After the NPDES Committee's final decision, the NPDES Permit will be modified in accordance with North Carolina's permitting process. 7. The permittee shall submit to the Division of Water Quality, the Technology Review Workgroup and the NPDES Committee by December 1, 2003, a report on the feasibility of achieving a target annual average color reduction within the range of 3,000 and 8,000 pounds per day from the reduction achieved by implementation of the 'Highest Certainty'actions. This report shall include an evaluation of the use of the Reasonable Certainty'actions identified in the EPA Tech Team Report and any other actions that would result in additional color reductions, actions taken by the permittee to reduce color loading(since permit issuance), and the technical,economic, and operational feasibility of implementing the Reasonable Certainty'actions on a continuous or intermittent basis, in order to achieve a target annual average color reduction within the range of 3,000 and 8,000 pounds per day. As identified in the EPA Tech Team Report, the'Reasonable Certainty'actions are the technologies of Ozone/Chlorine Dioxide stage for the hardwood bleach line and second stage oxygen delignification for the pine line.The report shall identify specific economic and implementation issues associated with the proposed improvements.The report shall also project expected additional color reduction for each technology evaluated and maximum color reduction possible using the identified technologies.The report shall also include a proposed schedule for implementation of process improvements or installation of technologies required to achieve an additional an effluent color reduction of 3,000- 8,000 pounds per day.The permittee shall provide this evaluation/report,together with an updated report on the results of ongoing and additional planned color reduction activities, to the Division of Water Quality, the Technology Review Workgroup and the NPDES Committee. By February 1, 2004,DWQ(in consultation with the Technology Review Workgroup) shall approve or modify the permittee's recommended plan for achieving an additional 3,000-8,000 pounds per day reduction to the target annual average. The Technology Review Workgroup shall act in an advisory role to the North Carolina Division of Water Quality,and NC DWQ Shall consult with the Technology Review Workgroup prior to making any decisions regarding color reduction activities at the Canton Mill. Permit Number: NC0000272 8. By December 1, 2005, the permittee shall submit, as related to the implementation of the process improvements evaluated according to Paragraph 7, a statistical analysis of Blue Ridge Paper's effluent quality performance.This report shall include a statistical analysis of the Blue Ridge Paper's monthly average and annual average color discharge, mill performance as related to color, and all available data necessary to derive the lowest achievable annual average and monthly average color loading limits. By February 1, 2006,the Division of Water Quality(in consultation with the Technology Review Workgroup) shall recommend to the NPDES Committee, considering the statistical analysis report submitted by the permittee and the demonstrated performance of the mill, the lowest achievable annual average and monthly average color loading effluent limitations. If the limits determined to be achievable are within or below the target range of 32,000-39,000 pounds per day as an annual average, the limits shall become effective on March 1, 2006,by written notification from the Director. If the limits determined to be achievable by the Division of Water Quality (in consultation with the Technology Review Workgroup) are above the target range,the Permit shall be modified in accordance with North Carolina's permitting process to reflect those limits. 9. By December 1, 2004, the permittee shall evaluate color reduction technologies associated with the Chloride Removal Process (CRP)wastestream. The CRP analysis shall concentrate on the technical, economic, and operational feasibility of implementing the applicable technologies on all or a portion of the purge stream. The report shall identify specific economic and implementation issues associated with the improvements.The report shall also project expected additional color reduction for each technology evaluated and maximum color reduction possible using the identified technologies.Though not limited to the following, the report shall include an analysis of the land application of the high chloride wastewater,commercial incineration, coagulant/precipitation technologies,and solidification for land disposal. The Division of Water Quality(in consultation with the Technology Review Workgroup) shall evaluate the feasibility of implementing identified technologies for further color reduction and shall submit to the NPDES Committee by February 1,2005, DWQ's recommendations regarding color reductions associated with the treatment of the CRP wastestream. If during the course of this evaluation Blue Ridge Paper identifies a technical,economic, and operationally feasible color reduction technology that can be implemented for treatment of the CRP wastestream, the permittee may request that the Technology Review Workgroup review this technology for implementation at the Canton mill. If the Technology Review Workgroup concurs that the identified technology is suitable for the Canton mill and that the color reductions achievable are adequate, the mill's obligation to research additional technologies will be waived after formal notification from Blue Ridge Paper that the identified technology will be installed and placed into operation.This notification shall include language indicating the permittee's commitment to the implementation of the technology, along with a schedule for implementation. The Division of Water Quality will notify the permittee in writing that the proposed implementation schedule is acceptable. 10. By March 1, 2006, the permittee shall submit a report to Division of Water Quality, the Technology Review Workgroup and the NPDES Committee on the color reduction efforts as part of the Variance review process(Triennial Review of North Carolina's Water Quality Standards). This report shall also include an evaluation of color in the Pigeon River at the Fiberville Bridge, and an evaluation on the feasibility of complying with North Carolina's Color Standard. Permit Number: NC0000272 11. The 1997 Settlement Agreement contained provisions to limit color in the Pigeon River at the Hepco USGS gauge station. The new effluent limits in this permit are more stringent than the provisions in the 1997 Permit and Color Variance and will result in reduced color levels in the Pigeon River. It is possible to calculate the monthly flow at the Canton gage station above which instream color at the Fiberville Bridge will not exceed 50 true color units. Using the 55,000 pounds per day monthly average true color loading limit(implemented on the effective date of the permit) the flow at the Canton Gage station, which will provide for color less than 50 true color units at the Fiberville Bridge is 171.8 MGD. Therefore,the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the monthly average flow (at the Canton gage station) is greater than 171.8 MGD. 12. The governing flow criterion for true color at Canton is 58.1 MGD (30Q2 stream flow). The flow established, pursuant to Paragraph 11, is greater than this 30Q2 stream flow, therefore, for flows less than the 171.8 MGD at the Canton Gage station but greater than 193.3 MGD (30Q2 flow) at the Hepco gage station, the monthly average color in the Pigeon River.at Hepco will be less than 50 true color units. 13. Beginning December 1,2003, the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the flow at Canton is greater than the flow established using the following equation and based on the monthly average effluent limit established per Paragraph 5: Flow—at—Canton—USG.S(MGD)—!Monthly Averaee Effluent Color Limit Ib/day-12468 31+31.6+2.4 308.58 For flows at the Canton Gage station less than the flow established here but greater than 193.3 MGD at the Hepco gage station,the monthly average color in the Pigeon River at Hepco will be less than 50 true color units. 14. Beginning March 1,2006,the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the flow at Canton is greater than the flow established using the following equation and based on the monthly average effluent limit established per Paragraph 8: Flow_at—Canton—USGS(MGD)—(Monthly Averaee Effluent Color Lim'Llb/day-12468 3)+31.6+2.4 308.58 For flows at the Canton Gage station less than the flow established here but greater than 193.3 MGD at the Hepco gage station,the monthly average color in the Pigeon River at Hepco will be less than 50 true color units. 15. The potential exists that there could still be periods of time corresponding to periods of lower flow in the river, when color at Fiberville might exceed 50 true color units. Therefore, the permittee shall continue to implement the approved Low Flow Contingency Plan for mitigating the occurrence and degree of this potential exceedence. 16. The permittee shall not increase the mill's pulp production capacity during the term of this permit, unless the permittee can demonstrate that the increased production can be achieved while reducing color loading. In addition, increasing the mill's pulp production capacity may require permit revision in accordance with North Carolina's NPDES Permitting rules. Permit Number: NC0000272 17. The NPDES Permit shall be subject to reopening in order to modify the color requirements based upon the following and in association with the required triennial reviews: ➢ Any breakthrough in color removal technologies. Such breakthroughs shall be brought to the NPDES Committee for consideration,by Blue Ridge Paper and the Division of Water Quality, as soon as they are discovered. ➢ An acceptable statistical analysis of effluent color discharge data demonstrating significantly better color removal performance than that currently prescribed in the variance and permit, except as noted herein. ➢ Successful application of end-of-pipe color reduction technology or in-mill color minimization effort that results in significant and measurable reduced mass color discharge. 18. The transfer of this NPDES permit will not proceed until any successor-in-interest to the current permittee has agreed to accept the provisions of this permit and request and received from the NPDES Committee a transfer of 2001 Revised Color Variance. Permit Number: NC0000272 A. (9.) DIOXIN MONITORING SPECIAL CONDITION The permittee shall perform the analyses for dioxin and dibenzofuran as outlined below: En g Point Monitoring Re uirements Measurement Sample Type Frequent ewater Quarterly Composite Quarterly Composite Annual Composite te Annual Composite 1. The samples shall be analyzed for 2,3,7,8-TCDD and 2,3,7,8 TCDF in accordance with EPA Method 1613. A single sample may be analyzed. Alternatively, the sample volumes may be collected to enable the sample to be split(duplicate analysis).The Minimum Level in the effluent for 2,3,7,8- TCDD and 2,3,7,8 TCDF by EPA Method 1613 is 10 pgil. 2. The samples shall be analyzed for the full range of dioxin and furan isomers as identified in the list below and shall be in accordance with EPA Method 1613. A single sample may be analyzed. Alternatively, the sample volumes may be collected to enable the sample to be split(duplicate analysis).The minimum level using these methods for the purpose of compliance evaluation is considered to be 10 picograms per liter DIOXIN DIBENZOFURAN Isomer Isomer 2,3,7,8 TCDD 2,3,7,8 TCDF 1,2,3,7,8 PeCDD 1,2,3,7,8 PeCDF 2,3,4,7,8 PeCDF 1,2,3,4,7,8 HxCDD 1,2,3,4,7,8 HxCDF 1,2,3,7,8,9 HxCDD 1,2,3,7,8,9 HxCDF 1,2,3,6,7,8 HpCDF 1,2,3,6,7,8 HxCDD 2,3,4,6,7,8 HxCDF 1,2,3,4,6,7,8 HpCDD 1,2,3,4,6,7,8 HpCDF 1,2,3,4,7,8,9 HpCDF If dioxins or dibenzofurans are detected in the effluent above the minimum level, the permittee shall initiate more frequent monitoring of sludge and landfill leachate. The dioxin and dibenzofuran monitoring as stipulated in this condition shall continue until such time that the fish consumption advisory is completely lifted in North Carolina, or if after sufficient data has been generated, statistical analysis indicates that the bleach plant effluent does not contain reasonable potential to exceed the permitted limits. Additional Requirements Fish tissue analysis shall be performed in accordance with the Division of Water Quality approved monitoring plan, which will be reviewed as necessary. The monitoring plan is an enforceable part of this permit. All dioxin data collected as part of this monitoring requirement will be reported as required in the plan, no later than'180 days after sampling. Permit Number: NC0000272 A. (10.) DISSOLVED OXYGEN SPECIAL CONDITION The permittee shall maintain an average daily dissolved oxygen concentration of not less than 5.0 mg/1 with a minimum instantaneous value of not less than 4.0 mg/1 at River Miles 62.9 (DNI) and 57.7(DN2). The permittee shall operate oxygen injection facilities at the outfall structure, at 0.9 miles downstream of the discharge, and at 2.1 miles downstream of the discharge, as necessary, to comply with this requirement. These facilities shall be operated in a manner which will maintain the water quality standard for dissolved oxygen in the Pigeon River downstream of the discharge. Blue Ridge Paper shall report the date and duration of oxygen injection use as a supplement to the monthly Discharge Monitoring Report (DMR)forms. If the dissolved oxygen drops below 5.0 mg/L at station DN2 then monitoring shall be required at stations DN3 and DN4. A. (11.) TOWN OF CANTON INFLOW AND INFILTRATION SPECIAL CONDITION The permittee shall make continued efforts to promote reduction of inflow/infiltration to the Town of Canton's wastewater collection system. A. (12.) WATERVILLE RESERVOIR SAMPLING SPECIAL CONDITION Sampling for Waterville Reservoir shall be conducted once annually during 2002 and 2004. Sampling shall be performed during a low flow period to correspond with the fish tissue study (see A. (9.)Dioxin Monitoring Special Condition). Sampling shall be performed at Waterville Reservoir prior to Laurel Branch,Waterville Reservoir near Wilkins Creek and Waterville Reservoir near the dam. Each location shall be sampled for the following parameters: PARAMETERS' Temperature Dissolved Oxygen Conductivity pH Total Nitrogen Nitrite+Nitrate Ammonia TKN PO4 Total Phosphorus Chloro hyll-a Secchi Depth All samples shall be collected at 0.1 meters beneath the surface of the water in the lake. A. (13.) TEMPERATURE VARIANCE REVIEW SPECIAL CONDITION During the next permit renewal,Blue Ridge Paper shall complete an analysis of temperature and shall submit a balanced and indigenous species study, no later than May 1, 2006. As part of this analysis,Blue Ridge Paper shall submit a complete temperature variance report documenting the need for a continued temperature variance. The study shall be performed in accordance with the Division of Water Quality approved plan. Request for revisions to this plan shall be submitted for approval no later than March 1, 2005. The temperature analysis and the balanced and indigenous study plan shall conform to the specifications outlined in 40 CFR 125 Subpart H and the EPA's Draft 316a Guidance Manual, dated 1977. State of North Carolina ROY COOPER Department of Justice REPLY TO:Francis W.Crawley ATTORNEY GENERAL Envimnmental Division P. O. BOX 629 R . Box 6 fcrawley@mailjus.state.nc.us Telephone:919n l 6.6600 27602-0629 Fax:919nl6-6767 October 15, 2001 Robert Williams,Director Certified Mail Environment Health & Safety Affairs Return Receipt Requested Blue Ridge Paper Products, Inc. P. O.Box 4000 Canton, North Carolina 28716 RE: NPDES Committee Decision on the Color Variance for the Canton Mill J Dear Mr. Williams: 1 The NPDES Committee of the Environmental Management Commission at its October 10,2001 meeting received the hearing officer's report of the public hearing and, upon duly made motion and vote, approved the color variance with its conditions for the Blue Ridge Paper Products mill in Canton. The variance will be effective as of the effective date of the renewed NPDES Permit No. NC 0000272 for the Canton Mill and the terms of the previously existing variance will continue in effect until that time. A copy of the Color Variance is enclosed. Very truly yours, ancis W. Crawley Special Deputy Attorney General Commission Counsel cc: William Clarke Gregory Thorpe Paul Davis Davis McKinney Davis Jenkins Charles Moore Roland Dykes a) r ENVIRONMENTAL MANAGEMENT COMMISSION l NPDES Committee IN THE MATTER OF REQUEST FOR ) VARIANCE FROM WATER QUALITY ) STANDARD-BASED EFFLUENT ) COLOR VARIANCE LIMITATIONS BY BLUE RIDGE ) PAPER PRODUCTS, INC. ) CANTON, NORTH CAROLINA ) THIS MATTER came on to be heard before the NPDES (National Pollutant Discharge Elimination System) Committee of the North Carolina Environmental Management Commission at its scheduled meeting in Raleigh, North Carolina, on October 10, 2001, for consideration of re- issuing a color variance, originally granted to Champion International Corporation on July 13, 1988, and modified on October 9, 1996, on December 11, 1996, and on December 11, 1997, to Blue Ridge Paper Products, Inc. ("Blue Ridge Paper") the successor corporation. Upon duly made motion and vote, the NPDES Committee hereby adopts the following Findings of Fact and Conclusions of Law: FINDINGS OF FACT (taken from the October 9, 1996, Order) 1. Pursuant to a request for variance, dated January 12, 1988, submitted by Champion International Corporation ("Champion"), the NPDES (National Pollutant Discharge Elimination System) Committee of the North Carolina Environmental Management Commission granted Champion a variance from the North Carolina water quality standard for color, as that standard is interpreted by the U.S. Environmental Protection Agency. The .variance was r memorialized in the NPDES Committee's Final Decision, dated July 13, 1988: l 2 2. Pursuant to Ordering Paragraph 6 of its Final Decision, the NPDES Committee established a Variance Review Committee to review the Canton Mill's proposed modernization program and to recommend any changes to the existing variance. As stated in Ordering Paragraph 6 of its Final Decision, the NPDES Committee was charged with determining "if changes in the variance are warranted due to the effectiveness of the treatment system or because of advances in color reduction technologies for this type wastewater." 3. Modification of the variance as recommended by the Variance Review Committee would,not result in any discharge of waste that would endanger human health or safety. The variance for color was to allow discharge of wastewater at levels that would prevent Champion's contribution to the true color from causing the true color at the North Carolina/Tennessee State ( line to exceed 50 true color units at all flows equal to or greater than 126 cfs at the Hepco ` Gauging Station. The substance being discharged, for which.the variance was sought, is not bioaccumulative. The color does not, at the volumes and levels involved here, present a risk of indirect or direct human impact or broad environmental -damage. The waters are not water supply. Therefore, the discharge would not endanger human health or safety. 4. Reduction of color discharge by application of best available technology was found to be not economically reasonable and to result in serious hardship without equal or greater benefit to the public. A detailed and thorough study and evaluation of color removal technologies was performed and reported in Champion's 1995 and 1996 Color Removal Technology Reports submitted to Division as required by the then-existing color variance. 5. Champion completed its mill modernization project which re-configured its facility as an oxygen delignification, 100% chlorine dioxide substitution (OD-100) bleach mill. 3 The project resulted in limited color reduction in its effluent discharge. The end-of-pipe technologies considered in 1988 and updated for the 1996 review established: a) standard water/wastewater separation technology (lime, alum, or polymer) had not been applied in a similar fashion, b) these technologies would result in high capital and operating costs at the mill, c) color reduction on this type of waste, using these type technologies had no operational efficiency "track record" (effective under normal paper mill production variations, and consistent and reproducible color removal), and d) the process color removal effectiveness of OD-100 may present other in-process reduction opportunities that were not realized as of October 9, 1996. 6. In review of the color data, including the short time since the re-configured mill became fully operational, it was determined that a more restrictive limitation should apply for color. Therefore, the more restrictive monthly and annual average color limitations contained in the Ordering Paragraph 2, of the October 9, 1996, Order, were established. 7. Based on the continued development of color discharge information from the reconfigured mill, Champion was required to statistically evaluate its monthly average color discharge, its.annual average color discharge, and the performance of the State line color model. These evaluation processes were to be ongoing and the results of the evaluations were required to be reported to the Division of Water Quality ("Division" or "DWQ") prior to each water quality standards triennial review period. The results of these evaluation processes were to be utilized by the Division and the next Variance Review Committee to make recommendations to the NPDES Committee on future revisions to the variance. Champion was:to follow the Color Data Variance Review Requirements proposed by the staff and the hearing officer, in reporting these evaluations. 4 8. Champion was also required to take such actions as necessary to prevent their contribution of true color from exceeding 50 true color units at the North Carolina/Tennessee State line at all flows equal to or greater than 126 cfs at the Hepco Gauging Station. Furthermore, the method by which compliance was to be determined continued to be the color predictive model. (taken from the December 11, 1996, Order) 9. On October 17, 1996, the Director of the Division of Water Quality transmitted to the United States Environmental Protection Agency, for its review, the October 9, 1996, order for Modification of Color Variance Granted on July 18, 1988. 10. By letter dated December 23, 1996, Tennessee advised EPA that it considered the permit to be invalidly issued, and that North Carolina had failed to comply with §402(b)(5) of the Clean Water Act, 33 U.S.C. §1342(b)(5). Subsequently, on January 13, 1997, Tennessee filed a contested case petition with the North Carolina Office of Administrative Hearings challenging the permit and color variance. Thereafter, Champion, Cocke County, and Newport were allowed to intervene in the North Carolina contested case proceeding. 11. In an effort to resolve the color issue without time- and resource-consuming litigation, North Carolina, Tennessee, Cocke County, Newport,Champion, and EPA agreed to an informal negotiation process. The North Carolina contested case proceeding was stayed during this process. On November 21, 1997, Tennessee Environmental Council and American Canoe Association were also allowed to intervene in the North Carolina contested case proceeding. 12. The parties to the contested case agreed to measures to achieve additional color reduction over that required in the permit issued on December 12, 1996 and by the color variance 5 i adopted on December 11, 1996. The parties agreed that the December 1996 Permit and Variance would be modified to reflect these requirements and effectuated a Settlement Agreement which would be entered in the contested case. 13. The December 1996 permit and variance required that Champion implement a one year demonstration of full-scale bleach filtrate recycling (BFRT") technology on the mill's pine line and that, as of December 1, 1998, Champion implement and operate BFRT"' technology on its pine line, unless Champion could demonstrate to the NPDES Committee that BFRT' was not commercially viable. 14. The 1996 permit and variance required Champion to evaluate the potential for additional minimization of color losses from the manufacturing process and raw material storage . areas (i.e. in-mill color minimization; or, spill prevention/control measures) that might result in Further color reduction and to report its findings to the NPDES Committee. Reports were to be submitted by March 1, 1998 and again by June 1, 2001, so that they could be used by the Committee in conjunction with the required Variance review process held every three years to determine if the variance would be readopted or made more stringent. As a part of the efforts to resolve the challenge to the 1996 permit and variance, a Technology Review Workgroup (TRW ) was formed, comprised of experts on the pulp and paper industry from EPA and representatives of the environmental agencies for the State of Tennessee and North Carolina. 15. The 1996 permit and variance required Champion to evaluate and report to the NPDES Committee on end-of-pipe color reduction technologies that could conceivably be implemented at the mill. The evaluation was to include an incremental color improvement analysis which concentrated on the technical, economic, and operational feasibility of the 6 application of these technologies on a continuous or intermittent basis. The intermittent application of these technologies was to look particularly at periods of low river flow. These reports were to be submitted to the NPDES Committee for its consideration as part of the water quality standards Triennial Reviews to determine whether the variance should be readopted or . made more stringent. The reports were to identify specific economic and implementation issues associated with the incremental improvements of color levels expected by installing these technologies at the mill. They were also to project the expected additional color reduction possible using the identified technology. (Events and Activities since Champion conveyed the Canton Mill) 16. On May 14, 1999 the ownership and operation of the Canton Mill along with several related production facilities was transferred from Champion to Blue. Ridge Paper Products Inc. ("Blue Ridge Paper"). Subsequent to that change, Blue Ridge Paper in a letter dated May 7, 1999, requested that DWQ reissue the Canton Mill permit to the new owners. On July 14, 1999 the DWQ issued to Blue Ridge Paper the NPDES permit for the Canton Mill. In taking this action, the DWQ reminded Blue Ridge Paper of the new owner's responsibility to comply with all the requirements of the Settlement Agreement and the 1997 Revised Color Variance. 17. In accordance with the requirements of the Settlement Agreement, the 1997 Revised Color Variance, and the revised 1996 NPDES Permit for the Canton Mill, Blue Ridge Paper assumed the responsibility for submission of all reports and evaluations required by these documents and due after May 14, 1999. Blue Ridge Paper has submitted all required reports and has complied with the conditions of the Agreement, Variance and Permit. In a letter dated February 21, 2001,.Blue Ridge Paper submitted to the DWQ its request for renewal of the facility's NPDES Permit which is scheduled to expire on November 30, 2001, permit number: NC0000272. The Division, along with the EPA and the TRW has worked to evaluate the Canton facility and the information submitted by the permittee in support of its request for renewal of the permit. It was anticipated by the Division that the variance and the permit would be considered for re-issuance in the same time frame. 18. The TRW has been provided copies of all correspondence and report materials, has visited the facility, consulted with EPA's Technology Team ("Tech Team," the group of staff and consultants assigned by the federal agency to support this review effort), met on site, and discussed the issues by telephone on several occasions in an effort to provide recommendations to the parties to the Settlement Agreement and to the NPDES Committee on what revised color conditions should be placed in the variance and renewal permit for the Canton Mill. Those efforts culminated in two important documents: the EPA Tech Team Report dated July 25, 2001 and the TRW recommendation report dated August 3, 2001. A critical component of these evaluations was the report funded jointly by Blue Ridge Paper and a consortium of environmental groups interested in the mill and its impact on the Pigeon River (Bleach Environmental Process Evaluation and Report prepared by Dr.Norm Liebergott, PhD, Liebergott & Associates Consulting Inc. and Mr. Lewis Shackford, GL&V Pulp Group, Inc.). The TRW and the Tech Team utilized this report in developing their final recommendations. 19. In support of the need for the color variance, Blue Ridge Paper submitted to the Division a report dated June 1, 2001 and entitled: Analysis of the Impact of Additional Water Treatment Technology on the Profitability of the Blue Ridge Paper Products, Inc. Canton Mill. 8 This evaluation provides the basis for examining the economic impacts that would occur if the Mill were to be required to provide color reductions beyond those outlined in this Color Variance. 20. Based on this foundation of information, the Division developed a draft color requirement for the Canton Mill and submitted that condition along with the draft NPDES permit and variance to public notice on August 3, 2001. On September 6, 2001, Ms. Marion Deerhake, EMC and NPDES Committee of the EMC, convened and conducted a public hearing on the draft permit and an effluent color variance for the Canton Mill. Ms. Deerhake's Hearing Officer Report and the recommendations made concerning the Color Variance are the basis of the variance language appearing below, and are further incorporated by reference herein. 21. The Color Variance conditions established as the result of the work of the TRW will continue the improvements to color in the Pigeon River, leading to reduced pounds per day of color over the life of the Permit, which is to be issued contemporaneously with this Color Variance; the discharges allowed do not endanger human health or safety, and actually result in improved water quality from the previous permitted period of operation; and a continued variance from the North Carolina narrative water quality standard for color, as interpreted numerically by the United States Environmental Protection Agency, is necessary due to the fact further reductions cannot be made at this time in an economically reasonable manner and, if required, would produce serious hardship without equal or greater benefits to the public. 22. The NPDES Permit No. NC0000272 for the Canton Mill and this Color Variance are, to the extent feasible, to be issued contemporaneously and the terms of this Color Variance included as Special Conditions in the permit. 9 CONCLUSIONS OF LAW (from the October 9, 1996, Order) 1. Pursuant to Ordering Paragraph 6 of the July 18, 1988, Final Decision, the NPDES Committee reviewed the then-existing variance following the Champion Canton Mill modernization program. 2. The previously existing variance from the North Carolina water quality standard for color, memorialized in the NPDES Committee's Final Decision, dated July 18, 1988, was determined to remain in effect except as specifically modified by the October 9, 1996, order. 3. Based on the effectiveness of the treatment system subsequent to the Canton Mill modernization project and due to the potential for improvements in color reductions by use of bleach filtrate recycling (BFIZ7 '), changes to the variance were determined to be warranted. (from the December 11, 1996, Order) 4. On its own motion and prior to the effective date of the October 9, 1996, order for Modification of Color Variance Granted on July 18, 1988. the NPDES Committee amended its October 9, 1996, order, to satisfy concerns of the United States Environmental Protection Agency, to clarify its conditions and to make the conditions more restrictive on Champion International Corporation. (from the December 11, 1997, Revision to Color Variance) 5. By duly adopted motion and vote, the NPDES Committee Ordered that the Color Variance to Champion International Corporation be granted as a Revised Color Variance, with an effective date of December 11, 1997. ( 10 (Issuance to Blue Ridge Paper) 6. The NPDES Committee has reviewed and considered the Color Variance for application to Blue Ridge Paper Products, Inc.; and finds that the color variance should be granted and re-issued during the term of the corresponding NPDES permit. 7. This Color Variance is granted and re-issued pursuant to N.C.G.S. 143-215.3(e); further reductions in color cannot be made at this time in an economically reasonable manner, and, if required, would produce serious hardship without equal or greater benefits to the public. Based on the foregoing Findings of Fact and Conclusions of Law, it is hereby ORDERED that the variance from the North Carolina water quality standard for color, as previously memorialized in the orders of July 18, 1998, October 9, 1996, December 11, 1996, and December 11, 1997 granted to Champion International Corporation, is re-issued to Blue Ridge Paper Products, Inc. and now reads as follows: A. Blue Ridge Paper Products, Inc. is granted this Color Variance, pursuant to N.C.G.S. 143-215.3(e), as a variance to water quality based effluent limitations for color. B. The Division of Water Quality shall issue NPDES Permit No. NC0000272, for the Canton Mill, and draft its provisions to reflect all the conditions of this Color Variance including the following specific wording: 1. The color reduction requirements contained in this. special condition have been derived directly from the mill's efforts to identify possible reduction measures and from the EPA Technology Review Workgroup (TRW) (report dated August 3, 2001), and the EPA Tech Team Report (dated July 25, 2001). These requirements are aimed at securing the highest feasible reduction of the,mill's effluent color over the permit cycle and for laying the foundation for removal of the color variance by the expiration date of this permit. r 11 The EPA Tech Team Report identified three levels of possible color reduction actions (identified in the report as .Highest Certainty, Reasonable Certainty and Lowest Certainty). Each of these tiers of reductions have identified specific actions or technologies that when implemented may result in additional color reductions in the mill's effluent. For example, the color reduction goals of the condition in Paragraph 6 of this special condition is premised on the implementation of all the actions of'Highest Certainty.' Paragraph 7 of this special condition requires the company to evaluate actions of'Reasonable Certainty'. Identified under 'Reasonable Certainty' are the technologies of Ozone/Chlorine Dioxide stage for the hardwood bleach line and second stage oxygen delignification for the pine line. This condition requires the permittee to examine the technical, economic and operational feasibility of implementing these technologies. The review of this required evaluation (Paragraph 7) will be supported by the EPA TRW. Regardless of the outcome of this feasibility analysis, the permittee is required to achieve 3,000 - 8,000 pounds per day additional color reduction, except to the extent allowed by Paragraph 6. This is considered the equivalent reduction of what would be expected from the _ installation of the two technologies identified by the EPA TRW process. Color Treatment of the Chloride Removal Process Purge Stream is the color reduction methodology with the 'Lowest Certainty'. Therefore, this condition requires the permittee to evaluate potential technologies for treatment of this wastestream and to implement those if shown technologically, economically and operationally feasible. Built into this special condition is a series of regulatory requirements that the permittee achieve reductions of the mill's effluent color consistent with each series of reduction actions. This means that following implementation of the 'Highest Certainty' actions the mill's annual color limit must be reduced by 6,000- 8,000 pounds per day, except to the extent allowed by Paragraph 6. If the implementation of all the actions identified under 'Highest Certainty' actually result in better long term effluent quality, this in no way reduces the permittee's responsibility to achieve the color reductions measured by those action identified as having 'Reasonable Certainty' of success and determined to be technically, economically and operationally feasible under paragraph 7. The mechanism for applying the overall success of the mill's efforts to reduce color is demonstrated by the actual color performance. This performance will be the basis for limitations established following implementation of the 'Reasonable Certainty' category actions and the process of developing the mill's limitations for the next permit renewal. Again, it is the goal of this special / 12 ` condition to achieve the color reductions identified by the EPA TRW and lay the foundation for removal of the color variance by the expiration date of this permit. 2. The average annual discharge of true color for each calendar month shall not exceed 48,000 pounds per day. The monthly average effluent true color loading shall not exceed 55,000 pounds per day. For the purpose of this permit/variance only, "pounds of true color" is calculated by the following equation: Effluent Flow (mgd) x Effluent True Color Level(Platinum Cobalt Units)x 8.34. 3. All samples collected for color analysis and for use in the above calculation shall be measured and reported using the procedure referenced in 39 FR 430.11 (b) (May 29, 1974) - true and apparent color or as amended by the EPA. 4. Blue Ridge Paper, in accordance with activities underway at the mill and in response to the work of the EPA Technology Review Workgroup (EPA TRW), has already begun the process of identifying and implementing technically, economically and operationally feasible process optimization measures, which can _ be taken to further reduce color discharges from the mill. The permittee is directed to continue evaluating mill operations with the goal of fully identifying opportunities for preventing and controlling measurable black liquor leaks and spills (Best Management Practices - BMPs). Such BMPs include but are not limited to: Continuous improvement of operating practices so more leaks and spills are recovered rather than discharged to sewer; Improvement in preparation for planned outages to maximize capture of tank clean-out waste and routing to recovery; Reduction of clean water that continuously runs into sewers to prevent dilution of smaller spills and facilitate recovery of highly colored wastewaters; and Improvement in the equipment used for handling of knot rejects to prevent black liquor leaks into the recovery sumps. 5. As indicated in Paragraph 4, the permittee has already begun the process of implementing the specific actions and technologies identified by the EPA Tech Team as having the 'Highest Certainty'. The permittee is directed to implement all the specific actions and technologies the EPA Tech Team Report identified as having the 'Highest Certainty'. The specific action items identified as having the 'Highest Certainty' include: Process Optimization, Improved black liquor leak & { 13 spill collection and control, and BFR reliability improvement. These 'Highest Certainty' action items and technologies shall be implemented in sufficient time to generate a sufficient database of representative mill effluent data for statistical analysis by October 1, 2003. By October 1, 2003, the permittee shall submit to the North Carolina Division of Water Quality a report including a statistical analysis of the permittee's monthly average color discharge, mill performance as related to color, all available data necessary to derive the lowest achievable annual average and monthly average color loading limits. By November 1, 2003, the Division of Water Quality (in consultation with the Technology Review Workgroup) shall recommend, considering the statistical analysis report submitted by the permittee and the demonstrated performance of the mill, the lowest achievable annual average and monthly average color loading effluent limitations. If the limits determined to be achievable are within or below the target range of 40,000 - 42,000 pounds per day as an annual average, the limits shall become effective on December 1, 2003, by written notification from the Director. If the limits determined to be achievable by the Division of Water Quality (in consultation with the Technology Review Workgroup) are above the target range, the Permit shall be modified in accordance with North Carolina's permitting process to reflect those limits. 6. Implementation of the 'Highest Certainty' action items or technologies shall reduce the annual average color discharge limit 6,000 - 8,000 lbs/day, based on the statistical analysis conducted according to Paragraph 5. Beginning December 1, 2003, upon notification from the Division of Water Quality the annual average discharge of true color shall not exceed 40,000 - 42,000 pounds per day. However, if by November 1, 2003, the Division of Water Quality (DWQ), in consultation with the Technology Review Committee', and the NPDES Committee agree that there are overwhelming technical, economic, or operational barriers to the Permittee's ability to attain a 40,000 - 42,000 lbs/day annual color loading limit, DWQ shall recommend to the NPDES Committee, alternate interim limits to become effective December 1, 2003. At that time, DWQ shall recommend a new effective date for achieving an annual average color loading limit of 40,000 - 42,000 pounds per day. These recommendations shall be based on what DWQ concludes Blue Ridge Paper can reasonably achieve, giving consideration to the actual demonstrated color levels discharged and the 'Highest Certainty' action items and technologies implemented pursuant to Paragraphs 4 ' The Technology Review Workgroup shall act in an advisory role to the North Carolina _. Division of Water Quality, and NC DWQ Shall consult with the Technology Review Workgroup prior to making any decisions regarding color reduction activities at the Canton Mill. 14 and 5. Based on DWQ's recommendations, the NPDES Committee will determine an alternate interim limit to become effective on December 1, 2003, and the new effective date for achieving an annual average color loading limit of 40,000 - 42,000 pounds per day. After the NPDES Committee's final decision, the NPDES Permit will be modified in accordance with North Carolina's permitting process. 7. The permittee shall submit to the Division of Water Quality, the Technology Review Workgroup and the NPDES Committee by December 1, 2003, a report on the feasibility of achieving a target annual average color reduction within the range of 3,000 pounds per day and 8,000 pounds per day from the reduction achieved by implementation of the 'Highest Certainty' actions. This report shall include an evaluation of the use of the 'Reasonable Certainty' actions identified in the EPA Tech Team Report and any other actions that would result in additional color reductions, actions taken by the permittee to reduce color loading (since permit issuance), and the technical, economic, and operational feasibility .of implementing the 'Reasonable Certainty' actions on a continuous or intermittent basis, in order to achieve a target annual average color reduction within the range - of 3,000 pounds per day and 8,000 pounds per day. As identified in the EPA Tech Team Report, the 'Reasonable . Certainty' actions are the technologies of y Ozone/Chlorine Dioxide stage for the hardwood bleach line and second stage oxygen delignification for the pine line. The report shall identify specific economic and implementation issues associated with the proposed improvements. The report shall also project expected additional color reduction for each technology evaluated and maximum color reduction possible using the identified technologies. The report shall also include a proposed schedule for implementation of process improvements or installation of technologies required to achieve an effluent color reduction of 3,000 - 8,000 pounds per day. The permittee shall provide this evaluation/report, together with an updated report on the results of ongoing and additional planned color reduction activities, to the Division of Water Quality, the Technology Review Workgroup and the NPDES Committee. By February 1, 2004, DWQ (in consultation with the Technology Review Workgroup) shall approve or modify the permittee's recommended plan for achieving a 3,000 - 8,000 pounds per day reduction to the target annual average. 8. By December 1, 2005, the permittee shall submit, as related to the implementation of the process improvements evaluated according to Paragraph 7, a statistical analysis of Blue Ridge Paper's effluent quality performance. This report shall include a statistical analysis of the Blue Ridge Paper's monthly average and annual average color discharge, mill performance as related to color, all available data necessary to derive the lowest achievable annual average and monthly average color loading limits. ( 15 By February 1, 2006, the Division of Water Quality (in consultation with the Technology Review Workgroup) shall recommend, considering the statistical analysis report submitted by the permittee and the demonstrated performance of the mill, the lowest achievable annual average and monthly average color loading effluent limitations. If the limits determined to be achievable are within or below the target range of 32,000 - 39,000 pounds per day as an annual average, the limits shall become effective on March 1, 2006, by written notification from the Director. If the limits determined to be achievable by the Division of Water Quality (in consultation with the Technology Review Workgroup) are above the target range, the Permit shall be modified in accordance with North Carolina's permitting process to reflect those limits. 9. By December 1, 2004, the permittee shall evaluate color reduction technologies associated with the Chloride Removal Process (CRP) wastestream. The CRP analysis shall concentrate on the technical, economic, and operational feasibility of implementing the applicable technologies on all or a portion of the purge stream. The report shall identify specific economic and implementation issues associated with the improvements. The report shall also project expected _ additional color reduction for each technology evaluated and maximum color reduction possible.using the identified technologies. Though not limited to the following, the report shall include an analysis of the land application of the high - chloride wastewater, commercial incineration, coagulant/precipitation technologies, and solidification for land disposal. The Division of Water Quality (in consultation with the Technology Review Workgroup) shall evaluate the feasibility of implementing identified technologies for further color reduction and shall submit to the NPDES Committee by February 1, 2005, DWQ's recommendations regarding color reductions associated with the treatment of the CRP wastestream. If during the course of this evaluation Blue Ridge Paper identifies a technical, economic, and operationally feasible color reduction technology that can be implemented for treatment of the CRP wastestream, the permittee may request that the Technology Review Workgroup review this technology for implementation at the Canton mill. If the Technology Review Workgroup concurs that the identified technology is suitable for the Canton mill and that the color reductions achievable are adequate, the mill's obligation to research additional technologies will be waived after formal notification from Blue Ridge Paper that the identified technology will be installed and placed into operation. This notification shall include language indicating the permittee's commitment to the implementation of the technology, along with a schedule for implementation. The Division of Water Quality will notify the permittee in writing that the proposed implementation schedule is acceptable. 16 r 10. By March 1, 2006, the permittee shall submit a report to Division of Water Quality, the Technology Review Workgroup and the NPDES Committee on the color reduction efforts as part of the Variance review process (Triennial Review of North Carolina's Water Quality Standards). This report shall also include an evaluation of color in the Pigeon River at the Fiberville Bridge, and an evaluation on the feasibility of complying with North Carolina's Color Standard. 11. The 1997 Settlement Agreement contained provisions to limit color in the Pigeon River at the Hepco USGS gauge station. The new effluent limits in this permit are more stringent than the provisions in the 1997 Permit and Color Variance and will result in reduced color levels in the Pigeon River. It is possible to calculate the monthly flow at the Canton gage station above which instream color at the Fiberville Bridge will not exceed 50 true color units. Using the 55,000 pounds per day monthly average true color loading limit (implemented on the effective date of the permit) the flow at the Canton Gage station,'which will provide for color less than 50 true color units at the Fiberville Bridge is 171.8 MGD. Therefore, the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the monthly average flow (at the Canton gage station) is greater than 171.8 MGD. 12. The governing flow criterion for true color at Canton is 58.1 MGD (30Q2 stream flow). The flow established, pursuant to Paragraph 10, is greater than this 30Q2 stream flow, therefore, for flows less than the 171.8 MGD at the Canton Gage station but greater than 193.3 MGD (30Q2 flow) at the Hepco gage station, the monthly average color in the Pigeon River at Hepco will be less than 50 true color units. 13. Beginning December 1, 2003, the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the flow at Canton is greater than the flow established using the following equation and based on the monthly average effluent limit established per Paragraph 5: Flow at Canton_USGS(MGD)=(Monthly Aveme Effluent Color Limidb/dav-12468.3)+31.6+2.4 308.58 For flows at the Canton Gage station less than the flow established here but greater than 193.3 MGD at the Hepco gage station, the monthly average color in the Pigeon River at Hepco will be less than 50 true color units. 14. Beginning March 1, 2006, the monthly average color in the Pigeon River at the Fiberville Bridge will be less than 50 true color units whenever the flow at Canton is greater than the flow established using the following equation and based on the monthly average effluent limit established per Paragraph 8: 17 Flow at Canton_USGS(MGD)=(M`hly Awraee Effluent Cola[ Limit.lb/day-12468 31+31.6 +2.4 308.58 For flows at the Canton. Gage station less than the flow established here but greater than 193.3 MGD at the Hepco gage station, the monthly average color in the Pigeon River at Hepco will be less than 50 true color units. 15. The potential exists that there could still be periods of time corresponding to periods of lower flow in the river, when color at Fiberville might exceed 50 true color units. Therefore, the permittee shall continue to implement the approved Low Flow Contingency Plan for mitigating the occurrence and degree of this potential exceedence. 16. The permittee shall not increase the mill's pulp production capacity during the term of this permit, unless the permittee can demonstrate that the increased production can be achieved while reducing color loading. In addition, increasing the mill's pulp production capacity may require permit revision in accordance with North Carolina's NPDES Permitting rules. 17. The NPDES Permit shall be subject to reopening in order to modify the color / requirements based upon the following and in association with the required l triennial reviews: Any breakthrough in color removal technologies. Such breakthroughs shall be brought to the NPDES Committee for consideration, by Blue Ridge Paper and the Division of Water Quality, as soon as they are discovered. An acceptable statistical analysis of effluent color discharge data demonstrating significantly better color removal performance than that currently prescribed in the variance and permit, except as noted herein. Successful application of end-of-pipe color reduction technology or in-mill color minimization effort that results in significant and measurable reduced mass color discharge. 18. The transfer of this NPDES permit will not proceed until any successor-in-interest to the current permittee has agreed to accept the provisions of this permit and request and received from the NPDES Committee a transfer of 2001 Revised Color Variance. 1 a 18 C. The Division of Water Quality shall include review of this variance as a specific item in its Triennial Water Quality Standards review, as required by the federal Clean Water Act, and make appropriate recommendations to the NPDES Committee. D. This variance shall extend for an indefinite period of time, subject to consideration during the water quality standards triennial reviews. Any modification or termination based thereon shall be subjected to the public hearing process required by N.C.G.S. 143-215.3(e). It is further ORDERED that this Color Variance shall be effective as of the effective date of the renewed NPDES Permit No. NC 0000272 for the Canton Mill, and the terms of the previously existing variance shall continue in effect until that time. This the b--6-1 day of October, 2001. Charles H. Peterson, Acting Chairman NPDES Committee i 19 CERTIFICATE OF SERVICE This is to certify that I have this day served a copy of the foregoing COLOR VARIANCE on the parties listed below by the methods indicated, addressed to each as follows: Robert Williams, Director CERTIFIED MAIL Environment Health & Safety Affairs RETURN RECEIPT REQUESTED Blue Ridge Paper Products, Inc. P. O. Box 4000 Canton, North Carolina 28716 William Clarke, Esq. CERTIFIED MAIL Roberts & Stevens RETURN RECEIPT REQUESTED P.O. Box 7647 Asheville, North Carolina 28802 Gregory J. Thorpe, Acting Director HAND DELIVERY Division of Water Quality N.C. Department of Environment and Natural Resources ' 9th floor, Archdale Building Raleigh, North Carolina 27601-7687 Jennie Odette, Clerk HAND DELIVERY Environmental Management Commission N.C. Department of Environment and Natural Resources 9th floor, Archdale Building Raleigh, North Carolina 27601-7687 Paul Davis CERTIFIED MAIL Tennessee Department of RETURN RECEIPT REQUESTED Environment & Conservation 6th floor, L & C Annex 401 Church Street Nashville, Tennessee 37243-1534 David McKinney CERTIFIED MAIL Tennessee Wildlife Resources RETURN RECEIPT REQUESTED Ellington Agriculture Center P. O. Box 40747 Nashville, Tennessee 37204 20 Gary A. Davis CERTIFIED MAIL Tennessee Environmental Council RETURN RECEIPT REQUESTED P. 0. Box 2346 Knoxville, Tennessee 27901-2346 Beverly Bannister CERTIFIED MAIL U.S. Environmental Protection RETURN RECEIPT REQUESTED Agency, Region 4 Director of Water Management 100 Alabama Street, SW Atlanta, Georgia 30303 David Jenkins CERTIFIED MAIL American Canoe Association RETURN RECEIPT REQUESTED 7432 Alban Station.Boulevard Suite B-226 Springfield, Virginia 22150 Charles Lewis Moore CERTIFIED MAIL County Executive RETURN RECEIPT REQUESTED Cocke County Tennessee 360 Main Street East Newport, Tennessee 37821 Roland Dykes CERTIFIED MAIL Mayor of Newport RETURN RECEIPT REQUESTED P.O. Box 370 Newport, Tennessee 37821 This the 154'i'day of October, 2001. ROY A COOPER Attorney General Francis W. Crawley Special Deputy Attorney General N. C. Department of Justice P. 0. Box 629 Raleigh, North Carolina 27602-0629 919/716-6600 MCO"110 co"" (q�tq rrW,4 -cam :�i 12131197NPDES Permit and Modified Variance Compliance Timeline Date: Requirements,Limitations & Details: January 1, 1998 Monthly average discharge of true color will not exceed 95,000 Ibs/day March I, 1998 Status Report Due to NPDES Committee on the analyses prepared for other permitting agencies concerning the effects of the BFRTM technology on air emissions June 1, 1998 Report Due to Technology Review Workgroup(TRW)and NPDES Committee which will identify a STRATEGY and TIMELINE for implementing the following color reduction measures until the target effluent limitations are met or all measures have been fully implemented: • Further upgrading and integrating of sewer monitoring — additional flow measurement and sampling stations — substantially improve the mass balance • Automated mill process control systems with operational procedures and management oversight to reduce black liquor leaks and spills. • Continued operator training • Identifying and implementing additional controls for known but unmeasured sources of liquor losses — evaporator set — knot rejects bins • Modifying digester area to facilitate capturing of leaks and spills • Diverting clean water discharges • Capturing and recycling liquors during fiber line disruptions: — detailed scheduling of planned outages — contingency planning for unplanned outages • Thoroughly evaluate additional measures to modify its process operations and controls to remove or reduce sewer generated color The report will include an explanation of and rationale for both the implementation strategy and proposed time line. The report will also identify those measures which will be implemented in the event the effluent limitations of December 1, 1998 are not met June 1, 1998 Fully implement the following four BMPs: • Installation of replacement digester recirculation pumps and a spill collection sump • Installation of a pine courtyard Parshall flume slide gate • Installation of weak black liquor containment • Other measures including: — Correction of evaporator set demister clogging — Installation of condensate instrumentation and sampling ports for the evaporator set — Assurance of continued dry conveying of knot rejects October I, 1998 If TRW determines, and NPDES Committee agrees,that there are overwhelming technical,economic or operational barriers to the permittee's ability to attain the 60,000 Ibs/day annual average and 69,000 lbs/day monthly average color loading limits,the TRW shall recommend to the NPDES Committee the alternate interim limits to become effective 12/1/98. TRW shall also recommend to the NPDES Committee a new effective date for achieving annual average color loading limit of 60,000 Ibs/day. December I, 1998 Submit to TRW a contingency plan, corresponding to periods of river flow less than 330 cfs at Hepco gauging station, for mitigating the occurrence and degree of potential exceedences of 50 true color units at Hepco by evaluating: • scheduling of maintenance • intermittent treatment • production curtailment • any other temporary measures NOTE: The model limitation maybe extended beyond 1211198 if the NPDES Committee establishes interim limits which require the model to be used to assure compliance with 50 true color units at the state line. Monthly average discharge of true color shall not exceed 69,000 Ibs/day Annual average discharge of true color shall not exceed 60,000 lbs/day Pigeon River color at Hepco gage shall be less than 50 true color units whenever monthly average flows are greater than 330 cfs. January 1, 1999 Begin implementation of Eo recycle on the hardwood fiber line February 1, 1999 TRW will recommend to the NPDES Committee either approval of or modification to the plan. March 1, 1999 The low flow contingency plan shall become effective upon approval December I, 1999 Report Due to TRW and NPDES Committee on: • Evaluation of color reduction benefit gained from Eo recycle on the hardwood fiber line • Potential color reduction benefit to be gained from full implementation of the BFRTM technology on hardwood fiber line --- NOTE: All of the above color related work is referred to as the NEAR-TEPMPACKAGE--- June 1,2000 Anticipated that full implementation of Near-Term Package could be effectuated January 1,2001 Report Due to TRW and NPDES Committee on the feasibility of achieving a target annual average color loading limit within the range of 48,000-52,000 lbs/day on full implementation of the Near-Term Package. March I,2001 A) Evaluate and report on end-of-pipe color reduction technologies in conjunction with the Triennial Review of NC Water Quality Standards. This evaluation shall include: • Incremental color improvement analysis • Technical, economic and operational feasibility of the application of these technologies on a continuous or intermittent basis (specifically at periods of low river flow) • Economic and Implementation issues associated with the incremental improvement of color levels expected by installing these technologies • Projection of the expected additional color reduction for each technology and the maximum color reduction possible B) Updated report on the results of all ongoing and any additional planned color reduction activities. April 1,2001 TRW shall recommend to the NPDES Committee and other Settlement Agreement parties,considering the feasibility report submitted on January 1, 2001 and the demonstrated performance of the mill,the lowest achievable annual average and monthly color loading effluent limitations. May I, 2001 The recommended limits, if within the target range(48,000-52,000 Ibs/day), shall become effective June 1, 2001 • Submit Report to the NPDES Committee and NCDENR, Division of Water Quality,on the comparative evaluation of the above collaborative efforts as part of the Variance review process. • Statistically evaluate the monthly average color discharge,annual average color discharge and performance of the mill in relation to color discharged. •Results used to make recommendations to the 1997 permit for the 2002 permit. November 30,2001 Permit shall expire at midnight GENERAL The mill's pulp production capacity will not be increased during the PROVISION permit unless this can be done in a way that also reduces color loading. V �son- ion Distribution List January 13, 1998 Ben Bilus �41 Canton. NC Mill - Settlement Agreement Regarding 1996 Water Quality Color Variance And 1996 NPDES Permit Issued to Champion Attached is a fully executed copy of the Settlement Agreement. BSB.jm Distribution Dick Diforio Ed Clem Tom Siegrist Bob Williams Derric Brown Al Joyce Bill Manzer Tucker Hill Dave Hearne Tom Griffen Billy Clarke Jeff McNealey Steve Brown Susan Jackson `A'Fs UNITED STATES ENVIRONMENTAL PROTECTION AGENCY - REGION 4 ° ATLANTA FEDERAL CENTER 61 FORSYTH STREET, SW ATLANTA, GEORGIA 30303-8909 RECEIVED JAN 13 1997 LEGAL AFFAIRS January 8, 1998 [See Addressed List Attached] SUBJ: Champion Permit Matter Gentlemen: Enclosed is a copy of the final,fully executed Settlement Agreement in the above- referenced matter. i I would like to take this opportunity to thank each of you with whom I had occasion to work on this project for the high level of professionalism and courtesy which you brought to this matter. I thoroughly enjoyed working with each of you and look forward to the opportunity to do so in the future. Sincerely, Mary J Associate gio ttorney Attachment Encl. I Recycif"*Cyolaale•Printed with Vegetable Oil Based Inks on 100%Recycled Paper(40%Postoensumer) ADDRESS LIST I Barry Turner Deputy Attorney General Office of the Attorney General Cordell Hull Building, 2nd Floor 425 5th Avenue North Nashville, TN 37243-0495 Paul E. Davis, Director Division of Water Pollution Control TN Department of Environment and Conservation 6th Floor L & C Annex 401 Church Street Nashville, TN 37243-1534 Daniel C. Oakley Senior Deputy Attorney General NC Department of Justice 114 West Edenton Street Suite 311 Raleigh, NC 27602 Forrest R. Westall Regional Water Quality Supervisor NC Department of Environment and Natural Resources Division of Water Quality, Asheville Regional Office 59 Woodfin Place Asheville, NC 28801 Benjamin S. Bilus Senior Associate Counsel Champion International Corporation One Champion Plaza Stamford, Connecticutt 06921 David E. Jenkins Director of Conservation and Public Policy American Canoe Association, Inc. 7432 Alban Station Boulevard, Suite B-226 Soringfield, VA 22 1 50-23 1 1 John Noel Pigeon River Coordinator Tennessee Environmental Council 1700 Hayes Street. Suite 101 Nashville, TN 37203 Honorable James E. Robinson Mayor, City of Newport P.O. Box 370 Newport, TN 37822 Mr. Harold Cates Cocke County Executive Court House Annex, Room 146 360 East Main Street Newport, TN 37821 1 SETTLEMENT A RE *^^ RQGARDIN 996 WATER nrrar r COLOR VARIANCE AND 1296 h nv4 PrRmTm T nSUEn TO CHAMPION IXTERNATTOhr T rOR ORATrnu I. INTRODUCTION 1. The United States Environmental Protection Agency (EPA) , the State of North Carolina (North Carolina) , the State of Tennessee (Tennessee) , Cocke County, Tennessee (Cocke County) , the City of Newport, Tennessee (Newport) , the Tennessee Environmental Council (TEC) , the American Canoe Association (ACA) , and Champion International Corporation (Champion) enter into this Settlement Agreement to resolve the concerns of Tennessee, Cocke County, Newport, TEC, and ACA with the amended modified water quality color variance granted by North Carolina to Champion on December 11, 1996, and approved by EPA on December 26, 1996, and with the NPDES permit issued by North Carolina to Champion on December 12, 1996. It is also intended that this Agreement will be the basis for resolution of the contested case Proceeding pending before the North Carolina Office of Administrative Hearings to which all of the foregoing, except EPA, are parties . II. PROCEDURAL HISTORY 2 . Champion operates a bleached kraft pulp and paper mill on the Pigeon River at Canton, North Carolina, and discharges treated wastewater from its mill operations, domestic wastewater from the Town of Canton, and leachate from its active landfill into the river. The Pigeon River below Canton is designated by cNorth Carolina as a Class C river (secondary recreation, fishing, aquatic life, including propagation and survival , and wildlife) and flows from North Carolina northwestwardly into Tennessee. Under the Federal Water Pollution Control Act (commonly referred to as the Clean Water Act) , 33 U.S.C. § 1251 st. 'sprT„ and under North Carolina ' s Water and Air Resources Act, N.C. Gen. Stat. §§ 143-211 aL z,_„ Champion is required to have an NPDES permit for these discharges . 3 . Until January 1, 1997, when the permit issued on December 12 , 1996, by the State of North Carolina took effect, Champion was operating its Canton mill under an NPDES permit issued by EPA, effective October 25, 1989 . EPA issued that permit after objecting to, and subsequently vetoing, the permit that North Carolina had issued to Champion in mid-1985 . EPA vetoed the North Carolina permit on the grounds that it did not reasonably ensure compliance with Tennessee ' s narrative water quality criteria for color. On November 13, 1985, EPA notified Champion that it had assumed permitting authority for the Champion permit . North Carolina and Champion challenged EPA' s authority to take over the permit in federal court . In 1987, the District Court for the Western District of North Carolina rendered an opinion upholding EPA' s permitting authority. Chamninn v. , 648 F.Supp. 1390 (W.D.N.C. 1987) . This opinion was upheld by the Fourth Circuit Court of Appeals in 1988, Champion v. , 850 F. 2d 182 (4th Cir. 1988) , and EPA issued its permit on September 25, 1989 . Champion and the Dead Pigeon River .Council appealed the EPA permit . After an administrative hearing before EPA Administrative Law Judge Thomas B. Yost, the permit ti- was upheld on February 12 , 1992 . 4 • In 1988, the NPDES Committee' of the North Carolina Environmental Management Commission granted Champion a variance from the North Carolina narrative water quality criterion for color. EPA approved this variance on August 11, 1988 . 5 . The EPA-issued permit and the North Carolina color variance have operated together to control the contribution of effluent color by Champion to the Pigeon River, by the use of a predictive model and a color limitation of 50 true color units on a monthly average basis at the North Carolina/Tennessee state line. 6 . Champion ' s EPA-issued permit for the Canton mill (NPDES Permit No. NC0000272 ) was set to expire on October 24, 1994 . On March 28, 1994, Champion applied to the North Carolina Department Of Environment, Health and Natural Resources (NCDEHNR) for -' renewal of this permit . At that time, North Carolina advised Champion that it believed EPA was the proper permitting agency, since EPA had assumed control of the facility ' s permit in the previous permit cycle . Champion, therefore, applied to EPA for a renewal on April 15, 1994 . EPA then advised Champion that North Carolina was , in fact , the proper permitting agency, and Champion filed its renewal application with North Carolina on November 18, 1994 . 7 . The 1988 color variance was reviewed by the North Carolina Environmental Management Commission as a part of its triennial review and was -continued on May 12 , 1993 . On November 29 , 1994, EPA approved the continued variance. 8 • On June 6, 1996, North Carolina conducted a public .............................. hearing in Haywood County, North Carolina, to consider renewal of NPDES Permit No. NC0000272 and modifications to the 1988 color variance. A public comment period extended for thirty (30) days after the public hearing. The effluent color limitation for the Canton Mill was one of the issues subject to comment . 9 • Tennessee provided public comment at the hearing as well as in writing thereafter through the Tennessee Department of Environment and Conservation (TDEC) and the Tennessee Wildlife Resources Agency (TWRA) . Those comments stated that color in the river in Tennessee was still objectionable, particularly during the low-flow period from mid-summer through fall. The comments further stated that additional conditions needed to be placed on effluent color to meet the Tennessee narrative water quality criterion for color. ACA members also participated in the public hearing. TEC provided written comments which also raised objections to the noticed permit . EPA also provided comments on the publicly-noticed draft permit by letter, dated July 3 , 1996. TEC and ACA also subsequently submitted additional comments to EPA expressing concerns regarding the permit and variance. 10 . Following the public hearing, North Carolina, Tennessee, EPA and Champion attempted to resolve the color issue through several formal and informal mechanisms . Based on the Public record and EPA' s comments, a proposed final permit was prepared on October 1, 1996 . The North Carolina NPDES Committee then mod----I mite 1988 color variance un uctober 15, 1996 . 11 . Discussions among North Carolina, Tennessee and EPA continued thereafter; additional targets for continued color w. reductions and more restrictive mass-based color limits were Placed in the permit and variance by North Carolina, based on comments received, and Tennessee was added as a specifically- named member of the Variance Review Committee, which would periodically consider the variance conditions . These changes were documented in the variance modification by a new Amended Order of the North Carolina NPDES Committee issued on December 11, 1996, and in the permit issued on December 12, 1996. 12 . EPA Region 4 supported the December 1996 variance amendments by letter dated December 9, 1996; and EPA Region 4 subsequently approved the amended color variance modification by letter dated December 26, 1996. 13 . By letter dated December 23 , 1996, Tennessee advised EPA that it considered the permit to be invalidly issued and that North Carolina had failed to comply with § 402 (b) (5) of the Clean Water Act, 33 U.S.C. § 1342 (b) (5) . Subsequently, on January 13 , 1997, Tennessee filed a contested case petition with the North Carolina Office of Administrative Hearings challenging the permit and color variance. Thereafter, Champion, Cocke County, and Newport were allowed to intervene in the North Carolina contested case proceeding. 14 . In an effort to resolve the color issue without time- and resource-consuming litigation, North Carolina, Tennessee, Cocke County, Newport, Champion, and EPA agreed to an informal negotiation process . The North Carolina contested case Proceeding was stayed during this process until September 26, �� 1997 . On November 21, 1997, TEC and ACA were also allowed to intervene in the North Carolina contested case proceeding. 15 . The agreements which follow constitute what the parties to this Agreement believe to be an appropriate and reasonable resolution of the pending disputes surrounding the contested permit and variance. All parties to this Agreement are committed to the ultimate achievement of water quality standards in the Pigeon River, both in North Carolina and in Tennessee. This Agreement and the modified variance and the permit resulting therefrom represent a major step toward that goal. At the same time, the parties recognize that there is further work to be done and they are committed to attaining further reductions in color in the river at the quickest possible pace. III. TECHNOLOGY MODIFICATIONS TO THE VARIANCE/PERMIT _.. 16. The parties hereby agree to the following measures to achieve additional color reduction over that *required in the permit issued on December 12 , 1996 and by the color variance adopted on December 11, 1996 [hereinafter the December 1996 Permit and variance] . The parties further agree that the December 1996 permit and variance will be modified [hereinafter the 1997 Permit and the Revised Variance] to reflect these requirements and effectuate this Settlement Agreement . Except as modified by the Settlement Agreement, all other provisions of the December 1996 permit and variance, including the monitoring and reopener provisions, will be maintained in the 1997 Permit and the Revised Variance. i 17 . The Dece mber 1996 permit and variance required that Champion implement a one-year demonstration of full-scale bleach filtrate recycling (BFR7") technology on the mill ' s pine line and that, as of December 1, 1998, Champion implement and operate BFRTH technology on its pine line, unless Champion could demonstrate to the NPDES Committee that BFRT" was not commercially viable. Champion has nearly completed the process of the required demonstration phase of BFRT . Based on the results of the demonstration effort, Champion commits to continue the full operation of the BFRT" technology on the mills pine line on a continuing basis, subject to the process set forth in Paragraph 22 . 18 . The 1996 permit and variance required Champion to evaluate the potential for additional minimization of color losses from the manufacturing processes and raw material storage areas (i.e. in-mill color minimization; or, spill prevention/control measures) that might result in further color reductions and to report its findings to the NPDES Committee. Reports were to be submitted by March 1, 1998 and again by June 1, 2001, so that they could be used by the Committee in conjunction with the required variance review process held every three years to determine if the variance would be readopted or made more stringent . As a part of the efforts to resolve the challenge to the 1996 permit and variance, a Technology Review Wor?c--=u-. .. , , formed, com r4sed cf F - experts on the pulp and paper industry from EPA and representatives of the environmental agencies for the States of Tennessee and North Carolina . The Technology Review Workgroup shall replace the'-previously existing North Carolina Variance Review Committee and *shall be maintained during the life of the 1997 Permit in order: to make the recommendations and determinations which this Agreement calls for such Workgroup to make. The Technology Review Workgroup shall, at all times, be chaired by EPA and be comprised of three technical representatives from EPA with expertise on the pulp and paper industry, two environmental agency representatives from the State of Tennessee, and two environmental agency representatives from the State of North Carolina. The Workgroup shall make itself available to consult with and provide information to community representatives at appropriate times . In addition, consistent with any limitations under law or regulation relating to confidential business information, copies of all written reports and recommendations generated pursuant to this Agreement shall be provided to the parties to the Agreement at least 20 days before any recommendation or determination by the Workgroup becomes final . The Workgroup shall review any comments or input received on such documents prior to making its final recommendations or determinations . Any comments or input received by the Workgroup shall be made available to all parties to this Agreement . 19 . Working with the Technology Review Workgroup, Champion has already begun the process of identifying and implementing Possible prevention- anc control measures which can !De Laken to further reduce color discharges from the mill . Champion commits to further evaluate mill operation so as to fully identify .............. ... opportunities for preventing and controlling measurable black I liquor leaks and spills (best management practices - BMPs) . This evaluation will include gathering more extensive and detailed data on sources of color within the mill to substantially improve the accuracy of measurements, to improve the mill ' s existing BMP program, and to complete efforts to identify, quantify and substantially improve the accuracy of a mass balance of sources of leaks and spills of black liquors, including unmeasured sources and discharges during periods of fiber line disruption. Such BMPs include: further upgrading and integrating of sewer monitoring (e.g. , additional flow measurement and sampling stations to facilitate more comprehensive and daily monitoring of sources) and automated mill process control systems with operational procedures and management oversight to reduce black liquor leaks and spills ; continuing operator training; identifying and implementing additional controls for known but unmeasured sources (e.g. , evaporator set, knot rejects bin, etc . ) Of liquor losses ; modifying the digester area to facilitate capturing leaks and spills; diverting clean water discharges; and capturing and recycling liquors during fiber line disruptions through detailed scheduling of planned outages and contingency planning for unplanned outages . Champion also commits to thoroughly evaluate additional measures to modify its process operations and controls to remove or reduce sewer generated color. 20 . Champion agrees to provide a report to the Technology t Review Workgroup and the NPDES Committee no later than June 1, i 1998 . This report will identify a strate gy •and time line for implementing those color reduction measures identified in Paragraph 19 until the target effluent limitations in Paragraph 24 are met or all measures in Paragraph 19 have been fully implemented. The report will include an explanation of and rationale for both the implementation strategy and the proposed time line. The report will also identify those measures which will be implemented in the event that the effluent limitations set out in Paragraph 22 are not achieved by the color reduction measures specified in that paragraph. 21 . Four BMPs which have already been identified as having both a high potential for achieving color reduction and a high level of implementability are: a) installation of replacement digester recirculation pumps and a spill collection sump; b) installation of a pine courtyard Parshall flume slide gate; c) installation of weak black liquor tank containment, and; d) correction of evaporate set demister clogging, installation of condensate instrumentation and sampling ports for the evaporator set, and assurance of continued dry conveying of knot rejects . Champion commits to fully implement all four of these BMPs by June 1, 1998 . 22 . The 1996 permit and variance required that the annual average effluent true color loading should not exceed 98, 168 lbs/day and that the monthly average true color loading should not exread 125, 434 lbs/day . Based on current demonstrated achievable levels which have resulted from measures that Champion has already undertaken to reduce color from the mill , the parties agree that the 1997 Permit and Revised Variance shall provide that beginning January 1, 1998, the monthly -average discharge of true color from the mill shall not exceed 95, 000` lbs/day. Based on an analysis of the available data from the BFR2T demonstration Project and the spill prevention/control measures that have already been identified by Champion and the Technology Review Workgroup as being implementable in the near-term, it is anticipated that full-scale implementation of BFR29 on the pine line combined with the four BMPs identified in Paragraph 21 will reduce annual average color loading by approximately 40% below the limits in the December 1996 permit . Therefore, the 1997 Permit and Revised Variance will require that, beginning December 1, 1998, the annual average discharge of true color shall not exceed 60, 000 lbs/day and the monthly average true color loading shall not exceed 69, 000 lbs/day. However, if by October 1, 1998, the Technology Review Workgroup determines, and the NPDES Committee agrees, that there are overwhelming technical, economic or operational barriers to Champion' s ability to attain the above-stated color loading limits, the Technology Review Workgroup shall recommend to the NPDES Committee the alternate interim limits to become effective December 1 , 1998 . The Workgroup shall, at the same time, also recommend to the NPDES Committee a new effective date for achieving an annual average color loading limit of 60, 000 lbs/day. These recommendations shall be based cn wh.L Caie Workgroup concludes Ci.amoion can reasonably be expected to achieve, giving due consideration to the demonstrated discharge levels which the mill has , in fact, achieved and taking into account the evaluations conducted pursuant to Paragraph 19 and the report submitted by Champion pursuant to Paragraph 20 . Based on the Workgroup' s recommendations, the NPDES Committee will determine the alternate interim limits to become effective on December 1, 1998, as well as a new effective date for achieving an annual average color loading limit of 60, 000 lbs/day. The permit will then be modified in accordance with North Carolina' s permitting process to reflect these determinations . 23 . The 1996 permit and variance required Champion to evaluate color reduction strategies for further optimization of BFR1" technology and to report on the feasibility of implementation on the hardwood line. Champion commits to begin implementation of that portion of the BFRTm technology which involves the recycling of the Eo stage of the hardwood line by no later than January 1, 1999 . Champion further agrees to provide an evaluation of that implementation as well as the potential for full implementation of the BFRT" technology on the mill ' s hardwood line to the Technology Review Workgroup and the NPDES Committee by December 1, 1999 . The evaluation will include data reflecting the color reduction benefit gained from the partial implementation and a projection of potential color reduction benefit to be gained from full implementation of the BFR technology on the hardwood line . 24.. . Based on the work that Champion and the Technology Review Workgroup have already done in the area of in-mill color I `- reduction measures, it is anticipated that further color reductions, beyond those to be obtained by BFR"` on the pine line in combination with the four BMPs identified in Paragraph 21, could be expected after implementation of the BMPs and measures to reduce and/or remove sewer generated color identified in Paragraph 19, and partial BFR " (i. e. , recycle of Eo filtrate) on the hardwood line. This combined package of in-mill color reduction measures (i .e. , the four BMPs in Paragraph 21, the additional BMPs and sewer-generated color reduction measures identified in Paragraph 19 as implemented pursuant to Paragraph 20, full implementation of BFR on the pine line, and partial BFR on the hardwood line) shall hereinafter collectively be referred to as the Near-Term Package. It is further anticipated that full implementation of the Near-Term Package could be effectuated by ( June 1, 2000 , resulting in a target color annual average loading within a range of 48, 000-52, 000 lbs/day. Champion shall submit to the Technology Review Workgroup by January 1, 2001, a report on the feasibility of achieving a target annual average color loading limit within the range of 48, 000-52 , 000 1bs/day based on full implementation of the Near-Term Package. This report shall include all available data necessary to derive the lowest achievable annual average and monthly color loading limits . By April 1, 2001, the Technology Review Workgroup shall recommend, considering the feasibility report submitted by Champion and the demonstrated performance of the mill, the lowest achievable a :ual average and month-,'•• color loading effluent limitations . The Workgroup evaluation and recommendation report shall be submitted to the NPDES Committee and the other parties to this Agreement. If the recommended limits are within the target range, the limits shall become effective on May 1, 2001, by written notification from the Director of the North Carolina Division of Water Quality. If the limits determined to be achievable by the Workgroup are not within the target range, the Permit shall be modified in accordance with North Carolina's Permitting process to reflect those limits . The Workgroup's recommendation of limits under this Paragraph shall take into account appropriate effluent variability. 25 . The 1996 permit and variance contain provisions to limit color in the Pigeon River at the NC-TN state line to a maximum monthly average of 50 true color units . The new effluent limitations in this Agreement at Paragraphs 22 and 24 are more stringent than the provisions in the 1996 permit and variance and will result in color levels at the state line well below 50 true color units . It is possible to calculate the monthly flow at the Hepco gage above which instream color will not exceed 50 true color units for any specific color discharge from the Champion facility. Using the 69, 000 lbs/day monthly average true color loading limit anticipated in Paragraph 22 to become effective December 1, 1998, the flow which will provide for color less than 50 true color units at the Hepco gage is 330 cubic feet per second (cfs) . Therefore, the parties to this Agreement agree that the scope and magnitude of the 1996 variance will be reduced in the Revised 'variance to provide that : c-Zfe-uLive December 1, 1998, color in the Pigeon River at the Hepco gage shall be less than 50 true color units whenever monthly average flows are I greater than 330 cfs . The parties to this Agreement further I agree that should alternate interim limits be set pursuant to Paragraph 22 , or when monthly limits are established pursuant to Paragraph 24, the above variance conditions will be revised in accordance with the above approach. Using North Carolina's governing flow criteria (30Q2) , historical flow records, and the December 1, 1998 effluent limits in Paragraph 22 , it is expected that color in the Pigeon River at the Hepco gage will be less than 5o true color units 91% of the applicable time. Similarly, using the May 1, 2001 effluent limits in Paragraph 24, it is expected that color in the Pigeon River at the Hepco gage will be less than 50 true color units 96% of the applicable time. Champion agrees to cooperate fully with any periodic independent monitoring (including activities such as splitting samples) requested by EPA or the State of North Carolina. In-stream monitoring data gathered during the 1997 Permit term will be evaluated at the end of the 1997 Permit term to determine whether the limits established under the Permit, in fact, attained the color levels as expressed in the Variance. This information will be used to develop new requirements for the next permit which further reduce color levels in the Pigeon River. 26. As Paragraph 25 recognizes, there could still be some Periods of time, corresponding to periods of lower flows in the river, when color at the Hepco gage might exceed 50 true color units . Champion agrees to develop a contingency plan for mitigating the occurrence and degree of these potential exceedances which correlates measures designed to achieve mitigation with periods of lowest flow, with"particular attention ' I being given to periods of higher recreational use in the river. In developing the plan, Champion shall evaluate any reasonable means, including scheduling of maintenance, intermittent treatment, and production curtailment, which would achieve additional color reductions during temporary periods of lower flows in the river, when color at the Hepco gage might exceed 50 true color units . The contingency plan shall be submitted by December 1, 1998, for review by the Technology Review Workgroup. Champion agrees to work in good faith with the Workgroup to resolve any issues which arise during this review in order to achieve a mutually acceptable plan. By February 1, 1999, the Technology Review Workgroup will recommend to the NPDES Committee / either approval of or modifications to the plan. The NPDES Committee will approve the contingency plan, either as submitted or with the changes the Committee determines are appropriate. The plan shall become effective upon approval, which shall be no later than March 1, 1999 . 27 . Champion commits to, and North Carolina will direct, the continuing improvement of existing process and related technologies which could improve the efficiency of all water- using equipment and operations throughout the mill, with the goal of meeting North Carolina' s water quality standards under the Clean Water Act without a variance . 28 . The 199, pe-mit and variance required Champion to evaluate and report to the NPDES Committee on end-of-pipe color L4 reduction technologies that could conceivably be implemented at the mill. The evaluation was to include an incremental color I improvement analysis which concentrated on the technical, economic, and operational feasibility of the application of these technologies on a continuous or intermittent basis . The intermittent application of these technologies was to look particularly at periods of low river flow. , These reports were to be submitted to the NPDES Committee for its consideration as part of the water quality standards Triennial Reviews to determine whether the variance should be readopted or made more stringent. The reports were to identify specific economic and implementation issues associated with the incremental improvement of color levels expected by installing these technologies at the mill. They were also to project the expected additional color reduction Possible using the identified technology. The first such evaluation/report, which was due March 1, 1998, has essentially been completed as a result of the Technology Review Workgroup's efforts . A subsequent evaluation/report was to be due March 1, 2001 . Champion agrees to provide this evaluation/report, together with an updated report on the results of all ongoing and any additional planned color reduction activities , to the Technology Review Workgroup and the NPDES Committee March 1, 2001 . The Technology Review Workgroup shall evaluate this combined report and make recommendations to the NPDES Committee for further color reduction targets for inclusion in the next NPDES penui� . 29 . The parties agree that the 1997 Permit shall require ��J that Champion and any successor-in-interest to Champion's PUP 'saATgPTgruT 'SuleaBozd aTgPTTPAP A3TauapT TTTM Vd3 sPazP asogg UT saTaTungzoddo oTurouooa zaggo pup 'ursTanog 'uoTgpaaoaa ;o guaurdoTanap 'aqg ul asTssP oa saTgTunmwoo ur2az:jsuMop asoga ggTM buTNJOtA og paggTunuoo aaQ saTgzad aqs, • sz2aA agq zano abzPgosTp s ,uoTdurPgD uroz3 pagTnsaz anPq APur gPgg sgo2durT oTurouooa aqg buTPzPbaa TTTur uoTdurPgo aqg uroi3 ureazgsuyop saTgTununuoo 3o suzaouoo aqg azTubooaz guauraaa5V sTgg oa s9Tgz2d aqs ' Z£ maxi JUINnmoo amy sal"NnMoo KraxssrMOa os aocntsSISSY 'Al ' aTn,d aqa oa �uensznd PagsTTgPgsa saWpagaurTg g-ITM aouPpz000P UT uoTdurEgo og ATddP TTTM 'sguaurazTnbaz buTzogTuoru AuP buTpnTouT 'aTng zagsnTD aqa go sguameaTnbea zaggo TT'd ' sguaurazTnbaz asogg gaau oQ anuTguoo TTTur uoguPo aqa qugg azTnbaz TTPgs gTuued L66T @14LL 'uTxotp uo sgTurTT zo3 aTng zagsnTO zadPd Pup dTnd aqg 30 sguaurazTnbaz AboTougoag aqg spaaoxa zo sgaaru APPazTP TTTur uoguPD s ,uoTdun=go ' T£ •buTpeoT zoToo saonpea osTP gPgg APM uT auop aq uPo sTgg ssaTun 'uuag gTuuad aqg buTznp AgTovdPo uoTgonpozd dTnd guazzno s, TTT'u agg asPazouT TTTM TTTM uoguuD aqa 30 uoTgPzado zo/puP dtgszauMo s,uoTdu:PgD og gsazaguT-uT-zossaoons Au? zou uotdumLID zaggTau gPgg GPTnozd osTP TTPgs QTurzad L66T aW, ' 0£ * pZ gdpaBvaPd Aq psainbaz sgabzPg uoTgQgTwTT guanT33a egg sP TTaM sP 'guauraazby sTgg zapun pauTuuagap aq og pup Aq pazTnbaz suoTgPaTuiTT guanTgga aqa anaTgoP og pup 'a uauraazby sTgg go suuag aqg ggTM aouepz000P uT saznsaaur uoTgonpaz zoToo zaggo Pup sdW9 'AboTougoag Hggg aqg guauraidruT og ggTPg pooh uT sgzo3ga gsaq zTagg asn .TTTur uoguPo aqg 90 uoTg2zado zo/puP dTgszauMo technical resources within the Agency which may be available to support and further such development opportunities in Cocke County. EPA will also support and work closely with TVA on its Quality Communities Initiative, a community based effort being undertaken by TVA, the goal of which is to develop a long-term economic development strategy for Cocke County and surrounding areas . In addition, North Carolina and Tennessee will foster joint planning and public input on decisions affecting the Pigeon River by establishing a Joint Watershed Advisory Committee and Champion will establish a facility Community Advisory Committee. V. ECOLOGICAL ASSESSMENT OF THE PIGEON RIVER SYSTEM AND THE WATERVILLE RESERVOIR 33 . Over the years, a number of studies have been conducted by various entities on the health of the aquatic biological community in the Pigeon River and, in particular, analysis of fish flesh contamination. However, EPA believes* that a more current evaluation of the level of contaminants remaining in the system and the overall health of the river and of the Waterville Reservoir should be undertaken. EPA will lead, in cooperation with North Carolina and Tennessee, an independent evaluation of current information on the Pigeon River. The evaluation will include convening a group of scientists to evaluate existing data, to identify additional data needed, and, if necessary, to conduct an ecological assessment . EPA agrees to take the lead in convening the scientific panel . The information gather-d from such an assessment would be used to determine whether any significant ecological or health risks exist, and, if so, what, i -•- if any, steps could and should be taken to address those risks . VI. ADDITIONAL, COVENANTS AND AGREEMENTS OF THE PARTIES 34 . In consideration of the covenants and agreements made by the other parties to this Settlement Agreement, North Carolina covenants and agrees to modify the amended modified color variance granted to Champion on December 11, 1996, and to revise NPDES Permit No. NCO000272 issued to Champion on December _12, 1996, to reflect the requirements found in' Section III of this Settlement Agreement . North Carolina agrees that these modifications to the variance and permit will be made and the 1997 Permit and Revised variance incorporating those requirements will be finalized and will become effective no later than December 31, 1997 . North Carolina agrees that it will not further modify the 1997 Revised Variance prior to the triennial � ._. review, or further modify the 1997 Permit prior to its expiration in 2001 except as provided in this Agreement, unless North Carolina seeks to impose more stringent requirements in the variance and/or the permit to protect water quality. North Carolina agrees to conduct public hearings on Champion' s next NPDES permit renewal application by June or July of 2001 and to make its decision on reissuance of the NPDES permit, as well as its decision on extension of or modifications to the color variance, by October 31, 2001 . 35 . In consideration of the covenants and agreements made by the other parties to this Settlement Agreement, Champion agrees to the modifications to be made by North Carolina to the variance granted it on December 11, 1996, and to the NPDES permit issued to it on December 12, 1996 . Champion further agrees not to seek administrative or judicial review of 'the 1997 Revised Variance and/or the 1997 Permit as long as they are consistent with this Agreement . Champion agrees to submit its NPDES permit renewal application for the Canton mill no later than March 1, 2001 . 36 . In consideration of the covenants and agreements made by the other parties to this Settlement Agreement, Tennessee, Cocke County, Newport, TEC and ACA agree that they will neither Oppose EPA' s approval of the 1997 Revised Variance, nor request that EPA object to the 1997 Permit . Tennessee, Cocke County, Newport, TEC and ACA further agree that they will not seek administrative or judicial review of the 1997 Revised Variance and/or the 1997 Permit so long as they are consistent with this Agreement . The same parties further agree that they will not seek to have any change in water quality standards that Tennessee might make during the life of the 1997 Permit effective against Champion prior to the next permit term. 37 . EPA has reviewed and considered the proposed changes to the December 12, 1996 permit and the December 11, 1996 variance called for by this Agreement in accordance with its obligations under the Clean Water Act . EPA hereby represents that as long as the 1997 Permit and Revised Variance are consistent with this Agreement, it will approve the 1997 Revised Variance and will not object to the 1997 Permit . 38 . Tennessee, CO kc: \Liiuuty, Newport , TEC, `^ r.�ts, North Carolina and Champion agree to enter into an agreed order to resolve the North Carolina contested case proceeding, State o Tenneaapa at a1 v. North Ca of ;na n o Huh and jijatur^l Rasrnir t al No. 97 EHR 0041. That agreed order, which will be filed with the Administrative Hearing Officer as soon as the 1997 Permit and Revised Variance have both been issued, will incorporate by reference this Settlement Agreement and will constitute a dismissal with prejudice of the contested case Petition. The agreed order also will reflect that North Carolina Senior Administrative Law Judge Fred G. Morrison is suitable to all parties as a mediator of any disputes that may arise regarding North Carolina's or Champion's compliance with this Settlement Agreement . Disputes will be presented to Judge Morrison if the parties are unable to reach resolution under the informal dispute resolution procedures specified in Section VII + of this Settlement Agreement. VII. DISPUTE RESOLUTION 39 . North Carolina, Tennessee, Cocke County, Newport, TEC, ACA and Champion agree that should a dispute arise regarding compliance with this Settlement Agreement by any of those Parties, the parties shall first attempt to resolve the dispute informally. It is the intent of the parties that EPA, which is not a party to the North Carolina contested case proceeding, may participate so as to facilitate informal dispute resolution if requested by any other party to do so, and if EPA chooses to do SO . 40 . As a condition precedent to a party bringing any civil suit for breach of this Settlement Agreement, that party must first attempt to resolve the purported dispute as expeditiously as possible within the following framework. All time frames for informally resolving disputes may be lengthened by mutual consent . Each of the parties will designate a representative for informal dispute resolution. A party representative claiming that a dispute has arisen will summarize the dispute in writing, and circulate the- written summary to all other party representatives within five (5) working days . If the party representatives fail to resolve the dispute within twenty (20) working days, the parties agree that any party, except EPA, shall next seek resolution of the dispute by calling for a formal mediation, to be conducted by Senior Administrative Law Judge Fred G. Morrison. Notwithstanding any other provision in Paragraphs 39 & 40 of this Agreement, if a dispute arises regarding this Agreement, the parties agree that any party may make any administrative or judicial filing necessary to avoid the running of any limitations period for bringing such administrative or judicial action. 41 . All the parties agree that should a dispute arise regarding any actions EPA is to undertake as part of this Settlement Agreement, the parties shall attempt to resolve the dispute informally. All time frames for informally resolving disputes may be lengthened by mutual consent . Each of the parties shall designate a representative for informal dispute resolution . These representatives may be the same representatives designated under paragraph 40, above. A paccy representative claiming that a dispute has arisen shall summarize ( the dispute in writing, and circulate the written summary to all other party. representatives within five (5) working days . The party representatives will endeavor to resolve the dispute P within twenty (20) working days . For any such dispute, EPA' s party representative will initially be designated by the Region 4 Administrator. If the parties are unable to resolve the dispute With the Region 4 representative, any party may request that EPA Headquarters designate a representative for that particular dispute, and the parties, working with the EPA representative, will have an additional ten (10) working days to resolve the dispute . VIII. RESERVATION OF RIGHTS 42 • The covenants and agreements set forth in this Settlement Agreement do not pertain to any matters other than those expressly specified in the Settlement Agreement . All { parties reserve, and this Settlement Agreement is without Prejudice to, all rights any party to this Agreement may have against any other party to this Agreement with respect to all other matters . IX. EFFECTIVE DATE 43 . Each party shall execute the signature page of this Settlement Agreement and return the executed signature page to EPA. The Settlement Agreement shall become effective upon EPA's receipt of executed signature pages from all of the parties . Upon receipt of all executed signature pages, EPA shall immediately issue a notice ' trcr to all parties st?ting the date on which the Settlement Agreement became effective. The parties all acknowledge that because this Settlement Agreement is intended to be the basis for resolution of the North Carolina contested case proceeding, State o Ten a Carolina nPn of Fnv; o7Lm n u ,l h d N Pr alp, No. EHR 0041, Tennessee was required to have the Settlement Agreement approved through its statutory compromise and settlement procedure before it executed the Agreement. Under Tenn. Code Ann. § 20-3-103, the settlement of any litigation to which Tennessee is a party must be approved by the Attorney General and Reporter, the Comptroller of the Treasury, and the Governor. North Carolina was required to have the Settlement Agreement approved by the Department of Environment and Natural Resources as the agency responsible for issuing the permit, and by the NPDES Committee, as the agency responsible for issuing the variance, X• AUTHORIZED SIGNATURES 44 . Each of the undersigned representatives of the parties certifies that he or she is fully authorized by the party he or she represents to enter into the terms and conditions of this Settlement Agreement and to legally bind such party to this Agreement , IT IS SO AGREED: UNITED STATES ENVIRONMENTAL%PROTECTION AGENCY ./ BY "- Date : ��/ �A /q -7 John ,H.. Hankinson, Jr: Regional Administrator STATE OFF NORTH CAROLINA p 4 BY: "/ ^^`tic C . Date: IZ� Wayne McDevitt 3e51 Secretary, DENR By. .. B C"d Date: 17-13d -7 Daniel V. Besse Chairman, NPDES Commit ee [Co orming to original si. dated 12/22/971 S T OF T By. lei ��- ustin P. Wilson Date: eputy Governor for Policy COCK C UNPY, TE S By: Date: f, l� 7 arold E. ates County Commissioner CITY OF ftWPORT, NNESSEE ames Rob nson Date: Mayor TENNESSEE ENV, ONMENTAL COUNCIL John Noel \ Date : /=•� Pig n iye-r-Coordinator AME CANOE SO IATION By s David E. Date: n n Director fi6onservation and Publis_,policy CHAMPION I ATE AL ,L PORAT N By: Richa Date: i�rio, Senior Vi Preside t, Envir°nm nt, Health & Safety �� [Conforming to original signature dated 12/19/971 SENT BY:ROBERT & STEVENS. F.A. ; 3-12-08 ; 3:33PM ; KOISLICTS & MhVIINS-> 'IKAINING;g it 5 Roberts & Stevens, P.A. ATTORRTYSAT LAW BB&T Building One Pack Square(28801) Post Offire Bnr 7647 Asheville,North Carolina 288w Telephone(704)252-6600 .7-clecopier(704)258-6999 FAX TRANSMISSION COVER SHEET Date: N4ttrch 12, 1998 To; Ben 1311m; Derric Brown; Bob Williams; Tom Siegrist; Dick Diforio; Ed Clem;Jeff McNcaley;and Al Joyce ,/ 40 Fax: "V358-2941; 646•6892;203/358�7407;614/227-4522; 646-2929 Rc: Dismissal in Contusred Caseand New DENRAssistant Secretary Scnden William Clarke Comments: Attached is a sipped espy of the Order of Dismissal which wsa nigted on February 20, 1999. YOU SHOULD RECEIVE,_pAGE(S), INCLUDING'1'H1S COVER SHEET. IF YOU DO NOT KECEIV'h ALL PACES,PLEASE CALL TANYA BALLENGER Notice.: The inforumban contained in this fmin ile massage Is atlorney privileged and nuiritmtinl inforrnaflon huendcd only for the use of the individual or entity named nbove. If the reads of this rnesiage is trot the intmdcd rcciplent,you are huchy nnt;nrd that any dose nination,distribution or copy of this communication is stricdy prohibited. If you have r&v3vcd this conunwtication in error, ;lease Immedtnrely notify us by telephone and return the original mcssago to us at the shove address via the U.S.Postal Service. ttX.S:a6900.1 C SENT BY:ROBERT & STEVENS. P..a. ; 3-12-08 3;33PNI ROBERTS & STEVENS- TRAINING;# 2/ 5 r"IlEO r IN TIE OFFICE OF ADMINIS"IMTIVE HEARINGS 1 WAKRk0%Tl2 NQIR:!IIMAROLR4A 99 EHR 0041 STATE OF TRNN'ESSEE, ) TENNESSEE DEPARTML.NT OF ) ENVIRONMENT AND CONSERM-10N, THINNESSHE WILDLIFE RESOURCES ) COMMISSION, and TENNESSEE ) WILDLIFE RESOURCES AGENCY, ) Petitioners, ) ) and ) ORbER CITY OF NEWPORT, TENNESSEE. } COCKE COUNTY, TENNFS4RF; } AMEII.ICAN CANOE ASSOCIATION, and ) TENNESSEE ENVIRONMENTAL } COUNCIL, ) Intervenor-Petitiouars, ) V. } ) NORTH CAROLINA DEPAIZTIvMM ) OF ENVIRONMENT AND ) NATURAL RESOURCES,DIVISION OF ) WAIF( QUALITY,NORTH ) CAROLINA ENVIRONMENTAL. ) MANAGEMBNT COMNIS5ION, ) NPAES COMMITTEE, ) } Respondents, ) and ' CHAMPION UI JTRNATTONAL ) CORPORATION, ) i�rten'enor-Respondent. ) SPENT BT:ROBERT & STEVENS. P.A. ; 3-12-08 ; 3:34PAI ROBERTS & STEVENS- TRAINING;# 3/ 5 TITIS MATTER COh11NG ONTO BE HEARD before the undersigned Administrative Law ( Judge and it appearing to the Court as follows: 1. The parties have amicably resolved all matters at issue in this contested cizc and have entered into a Settlement Agreement which has been filed in this matter, The Settlement Agreement is hereby incorporated in this Ozder by reference, 2. The parties have agreed that the undersigned Administrative Law Judge is a suitable ,person to serve as mediator in any disputes which clay arise folder the Settlemenc AS 80me11t. J. The parties, by their signatures below, have agreed that this contested case should now be dismissed. IT IS THEREFORE ORDERED; 1. This contested case is brreby dismissed with prejudice. 2. Thu uadmignad shall serve as mediator in any disputes which may arise under the Settlement Agreement, This the. day of 1998 FRED 0.MORRISON,Jdt. Administrative Law Judge 2 SENT 1iYMBEff & SICVhMS, r.A. i U-12-Ud i ;J;04rrd i rVf5r CIS & wtyt J HERIMINUiF 4/ A CONSBNT: MICHAEL F. EASLE'Y JOHN KNOX WALKUP Attorney Guncra� � Attome and Reporter autakleY My cr SeniorAeputy General Aeput AttomCy General N.C. Department of Justice State Tennessee P.O.Box 629 Office of the Attorney General Raleigh NC 27602-0629 433 Fifth Avenue North (919)716-6600 Nashville TN 37243-0485 (615)741-3491 J. CONVNER&ASSOCIArro Attorneys for State of Tennessee James L. ConECIIIMA� irI2 0 311 East Main street Durham NC 27701 rHAMPION INTERNATIONAL CORPORATION By' Benjaoxin S. Bilus Senior Ai%wciatc Counstl Charttpiort International Corporation One Champion Plaza ord C i (1fi971 ROB S AND S'TEVENS PURTP-.It.,WRIGHT,MODS &AILTHUR Atlort a for Champion Attorneys for Champions tnternationfil C�[�K� Inte 'Deal Co�pornti By: williwn Clafke, > sq By;, ey F_U. Box 7647 41 o trw.t Asheville NO 28802 ast ain Street (704) 252-6600 Columbus 01143215 3 SENT BY;ROBERT & STEVENS, P.A, ; 3-12-38 ; 3:35PN ; ROBERTS & S'I'hVfN5� I1tA rvIY[i s 5/ ti DUNIN& TUCKER ASSOCIATES Atto p fu:Cocke County, Tennessee 4 / By: Clydr iWDAt' n 317 East Main Street Newport TN 37821 CAMPBEL.L& HOOPER Aftrnrys for City ofNowport,Tennessee By: Roy 4 Campbell,Jr_ 335 East Main Street Newport TN 37821 AJNTERICAN CANOE ASSOCIATION, INC, By: David Bookbinder General Counsel 7432 Alban Station Blvd. Suitt B-226 13y. k,aakJo> Rzq Attorney for Ameilo= Canoe Association, JnC, P.O.Box 3793 /Chapel Hill NC 27515 TgNNI;SSEE 4NVIRONMENTAL COUNCIL By: Crazy A.Davie,F..sq Attomey for Tennessee I;nviAwuncntal Council P.O. Box 2346 Knoxvtlle'I'N 27901.2346 Cam.•�7�.. By: John D.Runkle, ER. Attonley for Tennessee Frvironmental Council P.O.13ox 3793 Chapel Bill NC 27515 IbLI1�U1JSr0199111AI 4 l` 1 i C LY TimUNIVERSITYOTENNESSEE Institute of Agriculture Department of Forestry,Wildlife and Fisheries 274 Ellington Plant Sciences Building Knoxville„TN 37996-4563 Phone.(865)974-7126 Fax:(865)974-4714 E-mailt httpY/twf.ag.utkedu, 2005 Study Plan- Canton Mill Thermal Assessment NPDES Permit No.NC 0000272 Principal Investigator:J.Larry Wilson,PhD,University of Tennessee,Knoxville Blue Ridge Paper Products,Inc(BRPP) is required to submit a thermal variance report under Section 316a of the Clean Water Act as part of the May 2006 application to renew the NPDES permit for their Canton Mill on the Pigeon River in the French Broad River Basin of North Carolina. Blue Ridge Paper has selected a team led by the Department of Forestry,Wildlife and Fisheries at University of Tennessee,Knoxville(UTIq to complete fieldwork and prepare the 316a Thermal Variance Report. The following Study Plan (with a brief summary of each task) is provided to fulfill various monitoring requirements in the NPDES permit for the 316(a) demonstration. Under the permit,this study plan must be submitted to the Division of Water Quality (DWQ) of the North Carolina Department of Environment and Natural Resources (NC DENR)by March 1,2005. The 2005 study will include sampling locations examined during previous thermal variance studies in 1995 and 2000. EA Engineering,Science and Technology conducted the 1995 and 2000 studies under contract to Blue Ridge Paper. For 2005, the UTK team will include other work in the Pigeon River involving non-game species reintroduction and related watershed assessment studies.This approach is intended to provide a multi-seasonal assessment of biological conditions in the Pigeon River to supplement intensive sampling during the summer period of potential thermal stress.The additional data are being collected as part of the Pigeon River Restoration Project,which began in 2001 in the Tennessee portion of the river and was expanded into North Carolina portions of the river in 2004. The Pigeon River has been impacted by human activities since the late 19th century. Since the Canton Mill modernization project in the early 1990s, there has been substantial improvement in water quality in the river downstream from the mill.The 2005 study will assess the appropriate biological and physical parameters necessary to prepare the thermal assessment report.The effects,if any,of the September 2004 historic floods on aquatic habitat and species restoration efforts will also be addressed. 2005 Study Plan- Canton Mill Thermal Assessment Page 2 ( -- Task 1- Conduct Biological Surveys to Support a Continuation of the Mill's Thermal Variance During July and August 2005, UTK will survey fish and macro-invertebrates at the following 13 stations on the Pigeon River in North Carolina(11 stations) and Tennessee (2 stations).River mile refers to distance upstream of the confluence of the Pigeon River with the French Broad River in Tennessee. River Mile Location 64.5 Upstream of mill 63 Fiberville 61 D.O. augmentation station 59 Upstream of Clyde 55.5 Downstream of Clyde 54.5 Downstream of Waynesville WWTP 52.3 Old Rt 209 48.2 Ferguson Bridge 42.6 New Hepco Bridge Trib Richland Creek Trib Jonathan Creek 24.7 Waterville(IN) 19.3 Groundhog Creek-Bluffton (IN) These data will be augmented (where applicable)with spring and fall fish and invertebrate data compiled from Pigeon River samples that have been,and will continue to be,collected as part of an on-going Pigeon River Restoration Project since 2001. Collection procedures to be used at each location will follow methodologies established and presently used by TVA,TWRA,TDEC,and EPA;specific protocols include TVA 2004(fish / sampling),TVA 2002 (benthic sampling),and Barbour et al. 1999 (benthic sampling). Collection techniques will also be consistent with NCDENR sampling guidelines (NCDENR 2001,2003) and are comparable to those used during previous thermal assessment data collections (EA-EST,Inc. 1995,2000,2001a,2001b). The 2005 study will be restricted to fish,macro-invertebrates,and habitat evaluation and will include measurement of routinely-collected field physical/chemical parameters (i.e., temperature,DO, conductivity, and water transparency [Secch depth (visual) and/or turbidity levels (meter)]. Field data will be summarized and used to assess the biological communities at selected sites and may include various comparative descriptors such as species richness and composition,indicator species, trophic function,abundance and condition,and reproductive function.These categories, and specifically the individual parameters (metrics), are often used to determine index of biotic integrity(IBI) scores;however, care must be taken to ensure the protocols used are designed for the specific stream/river sampled. Task 2- Representative Important Species Based on collections from Task 1,representative important species (RIS)will be identified to represent a range of thermal tolerances, trophic levels, and recreational importance. It is important to note that as a human-activity impacted river,not all species present in reference watersheds or historically found in the Pigeon River may be collected during the 2005 thermal variance study.The RIS determination will be based on life history characteristics of native fish presently inhabiting the Pigeon River and from historically documented records.Native species of recreational importance include smallmouth bass,largemouth bass, rock bass, and channel catfish.Targeted trophic level groupings (and example species) include herbivores (stoneroller,),insectivores (river chub,mottled sculpin,bluegill,northern hogsucker,black redhorse), and piscivores (smallmouth and largemouth bass,rock bass,channel catfish)(Barbour et al. 1999).Based on the EPA protocols,most of the above species are listed as `tolerant'to `intermediate tolerance' (depending on t region of the country) based on thermal variations while a few(northern hogsucker,black redhorse,mottled sculpin,river chub) are generally considered thermally sensitive,i.e., `intolerant'. 2005 Study Plan- Canton Mill Thermal Assessment Page 3 Task 3 -Update the Previously Developed Temperature Model and Low Flow Statistics A temperature model has previously been developed for the discharge of the Blue Ridge Paper Products (BRPP) Canton NO to the Pigeon River(EA Engr 2001a). Model calibration was based upon data collected by mill personnel for the 6-year period 1994 to 1999.Additional verification of the diel temperature range was provided by the deployment of continuously recording thermographs at Pigeon River locations during July 2000.As part of the year 2005 316(a)Temperature Variance Study, the temperature model will be further verified by making comparisons between model predictions and more recent temperature data collected by mill personnel and deployed thermographs. Pigeon River temperature data collected by mill personnel since 1999 include daily values at Canton, Fiberville,and Clyde,and weekly values at Hepco.Additional temperature data will be obtained by six thermographs which will be deployed for a 4-6-week period during July and August 2005.The thermographs will be deployed during the fast biological survey and retrieved during the second survey.They will be deployed in the river at six specific locations: Canton (upstream of mill discharge),mill discharge, Fiberville, Clyde,Richland Creek,and Crabtree Creek. The model calculates at an hourly time step using hourly meteorological data for surface heat exchange. Hourly air temperature,wind speed,and solar radiation data are available from the mill.The surface heat exchange calculation also requires relative humidity,which will be obtained from the NOAA station at Asheville.The model is executed using the reported discharge temperature and flow data at the mill and using the USGS river flow data at Canton and Hepco. The Pigeon River temperature model will be executed for the duration of the summer 2005 thermograph deployment period, and for an extended period corresponding to the collection of river data by mill personnel.A standard error of estimate between predicted and observed temperatures will be calculated and compared to previous values determined during the original model calibration/verification.The model calibration will be adjusted if deemed appropriate. The re-verified Pigeon River temperature model will be used in support of the thermal variance study.Year- long model run outputs can be summarized as daily/weekly mean temperatures or other intervals of interest as a function of season.Worst-case mill discharge or receiving water conditions can also be presented. Low flow frequency statistics including the 30Q2 and 7Q10 will be updated as part of the study.The USGS Canton and Hepco station data will be obtained for the historical period of record.The frequency statistics will be generated using a log Pearson program that has previously been verified against flow statistics generated by the USGS.The program allows multiple daily averaging periods and yearly return intervals to be used. Comparisons can also be made between the historical period of record and more recent periods to demonstrate changes in the runoff characteristics of the watershed. Task 4-Prepare a 316(a) Demonstration Report Based on the data collected during Task 1, the results of the temperature model (Task 3),an updated review of the thermal tolerance literature,and any other applicable data (e.g.,NC DENR data,Progress Energy data), UTK will prepare an updated 316(a) Demonstration Report(i.e., "Balanced Indigenous"Report).This report will address the central question posed by 5316(a) of the Clean Water Act,i.e.,does the thermal discharge in question allow for the maintenance or establishment of a balanced indigenous population(BIP) (community) of aquatic organisms? 4 2005 Study Plan- Canton Mill Thermal Assessment Page 4 r A BIP (BIC) is a biotic community typically characterized by diversity, the capacity to sustain itself through cyclic seasonal changes,presence of necessary food chain species, and non-denomination of pollution- tolerant species (Coutant 2000). The term"balanced"derives from long-standing knowledge that most natural aquatic communities are composed of many species of organisms without an overwhelming number of any one of them. "Indigenous"generally refers to the presence of species that would be normally found at the site,although it is not restricted to only truly native species,and managed,introduced species are often included. The UTK team will use the previously prepared successful demonstration (EA-EST 2001b) as a template for the 316a Thermal Variance Report due in May 2006. References Barbour,M.T.,J. Gerritsen,B.D. Snyder,and J.B. Stribling. 1999. Rapid bio-assessment protocols for use in streams and wadeable rivers:Periphyton,benthic macro-invertebrates, and fish. 2nd Edition. EPA 841-B-99-002.U.S. Environmental Protection Agency,Office of Water,Washington,D.C. Courant, C.C. 2000. Summary of 316(a).Precedents.Mimeo compiled from numerous sources. 4 pp. EA Engineering Science and Technology,Inc. 1995.A Study of the Aquatic Resources and Water Quality of the Pigeon River.Prepared for Blue Ridge Paper Products,Inc. EA Engineering Science and Technology,Inc. Deerfield,IL. EA Engineering Science and Technology,Inc. 2000. A Study of the Aquatic Resources of the Pigeon River during 2000. Prepared for Blue Ridge Paper Products,Inc. EA Engineering Science and Technology,Inc.Deerfield,IL. EA Engineering Science and Technology,Inc. 2001a. Pigeon River Temperature Model. Prepared for Blue Ridge Paper Products,Inc. EA Engineering Science and Technology,Inc. Deerfield,IL. EA Engineering Science and Technology,Inc. 2001b. Canton Mill Balanced and Indigenous Species Study for the Pigeon River. Prepared for Blue Ridge Paper Products,Inc. EA Engineering Science and Technology,Inc.Deerfield,IL. North Carolina Department of Environment and Natural Resources. 2001. Standard Operating Procedures - Stream Fish Community Assessment&Fish Tissue. Division of Water Quality,Environmental Services Branch,Raleigh,NC. North Carolina Department of Environment and Natural Resources. 2003. Standard Operating Procedures for Benthic Macro-invertebrates.Division of Water Quality,Environmental Services Branch,Raleigh, NC. Tennessee Valley Authority.2004. IBI designations for fish species of the Tennessee Valley.Mimeo. 6 pp. Tennessee Valley Authority. 2002.Benthic macro-invertebrate assessment:Level 1. Mimeo. 5 pp. Tennessee Valley Authority. 2004. Protocol for conducting an index of biotic integrity biological assessment. 15 pp. 2005 — 2006 Scope of Work University of Tennessee Non-game Species Reintroduction Project Support Balanced and Indigenous Species Study/316a Thermal Variance Renewal Reference UTK Proposals dated 12/13/04 Dr. Larry Wilson,Principal Investigator Paul Dickens and Glenn Rogers, Blue Ridge Paper Products oversight Greg Seegert,EA Engr-technical advisor to Blue Ridge for project Project Milestones Work Plan 3/1/05 - complete Biological survey site tour with EA Engr for continuity with previous studies 4/19-20/05 -complete Train field crews and conduct biological surveys using study plan methods as part of non-game species reintroduction work—May&June 2005 Blue Ridge/UTK fieldwork progress meeting June 2005 I • review schedule and final preparations for thermal assessment intensive sampling in July and August Intensive sampling-— 13 weeks starting 7/13/05 • benthic and fish crews to work each site at same time Blue Ridge/UTK field work progress meeting late July/early August 2005 • review field work preliminary results and make final preparations for annual dioxin fish tissue sampling • non-game species work plan for 2006 support renewal(budget planning) Annual dioxin fish tissue sam line- first half of August 2005 before UTK fall registration Blue Ridge/UTK data review meeting October 2005 • review field data summaries and confirm that biological survey and thermal assessment data (including dioxin fish tissue results) are ready for preparation of the biological assessment report, thermal model report and dioxin fish tissue report • determine schedule for project meetings for preparation,review and production of project reports Milestones - Balanced and Indigenous Species Study/316a Thermal Variance Renewal Page 2 Reports November 2005 • Draft biological assessment study • Draft thermal model • Draft dioxin fish tissue report December 2005 • Final biological assessment study • Final thermal model • Final dioxin fish tissue report January 2006 • Draft 316a Thermal Variance Assessment/Demonstration • Annual dioxin fish tissue sampling report is due to NC DENR February 2006 • Final 316A Thermal Variance Assessment/Demonstration April 2006 • Application for NPDES permit renewal including Thermal Variance Assessment is due to NC DENR Team List: Pigeon River Permitting Process Studies UTK Proposal: 12/O1/04 Project Leader: Dr.Larry Wilson,Professor,Fisheries/Aquatic Biology Forestry,Wildlife and Fisheries -University of Tennessee,Knoxville (UTIq Data collection/analysis crew: Joyce Coombs-Research Specialist II Melinda Wilson-Ph.D. candidate,Macro-invertebrate monitoring and assessment Brac Salyers-M.S. candidate,Tangerine darter propagation Michael Gaugler-Ph.D. candidate,Habitat evaluation/assessment Other UTK Personnel: Dr.John Tyner-Assistant.Professor,Water Resources (thermal modeling, oxygen sag) Biosystems Engineering and Environmental Science Dr. Ted Henry-Adjunct Assistant Professor,Environmental toxicology(tissue analysis/tox screen) Center for Environmental Biotechnology/Forestry,Wildlife and Fisheries Other Agency Personnel: Dr.Ray Albright-Adjunct Professor,Water resource inventory/monitoring(oxygen model) National Park Service(Adjunct with Forestry,Wildlife and Fisheries) Project Collaborators: Dr. Chuck Coutant-Distinguished Research Ecologist(316a thermal studies) Environmental Sciences Division,ORNL Dr. David Etnier-Emeritus Professor,fish/invertebrate taxonomy and distribution (aquatic resources inventory) Ecology and Evolutionary Biology(retired) Included are brief CVs from team personnel along with several selected examples of work.The academic folks have provided publication lists;if you need copies of selected pubs,I'm sure we can get them for you. Note that some item(s) in Dr. Coutant's packet are labeled `Privileged and Confidential' and should be handled accordingly. Pigeon River Restoration Project Page 1 of 3 University Links AZ /WebMail / Dew Enter search select type of search �;= Index Directory LI- Pigeon River Restoration Project (PRRP) Front Page Pigeon River Maps non-game species reintroductions Cocke County, TN Haywood County, NC PRRP Projects Fish Reintroduction Tangerine Darter Propa ag tion Benthic Invertebrate Survey Video Resources PRRP Partners UTK Fisheries TDEC-WPC Blue Ridge Paper CFI. Inc. TVA TWRA US Fish &Wildlife Service USGS NCWRC NCDWO Haywood Waterways PRRP Supporters Pigeon River Fund Haywood Comm. College W. Carolina University UNC-Asheville Contact Information Pigeon River (North Carolina &Tennessee) http://web.utk.edu/—mjwilson/index.php 5/18/2005 Pigeon River Restoration Project Page 2 of 3 Pigeon River Topography The headwaters of the Pigeon River are located at Sam Knob on Black Mountain, at an elevation of approximately 6130 feet. Sam Knob is 30 miles southwest of Asheville, North Carolina. The river flows from Sam Knob north to Canton, North Carolina. Blue Ridge Paper Products, Inc, is located on the river in Canton. The Pigeon River flows through the papermill at Canton and then along Interstate 40 for approximately 25 river miles to Waterville and the Progress Energy Hydroelectric Dam. From Canton to Waterville, the elevation changes from 2580 to 2258 feet. A small bypass channel curves around the dam and runs 12.5 river miles before merging with the water being released from the dam aquaducts at the Tennessee State Line. The Pigeon River then flows 4.5 river miles to Hartford, Tennessee. The elevation at Hartford is about 1260 feet. This 160 foot drop in river elevation produces class III and IV rapids. Progress Energy and the 12 Hartford white-water rafting companies work together to plan recreational water releases from the Waterville Dam for rafting. After passing through Hartford, the Pigeon flows through Denton (1800 ft) and Newport (1040 ft), Tennessee. The Pigeon empties into the French Broad River at an elevation of about 1000 feet.Due to these elevational changes, the Pigeon River is divided into two regions or ecoregions; a high gradient stream from Sam Knob to around Denton, Tennessee and a low gradient stream from Newport, Tennessee to the French Broad River. A Brief History of the Pigeon River A papermill was established in Canton, North Carolina on the Pigeon River in the early 1900's. The mill has been operated in that locality for about 100 years. After 1983, Champion Paper began to upgrade the papermill to reduce emissions going into the river. Blue Ridge Paper Products, Inc. bought out Champion and completed the upgrades in equipment and the reductions in emissions biased on EPA criteria. Blue Ridge Paper is an employee-owned and operated facility and has spent millions of dollars to upgrade the papermill. This corporation continues researching methods to increase efficiency and reduce any adverse impacts on the Pigeon River. UTK Fisheries began working with Blue Ridge Paper in 2001. A plan was launched to reintroduce native non-game fish species into the Pigeon near Newport, Tennessee. The Tennessee Department of Environment and Conservation (TDEC),Water Pollution Control Division provided advice and assistance in collecting and relocating fish into the Pigeon River. In early 2004, the fish reintroduction project was expanded into North Carolina with the aid of the North Carolina Wildlife Resources Commission. Native Fish Reintroductions After 1993, the Pigeon River water quality and water clarity improved. Larger, native fish species were then able to recolonize the Pigeon River from its tributaries. The river was surveyed yearly for fish species by TVA, TWRA and TDEC-WPC. These organizations realized that several of the smaller http://web.utk.edu/—mjwilson/index.php 5/18/2005 Pigeon River Restoration Project Page 3 of 3 native fish species had not returned to the Pigeon. In 2001, in conjunction with UTK Fisheries, US Fish & Wildlife Service, USGS and Blue Ridge Paper, these Tennessee state agencies put together a list of native, non-game fish species missing from the Pigeon River. The first species of fish to be collected and relocated were the Bluebreast Darter, Blueside Darter and Guilt Darter. And in 2002, additional species were added; Stargazing Minnow and Smoky Madtom (small catfish). In 2003, the Stripetail Darter and the non-parasitic American Brook Lamprey and Mountain Brook Lamprey were also collected for relocation into the Pigeon River. In 2004, with financial support from Blue Ridge Paper Products, the Pigeon River Restoration Project was expanded to include the Upper Pigeon River in North Carolina. The project team met in March 2004 and invited the North Carolina Wildlife Resources Commission to participate. An additional list of missing fish from North Carolina's half of the Pigeon River was assembled. Efforts to relocate Saffron Shiners, Mirror Shiners, Silver Shiners and Telescope Shiners began soon after this meeting. UTK Fisheries and TDEC-WPC headed up the collection efforts. NCWRC assisted in the collections and relocations of these shiners to the Pigeon River a few miles downstream from the papermill. Native Freshwater Mussel & Snail Reintroduction Native freshwater snails (1996) and mussels (2000) were reintroduced into the Pigeon River near Newport, Tennessee. From 2000-2004, about 20,000 individuals from 3 snail genera were released;Io, Pleurocera, Leptoxis. The latter two genera are reproducing and spreading downstream in the Pigeon. Also during the past few years, around 200 individuals from 9 different mussel species have been reintroduced. The common names for these 9 species are the Elktoe,Threeridge, Purple Pimpleback, Spike, Wavyrayed Lampmussel,Plain Pocketbook, Kidneyshell, Pimpleback and Creeper. The life cycle of the mussel requires a host fish species to carry the free-living mussel larvae. Studies need to be conducted to determine if mussel reproduction is occuring and whether or not the Gilt Darter or any darter present in the Pigeon is a successful host species for any or all of the mussel species. ©2004 University of Tennessee, Dept. of Forestry, Wildlife&Fisheries http://web.utk.edu/—mjwilson/index.php 5/18/2005 UTK Proposal: Pigeon River Recovery Project (extension) 05/16/05 - 05/15/08 Proposed Plan of Work: Re-introductions of the blueside darter, stripetail darter, stargazing minnow, mountain madtom and the lampreys (ABL,MBL) will continue in the Tennessee reach (2005-2008).The bluebreast darter will be re-evaluated in 2005 because no collections have occurred in the past two years from our only source, the Nolichucky River, due to continuous high flows that made collections impossible. In 2005,we will also look into possible new candidates for re-introduction. We will continue the re- introduction of the mitror, saffron, silver and telescope shiners in the North Carolina reach (2005- 2008). Re-introduction of a species will continue until it is determined that a population has been established. New possible candidates for North Carolina include the gilt darter, a successful re- introduction in the TN reach, and the fantail darter. A habitat assessment (2005/2006) will need to be conducted to determine the availability and location of fantail habitat (slab rock). Habitat assessment will be conducted above Canton,NC, to assist in locating similar suitable habitat for targeted species to be relocated below the mill.A re-evaluation of Pigeon River habitat in both NC and TN reaches will be necessary as a result of changes in stream morphology due to flooding from two hurricanes. This will be started as soon as feasible in 2005. The potential for the use of geo-referenced underwater video mapping is being assessed, and if feasible,will provide a substantial upgrade in habitat assessment (2006-2008).This could also be used to provide a benchmark for riverine habitat in the Pigeon and possibly its major tributaries. The attempt to propagate the tangerine darter at Conservation Fisheries Inc. will continue (2005- 2008) with a possible spawn in the spring of 2005 but a more likely spawn in 2006, due to the age of the brood fish (juveniles when collected in fall of 2004). Offspring would be held for grow-out for at least one year or longer.Two other species are being considered for possible propagation and future release into the Pigeon as well: the ashy darter, and the blotchside logperch. Macro-invertebrate sampling will continue through 2008. Historical analysis will be completed in the spring/fall of 2006. Mollusk re-introductions will continue (2005-2008).An effort will be made to re-evaluate mussel survival and consider new re-introduction sites in Tennessee and North Carolina. Monitoring for re-introduced species will continue (2005-2008) at every low water opportunity to locate species and to make habitat observations. Seine collecting will begin in late winter and snorkel surveys will begin when water temperatures rise to >50 F.Annual IBI's will be conducted as scheduled. In the Spring of 2005, a snorkel survey for the blueside darter will be conducted from the re-introduction site (PRM5.5) to the mouth of the Pigeon to locate fish and to evaluate habitat. Development of a Pigeon River Recovery Project website will continue in 2005. Links to project contributors will be established as well as to related organizations such as Southern Appalachian Man and the Biosphere and the Southeast Watershed Forum, Inc. A timeline for the proposed activities is attached. Project Timeline 20051 20061 20071 2008 i } Monitoring l Fish Re-introductions � I Mollusk Re-introductions , I r + Habitat Assessment TN &NC Reaches Habitat Assessment - Above bove Canton,NC i Fantail Habitat Assessment t (Underwater Video Mapping of River Substrate ' angerine Propagation Ashy Darter Propagation 3. Macroinvertebrate Sampling, UTK Proposal: Pigeon River Recovery Project (extension) 05/16/05 - 05/15/08 Budget: Blue Ridge Paper Products: The proposed Pigeon River Recovery Project activities are scheduled for 36 months at a total cost of$252,000. If approved as an extension of the existing project, the monthly amount would be $6500 for the period 05/16/05 through 11/15/06, and $7500 per month for the period 12/16/06 through 05/15/08. The funds would provide salary/benefits for the Project Coordinator, Research Specialist II Q. Coombs), as well as associated project costs, such as collection equipment maintenance and replacement, student wages, supplies, travel, report preparation/presentations, indirect costs, etc. UTI{ and Other Agency/Organization Support: Dr. Larry Wilson (UTIq will continue to serve as Project Leader. The Department of Forestry, Wildlife and Fisheries also provides support for the following personnel: Melinda Wilson - a Ph.D. student who is doing the Pigeon River invertebrate assessment/recovery study, Michael Gaugler - a Ph.D student who will be working with Pigeon River habitat evaluation, and Brac Salyers - a M.S. student who is working with the tangerine darter propagation. The UTK team is working with Dr. Paul Ayers and his students (Biosystems Engineering Technology) to evaluate underwater video habitat mapping techniques and its applicability to Pigeon River studies. The UTK PRRP team will also be helping the Haywood Waterways Association in spring and summer 2005 with Pigeon River environmental educational activities, including the `Kids in the Creek" program. The Tennessee Wildlife Resources Agency and US Fish and Wildlife Service have contributed funds toward the tangerine darter propagation. Conservation Fisheries provides the culture expertise and the use of facilities (along with UTIq for artificial propagation activities. The Tennessee Department of Environment and Conservation has contributed substantially to the collection and relocation of targeted re-introduced fish species while the USGS-Water Resources Division has contributed in a similar manner with the relocation of snail and mussel species. Joyce Coombs "Cooper,Chris"<dccooper@tva.gov>, "jlwilson@utk.edu" •' <jcoombs@utk.edu> <jlwilson@utk.edu>, "Noturus@aol.com" 04/29/2005 09:16 AM <Noturus@aol.com>,"Saylor,Charles F." <cfsaylor@tva.gov>, "Scott, Edwin M."<emscott@tva.gov>, "Shute,Peggy W."<pwshute@tva.gov>, "Xenisma@aol.com"<Xenisma@aol.com>, Bo Baxter <jtbaxter@tva.gov>, Bob Williams <willib@blueridgepaper.com>, Bryn Tracy <bryn.tracy@ncmail.net>, Carl Williams <Carl.E.Williams@state.tn.us>,Dave McKinney <Dave.McKinney@state.tn.us>, David Yow <yowdl@earthlink.net>,Derric Brown <browndb@blueddgepaper.com>, dipnet<dipnet@utk.edu>, Eric Romaniszn<romaniszyne@yahoo.com>, Jeff Simmons <jeff.simmons@earthlink.net>,John Fridell <john_fridell@fws.gov>,Jonathon Burr <Jonathon.Burr@state.tn.us>,Keith Haynes <keith.haynes@ncmail.net>, Larry Everett To <Larry.Everett@state.tn.us>, Lorie Stroup <loriestroup@fs.fed.us>, Mark Campen <mark7@tnike.com>, Mark Fagg<Mark.Fagg@state.tn.us>, Matt Kulp<matt_kulp@nps.gov>, Mike Gaugler <mgaugler@utk.edu>,mjwilson<mjwilson@utk.edu>,Paul Dickens<dickep@blueddgepaper.com>, Pete Wyatt <Pete.Wyatt@state.tn.us>,Powell Wheeler <wheelerap@brinet.com>, Richard Kirk <Richard.Kirk@state.tn.us>, Rick Bivens <Rick.Bivens@state.tn.us>,Ron Moser <ronmoser@charter.net>,Sarah McRae <sarah.mcrae@ncmail.net>,Scott Van Horn <scott.vanhorn@ncwildlife.org>,Sheryl Bryan <sbryan@fs.fed.us>,Stephanie Chance <sachance@tva.gov>,Steve Fraley <fraleysj@earthlink.net>,Steven A Ahlstedt <ahlstedt@usgs.gov>,Tom Martin<tmartin@wcu.edu>, wayne h schacher<whschacher@natreserv.com>,Wayne Starnes<wayne.starnes@ncmail.net> cc bcc Subject New Re-intro Numbers and...... Pigeon River Folks: Not only do we have new collection and release data but we have great news - Conservation Fisheries, Inc. just notified us that the Tangerine Darters have spawned! ! ! Thanks again to all our volunteers and supporters! Joyce Joyce A. Coombs Research Specialist II Dept. of Forestry, Wildlife & Fisheries University of Tennessee, Knoxville (865)974-7229 R RE-INTROS 4.26.05.xis RE-INTR^^' CED SPECIES: NO VIE Tags' collection F +', -4 Mum ow Chub Madlom_Lamprey e$Lmer„f„-,,,:�,. „> +"r, }ti¢ +, VIE. Collect, relCase - Y" je 9_ __ : 1 „cilor --.. -r -- -.. ,m ,P dates - .Bluetircast.'Blueside;eStnpetailz, Staggazing River a;Mt7cs Am Brook M'*'....-'�..' ?blmvr;;`,SiiffrQnq iSilver,�Teleseo ei tags site SifO R red 1114/01 128 Rios+MPLP, TI G green 5/23/01 120 1 Rros;;MPLP TI Y yellow 10/2/01 132 4 G Pos, MPLP. TI O orange 10/9/01 41 121 Y'ros,N TI = P ink 11/6/01 52 122 6 Y,ros N TI .Ta 1 ocatton ' 2/8/021 51 113 4 Q,Aw MPLP TI*' ANT anterior dorsal fin 2/15102 43 107 18 O ANT MPLP TI* I POS 1posterior dorsal fin 3115/02 145 31 OlmT MPLP. TI 4/26/02 116 FB Ti ;IttvenSoacce "'" ' 5/21/02 157 56 O ANT MPLP TI-- CC I Cosby Creek 5/28/02 136 116 O ANT'MPLP TI FB 117rench Broad 6/25/02 1 68 " FB TI I LC ILittle Chucky Creek 8/28/02 28 86 9 P ANT N TI LRCB Little River Coulters Br 10/23/02 126 6 P iurr. MPLP TI LRT Little River,Townsend 3/13/03 61 1151 5 2 1 RANT MPLP, TT* MPLP Mid Prong,LPigeon 4/3/03 42 841 29 R wT, MPLp TI:* N Nolichucky 5/30/03 163 ;FI3 TI UPR Up Pigeon,RM 64.5 6/3/03 20 64 R wr MPLP TI* WC Wilhite Creek 7/21/03 14 5 5 2 R mT LRCB TI 7/28/03 1 48 10 LRT, ITI. 8/15/03 5 66 1 IRANT'WC "TI* _'Release;Site"s;a1'N ` 8/21/03 237 108 LRT TI TI Tannery Island 8/26/03 23 FI3 TI UPD Up Denton,RM 17.5 9/26/03 192 121 LRT. TI 10/14/03 27 141 4 IG ANT,MPLP` TI-*,_ ":Release Sites;NC` _: 10/28/03 12 11 188 28 JG-AW MPLP' TI* FBR Ferguson Br,Riverside 2/20/04 211 O Pos!LC' MMB GC Golf Course,RM 52.5 3/11/04 171 78 UPR FBR 3/30/04 167 2751 CC FBR 4/16/041 19 54 42 10 Fos MPLP TT* 4/30/04 174 1y1PLP; TT 5/12/04 194 FB TI 8/13/04 72 97 LRT _' TT 8120/04 102 FB T1 8/25/04 318 666 CC FBR, 8/26/04 973 155 UPR ' FBR 9/22/04 14 70 5 Pros- 1%4pLp-- TI ' 9/24/04 115 198 _; ;LRT: '.TI 10/22/04 112 1 1 IP,aos +MPLP TI,. 3/22/05 111 8 G ros_MPLF UPD Totals 1126 334 1010 729 499 ' 0 677 .664 534 :1144 233 485 941 *eiuc me Gilt `Bluet ers Blu�si8e3 Surpe ad'Stargazing River Mt 'Am Brook Mt Brook M uor Siiif ou uV i„T,el�scope; MNIB, Minnow Chub 1Mi @Wml Lamprey RE-INTF 'CED SPECIES: No;�'YE`Tags w _ couecrinn �' "`.�,i a� �„ �s*.� 4a.Minnow Chub ,hludtom; Lamprey Shmer""'t - 'Collect: ieleaSe', �., ,., .. ,r • dates axh. .Bliirbi;C2sf 'Bluesxa ?^Strlpetai Stargazing River # Mt,a Am Brook Mt sroox `a 'or„ ,$TffiVns SSdyolr` eloscope};ka s , site-. ., site ? R Ied Pg 1 TTI'- :-1126 334 -1010 . 729° -499 A 677 '4'"664 , , 534. 1144 -2331 485 9,41 r`� � �� a G green 3/30/05 312 505 C,C. FBR Y yellow 3/31/OS 39 R;ros:, BC GC O orange 4111105 20 Wins MR" t' GC P pink 4/26/05 114 2 52 6 WIT', TLUP Zvi E'Ca ix,OcaL WKI ANT anterior dorsal fin POS 1posterior dorsal fin `7Rauer;So"eicq CC Cosby Creek ' BC Boylston Creek,NC FB lFrenchBroad LC Little Chucky Creek LRCB Little River Coulters Br LRT Little River;Townsend _..... - __ ..I MPLP Mid Prong,L Pigeon MR Mills River,NC - N Nolichucky UPR Up Pigeon,RM 64.5 WC Wilhite Creek 17 Sitiesm TI ITannery Island UPD jUp Denton,RM I to . 'lteleaS .Sites`r*'NC FBR Ferguson Br,Riverside GC Golf Course,RM 52.5 Totals 1299 334 . 4010 '731`'.. 551 6 F• AV ; 664 "534 '1144 z.233 797.S;. ,1496 GilC' 156&gst%B1u"'"'esi7 Stnpetaiti Stargazing River Mt*s.'"-�''s*,K Am amok Mt Brook 1VIm""am",Sal'fi"oa"" Save Tel cgp`e^ Minnow Chub 1S1'adedi 'Lamprey canton KIM Sewers C a �oT, Canducfivky, Haw and Hoher Loss t Plan -_ Overview 'Mill Sewers Hill Filter „ Erco Flows - Color - Fiber Chemical Storage 0 6130102 10.46:04 AM 0.42 MGD I FIL 4.61 MLbs Color Eo F ____. MGD19 PM Fill Rile Bark Depoly 4.60 To Fiber y leach 5.68 Mlbs Color D-1 Ctlg Boiler Broke Plant 1.57 MGD #20 PM i' 3.75 Tons Fiber #2 Fiberline D i a I i' �, s G 1.9 Delta T - }� ,dJ= a1 A.rs"i E 20.8 River Temperature T #1 FIL E Brown N, 0.27 Tons Fiber RL Stock #14 PM Area S Washing tr a 1.SA l WBL MGD �#11 R8 k Evaps Power y2P #t2 PM i Power BoilersBoiler MJ #10 RB MGD 2 a r,•� � a x� }J #11 PM Kilns 1.61 Tons Fiber Sysle s Off 2.53 Tons Fiber 1.44 MLbs Color 4.08 MGD J Re Elul _ 2291 Color @ TN 4.00 � 7.04 DA. C) F.vl MGDP HW 5.30 Caust y, Screen Tons Fiber a­0 0 --- Room { 20.30 ons Fiber 1.48 MGD 29879 WTP 8 _27745 #Color z?� 25.82 MGD Mill f ,: ^� �ii luai t°°la°a LciiL (Yesterday) i 3. , �1 4 Turbidity #Color 7256 17.24 MGD River Flow _ Y am- #/DayTSS 26.27 MGD 4• ,., i` .� _ r' �• ... rq 1 4 .. Color Removal Technology Assessment for Chloride Removal Process (CRP) Purge Stream - March 2005 Blue Ridge Paper Products NPDES Permit No. NC0000272 Permit-Specified Technologies Other Technologies Commercial Coagulation/ Solidification for Land Bleaching-Clozone Bleaching-Chlorine CRP on Lime Precoat Technology Land Application Incineration Precipitation Disposal (C102&03) Dioxide(CI02) Filter Other EVALUATION Literature review and Commercial quote for off Bench scale treatability Commercial quotes for Engineering estimate for Bench scale&field trials Series of field trials Short duration field trails Third party evaluations METHODS engineering calculations site incineration study of lime,aluminum off-site solidification and on-site evaporation and quotes for salts, iron salts and land disposal equipment to solidify the proprietary treatment polyamine CRP purge stream technologies including wet air oxidation, activated carbon,filter paper solids separation, catalyzed oxidation and ultra filtration. TECHNICAL& Not an appropriate Not an appropriate Infeasible technology- Infeasible technology Infeasible technology Infeasible technology- Infeasible technology- Unproven technology- Proprietary technologies OPERATIONAL technology due to high technology due to high low to moderate color due to large operating due to high operating consistent bleaching consistent bleaching wide variation in color evaluated were not FEASIBILITY chlorides in CRP purge chlorides and dissolved removal with large expense associated with and capital cost. performance difficult to performance difficult to removal. Needs more effective or not stream. salts in CRP purge sludge generation. off-site hauling and maintain. CI02 alone is maintain. Operating work to confirm commercially viable for stream. Potential for effluent treatment. equally effective problems with off- feasibility. color removal from the toxicity. bleaching agent for CRP gassing and foam. CRP purge stream. pure stream. ESTIMATED ANNUAL NA >$25 million >$370 k >$3.6 million >$2.1 million >$615 k >$145k Undetermined NA OPERATING COST ESTIMATED CAPITAL NA >$150 k for tank truck >$1.7 million >$150 k for tank truck > 11.1 million >$1.8 million >$1.2 million Undetermined NA COST loading facility loading facility POTENTIAL FOR SECONDARY The contribution of CRP color to secondary effluent color is small and less than the normal variation in day to day secondary color measurements. There is no certainty that color removal in the CRP purge stream will result in an equivalent EFFLUENT COLOR secondary effluent color reduction. EVALUATION NOTES NA Potential to remove all High chloride content of Potential to remove all Ruled out as option in Inconsistent color Inconsistent color High chlorides in CRP NA CRP color from mill. CRP purge stream may CRP color from mill. 2001 Color Removal removal performance removal performance purge stream may CRP purge stream require special materials CRP purge stream Technology Assessment during trial. Operating during trial. Process corrode mud filters and handling without and higher equipment handling without Report. problems with off- control strategy for full other equipment. crystallization and cost. No indication that crystallization and gassing and foam. scale system is not Special materials of plugging during truck color removal in CRP plugging during truck Process control strategy defined. Operating cost construction may be loading and purge stream will result loading and for full scale system is assumes on-site bulk required. Need to transportation will be in equivalent secondary transportation will be not defined. Operating CI02 supply. No evaluate effect of CRP difficult. May require effluent color reduction. difficult. May require cost is power and indication that color filtrate recycling back dilution and add to cost. Polyamine can adversely dilution and add to cost. chemical reagents. No removal in CRP purge into process. Precoat Requires at least 3 effect secondary effluent Requires at least 3 indication that color stream resulted in filter does not operate tanker trucks per day. toxicity. tanker trucks per day. removal in CRP purge equivalent secondary continuously. Impacts Requires heated storage Requires heated storage stream resulted in effluent color reduction. on landfill leachate and tank and truck loading tank and truck loading equivalent secondary potential for color return facility. facility. effluent color reduction. to mill not known. CONCLUSION TECHNICALLY, ECONOMICALLY AND NO NO NO NO NO NO NO Undetermined NO OPERATIONALLY FEASIBLE ? 2005 CRP Report Summary Final.xls, Report Summary 11x17, Rev 4- Final Page 1 of 1 Printed 5/18/2006 _ M/ I LN � � IN WOU LE erde' Lj FF �i�.Fo s 4'er �lE ty __ - :}. . $� I I •� /ram_ It/_ 01 p-Bon >A-Ven e ice, �j Ilo 1, d° �� 3I o_V 1_.F ... / �, l>`� /i / � e0 II' � oll . '�� fir/ �__• _ o�- _ q0/I a� �pv' �• �� IN° Can �� &eJ ATTACIE"ENT II NOTE: The legal boundaries of the II I / /,11 j ` _ / '( \• rt n C Iv r. •h, I O \ �o? O I facility are shown on Attachment III. 1 II 1137_-e � � ( I II Imo' �� ,. t �� f � `I..• � IL /i . .I•: esj7 � � i,(N aCr l,. •�" � .. 4:.`,a ,� �_�e r�o0 �� ©wijl S;.S�1! Pa• .0 YT 7 `� � 'r1,3"f .II 1 .,. C - ) �.Q\\l\ �� � �� /�.�� ///��71�,/,, .III � h TT`' •�: .�/ lT o o I _ � � (�)��-. �) ��- II ri• � Sm•• N O • • IvIII;L S`a., a r 4 •� � xftj/ �_�,+�i •-•`rl P •i t ® ,�� I' etlli ri e % '/. 8 3. \ i�50 J u� _� � 3 in gt••� � ;� G1J fl e•/� .III .SIP � .�>� ti-1i � � 4� `�'J � 'p 0 R o I Io Off!/ � � � t�P ania Ave � t c� .�.� .1 ���•\\`�I io f O' I h .•� � IFlltl .r .I ."r7• __ _ ��J / _� �ol e� _ Vk �/J� ( 1 •• J -� -i .\ Via\ ��L//.�7 •',� ,\ 1977 \ �� • .1 \� . � ` .//.�/, o•� ..{ /. ! `l icE_ NORTH O 1 :\ p• 1) T��I� �� j` I oo / O _J l: 2000 1000 0 2000 SCALE IN FEET ,`r •O$ G C r ��, % I I I >��y y - 1 500 200 0 500 SCALE IN METERS • ° 7 `.� o ,.1 '�••P,•• EO �5• j/ 161M5 _ 0.` .o '.,y - .� �.��• SOURCE: f a Base map adapted from USGS 7.5 minute senas quadrangle(1:24,000) PR39�5, �: n ov . h \(n° 'lo ���\ // •��` / �s/o --`/`. moo '-`� (\ �: o` - ( 'G Canton,NC(1990). I \ � - o • , `�• I". r 6eo lJ 6 _ • ' 60�`� �' _•„- f l BLUE RIDGE PAPER PRODUCTS,INC. HAYWOOD COUNTY o � k h.» ° •e -/I.% ; \r o ' F;t CANTON,NC MILL 'wo Poem ial h S ..p �t _ _ _ e I''PI[�wO vJ\i '..��•1v .Ee t nPi' nOn3 .: N t` i I ��Y�/ +'%m-. � , � �'-qi� Ji�'� j .. ..nc i� I I� .� ,'�• 858 n. .�� �� 0 Location Map NPDES Permit No.NC0000272 ) �,;-1 �• a f -�ii I ,���.;AllZlv�J�i tl 11 ..,� . 1 2 3 4 5 6 7 8 9 10 ; 11 12 13 K BY-PASS WASTE MIXED LIOUOR K r------- NUTRIENT FEED I H2SO4 PH CONTROL NH40H H3PO4 � r ------rt ----------- ( BACK-UP ) AB OR AERATION DIGESTER If BASIN j J i 2. 3 MG i 3.4 MG i ' POLYMER ADDITION AB OR 54.82 i D2G3SMGR A BASIN N i FOR TSS CONTROL 3. 4 MG i Ii 1---------- ----------� I INTERMITTENT ADDITION AERATION BASIN PRIMARY EFFLUENT i OF CACO 20 SURFACE AERATORS i 0 INJECTION INTERMITTENT 2 SULFIDE CONTROL H ad* i H i i *4 CLARIFIER 200' DIAMETER 11. 48 *3 0 SLUDGE D i 2.82 DILLI M ON CLARIFIER G 15.5 200' DIAMETER GALLONS 0 14. 75 DEEP i w 3.47 MILLION 1-f GALLONS �� i "- _____RECYCLE_SLUDGE Cow ------- - l�� 23. 92 OUR F `� _ PRIMARY SLUDGE ARUSFANDRITZ �� z F �---- 0.6 ---- BELT PRESSES i � 05 2 20012AD CLARIFIER TER 11.48 w E CLARIFIER i FLOW i 2. 82 MILLION � E i GALLONS 15.5 200 DIAMETER SPLITTING 0 14. 75' DEEP i STATION i o 3. 47 GALLONSION i w N OXYGEN D e ❑ COZPH CONTR0 ��� CLARIFIER FLUME REAERATION \ 150' DIAMETE * 1 CASCADE 14' DEEP C CLARIFIER 1.85 MILLION 125' DIAMETER �' LOW z GALLONS 6.22 C 11' DEEP LIFT ¢w GRIT FINAL 1.01 MILLION PUMPS mw CHAMBER EFFLLUEENT GALLONS u B SPILLLLY OUR FOR FLOW COMPLIANCE COLLECTION •. B �; urt xvvmr u.. GRAVING TITLE MILL 29. 0 CITY WWTP - FLOW DIAGRAM WASTEWATER SEWER BLUE RIDGE PAPER PRODUCTS NOTE$ 0.9 - CANTON MILL 1 . ALL FLOWS AT DESIGN RATES IN M6D A MILL WIIIFERINO wnaR.xmrn Glbl.11q 1pOES pEFll[T N0. NC0000272 c OB L. GONTEPoRTO ORTE B2-05-01 '- cu. ,� M[LL ORNYINO NUMBER - F- 107A-526 1 2 3 4 5 6 7 8 9 10 11 ' 12 13 is — .. i 7. .. - �� .!