NC0005258_Permit Issuance_20100311

NPDES DOCUMENT SCANNINO COVER SHEET
NC0005258
SGL Carbon
NPDES Permit:
Document Type:
ce
Permit Issuanai
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Speculative Limits
Monitoring Information
Instream Assessment (67B)
Environmental
Assessment (EA)
Permit
History
Document Date:
March 11, 2010
This document ios printed on reuse paper - ignore any
content on the reYerse side

Beverly Eaves Perdu
Govemor
-
NCDENRTA
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins Dee Freeman
Director Secretary
March 11, 2010
Mr. Charlie Conner, Plant Manager
SGL Carbon LLC
307 Jamestown Road
Morganton, North C olina 28655
Subject: Issuance of NPDES Permit NC0005258
SGL Carbon LLC
Burke County
Dear Mr. Conner:
Division pers nnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are f rwarding the attached NPDES discharge permit. This permit is issued pursuant to the,
requirements of Nor Carolina General Statute 143-215.1 and the Memorandum of Agreement between North
Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as subsequently amended).
This final peit includes no major changes from the draft sent to you on December 16, 2009.
If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable
to you, you have the r ght to an adjudicatory hearing upon written request within thirty (30) days following receipt
of this letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh,
North Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet www.ncwaterqua ity.org
An Equal Opportunity l Affirmative Action Employer
•
Nose Carolina
-iura!!y

Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the legal requirements
to obtain other permits which may be required by the Division of Water Quality or permits required by the
Division of Land Resources, the Coastal Area Management Act or any other Federal or Local governmental permit
that may be required. If you have any questions concerning this permit, please contact Sergei Chernikov at
telephone number [phone].
Sincerely,
Coleen H. Sullins
cc: NPDES Files
Central Files
Asheville Regional Office -Surface Water Protection
Aquatic Toxicology Unit (e-copy)
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service:1-877-623.6748
Internet www.ncwaterquality.org
An Equal opportunity \ Affirmative Action Employer
NorthCarolina
Naturally

. Permit No. NCQ005258
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,
SGL Carbon, LLC
is hereby authorized to discharge wastewater from a facility located at
SGL Carbon
307 Jamestown Road
Morganton, North Carolina
Burke County
to receiving wa ers designated as Silver Creek in the Catawba River Basin in accqrdance with
effluent limitati ns, monitoring requirements, and other conditions set forth in Parts I, II, III,
and IV hereof.
The permit shall become effective April 1, 2010.
This permit and the authorization to discharge shall expire at midnight on February 28, 2015
Signed this day March 11, 2010.
f
oleen H. Sullins
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0005258
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked, and as of this issuance, any previously issued permit bearing this number is no .longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
SGL Carbon, LLC
is hereby authorized to:
1. Continue to discharge untreated contact and non -contact cooling water from a
facility located at SGL Carbon, 307 Jamestown Road, Morganton, Burke County,
and;
2. Discharge via Outfall 001 into Silver Creek, a Class WS-IV water in the Catawba
River Basin, at the location specified on the attached map.
,

Latitude: 35° 43' 41"
Longitude: 81° 43' 45"
USGS Quad #: El2NW
River Basin #: 03-08-31
Receiving Stream: Silver Creek
Stream Class: WS-IV
Nt
SGL Carbon Corporation
Burke County
NC0005258
0 5 0 %

Permit No. NC0005258
•
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Beginning on the effective date of this permit and lasting until expiration, the Permittee is
authorized to discharge contact and non -contact cooling water from Outfall 001. Such
discharges shall be limited and monitored by the Permittee as specified below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location'
Flow (MGD)
Daily
Instantaneous
Effluent
Temperature2
Daily
Grab
Effluent,
U&D
Total Suspended Solids
30.0 mg/L
45.0 mg/L
2/Month
Composite
Effluent
Oil and Grease
10.0 mg/L
15.0 mg/L
2/Month
Grab
Effluent
Total Copper
Monthly
Composite
Effluent
Total Lead
Annual
Composite
Effluent
Total Selenium
Annual
Composite
Effluent
Total Silver
Annual
Composite
Effluent
Total Zinc
Annual
Composite
Effluent
pH
Weekly
Grab
Effluent
Chronic Toxicity3
Quarterly
Composite
Effluent
Notes:
1. U: at least 100 feet upstream from the outfall. D: at least 300 feet downstream from the outfall.
2. The temperature of the effluent shall cause an increase in the temperature of the receiving stream of
more than 2.8°C; in no case shall it cause the ambient water temperature to exceed 29°C.
3. Chronic Toxicity (Ceriodaphnia) at 13%; March, June, September, December [see A. (2)1.
There shall be no
•
discharge of floating solids or visible foam in other than trace amounts.
MGD= million gallons per day
mg/L= milligrams r$er liter

• , Permit No. NC0005258
A. (2) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 13%.
The permit holder shall perform at a minimum, auarterlq monitoring using test procedures outlined in the "North
Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or
"North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent
versions. The tests will be performed during the months of March, June, September, and December. Effluent
sampling for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment
processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit
limit, then multiple -concentration testing shall be performed at a minimum, in each of the two following months as
described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or
subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest
concentration having no detectable impairment of reproduction or survival and the lowest concentration that does
have a detectable impairment of reproduction or survival. The definition of "detectable impairment," collection
methods, exposure regimes, and further statistical methods are specified in the "North Carolina Phase 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: NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30
days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature.
Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the
permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility
name, permit number, pipe number, . county, and the month/year of the report with the notation of "No Flow" in the
comment area of the form. The report shall be submitted to the Environmental Sciences Branch at the address
cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be
required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water
Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include
alternate monitoring requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring
shall be included in the calculation & reporting of the data submitted on the DMR & all AT Forms submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an
invalid test and will require immediate follow-up testing to be completed no later than the last day of the month
following the month of the initial monitoring. •

ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Environmental Health
Beverly Eaves Perdue Terry L. Pierce Dee Freeman
Governor Director Secretary
March 5, 2010
Sergei Chernikov, Ph.D., NPDES Unit
North Carolina Department of
Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina, 27699-1617
Re:
Dear Dr. Chernikov:
NPDES Review Comments
Draft NPDES Permit NC0005258
SGL Carbon LLC
Burke
In reference to tlr above listed NPDES permit for the SGL Carbon LLC, we concur with the issuance of
this permit provided the facility is operated and maintained properly, the effluent limits are met prior to
discharge, and the discharge does not contravene the designated water quality standards.
Should you have questions regarding this concurrence please feel free to contact.
Sincerely
P
mes P. Adams P.E.
Regional Engineer
Public Water Supply Section
Cc: Jessica Miles, Chief, Public Water Supply Section
Public Water Supply Section — Jessica G. Miles, Chief
Asheville Regional Office
2090 U.S. Highway 70, Swannanoa, North Carolina 28778
Phone: [phone] FAX [phone] Internet: ncdrinkingwater.state.nc.us
An Equal Opportunity 1 Affirmative Action Employer
Nose Carolina
�tura!ly

North Carolina } ss
Mecklenburg County}
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
DINA SPRINKLE
NCDENR/DWQ/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6420688 multi -permit request
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of Mecklenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and Publication.
PUBLISHED ON: 12/18
AD SPACE:
FILED ON:
NAME:
96 LINE
12/25/09
rourix
TITLE:
DATE:
Public Notice -
North Carolina Environmental Management .•
Commission/NPDES Unit 1617 Mail Service Center •
Raleigh, NC 27699.1617 •
Notice o1 Intent to Issue a NPDES Wastewater Permit • •
The North Carolina Environmental Management Commission
proposes 10 issue a NPDES wastewater discharge permit to the
• per50h(S) listed below.
Written commentsregarding the proposed - permit will be
accepted until 30 days after the publish date of this notice.
The Director 01 the NC Division of Water Quality (DWQ) may hold
a public hearing should there be a significant degree of public
interest. Please mail comments and/or information requests to
DWO at the above address. Interested persons may visa the DWQ
at 512 N. Salisbury Street, Raleigh, NC to review information on
file. Additional information on NPDES permits and this notice may
be found on our website: wwwncwaterqualityorg, or by calling
[phone]. - •
-
FA•BE Enterprises, Inc. requested. renewal of permit NC0072621
for the Lakewood Care center WWTP in Lincoln County;
this permitted discharge is treated domestic wastewater to Forney
Creek -in the Catawba River Basin.
The Aluminum Company of America, NC0004308, has applied for
modification of its permit which authorizes discharge to Badin.
Lake in the Yadkin/ Pee Dee River Basin.
Wachovia Bank has applied for a modification of its NPDES permit
NC0088226 tor the Wachovia • Tryon Street discharge in
Mecklenburg County within Catawba River Basin.
Belmont Textiie.Machinerryy Company requested renewal cf permit
NC0023540 ton its WWTP in Gaston County; this permitted
discharge is treated wastewater ,to Files Creek in. the Catawba
River Basin..;
The City of Mount' Holly requested renewal of NPDES permit
NC0084689 for the City's water treatment plant in Gaston County;
this permitted discharge Is treated filter backwash wastewater to
an unnamed tributary to the Catawba River in the Catawba
River Basin.: • •
The SGL Carbon Carporalion requested renewal of permit
NC0005258 -for SGL Carbon in Burke; this-faciliy discharge is
cooling water to Silver Creek, Catawba River Basin.
LP6420688'•
In Testimony Whereof I have hereunto set my hand and affixed my seal, the
day and'y r aforesaid. - -
Notary
r y Commission Expires: _/_/_
My Commission Expires May 27, 2011

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0005258
Facility Information
Applicant/Facility Name:
SGL Carbon, LLC
Applicant Address:
307 Jamestown Road
Facility Address:
Morganton NC 28655
Permitted Flow
NA
Type of Waste:
Non -contact and contact cooling water
Facility/Permiut Status:
Existing/Renewal
Facility Classification
I
County: I
Burke
Miscellaneous
Receiving Stream:
Silver Creek
Regional Office:
Asheville
Stream Classification:
WS-IV
USGS Topo Quad:
E13NW/Morganton
South.
303(d) Listed?:
No
Permit Writer:
Sergei Chernikov
Subbasin:
03-08-30
Date:
December 1, 2009
Drainage Area (mi2):
49.9
..:►
-AO
Summer 7Q10 (cfs)
20.9
30Q2 (cfs):
34.2
Average Flow (cfs):
74.8
IWC (%):
10
Primary SIC Code:
3624
1.0 Summary
SGL Carbon is requesting renewal of its existing NPDES permit. Permittee also has a stormwater
permit (NCS000009) and notes that facility stormwater drains also discharge to outfall 001. This
may account for TSS, O&G and copper residuals in the effluent.
The facility is a manufacturer of synthetic graphite products. Raw materials consumed include coke,
coal tar pitch, and petroleum pitch. The main products are mainly electrodes for use in the steel
industry. They produce 3.3 million pounds of graphite product per month.
The types of wastewater are 0.6 mgd of noncontact cooling water and 0.3 mgd of contact cooling
water. Cooling towers are used. Application notes that most of the discharge is from non -contact
cooling water. There is some contact cooling water discharge from baking furnaces that utilize
water seals to prevent combustion gas emissions, there are not significant chemical additions to the
discharge from this process.
2.0 Major/Minor Facility Rating
SGL Carbon LLC has been previously rated as a major industrial facility. The facility has no
treatment processes and discharges primarily non -contact and contact cooling water. Company
manufactures synthetic graphite products.
SGL Carbon I T,C's renewal application lists SIC Code 3624. The 1987 SIC Code has the title of
Carbon and Graphite Products. There is no CFR Part or Subpart listed in Appendix A SIC Code
Cross Reference Guide and Total and Human Health Toxicity Number. The previous permit writer
contacted Samantha Lewis of EPA, and asked whether an industry with an SIC Code of 3624 would
be included in the Electrical and Electronic Components Category. Her email response was that
Carbon and Graphite Products subcategory was excluded from the Electrical and Electronic
SQL Carbon LLC Fact Sheet
NPDES Permit Issuance
Page 1

Components category because "pollutants would be in trace amounts and in quantities too small to
be effectively reduced by treatment." Based on the NPDES Rating Sheet score (completed on
08/22/05) , it was determined that the facility should be considered a Minor Facility.
3.0 Compliance Summary
Facility has a very good compliance history. During the period from 01 /01 /2006 through
12/31/2009 the facility has only one limit violation (oil and grease -03/2009). The latest
compliance evaluation inspection conducted on 10/23/08 concluded that the facility is in
compliance.
4.0 RPA
Reasonable potential analysis was conducted for: Cu, Pb, Se, Ag, and Zn (please see attached).
5.0 Toxicity Testing
Type of Toxicity Test: Chronic P/F
Existing Limit: 001: Chronic P/F @ 13%
Recommended Limit: 001: Chronic P/F @ 13%
Monitoring Schedule: March, June, September, December
IWC calculated based using highest monthly flow of 2.0 MGD in 2003
The facility has been consistently passing its WET tests.
6.0 Instream Data Review
Instream data was reviewed for the period of January 2006 through August 2009. The facility has no
significant impact on the receiving stream.
7.0 Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: December 16, 2009 (est.)
Permit Scheduled to Issue: February 8 , 2010 (est.)
8.0 State Contact Information
If you have any questions on any of the above information or on the attached permit, please contact
Sergei Chernikov at [phone].
Regional Office Comments:
Date: Name:
SGL Carbon LLC Fact Sheet
NPDES Permit Issuance
Page 2

REASONABLE POTENTIAL ANALYSIS
SGL Carbon
NC0005258
LLC
Time Period 2005-2009
Ow (MGD) 0.85
7Q10S (cfs) 20.9
7Q10W (cfs) 0
30Q2 (cfs) 34.2
Avg. Stream Flow, QA (cfs) 74.8
Rec'ving Stream Silver Creek
WWTP Class
IWC (%) @ 7Q10S 5.93
© 7Q10W N/A
© 30Q2 3.7094
@ QA 1.7309
Stream Class WS-IV
Outfall 001
Qw=0.85MGD
PARAMETER
TYPE
{1)
STANDARDS &
CRITERIA (2)
PQL
Units
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NC WQS/ % FAV/
Chronic Acute
n # Dot. Max Pred Cw Allowable Cw
1
Acute: 7
Copper
NC
7 AL 7.3
ug/L
46 29
126.8
no Omit, action level standard
Chronic: 118
Acute: 34
Lead
NC
25 N 33.8
uglL
4 0
5.0
no limit
Note: n<12
_ _ _ _ _ _
Chronic 422
----------------
Limited data set
Acute: 56
no limit
Selenium
NC
5.0 56
ug/L
4 0
Note: n<12
5.0
_ _ -
Chronic-84 —
------
Limited data set
Acute: 1
Silver
NC
0.06 AL 1.23
ug/L
4 0
2.5
_ _
^------------------------------------
no limit, action level standard
Note: n<12
Chronic:_
Limited data set
_
Acute: 67
n_o lim_ it, action level s_tan_dard_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Zinc
NC
50 AL 67
ug/L
4 3
633.3
Note: n<12
_ _ __ _ _-
Chronic 843 -------------------------------
Limited data set
* Legend:
C = Carcinogenic
NC = Non -carcinogenic
A = Aesthetic
** Freshwater Discharge
5258-RP 009xIs, rpa
:Y •,11%30/20Q9

REASONABLE POTENTIAL ANALYSIS
Copper
Lead
Date
Data
BDL=1/2DL
Results
Date
Data
BDL=1/2DL
Results
1
<
2
1.0
Std Dev.
6.2249
1
<
10 5.0
Std Dev.
0.0000
2
<
2
1.0
Mean
3.6957
2
<
10 5.0
Mean
5.0000
3
<
2
1.0
C.V.
1.6844
3
<
10 5.0
C.V.
0.0000
4
3
3.0
n
46
4
<
10 5.0
n
4
5
3
3.0
5
6
2
2.0
Mult Factor =
3.2500
6
Mutt Factor =
1.0000
7
<
2
1.0
Max. Value
39.0 ug/L
7
Max. Value
5.0 ug/L
8
7
7.0
Max. Pred Cw
126.8 ug/L
8
Max. Pred Cw
5.0 ug/L
9
<
2
1.0
9
10
<
2
1.0
10
11
<
2
1.0
11
12
<
2
1.0
12
13
<
2
1.0
13
14
<
2
1.0
14
15
<
2
1.0
15
16
2
2.0
16
17
5
5.0
17
18
<
2
1.0
18
19
<
2
1.0
19
20
2
2.0
20
21
2
2.0
21
22
Dec-2007
19
19.0
22
23
4
4.0
23
24
Oct-2007
39
39.0
24
25
<
2
1.0
25
26
4
4.0
26
27
2
2.0
27
28
<
2
1.0
28
29
2
2.0
29
30
6
6.0
30
31
3
3.0
31
32
3
3.0
32
33
4
4.0
33
34
<
2
1.0
34
35
13
13.0
35
36
3
3.0
36
37
2
2.0
37
38
2
2.0
38
39
2
2.0
39
40
2
2.0
40
41
3
3.0
41
42
3
3.0
42
43
5
5.0
43
44
3
3.0
44
45
3
3.0
45
46
<
2
1.0
46
47
47
48
48
49
49
50
50
51
51
52
52
53
53
54
54
55
55
56
56
57
57
58
58
59
59
60
60
199
199
200
200
- 2 -
5258-RPA-2009.xls, data
11/30/2009

REASONABLE POTENTIAL ANALYSIS
Selenium
Silver
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
199
200
Date
Data
<
<
<
<
BDL=1/2DL
10 5.0
10 5.0
10 5.0
10 5.0
Results
Std Dev.
Mean
C.V.
n
Mult Factor =
Max. Value
Max. Pred Cw
0.0000
5.0000
0.0000
4
1.0000
5.0 ug/L
5.0 ug/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
199
200
Date
Data
<
<
<
<
BDL=1/2DL
5 2.5
5 2.5
5 2.5
5 2.5
Results
Std Dev.
Mean
C.V.
n
Mult Factor =
Max. Value
Max. Pred Cw
0.0000
2.5000
0.0000
4
1.0000
2.5 ug/L
2.5 ug/L
-3-
5258-RPA-2009.xls, data
11/30/2009

REASONABLE POTENTIAL ANALYSIS
Zinc
Date Data BDL=1/2DL Results
1 71 71.0 Std Dev. 34.3074
2 11 11.0 Mean 37.5000
3 63 63.0 C.V. 0.9149
4 < 10 5.0 n 4
5
6 Mult Factor = 8.9200
7 Max. Value 71.0 ug/L
8 Max. Pred Cw 633.3 ug/L
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
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5258-RPA-2009.xls, data
11/30/2009

August 25, 2009
Mrs. Dina Sprinkle
NC DENR / DWQ / Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
SGL GROUP
THE CARBON COMPANY
BROAD BASE
BEST SOLUTIONS
Re: Renewal Request and Application for NPDES Permit Number NC0005258
SGL Carbon, LLC
Burke County
Dear Mrs. Sprinkle;
The SGL Carbon, LLC facility located in Morganton, North Carolina request the renewal of NPDES Permit
Number NC0005258. We have not had any significant physical changes to the facility since the issuance of our
last permit; however, we have had a decrease in the number of employees and a decrease in production due to
the downturn in the economy.
Please find enclosed one original and two copies of the following items and attachments as requested in the
renewal application and checklist.
Item 1. This cover letter requesting renewal of the permit and description of facility changes
Item 2. Completed Short Form - C permit renewal application
Attachments:
1. Narrative description that the facility does not generate any solids and does not have a sludge
management plan
2. Priority Pollutant Analysis (PPA) for the purposes of this permit renewal should be completed some
time within the next week or two and we expect to have sampling results one month from now. The
priority pollutant analysis results will be forwarded to you and the NPDES Unit as soon as the results
are received.
3. Process description of facility
4. SIC Category description of facility
5. Map of the NPDES outfall location
RECEIVED
Thank you for your consideration of this information and timely renewal of this perrAgG 3 i
Sincerely,
Charlie Conner
Plant Manager
SGL Carbon, LLC
cc: Richard Ives, Engineering Manager
DENR - WATER QUALITY
POINT SOURCE BRANCH
SGL Carbon, LLC
307 Jamestown Road
Morganton, NC 28655
Sglcarbon.com
Phone: [phone]
Fax: [phone]

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. DENR / Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number
NC0005258
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
SGL Carbon, LLC
SGL Carbon, LLC
307 Jamestown Road
Morganton
North Carolina 28655
[phone]
[phone]
richard.ives(a sglcarbon.com
2. Location of facility producing discharge:
Check here if same as above El
Street Address or State Road
City
State / Zip Code
County
RECEIVED
AUG 3 1
DENR - WATER QUALITY
POINT SOURCE BRANCH
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
4. Ownership Status:
SGL Carbon, LLC
307 Jamestown Road
Morganton
North Carolina 28655
[phone]
[phone]
Federal ❑ State ❑
Private ® Public ❑
Page 1 of 4 C-MI 05/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
5. Standard Industrial Classification (SIC) code(s): 3624
6. Number of employees: 95
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the pro sses that generate wastewaters. If the space provided is not sufficient attach a
separate sheet o paper with the system description.
There is no wastewater treatment system in place. Wastewater generated is mostly non -
contact cooling water with the remaining wastewater being contact cooling water and
baking furnace seal water.
8. Is facility c vered under federal effluent limitation guidelines? No ® Yes ❑
If yes, specify the category?
9. Principal product(s) produced: Synthetic graphite products
Principal ra material(s) consumed: Coke, coal tar pitch, and petroleum pitch
Briefly desc be the manufacturing process[es]:
The SGL Carbon, LLC facility in Morganton, NC produces carbon and graphite rods that are used by
the steel manufacturing industry, as high temperature electrodes and/or milled by customers for
other processes. The process at this facility includes the following steps. The first step includes the
milling or grinding of petroleum coke to obtain a correct particle size distribution of the ground
material. This rcarbon black" milled petroleum coke material is then mixed with coal tar pitch. This
mixture is formed into large cylindrical and square rods and baked at high temperatures to form a
carbon rod that is solid and hard like concrete. Additional bulk density may be added to the carbon
rods by impre ating the rods with petroleum pitch under pressure. The petroleum pitch
impregnated r ds may then be baked again at about 800° C. This step of pitch impregnation and
additional b g is only performed as needed to add bulk density to the carbon rods. The final step
in the production process is the graphitization of the hardened baked carbon rods. This step is
performed by heating the carbon rods to about 2400° C via high electrical current to graphitize the
rods. The final products produced are large graphite rods, which have no leachable or volatile
material properties. These graphitized rods are essentially the same material as a No. 2 pencil.
10. Amount of principal product produced or raw material consumed
(List specafic amounts consumed and/or units of production over the last three years
Product Produced or Raw Material
Consumed
(AVERAGE)
Product Produced or Raw Material
Consumed
(PEAK)
per Day
per Month
Approximately 1.8 million pounds of
graphite product produced per month
per Year
Page 2 of 4
C-MI 05/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
11. Frequency of discharge: Continuous ® Intermittent ❑
If intermittent: Days per week discharge occurs: Duration:
12. Types of wastewater discharged to surface waters only
g
(Discharge
Flow
(GALLONS PER DAY)
Sanitary - monthly
average
None
Utility water, etc.
- monthly average
450,000 GPD non -contact cooling water
Process water -
monthly average
220,000 GPD contact seal water
Stormwater - monthly
average
180,000 GPD stormwater
Other - monthly
Explain:
average
Monthly Averag
total discharge
all types)
850,000 GPD
13. Number of separate discharge points: 1 Outfall Identification number(s) 001
14. Name of r ceiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and lon 'tude):
Silver Creek (Map is included as Attachment 5)
15. Effluent Data
Provide data for tke parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour
composite sampling shall be used. If multiple analyses are reported, report daily maximum and monthly average. If
only one analysis is reported, report as daily maximum.
1
,Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5) (1)
Chemical Oxygen Demand (COD) (1)
Total Organic Carbon (1)
Total Suspended Solids
4.0
2.3
Mg/L
Ammonia as N (1)
Temperature (Summer)
31.5
22.1
OC
Temperature (Winter)
25.5
14.8
oC
pH
6.8
6.6
SU
Fecal Coliform (If sanitary waste is present)
Total Residual Chlorine (if chlorine is used)
(1) Please note that
along with Priority
these parameters are not on the current NPDES Permit and data will be submitted to the DWQ
Pollutant Analysis (PPA) results upon completion of sampling and receipt of lab analysis.
Page 3 of 4
C-MI 05/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
16. List all permits, construction approvals and/or applications (check all that apply and prouide permit
numbers or check none if not applicable):
Permit
Type Permit Number Type Number
Hazardous Waste (RCRA) NCR00013821 NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NC0005258 86 Dredge or fill (Section 404 or
NPDES NCS000009 CWA)
PSD (CAA)
Non -attainment program
Title V Air Permit 03287T27
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Most of the discharge is from non -contact cooling water. There is some contact cooling and baking
furnace seal water discharge from baking furnaces that utilize water seals to prevent combustion gas
emissions; however, there are no significant chemical additions to the discharge from this process.
Because facility stormdrains that are located throughout the facility also discharge to the same
NPDES outfall, it is possible that some TSS or Oil and Grease may be discharged to the single NPDES
outfall via stormwater runoff. Stormwater discharges are addressed separately in the facility's
NPDES Stormwater Discharge Permit NCS000009.
18. Is this facility located on Indian country? (check one)
Yes ❑ No EI
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Charlie Conner Plant Manager
Printed name of Person Signing Title
2
Signature of Applicant Date
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false statement representation, or
certification in any application, record, report, plan, or other document files or required to be maintained under Article 21 or regulations of
the Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any
recording or monitoring device or method required to be operated or maintained under Article 21 or regulations of the Environmental
Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $25,000, or by
imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine of not more than $25,000 or
imprisonment not more than 5 years, or both, for a similar offense.)
Page 4 of 4 C-MI 05/08

Attachment 1
Narrative Description of Sludge Management at Facility
Facility: SGL Carbon, LLC
NPDES Permit Number: NC0005258
SIC Code: 3624 - Carbon and Graphite Products
I. Description of sludge management (no solids generated) at the SGL Carbon,
LLC, Morganton, NC facility
The SGL Carbon, LLC facility in Morganton, NC does not generate any solids via
wastewater treatment or via wastewater generated at the facility. All wastewater
generated and discharged from this facility is either non -contact cooling water or
contact cooling baking furnace seal water. There is no wastewater treatment system
or no generation of wastewater sludge from this facility.
Charlie Conner Plant Manager
Printed name of Person Signing Title
F/. -/e9
Signature of Applicant Date

L .L
achment
Priority Pollutant Analysis (PPA) for Facility
Facility: SGL Carbon, LLC
NPDES Permit Number: NC0005258
SIC Code: 36
4 - Carbon and Graphite Products
I. Priority Pojlutant Analysis (PPA) sampling
SGL Carbo , LLC has authorized that a priority pollutant analysis be performed for
the NPDES permit renewal. SGL Carbon, LLC will perform a priority pollutant
analysis as requested for the purposes of this permit renewal. Sampling for this
should be completed some time within the next week or two and we expect to have
sampling results hopefully within one month from now. The results of the priority
pollutant analysis will be forwarded to the NCDENR-DWQ-Point Source Branch as
soon as the results are received.
Several items of concern should be addressed regarding the priority pollutant
analysis. Based on previous PPA analysis results at SGL Carbon and based on some
recent priority pollutant analysis results performed by other industries in Morganton,
North Carolina, there were several contaminates detected as a result of the local
public water treatment processes. These parameters include chloroform and several
other chlorine water treatment byproducts resulting from the treatment of public
drinking tap water and byproducts of chlorinated tap water.
Another parameter of concern is fluorine and fluorine related byproducts that are
also a resulif of the fluorination of tap water at the Morganton water treatment plant.
Recent water quality reports on the City of Morganton tap water show fluoride in
detectable levels that may present a false concern in a priority pollutant analysis.
SGL Carbon, LLC neither uses nor discharges any materials containing fluoride or
fluorine products; therefore, SGL Carbon would attribute any fluoride or fluorine
results on the priority pollutant analysis to the tap water from the water treatment
plant that is located less than 1 mile from the facility.
We bring these items to attention only because of our knowledge of other area
facilities hating these same issues arise during their NPDES permit renewal process
and the knowledge that certain contaminates are known to be present in public
potable tap water. This is especially of concern because most of our discharge is
noncontact cooling water, which is obtained from the City of Morganton public water
supply and rthe fact that our facility is located in close proximity to the water
treatment plant.
Attached is a copy of the 2008 City of Morganton Water Quality Report documenting
disinfection by-products, detectable fluride, and copper levels, as well as other
possible pollutants of concern.

Attachme
t 3
Process Description of Facility
Facility: SGL Carbon, LLC
NPDES Permit Number: NC0005258
SIC Code: 36 4 - Carbon and Graphite Products
I. Descriptio
of process at the SGL Carbon, LLC, Morganton, NC facility
The SGL Carbon, LLC facility in Morganton, NC produces carbon and graphite rods
that are used by the steel manufacturing industry, as high temperature electrodes
and/or milled by customers for other processes. The process at this facility includes
the following steps. The first step includes the milling or grinding of petroleum coke to
obtain a collect particle size distribution of the ground material. This "carbon black"
milled petroleum coke material is then mixed with coal tar pitch. This mixture is
formed into arge cylindrical shaped rods and baked at high temperatures to form a
carbon rod at is solid and hard like concrete. Additional bulk density may be added
to the carbon rods by impregnating the rods with petroleum pitch under pressure. The
petroleum pitch impregnated rods may then be baked again at about 800° C. This
step of pitch impregnation and additional baking is only performed as needed to add
bulk density to the carbon rods. The final step in the production process is the
graphitization of the hardened baked carbon rods. This step is performed by heating
the carbon rods to about 2400° C via high electrical current to graphitize the rods. The
final products produced are large graphite rods which have no leachable or volatile
material properties. These graphitized rods are essentially the same material as a No.
2 pencil.
II. Raw Matel.ialsi Petroleum Coke, coal tar pitch, and petroleum pitch
III. Process Description Outline:
1. Milling ( grinding of petroleum coke.
2. Mixing of ground coke with coal tar pitch.
3. Forming / extrusion of cylindrical rods of the coke / coal tar pitch mix.
4. High temperature baking of rods to form a solid hard carbon rod.
5. If needed, the hard carbon rod is impregnated with petroleum pitch and baked
again at about 800° C. This step adds bulk density to the rod.
6. Carbon rod is graphitized at high temperature of about 2400° C producing a
graphite rod.

Attachment 4
SIC Category Description of Facility
Facility: SGL Carbon, LLC
NPDES Permit Number: NC0005258
SIC Code: 36 4 - Carbon and Graphite Products
I. Category f SGL Carbon, LLC based on SIC code 3624
In address' g the SIC Code for this facility, we have attached a copy of the description
from US D L - OSHA of the SIC Code 3624. The SIC code for this facility is correct
and is specific to what SGL Carbon does. SIC 3624 - Carbon and Graphite Products
applies to SGL Carbon, LLC, as it is an establishment engaged in manufacturing
carbon and graphite electrodes for thermal and electrolytic uses. The facility is not
engaged in any electronics manufacturing or any type of electronic equipment. The
facility should not be and is not a categorical discharger under the electronic or
electrical equipment manufacturing category. According to Appendix A (SIC Code
Cross Reference and Total and Human Health Toxicity Number) of the NPDES Permit
Rating Work Sheet, SIC Code 3624 Carbon and Graphite Products is not listed as a
CFR categorical industry. A copy of the applicable page of Appendix A is also
attached. Based on these SIC Code descriptions and the manufacturing process at
SGL Carbon, LLC in Morganton, this is the correct and accurate SIC for this facility
and this SGL Carbon, LLC facility is not subject to any categorical NPDES discharge
standards for electronics or electrical equipment manufacturing.
Supporting documentation:
US DOL SI Code Description for 3624
Page of Appendix A to NPDES Permit Rating Work Sheet showing SIC Code 3624

Description for 3624: Carbon and Graphite Products
U.S. Department of Labor
Occupational Safety & Health Administration
WWW.OSha.gov .41
MyOSHA Search
SIC Description for 3624
Description for 3624: Carbon and Graphite Products
GOJ Advanced Search 1 A-Z Index
Division D: Manufacturing
Major Group 36: Electronic And Other Electrical Equipment And Components, Except
Computer Equipment
Industry Group 362: Electrical Industrial Apparatus
3624 Carbon and Graphite Products
Establishments primarily engaged in manufacturing carbon, graphite, and metal -graphite
brushes and brush stock, carbon or graphite electrodes for thermal and electrolytic uses;
carbon and graphite fibers; and other carbon, graphite, and metal -graphite products.
• Brush blocks, carbon or molded graphite
• Brushes and brush stock contacts: carbon and graphite -electric
• Carbon specialties for electrical use
• Carbons, electric
• Electrodes for thermal and electrolytic uses, carbon and graphite
• Fibers, carbon and graphite
• Lighting carbons
[ SIC Search I Division Structure I Major Group Structure I OSHA Standards Cited ]
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Occupational Safety & Health Administration
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Washington, DC 20210
http://www.osha.gov/p1s/imis/sic_manual.display?id=806&tab=description 06/23/2005

USGS 7.5
Attachment 5 T
TOPOGRAPHY MAP N
July 1, 1996
NPDES Outfall Location
SGL Carbon, LLC
307 Jamestown Road; Morganton, NC
SGL Carbon, LLC - NPDES Permit No. NC0005258
Topographic Map of Outfall Location
Latitude: 35° 43' 42"
Longitude: 81° 43' 33"
Receiving Stream: Silver Creek