NC0004812_Permit Issuance_20100301

NPDES DOCIMENT 5CANNINO COVER SHEET
Permit:
NC0004812
NPDES
Document Type:
/Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Compliance / Enforcement
Permit History
Date Range:
Correspondence
Document Date:
9rd (a/ 0
/
THIS DOCUMENT I5 PRINTED ON REUSE PAPER - ICNORE ANY CONTENT ON THE
REVERSE SIDE

ATA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Govemor Director Secretary
March 1, 2010
Mr. James Davis, Environmental Manager
Pharr Yarns
P.O. Box 1939
McAdenville, N. c. 28101-1939
Subject: Issuance of NPDES Permit
NC0004812
Pharr Yarns Industrial WWTP
Gaston County
Dear Mr. Davis:
Division personnel have reviewed and approved your application for renewal of the subject
permit. AccordiTigly, we are forwarding the attached NPDES discharge permit. This permit is
issued pursuant! to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between North Carolina and the U.S. Environmental Protection
Agency dated October 15, 2007 (or as subsequently amended).
This final permit includes following changes from the draft sent to you on October 21,
2009.
• Limits for BOD and COD were recalculated (increased) to provide the facility full allocation
in accordance with 40 CFR 410.70 Subpart G Stock and Yarn Finishing Subcategory.
The Division is ' unable to grant your request to increase the Total Suspended Solids (TSS) limit.
The receiving steam is impaired due to high turbidity. According to current EPA policy,
Y,
facilities discharging to streams impaired for turbidity cannot increase their TSS load.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within
thirty (30) days following receipt of this letter. This request must be in the form of a written
petition, conforming to Chapter 150B of the North Carolina General,Statutes, and filed with the
Office of Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-
6714). Unless such demand is made, this decision shall be final and binding.
1617 Mail Service Center , Raleigh, North Carolina 27699-1617
512 North Salisbury Strut, Raleigh, North Carolina 27604
Phone: [phone] / FAX [phone] Internet: www.ncwaterquality.org
An Equal Opportunity/Affirmative Action Employer — 50% Recycledl10% Post Consumer Paper
No1ehCarolina
Xaturaiij

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 Dr. Sergei Chernikov at
telephone number [phone].
cc: Central Files
Asheville Regional Office/Surface Water Protection
NPDES Unit
Aquatic Toxicology Unit (e-copy)
EPA Region IV (e-copy)
Charles R. Froneberger (e-copy)

Permit NC0004812
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 wi h the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulati ns promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
Pharr Yarns, Incorporated
is hereby authorized to discharge wastewater from a facility located at the
Pharr Yarns Industrial WWTP
147 Willow Drive
McAdenville
Gaston County
to receiving waters designated as the South Fork Catawba River in the Catawba River
Basin in accordance with effluent limitations, monitoring requirements, and other
conditions set north in Parts I, II, III and IV hereof.
This permit shall become effective April 1, 2010.
This permit and
Signed this day
authorization to discharge shall expire at midnight on January 31, 2014.
March 1, 2010.
`C en H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

• Permit NC0004812
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
Pharr Yarns, Inc. is hereby authorized to:
1. Continue to operate an existing 1.0 MGD wastewater treatment facility for the
treatment of industrial and domestic wastewater that includes the following
components:
Extended aeration basin
Two clarifiers with alum and polymer addition
Two return activated sludge pumps
Three mixed media pressure filters
Two filter pumps
Aerobic digester
Sludge thickening tank
Dewatering belt press
Sludge storage and drying pad
Tablet chlorination
Dual chlorine contact chambers
This facility is located at the Pharr Yarns Industrial WWTP at 147 Willow Drive,
McAdenville in Gaston County.
2. Discharge from said treatment works at the location specified on the attached
map into the South Fork Catawba River, currently classified a WS-V waterbody in
subbasin 03-08-34 of the Catawba River Basin.

•, t c`,Fhr!
(• rrr. J� '•.
13nr,,a 1,11p
iI._ fir.
r
NC0004812
Pharr Yarns Industrial WWTP
State Grid/Quad: F 14 SE / MT Holly, NC
Latitude: 35° 15' 40" N Longitude: 81° 04' 39" W
Receiving Stream: South Fork Catawba River Sub -Basin: 03-08-34
Drainage Basin: Catawba River Basin Stream Class: WS-V
Map not to scale
Gaston County

Permit NC0004812
A. (1") EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [0.5 MGD]
During the period beginning on the effective date of this permit and lasting until the first time the monthly
average flow exceeds 0.5 MGD, the Permittee is authorized to discharge from outfall 001. Such discharges shall
be limited and monitored by the Permittee as specified below:
PARAMETER
.
LIMITS
MONITORING REQUIREMENTS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample
Type
Sample Location1
Flow
0.5 MGD
Continuous
Recording
Influent or Effluent
BOD5, 20°C
164.8 pounds/day
284.0 pounds/day
Weekly
Composite
Effluent
Total Suspended Solids
147.7 pounds/day
249.7 pounds/day
Weekly
Composite
Effluent
COD
1115.4 pounds/day
2130.3 pounds/day
Weekly
Composite
Effluent
Sulfide
2.6 pounds/day
5.2 pounds/day
,
Weekly
Composite
Effluent
Phenols
1.3 pounds/day
2.6 pounds/day
Weekly
Grab
Effluent
Total Chromium
1.3 pounds/day
2.6 pounds/day
Weekly
Composite
Effluent
Fecal Coliform (geometric mean)
200/100 mL
400/100 mL
Weekly
Grab
Effluent
Fecal Coliform (geometric mean)
Variable
Grab
U & D
NH3-N !
Weekly
Composite
Effluent
Dissolved Oxygen I
Weekly
Grab
Effluent
Dissolved Oxygen
Variable
Grab
U & D
pH !
> 6.0 and < 9.0
standard units
Weekly
Grab
Effluent
Temperature I
Daily
Grab
Effluent
Temperature
Weekly
Grab
U & D
Conductivity
Weekly
Grab
Effluent
Conductivity
Variable
Grab
U & D
Total Nitrogen
(NO2 + NO3 + TKN)2
No Effluent Limitation (mg1L)
No Effluent Limitation (pounds/month) (3)
13,698 pounds/year (annual mass loading) (3)
Weekly
Composite
Effluent
Monthly
(Calculated)
Effluent
Annually
(Calculated)
Effluent
Total Phosphorus2
No Effluent Limitation (mg/L)
No Effluent Limitation (pounds/month) (3>
1522 pounds/year (annual 'mass loading) (3)
Weekly
Composite
Effluent
Monthly
(Calculated)
Effluent
Annually
(Calculated)
Effluent
Color3
Monthly
Composite
Effluent
Color3
(April 1— October 31)
Monthly
Grab
U & D
Chronic Toxicity's
Quarterly
Composite
Effluent
Total Residual Chlorine
(TRC)5
28 pg/L
Weekly
Grab
Effluent
Notes:
1 U: upstream 50 feet or more above the outfall. D: downstream at Highway 7 bridge. Instream monitoring shall be
conducted 3/week from June through September and once per week the remainder of the year.
2 The annual mass loading for total nitrogen and total phosphorus for Outfall 001 shall be monitored and calculated as
prescribed in Part A.(5.).
3 See A.(6.) for more information on the permit requirements associated with color. Effluent color samples shall be taken
year round on a monthly basis. Instream sampling shall be performed on a monthly basis from April through October.
4 Chronic toxicity (Ceriodaphnia, P/F at 0.62%) testing in January, April, July and October [see A. (3)].
5 The facility shall report all effluent TRC values reported by a NC certified laboratory including field certified. However,
effluent values below 50 µg/L will be treated as zero for compliance purposes.
There shall be no rlischarge of floating solids or visible foam in other than trace amounts.

Permit NC00048 12
A. (2) EFFLUENT LIMITATIONS AND MONITORING'REQUIREMENTS [1.0 MGD]
During the period beginning on the month following the first time the monthly average flow exceeds O.5-MGD
and lasting until permit expiration, the Permittee is authorized to discharge from outfall 001. Such discharges
shall be limited and monitored by the Permittee as specified below:
PARAMETER
LIMITS
MONITORING REQUIREMENTS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample
Type
Sample Location1
Flow
1.0 MGD
Continuous
Recording
Influent or Effluent
BOD5, 200C
256.2 pounds/day
421.0 pounds/day
3/Week
Grab
Effluent •
Total Suspended Solids
239.0 pounds/day
386.7 pounds/day
3/Week
Grab
Effluent
COD
1316.3 pounds/day
2431.7 pounds/day
3/Week
Grab
Effluent
Sulfide
2.6 pounds/day
5.2 pounds/day
Weekly
Grab
Effluent
Phenols
1.3 pounds/day
2.6 pounds/day
Weekly
Grab
Effluent
Total Chromium
1.3 pounds/day
_
2.6 pounds/day
Weekly
Grab
Effluent
Fecal Coliform (geometric mean)
200/100 mL
400/100 mL
3/Week
Grab
Effluent
Fecal Coliform (geometric mean)
Variable
Grab
U & D
NH3-N
•
3/Week
Composite
Effluent
Dissolved Oxygen
3/Week
Grab
Effluent
Dissolved Oxygen
Variable
Grab
_
U & D
pH
> 6.0 and < 9.0 standard units
3/Week
Grab
Effluent
Temperature
Daily
Grab
Effluent
Temperature
3/Week
Grab
U & D
Conductivity
3/Week
Grab
Effluent
Conductivity
Variable
Grab
U & D
Total Nitrogen
(NO2 + NO3 + TKN)2
No Effluent Limitation (mg/L)
No Effluent Limitation (pounds/month) (3)
27397 pounds/year (annual mass loading)
(3)
Weekly
Composite
_
Effluent
Monthly
(Calculated)
Effluent
Annually
(Calculated)
Effluent
Total Phosphorus2
No Effluent Limitation (mg/L)
No Effluent Limitation (pounds/month) (3)
3044 pounds/year (annual mass loading) (3)
Weekly
Composite
Effluent
Monthly
(Calculated)
Effluent
Annually
(Calculated)
Effluent
Color3
Monthly
Composite
Effluents
Color3
(April 1— October 31)
Monthly
Grab
U & D
Chronic Toxicity'
Quarterly
Composite
Effluent
Total Residual Chlorine (TRC)5
28 pg/L
3/Week
Grab
Effluent
Notes:
1 Sample locations: Upstream - upstream 50 feet or more above the discharge point; Downstream - downstream at Highway
7 bridge. Instream monitoring shall be conducted 3/week from June through September and once per week the remainder
of the year.
2 The annual mass loading for total nitrogen and total phosphorus for Outfall 001 shall be monitored and calculated as
prescribed in. Part A. (5.).
3 See A. (6.) for more information on the permit requirements associated with color. Effluent color samples shall be taken
year round on a monthly basis. Instream sampling shall be performed on a monthly basis from April through October.
4 Chronic toxicity (Ceriodaphnia, P/F at 1.2%) testing in January, April, July and October [see A. (4)].
5 The facility shall report all effluent TRC values reported by a NC certified laboratory including field certified. However,
effluent values below 50 pg/L will be treated as zero for compliance purposes.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

•
Permit NC0004812
A. (3) CHRONIC TOXICITY MONITORING/LIMIT — 0.5-MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 0.62%.
The permit holderishall perform at a minimum, quarterlu 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 -Februarys 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. 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" (Revis d-February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentraayy ion having no detectable impairment of reproduction or survival and the lowest
concentration th4 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 "forth Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) oif 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 t}j a 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 brequired 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 than required by this permit, the results of
such monitoring shall be included in the calculation .86 reporting of the data submitted on the DMR 86
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.

Permit NC0004812
A. (4) CHRONIC TOXICITY MONITORING/LIMIT — 1.O-MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 1.2%.
The permit holder shall perform at a minimum, auarterlu 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
January, April, July and October. 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 than 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.

• •
Permit NC0004812
A.(5.) TOTAL NITROGEN AND PHOSPHORUS MONITORING
The Permittee shall calculate the annual mass loading of total nitrogen as the sum of
monthly loadings, according to the following equations:
(a) Monthly Mass Loading (pounds/month) = TN/TP x Q x 8.34
where: TN = the average total nitrogen concentration (mg/L) of the
composite samples collected during the month at the
outfall
TP = The average total phosphorus concentration (mg/L) of the
composite samples collected during the month at the
outfall
Q = the total wastewater flow discharged during the month at
the outfall(MG/mo.)
8.34 = conversion factor, from (mg/L x MG) to pounds
(b) Annual Mass Loading (pounds/year) = (Monthly Mass Loadings) for the
calendar year
The Permittee shall report the total nitrogen and total phosphorus concentration for each
sample and 4.1e monthly mass loading in the appropriate self -monitoring report and the
annual mash loading of total nitrogen and total phosphorus in the December self -
monitoring report for the year.
A. (6) Color Permitting Requirements for Tier 1 Facility
This facility has been classified as a Tier 1 color discharger. The permittee will conduct color
monitoring of instream stations (upstream, downstream) on a monthly basis during summer
season (April -October) . The permittee will record whether a color plume was observed
around the ouifall pipe during the monthly instream sampling events, and include that
information on the monthly discharge monitoring report. Effluent samples Will be collected
monthly for color on a year-round basis. Color samples will be analyzed for ADMI color at
natural pH. Effluent samples will consist of 24-hour composites, while instream samples
will be collected as grabs. Samples will be analyzed by a state certified laboratory.
If data show that water quality standards for color are being violated by the discharge
permitted by the terms of this permit, then the Director may reopen this permit for the
purpose of imposing additional requirements pursuant to 15A NCAC 2H.0114. Alternatively,
if future conditions change and color is no longer a component of the influent wastestream,
then the permittee may request a permit modification to remove color permit requirements.

Chernikov, Sergei
From:
Sent:
To:
Subject:
[e-mail]
Wednesday, February 24, 2010 1:47 PM
Chernikov, Sergei
RE: Pharr yarns
that's great. thanks.
1

Chernikov, Sergei
From:
Sent:
To:
Cc:
Subject:
Marshall,
Chernikov, Sergei
Wednesday, February 24, 2010 1:42 PM
'[e-mail]'
Belnick, Tom
RE: Pharr yarns
That's correct. I can keep the TSS at the level in the previous permit.
Sergei
Sergei Chernikov, Ph.D.
Environmental Engineer II
NPDES-West
Phone: [phone], fax [phone]
1617 Mail Service Center
Raleigh, NC 27699-1617
Express mail: 512 North Salisbury St.
Raleigh, NC 27606
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
Original Message
From: Hyatt.Marshall®epamail.epa.gov[mailto:Hyatt.Marshall®epamail.epa.gov]
Sent: Wednesday, February 24, 2010 1:10 PM
To: Chernikov, Sergei
Cc: Sayre.Dennis®epamail.epa.gov
Subject: Re: Pharr yarns
thanks for the chance to review. I do have one concern. It appears
the TSS limits in the final are an increase above those in the draft
permit. I believe the receiving stream is on NC's 208 303(d) list as
impaired for turbidity. If that is correct, this permit should not
increase the TSS loading. Do you agree?
If our enforcement
group has any other comments, I'll forward them to you.
1

Chernikov, Sergei
From:
Sent:
To:
Subject:
[e-mail]
Monday, January 04, 2010 8:53 AM
Chernikov, Sergei
re NC0004812, Pharr Yarns
EPA has no comments on this draft permit. Sorry for the delay in replying to you.

North Carolina ) ss
Mecklenburg County)
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
ATTN DINA SPRINKLE
NCDENR/DWO/NPDES
1617 MAIL SERVICE CTR
RALEIGH NC 27699-1617
REFERENCE: 30045571
6406921 wastewater permit
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: 11/07
AD SPACE: 72 LINE
FILED ON: 11/13/09
In Testimony Whereof I have hereunto
day and ygFir aforesaid.
TITLE:
DATE:
set my hand and affixed
r..
My Commission Expires May 27, 2011
Public Notice
North Carolina Environmental Management
Commission/NPDES Unit
1617 Mail Service Center,
Raleigh, NC 27699-1617
Notice or Intent to Issue.a NPDES Wastewater Permit
The North Carolina Environmental Management Commission
proposes to issue a NPDES wastewater discharge permit to the
person(s) listed below.
Written comments regarding the proposed permit will be
accepted until 30 days alter the publish date of this notice, The
Director of the NC Division of Water Quality (DWO) may hold a
public hearing should there be a significant degree of public
interest. Please mail comments and/or information requests to
D WQ at the above address, Interested persons may visit the DWQ
al 512 N. Salisbury Street, Raleigh. NC to review information
mayon l be ddtional found onnoournation on websi e: NPDES permits
notice
quallty.org, or by
calling [phone].
The Town of Cramerton has applied for renewal of permit
NC0006033 tor Eagle Road WWTP in.Gaston County; this facility
discharge is treated municipal wastewater to South Fork Catawba
River, Catawba River Basin.
Pharr Yarns. Inc. requested renewal of permit NC004228 for ifs
WWTP in Gaston County; this, tacitity discharge is treated
wastewater to South Fork Catawba River, Catawba River Basin.
N.0 Outward Bound requested .renewal- of NPDES permit
NC0040754 for its WWTP in Burke County. Facility discharges
treated wastewater to Roses Crreak l oolforrrithe aend lotalRiver
re asin.
Currently dissolved oxygen,
chlorine are water quality limited.
IP6406921
-------------
my
seal, the

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0004812
Facility Information
Applicant/Facility Name:
Pharr Yarns, Inc.
Applicant Address:
P.O. Box 1939, McAdenville, NC 28101
Facility Address:
147 Willow Drive, McAdenville, NC 28101
Permitted Flow
0.5/1.0 MGD
Type of Waste:
100% Industrial
Facility/Permit Status:
Class III/Active; Renewal
County:
Gaston County
Miscellaneous
Receiving Stream:
South Fork
Catawba River
Regional Office:
MRO
Stream Classification:
WS-V
State Grid / USGS Quad:
F14SE/
303(d) Listed?
No
Permit Writer:
Sergei Chemikov
Subbasin:
03-08-36
Date:
October 14, 2009
Drainage Area (mi2):
636
Summer 7Q10 (cfs)
125
Winter 7Q10 (cfs):
228
30Q2 (cfs)
310
Average Flow (cfs):
808
IWC (%):
1.2
iPiii-ip
[,at. 35° 15' 40" N Long. 81° 04' 39" W
BACKGROUND
Pharr Yarns, Inc. WWTP treats industrial waste created at the McAdenville facility as well as domestic
waste from three Pharr Yarns plants (including the McAdenville plant). The domestic waste from the
three Pharr Yarns plants constitutes the majority (73%) of the waste stream, the remainder is process
wastewater from the yam dying that occurs at the McAdenville plant.
As a discharger to the South Fork Catawba River, the facility is subject to the nutrient limits and special
monitoring requirements pertaining to color in an effort to improve water quality in that receiving stream.
TECHNOLOGY 113ASED EFFLUENT LIMIT DEVELOPMENT
Reasonable measure of actual production for the facility was established based on the EPA policy
(21,619 lb/day). BOD5, COD, and TSS are based on effluent guidelines (40 CFR 410.70 Subpart G Stock
and Yarn Finishing Subcategory) and have been recalculated to reflect the most current data available
(See attached spreadsheet). COD allocation for domestic wastewater component was calculated using
the formula 2.2 X BOD. The 2.2 multiplier was established during the previous permit renewal using
site -specific factors and Best Professional Judgment.
The results of these calculations are slightly different than the limits in the current permit. Since the
facility has no plans to expand production in the foreseeable future (per the facility), it is recommended
that the new limits be implemented.
TOXICITY TESTING
Current Requirement: Quarterly Chronic Toxicity @ 0.62%/1.2% JAN, APR, JUL, OCT
Recommended Requirement: Quarterly Chronic Toxicity @ 0.62%/1.2% JAN, APR, JUL, OCT. The
facility has been consistently passing its WET tests (please see attached).
COMPLIANCE SUMMARY
DMRs have been reviewed for the period from 01/01/2006 through 08/31/2009. Facility has a very
negative compliance record (please see attached).
Fact Sheet
NPDES NC0004812 Renewal
Page 1

Pharr Yarns has had operator and equipment issues and problems with slug loads (with high
BOD) being discharged into the plant's influent. They have changed over to a liquid chlorination
system but fecal violations continued. They requested a technical assistance visit, which was
performed during the summer of 2009. They have hired an engineering firm to go through the
entire plant and discussed making modifications to the plant. MRO has previously met with
Pharr Yarns staff to discuss these issues and the numerous limit violations.
INSTREAM MONITORING
The facility is required to conduct self -monitoring of the South Fork Catawba River at one location
upstream of the discharge and one location downstream of the discharge. The instream self -monitoring
includes: fecal coliform, temperature, conductivity, color and dissolved oxygen.
An analysis of DO, temperature and conductivity for the period from 01/01/2006 through 08/31/2009
showed that the facility have negligible negative impact on the receiving stream. During the review
period, the dissolved oxygen fell below 5 mg/L only once. On 07/05/07 dissolved oxygen downstream of
the discharge was measured at 3.0 mg/L, measurement upstream of the discharge was also 3.0 mg/L.
REASONABLE POTENTIAL ANALYSIS
Reasonable potential analysis was conducted for Chromium and Phenols at 0.5 MGD and 1.0
MGD. Based on RPA, no water quality based limits are recommended.
PROPOSED CHANGES
• Monitoring Frequencies: No changes are proposed.
• Limits: Limits for BOD, COD, TSS, Sulfide, Phenols, and Total Chromium have been
recalculated based on the most recent production data in the permit application.
STATE CONTACT
If you have any questions on any of the above information or on the attached permit, please contact
Sergei Chemikov at [phone].
CHANGES TO THE FINAL PERMIT:
Limits for BOD and COD, were recalculated (increased) to provide the facility full allocation in accordance with
40 CFR 410.70 Subpart G Stock and Yarn Finishing Subcategory.
DWQ received one request for a public hearing from the Catawba Riverkeeper . DWQ decided not to hold a
hearing because the facility has an EPA Administrative Order that should bring the facility into compliance.
Fact Sheet
NPDES NC00048 12 Renewal
Page 2

TEXTILE EFFLUENT LIMITS SPREADSHEET
PERMIT NO: NC0004812
PERMIT I tE: PHARR YARNS, INC.
COUNTY: GASTON
PERM I ED FLOW: 1 MGD
PRODUCTION DATA (in Ibs/day):
DAILY MAX.
MONTHLY AVG.
21619
21619
FROM 40CFR 410.70 SUBPART G (all limits in Ibs/1000 Ibs
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
6.8
84.6
17.4
0.24
0.12
0.12
3.4
42.3
8.7
0.12
0.06
0.06
must be between 6 and 9 at all times
LIMITS
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
147.0
1829.0
376.2
5.2
2.6
2.6
73.5
914.5
188.1
2.6
1.3
1.3
must be between 6 and 9 at all times
FINAL LIMITS (lb/day)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
421.0
2431.7
650.1
5.2
2.6
2.6
256.2
1316.3
370.7
2.6
1.3
1.3
must be between 6 and 9 at all times
BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
according to EPA recommendation
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
POLLUTANT
BOD5
TSS
DAILY MAX MONTHLY AVERAGE
274.01 182.6
274.0 182.6
CODS
" original BOD limits were 390 lb/day (monthly ave)
and 780 lb/day (daily max), so these limits are still
protective of DO
602.7318
401.8212

TEXTILE EFFLUENT LIMITS SPREADSHEET BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
PERMIT NO: NC0004812
PERMITTEE: PHARR YARNS, INC.
COUNTY: GASTON
PERMITTED FLOW:
PRODUCTION DATA:
0,5 MGD
DAILY MAX.
MONTHLY AVG.
FROM 40CFR 410.70 SUBPART G
21619
21619
(all limits in lbs/1000 Ibs)
POLLUTANT
BODS
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
6.8
84.6
17.4
0.24
0.12
0.12
must be between 6 and 9 at at times
3.4
42.3
8.7
0.12
0.06
0.06
LIMITS
POLLUTANT
BODS
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
147.0 73.5
1829.0
376.2
5.2
2,6
2.6
must be between 6 and 9 at all times
914.5
188.1
2.6
1.3
1.3
FINAL LIMITS (lb/day)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
284.0 164.8
2130.3
513.2
5.2
2.6
2.6
must be between 6 and 9 at all times
1115.4
279.4
0.0
0.0
0.0
according to EPA recommendation
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
POLLUTANT
BODS
TSS
DAILY MAX MONTHLY AVERAGE
137.01 91.3
137.0 91.3
COD
301.3659
" original BOD limits were 390 lb/day (monthly ave)
and 780 lb/day (daily max), so these limits are still
protective of DO
200.9106

TEXTILE EFFLUENT LIMITS SPREADSHEET
PERMIT NO:
PERM1 I 1 tE:
COUNTY:
NC0004812
PHARR YARNS, INC.
GASTON
PERMITTED FLOW: 1 MGD
PRODUCTION DATA (in Ibs/day):
DAILY MAX.
MONTHLY AVG.
FROM 40CFR 410.70 SUBPART G (all limits in Ibs/1000 Ibs)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
6.8
84.6
17.4
0.24
0.12
0.12
3.4
42.3
8.7
0.12
0.06
0.06
must be between 6 and 9 at all times
LIMITS
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
147.0 73.5
1829.0
376.2
5.2
2.6
2.6
914.5
188.1
2.6
1.3
1.3
must be between 6 and 9 at all times
BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
according to EPA recommendation
FOR PHARR YARNS, ONLY 27% OF FLOW IS
PROCESS FLOW ADJUST LIMITS ACCORDINGLY (except for: Sulfide, phenol, Cr)
POLLUTANT
BODS
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
39.7
493.8
101.6
5.2
2.6
2.6
19.8
246.9
50.8
2.6
1.3
1.3
must be between 6 and 9 at all times
FINAL LIMITS (lb/day)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
313.7
1096.6
375.5
5.2
2.6
2.6
202.5
648.7
233.4
2.6
1.3
1.3
must be between 6 and 9 at all times
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
POLLUTANT
BODS
TSS
DAILY MAX MONTHLY AVERAGE
274.01 182.6
274.0 182.6
COD5
* original BOD limits were 390 lb/day (monthly ave)
and 780 lb/day (daily max), so these limits are still
protective of DO
602.7318
401.8212

TEXTILE EFFLUENT LIMITS SPREADSHEET BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
PERMIT NO:
PERMITTEE:
COUNTY:
PERMITTED FLOW:
PRODUCTION DATA:
NC0004812
PHARR YARNS, INC.
GASTON
0.5 MGD
DAILY MAX.
MONTHLY AVG.
FROM 40CFR 410.70 SUBPART G
21619
21619
(all limits in Ibs/ 1000 Ibs)
POLLUTANT
BODS
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
6.8
84.6
17.4
0.24
0.12
0.12
must be between 6 and 9 at all times
3.4
42.3
8.7
0.12
0.06
0.06
LIMITS
POLLUTANT
BODS
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
147.0
1829.0
376.2
5.2
2.6
2,6
must be between 6 and 9 at all times
73.5
914.5
188.1
2.6
1.3
1.3
according to EPA recommendation
FOR PHARR YARNS, ONLY 27% OF FLOW IS
PROCESS FLOW ADJUST LIMITS ACCORDINGLY (except for: Sulfide, phenol, Cr)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX MONTHLY AVERAGE
39.7
493.8
101.6
5.2
2.6
2.6
must be between 6 and 9 at all times
19.8
246.9
50.8
2.6
1.3
1.3
FINAL LIMITS (Ib/day)
POLLUTANT
BOD5
COD
TSS
Sulfide
Phenol
Total Chromium
pH
DAILY MAX
176.7
795.2
238.6
5.2
2.6
2.6
must be between 6 and 9 at all times
MONTHLY AVERAGE
111.2
447.8
142.1
2.6
1.3
1.3
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
POLLUTANT
BOD5
TSS
DAILY MAX MONTHLY AVERAGE
137.0 91.3
137.0I 91.3
COD
301.3659
* original BOD limits were 390 lb/day (monthly ave)
and 780 lb/day (daily max), so these limits are still
protective of DO
200.9106

WK
gr,DICKSON
community infrastructure consultants
December 10, 2009
Dr. Sergei Chernikov
North Carolina DENR
NPDES — West
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: Pharr Yarns
Draft NPDES Permit NC0004812
WKD Project # 80422.00.CL
Dear Dr. Chernikov:
Thank you for providing the "Fact Sheet for NPDES Permit Development" with the attached spreadsheet
used by DENR for the development of the subject Pharr Yarns draft NPDES Permit.
On behalf of Phar Yarns, we would like to offer the following comments and request for modification of
this permit:
• The draft permit is based upon the Textile Effluent limits based upon 40CFR410.70, Subpart G —
Stock and Yarn Finishing Subcategory and a production level of 21,619 Ibs per day plus
considerations for a domestic wastewater contributing approximately 73% of the wastewater volume.
• The proposed mass limits for the Sulfide, Phenol, and Total Chromium are based upon the
categorical limits and production level with no additional mass contribution from the domestic waste
source.
• The determination of mass limits for BOD5, COD and TSS does not appear to be consistent with the
methodology utilized for Sulfide, Phenol and Total Chromium. The limits for BOD5, COD and TSS
are reduced by 27% based upon the domestic/industrial waste percentage with the mass limits
allocated for the 73% domestic volume added. Pharr Yarns does not agree with this methodology for
the BOD, COD and TSS as the textile production remains at 21,619 Ibs per day.
It is requested that 100% of the textile categorical mass loading for BOD, COD and TSS be included
within the mass limits and the mass limits allocated to the additional domestic waste portion be added as
r�_ t_ attached d _ w
reflected in i the czuu�.t �cu spreadsheet.
Thank you for your review and consideration of this matter. Should you have any questions or require
further information, please contact me.
Sincerely,
WK Dickson Inc. & Co.
CLL. R tL,,,E WED
Charles R. (Bob) Froneberger, P.E
Project Manager
Cc: Mr. George A. Altice
Mr. Jamie Davis
Mr. Fred Erickson
616 Colonnade Drive
Charlotte, NC 28205
Tel: [phone]
Fax: [phone]
www.wkdickson.com
DENR - WATER QUALITY
POINT SOURCE BRANCH
Transportation . Water Resources • Urban Development • Geomatics

PART I - GE
SOC PRIORITY PROJECT: No
To: Western NPDES Program Unit
Water Quality Section
Attention: Dina Sprinkle
Date: November 12, 2009
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Gaston
NPDES Permit No.: NC0004812
NERAL INFORMATION
1. Facility and address: Pharr Yarns WWTP
101 Main Street
Post Office Box 1939
McAdenville, N.C. 28101
2. Date of investigation: October 22, 2009
3. Report prepared by: Samar Bou-Ghazale, Environmental Engineer II
4. Person contacted and telephone number: James Davis, ORC, [phone].
5. Directions to site: From the j ct. of Hwy. 7 and I-85 in eastern Gaston County, travel south
on Hwy. 7 0.2 mile and turn left on Dickson Drive (no SR number). The WWTP site is on
the left side of Dickson Drive after traveling 0.2 mile.
6. Discharge point: Latitude: 35° 15' 40" Longitude: 81° 04' 39"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: F 14 SE
7. Site size and expansion area consistent with application: Yes. Very limited area is
available for expansion, if necessary.
8. Topography (relationship to flood plain included): The WWTP site did not appear to be
located in the 100 year flood plain (many of the primary treatment units are elevated and
protected from flooding by a concrete wall).
9. Location of nearest dwelling: Approx. 200± feet from the WWTP site.

4
Page Two
10. Receiving stream or affected surface waters: South Fork Catawba River
a. Classification: WS-V
b. River basin and subbasin no.: Catawba 030834
c. Describe receiving stream features and pertinent downstream uses: Excellent flow in
the receiving stream. Downstream uses are fish and wildlife propagation, secondary
recreation, and agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater: 1.0 MGD (Design Capacity)
b. What is the current permitted capacity: 0.50 MGD and 1.0 MGD.
c. Actual treatment capacity of current facility (current design capacity): 1.0 MGD
d. Date(s) and construction activities allowed by previous ATCs issued in the previous
two years: There have been no ATCs issued to this facility in the past two years.
e. Description of existing or substantially constructed WWT facilities: The existing
WWT facilities consist of a bar screen followed by an aeration basin with four (4)
fixed floating aerators and two (2) mixers, polymer and alum addition, two (2)
clarifiers, two sludge return pumps, two (2) filter pumps, three mixed media filters,
liquid sodium hypochlorite disinfection, dual chlorine contact chamber, tablet
de -chlorination, aerobic digester with three fixed aerators, sludge thickening tank, belt
dewatering filter, sludge storage and drying pad. This facility has two power sources
(Duke Power and the adjacent mill).
f. Description of proposed WWT facilities: There are no proposed WWT facilities at this
time.
g. Possible toxic impacts to surface waters: Arsenic, Chromium, Copper, Lead, Nickel,
Zinc from dye waste. This facility has consistently passed its toxicity testing.
h. Pretreatment Program (POTWs only): Not applicable.
2. Residual handling and utilization/disposal scheme: Residuals are currently thickened and then
processed in a belt filter press. From there they are stored on a concrete pad until such time as
they are taken for disposal to the Gaston County Landfill. Also, Sludge from the Town's
WWTP is disposed off at the plant digester.
3. Treatment plant classification: Class II (based on current flow of 0.500 MGD)
4. SIC code(s): 2262 Wastewater code(s): 55 MTU code(s): 05602

Page Three
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? Public monies were not used in the construction of this facility.
2. Special monitoring or limitations (including toxicity) requests: None at this time.
3. Important SOC/JOC or Compliance Schedule dates: Not at this time.
4. Alternative analysis evaluation: There is no reasonable alternative for this facility.
Municipial sewer of sufficient capacity to accept this waste flow is currently unavailable to this
site. Spray/Drip Irrigation and/or subsurface disposal are not an option due to the lack of
sufficient area.
PART IV - EVALUATION AND RECOMMENDATIONS
Pharr Yarns is requesting renewal of the subject Permit. There have been no changes to the
existing WWT facility or the NPDES permit since the permit was last renewed.
Pharr Yarns and EPA had a Show cause on November 10, 2009 regarding non-compliance
issues at the WWT plant. It should be noted that Pharr Yarn has been in non-compliance with its
permit for several months during the past year. It is our understanding that the non-compliance
issues at the plant are due mainly to lack of operation and maintenance. Pharr Yarn is contributing
the non-compliance issues to many factors including the large volume of high strength batch
wastewater releases from the dying process to the WWTP, the loss of filter media from one of the
three (3) pressure filter, inconsistency in chlorine solution concentration as the tablets dissolved.
Also, in order to address the forgoing violations, Pharr Yarns has increased the frequency of effluent
sampling and analysis to provide a better representation of monthly average effluent quality,
minimize normal analytical variations and provide an earlier indication of WWTP process problems
to allow proces's adjustments. Also, as indicated in letter to the U.S. Environmental Protection
Agency dated l41ay 13, 2009, Pharr Yarns is planning a preliminary evaluation of wastewater
treatment operator practices and staffing for the facility. During the investigation on October 22,
2009, new media filters were placed at the facility but not yet connected to the WWTP.
Pending review and approval by the Western NPDES Program Unit, it is recommended that
the permit be renewed.
//. /a— 2 9
Signat�rg of Re ort ' .arer Date
Water Quality Regional Supervisor Date

PHARl
TRADITION OF INNOVATION
September 23, 2009
Mrs. Dina Sprinkle
NCDENR
DWQ/ Point Source Branch
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pharr Yarns, LLC
Renewal of NPDES Permit
No. NC0004812
Gaston County N.C.
Dear Mrs. Sprinkle,
L Ly 2009
- WATER QUALITY
WATER PROTECTION SECTION
We would like to request the renewal of our subject permit. Please find attached
the original and two copies of the application form, description of our sludge
management plan, and supplemental documentation.
There have been no major changes at our facility since the issuance of the previous
permit, if further information is needed please call me at 704-823-2310 or e-mail
james.davis(r mindspring.com.
James L. Davis
Pharr Yarns, Environmental Manager
Pharr Yarns, LLC • 100 Main Street • PO Box 1939 • McAdenville North Carolina 28101-1939 • Phone [phone]

PHARR YARNS WWTP
NPDES NO NC0004812
Dyed Yarn Production:
FISCAL 2007
Space Dye Print Dye- 82,526/week 13,754 / day 3 bd 5
Space Dye Belmont Dye: 47,190 / week 7,865 / day I
Complex 46 Heat -Set- 981,743 / week 163,624 / day
FISCAL 2008
Space Dye Print Dye- 48,906 / week 9,781 / day Al 1 Jcl-
Space Dye Belmont Dye- 36,380 / week 7,276 / day.
Complex 46 Heat -Set 994,687 / week 165,781 / day
FISCAL 2009
Space Dye Print Dye- 69,281 / week 13,656 / day n r00
Space Dye Belmont Dye 37,067 / week 7,413 / day
Complex 46 Heat -Set 1,310,313 / week 218,386 / day
Projected Fiscal 2009
Space Dye Print Dye- 46,187 / week 9,237 / day
Space Dye Belmont Dye- 24,711 / week 4,942 / day
Complex 46 Heat -Set — 873,542 / week 145,390 / day

Pharr Yarns, LLC WWTP
NPDES No. NC0OO4812
Present Status
The present operating status is under a two tiered permit. A.(1.) Effluent and Monitoring
Requirements- Final with a flow rate of 0.5 mgd monthly average. We do not expect to
exceed this flow. If the flow is exceeded we would be under the A.(2.) requirements with
a monthly flow average of 1.0 mgd.
Wastewater Treatments Components:
• 1.01 MG Aeration Basin 65'x182 `x11.3' depth with four 25hp aerators and two
15hp mixers.
• Chemical treatment for flocculation, Alum and polymer.
• Two clarifiers, 41' diameter (100,000 gals.), 35' diameter (72,000 gallons)
• Tv.o sludge return pumps, 350 gpm each.
• Two filter pumps, 700 gpm each.
• Thee mixed media filters, 8' diameter with backwash pump.
• Liquid sodium hypochiorite disinfection feed.
• Dual chlorine contact chamber 12'x30'x10' each.
• Tablet dechlorination feed.
• 1.0 MG aerobic digester with three 75hp fixed aerators.
• Sludge thickening tank, (6,800 gallons).
• De'vatering belt press with filtrate return to head of plant.
• Sludge storage and drying pad, 12O'x50' with liquid return to head of plant.

PHARR YARNS,LLC WWTP
NPDES NO. NC0004812
SLUDGE MANAGEMENT PLAN
Pharr Yarns runs a one million gallon per day activated sludge wastewater treatment
plant. Sludge generated in the plant is controlled by doing daily settleability tests
on the aeration basin and sludge depth tests on the clarifiers. The sludge is wasted
as needed to a one million gallon aerated digester.
The digested sludge is then transferred to a 6,800 gallon thickening tank to be
run on'a one meter belt press. This pressed sludge is then trucked to 120'x50'
concrete pad to be further dried then disposed of in Gaston County's lined landfill.

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