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Home My WebLink AboutNC0001899_permit issuance_20120523NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Charles Wakild, P.E. Dee Freeman Governor Director Secretary May 23, 2012 Mr. Don Patterson, Plant Manager Performance Fibers, Inc. 338 Pea Ridge Road New Hill, NC 27562 nizzi Subject: Issuance of NPDES Permit Permit NC0001899 Performance Fibers, Inc. WWTP Chatham County Class II Dear Mr. Patterson: Division personnel have reviewed and approved your application for renewal of the subject permit. Accordingly, we are forwarding the attached NPDES 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). In the future, any required mercury measurement must use EPA test Method 1631E. It is recommended that you obtain fmal approval for the requested relocation of Outfall 001 composite sampler from the Raleigh Regional Office. Summary of Changes in Final Permit from Existing Permit 1) Outfall 001: Total PAH monitoring was removed. 2) Outfall 001: A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS OCPSF - 001 technical corrections were made to some limits. Additional narrative was added to clarify non -detect impact on compliance. 3) Outfall 002: Total Aluminum quarterly monitoring was added. 4) . Special Condition A. (8) MERCURY TMDL REOPENER was added. 5) Special Condition A. (3) CHRONIC TOXICITY PERMIT LIMIT (Quarterly) - 001, A. (5) ACUTE TOXICITY MONITORING (ANNUAL) - 002, and SUPPLEMENT TO PERMIT COVER LE11 ER narratives were updated. Page 1 of 2 1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Location: 512 N. Salisbury St. Raleigh, North Carolina 27604 Phone: 919-807-63001 FAX: 919-807-64921 Customer Service: 1-877-623-6748 Internet: www.ncwaterquality,org An Equal Opportunity \ Affirmative Action Employer NorthCarolina Nature, 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 permits that may be required. If you have any questions concerning this permit, please contact Ron Berry at telephone number (919) 807-6396 or at email ron.berry@ncdenr.gov. Sincerely, ifriCharles Wakild, P.E. Attachments Cc: Raleigh Regional Office/Surface Water Protection Section (with copy of Fact Sheet and Addendum) EPA Region IV/Pamala Myers (email with copy of Fact Sheet and Addendum) Environmental Sciences Section/Aquatic Toxicology Unit/Susan Meadows (email) Environmental Sciences Section/Ecosystems Unit/Steve Kroeger (email) Environmental Sciences Section/Ecosystems Unit/Carrie Rulhman (email) Marty Stewart/Performance Fibers, Inc. (email: Marty.Stewart@performancefibers.com) Central Files NPDES File Page 2 of 2 • Permit NC0001899 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 provisions of North Carolina General Statute 143-215.1, other lawful standards and regulations promulgated and adopted by the North Carolina Water Quality Commission, and the Federal Water Pollution Control Act, as amended, Performance Fibers, Inc. is hereby authorized to discharge wastewater from a facility located at the Performance Fibers, Inc. WWTP 338 Pea Ridge Road East of Moncure Chatham County to receiving waters designated as the Haw River in the Cape Fear River Basin in accordance with the discharge limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof. This permit shall become effective July 1, 2012. This permit and the authorization to discharge shall expire at midnight on July 31, 2016. Signed this day May 23, 2012. oeAS, es Wakild, P.E., Director ivision of Water Quality By the Authority of the Environmental Management Commission 414 Permit NC0001899 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. Performance Fibers, Inc. is hereby authorized to: 1. Continue to discharge the combined treated process and domestic wastewater, and treated water treatment plant backwash wastewater to Outfall 001 permitted for 0.244 MGD, consisting of wastewater treatment components: o Sanitary bar screen, grinder, and lift station o Process wastewater lift station o One (1) 1,200 gallons mixing/neutralization chamber with automatic pH control o One (1) 650,000 gallons aeration basin with mechanical aerators o Coagulent addition system o One (1) 18,500 gallons clarifier o One (1) 1000 ft2 sludge drying bed o Chlorine contact chamber (no chlorination) o Conventional water treatment plant with chemical addition systems o One (1) 20,000 gallons clarifier o Two (2) alum settling ponds, one 300,000 gallons, one 500,000 gallons o One (1) 1,000,000 gallon polishing pond o Effluent composite sampler o Effluent meter 2. Continue to discharge stormwater, condensate, and overflow from two 1,200,000 gallons fire ponds to Outfall 002. This facility is located at the Performance Fibers, Inc., -3:38. Pea Ridge Road east of Moncure in Chatham County. 3. Discharge wastewater from said treatment works at the location specified on the attached map via outfall 001 into the Haw River and via outfall 002 to Shaddox Creek, both of which are classified WS-IV,waters in the Cape Fear River Basin.. U HWY1 'Upstream NC0001899 NC0001899 rP. Downstream NC0001899 USGS Quad: E22SE Moncure, NC Latitude Longitude Facility: 35° 37' 7" N 79° 2' 46" N Outfall 001: 35° 37' 1" W 79° 3' 25" W Outfall 002: 35° 37' 0" W 79° 2' 36" W Stream Class: WS-IV Subbasin: 03-06-07 HUC: 03030002 Receiving Streams: Outfall 001 Haw River Outfall 002 Shaddox Creek Performance Fibers, Inc. NC0001899 North NC0001899 tfal 002 Facility Location Performance Fibers, Inc. NC0001899 Chatham County Permit NC0001899 A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - 001 During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge treated process, domestic, and filter backwash wastewater from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: Effluent Characteristics Limits Monitoring Requirements Monthly Average Weekly Average Daily Maximum Measurement Frequency Sample Type Sample Location 1 Flow 0.244 MGD Continuous RecordingInfluent or Effluent pH 2 Not greater than 9.0 S U. nor less than 6.0 S.U. Continuous Recording Effluent BOD, 5 day (20°C) 10.4 lbs/day 16.7 lbs/day Weekly Composite Effluent - Total Suspended Solids 5.0 lbs/day 10.6 lbs/day Weekly Composite Effluent Oil and Grease 20.0 lbs/day 30.0 lbs/day Weekly Grab Effluent Temperature, °C Monthly Grab Effluent Temperature, °C Monthly Grab Upstream & Downstream Conductivity, p.mohs/cm Monthly Grab Effluent Conductivity, µmohs/cm Monthly Grab Upstream & Downstream Dissolved Oxygen, mg/L Monthly Grab Effluent Dissolved Oxygen, mg/L Monthly Grab Upstream & Downstream Total Nitrogen, mg/L 3 Quarterly Composite Effluent Total Phosphorus, mg/L Quarterly Composite Effluent Chronic Toxicity 4 Quarterly Composite Effluent OCPSF 5 Annually Grab Effluent Footnotes: 1. Upstream: valve at Permittee's river water pump house. Downstream: nearest accessible point at least 100 yards below the outfall and above the confluence of the Deep and Haw Rivers. Instream monitoring is provisionally waived due to the permittee's participation in the Upper Cape Fear River Basin Association. Instream monitoring shall be conducted as stated in this permit should the permittee end its participation in the Association. 2. The pH shall be monitored continuously at the -effluent. In accordance with 40 CFR 401.17, the total time during which the pH values are allowed to be less than 6.0 standard units or greater than 9.0 standard units shall not exceed 7 hours and 26 minutes in any calendar month, and no individual excursion outside the 6.0 to 9.0 range shall exceed 60 minutes. 3. TN = TKN + NO3-N + NO2-N, where TN is Total Nitrogen, TKN is Total Kjeldahl Nitrogen, and ' NO3-N and NO2-N are Nitrate and Nitrite Nitrogen, respectively. 4. Chronic Toxicity (Ceriodaphnia) Chronic P/F at 0.94%; January, April, July, and October; see A. (3). 5. Refer to A. (2) regarding OCPSF monitoring. Where any compound is detected, quarterly monitoring is required for that compound until not detected in twelve consecutive samples. Performance Fibers may use EPA test method 524.2 to monitor OCPSF. parameters (provided the method allows a detection level at or below the permitted limit). THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. 4 Permit NC0001899 A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS OCPSF - 001 During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge OCPSF related process wastewater from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: Effluent Characteristic Daily Maximum (lbs/day) Monthly Average (lbs/day) Frequency Measurement 1 Sample Type Sample Location Acenaphthene 0.004 0.001 Annually Grab Effluent Acenaphthylene 0.004 0.001 Annually Grab Effluent Acrylonitrile 0.015 0.006 Annually Grab Effluent Anthracene 0.004 0.001 Annually Grab Effluent Benzene 0.009 0.002 Annually Grab Effluent Benzo(a)anthracene 0.004 0.001 Annually Grab Effluent 3,4-Benzofluoranthene 0.004 0.001 Annually Grab Effluent Benzo(k)fluoranthene 0.004 0.001 Annually Grab Effluent Benzo(a)pyrene 0.004 0.001 Annually Grab Effluent Bis (2-ethylhexyl) phthalate Carbon Tetrachloride 0.017 0.002 0.006 0.001 Annually Annually Grab Grab Effluent Effluent Chlorobenzene 0.002 0.001 Annually Grab Effluent Chloroethane 0.017 0.007 Annually Grab Effluent Chloroform 0.003 0.001 Annually Grab Effluent 2-Chlorophenol 0.006 0.002 Annually Grab Effluent Chrysene 0.004 0.001 Annually Grab Effluent Di-n-butyl phthalate 0.004 0.002 Annually Grab Effluent 1,2-Dichlorobenzene 0.010 0.005 Annually Grab Effluent 1,3-Dichlorobenzene 0.003 0.002 Annually Grab Effluent 1,4-Dichlorobenzene 0.002 0.001 Annually Grab Effluent 1,1-Dichloroethane 0.004 0.001 Annually Grab Effluent 1,2-Dichloroethane 0.013 0.004 Annually Grab Effluent 1,1-Dichloroethylene 0.002 0.001 Annually Grab Effluent 1,2-trans-Dichloroethylene 2,4-Dichlorophenol 1,2-Dichloropropane 0.003 0.007 0.014 0.001 0.002 0.010 Annually Annually Annually Grab Grab Grab Effluent Effluent Effluent 1,3-Dichloropropylene 0.003 0.002 Annually Grab Effluent Diethyl phthalate 0.013 0.005 Annually Grab Effluent 2,4-Dimethylphenol 0.002 0.001 Annually Grab Effluent Dimethyl phthalate 0.003 0.001 Annually Grab Effluent 4,6-Dinitro-o-cresol 0.017 0.005 Annually Grab Effluent 2,4-Dinitrophenol 0.008 0.004 Annually Grab Effluent 2,4-Dinitrotoluene 0.018 0.007 Annually Grab Effluent 2,6-Dinitrotoluene 0.040 0.016 Annually Grab Effluent Ethylbenzene Fluoranthene 0.007 0.004 0.002 0.002 Annually Annually Grab Grab Effluent Effluent Fluorene 0.004 0.001 Annually Grab Effluent Hexachlorobenzene 0.002 0.001 Annually Grab Effluent Permit NC0001899 (Continued A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS OCPSF - 001) Effluent Characteristic Daily Maximum (lbs/day) Monthly Average (lbs/day) Frequency Measurement 1 Sample Type Sample Location Hexachlorobutadiene 0.003 0.001 Annually Grab Effluent Hexachloroethane 0.003 0.001 Annually Grab Effluent Methyl Chloride 0.012 0.005 Annually Grab Effluent Methylene Chloride 0.006 0.003 Annually Grab Effluent Naphthalene 0.004 0.001 Annually Grab Effluent Nitrobenzene 0.004 0.002 Annually Grab Effluent 2-Nitrophenol 0.004 0.003 Annually Grab Effluent 4-Nitrophenol 0.008 0.005 Annually Grab Effluent Phenanthrene 0.004 0.001 Annually Grab Effluent Phenol 0 0.002 0.001 Annually Grab Effluent Pyrene 0.004 0.002 Annually Grab Effluent Tetrachloroethylene 0.004 0.001 Annually Grab Effluent Toluene 0.005 0.002 Annually Grab Effluent 1,2,4-Trichlorobenzene 0.009 0.004 Annually Grab Effluent 1,1,1-Trichloroethane 0.003 0.001 Annually Grab Effluent 1,1,2-Trichloroethane 0.003 0.001 Annually Grab Effluent Trichloroethylene 0.003 0.001 Annually Grab Effluent Vinyl Chloride 0.017 0.007 Annually Grab Effluent When the required EPA analytical method with the appropriate minimum detection level is followed and a result of "non -detectable" or "below quantitation limit" is obtained, the permittee will be considered to be in compliance with the numerical permit limit for that pollutant. Footnote: 1. Where any compound is detected, quarterly monitoring is required for that compound until not detected in twelve consecutive samples. Performance Fibers may use EPA test method 524.2 to monitor OCPSF parameters (provided the method allows a detection level at or below the permitted limit). A. (3) CHRONIC TOXICITY PERMIT LIMIT (Quarterly) - 001 The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia dubia at an effluent concentration of 0.94%. The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase 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. Permit NC0001899 (Continued A. (3) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)- 001) 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 Section 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the Environmental Sciences Section 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. If the Permittee monitors any pollutant more frequently than required by this permit, the results of such monitoring shall be included in the calculation and reporting of the data submitted on the DMR and AT Forms. 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 NC0001899 A. (4) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - 002 During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge stormwater, steam condensate, and fire pond overflow wastewater from Outfall 002. Such discharges shall be limited and monitored by the Permittee as specified below: Effluent Characteristics Limits Monitoring Requirements Monthly Average Weekly Average Daily Maximum Measurement Frequency Sample . Type Sample Location Flow Weekly Instantaneous Effluent Temperature, °C 1 Weekly Grab Effluent pH Not greater than 9.0 S.U. nor less than60S.U. Weekly Grab Effluent Total Aluminum, µg/L Quarterly Grab Effluent Total Zinc, gg/L Quarterly Grab Effluent Acute Toxicity 2 Annually Grab Effluent Footnotes: 1. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C. 2. Acute Toxicity (Fathead Minnow) Annual Monitoring, see A. (5). THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. A. (5) ACUTE TOXICITY MONITORING (ANNUAL) - 002 The permittee shall conduct annual toxicity tests using protocols defined as definitive in E.P.A. Document EPA/600/4-90/027 entitled "Methods for Measuring the Acute Toxicity of Effluents to Freshwater and Marine Organisms." The monitoring shall be performed as a Fathead Minnow (Pimephales promelas) 24-hour static test. Effluent samples for self -monitoring purposes must be obtained below all waste treatment. The permittee will conduct one test annually, with the annual period beginning in January of the calendar year of the effective date of the permit. The annual toxicity test must be performed by June 30. Should there be no discharge of flow from the facility during the six month period January 1-June 30, 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 in the comments section indicate "No Flow for January 1-June 30, {calendar year}." The report must be signed and submitted to the Environmental Sciences Section at the address noted below. If no discharge event occurs from January 1-June 30, yet a discharge event occurs from July 1- December 31, then the facility must perform toxicity monitoring and report the data as noted below. The parameter code for this test is TAE6C. All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it was performed, using the appropriate parameter code. Additionally, DWQ Form AT-1 (original) is to be sent to the following address: Permit NC0001899 (Continued A. (5) ACUTE TOXICITY MONITORING (Annual) - 002) Attention: North Carolina Division of Water Quality Environmental Sciences Section 1621 Mail Service Center Raleigh, N.C. 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in association with the toxicity tests, as well as all dose/response data. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. If the Permittee monitors any pollutant more frequently than required by this permit, the results of such monitoring shall be included in the calculation and reporting of the data submitted on the DMR and AT Forms. Should any test data from either these monitoring requirements 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 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. A. (6) WASTEWATER TREATMENT PONDS - 002 The wastewater treatment ponds at the facility shall maintain a freeboard height of 2 feet. A. (7) PERMIT REOPENER: SUPPLEMENTARY NUTRIENT MONITORING Pursuant to N.C. General Statutes Section 143-215.1 and the implementing rules found in Title 15A of the North Carolina Administrative Code, Subchapter 02H, specifically, 15A NCAC 02H.0112(b)(1) and 02H.0114(a), and Part II, Sections B.12. and B.13. of this Permit, the Director of DWQ may reopen this permit to require supplemental nutrient monitoring of the discharge. The additional monitoring will be to support water quality modeling efforts within the Cape Fear River Basin, and shall be consistent with a monitoring plan developed jointly by the Division and affected stakeholders. A. (8) MERCURY TMDL REOPENER The Division may, upon written notification to the permittee, re -open this permit in order to incorporate or modify effluent limitations and monitoring and reporting requirements when such action is necessary to implement a TMDL for mercury approved by the U.S. EPA. ADDENDUM — 5/15/12 DENR/D WQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT NPDES PERMIT NC0001899 The final permit was amended per the following actions: 1) The aluminum monitoring requirement for Outfall 002 was reduced to quarterly to match Division strategy. 2) The special condition for Analytical Detection Levels was replaced with a new narrative added to Outfall 001 OCPSF effluent requirement page for better clarity. 3) Outfall designations were added to each appropriate special condition header for better clarity. 4) The permit structure was rearranged to organize special conditions in order of each outfall to provide more effective access to requirements. Additional Clarifications: The BOD and TSS mass -based limits for Outfall 001 used the following wastewater flows provided by the Permittee to calculate limits and were compared to the existing limits: Process wastewater = 7,500 gpd applied 40 CFR 414.31 Domestic wastewater = 7,900 gpd applied secondary treatment standards Non -process wastewater = 50,600 gpd applied 1996 study results The PAH requirement is a NC WQS, based on detects and Division strategy was removed. However, the individual chemical compounds that comprise the PAH group of chemical are part of the federal requirement for Subpart I and can be totaled and re-evaluated as PAH in future permits. Currently the whole state is impaired for mercury. Facilities that report mercury data are being instructed to use method 1631E to enable evaluation of mercury in its discharge. In 2012 a mercury TMDL is scheduled to be approved that will redefine mercury requirements state wide. It may be necessary to reopen this permit once new mercury data is available and the approved TMDL is in place before the next renewal to determine if a limit is required. Regardless, mercury will be evaluated at the next renewal. NPDES DIVISION CONTACT If you have questions regarding any of the above information or on the attached permit, please contact Ron B ry at (9 807-6396 or email ron.berry@ncd nf .gov. NAME: DATE: VA�/ DENR/DWQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT NPDES PERMIT NC0001899 Facility Information Applicant/Facility Name: Performance Fibers, Inc Applicant Address: 338 Pea Ridge Road; New Hill, NC 27562 Facility Address: 338 Pea Ridge Road; New Hill, NC 27562 Permitted Flow Outfall 001: 0.244 MGD Type of Waste: Outfall 001: 92% industrial/8% domestic; Outfall 002: 52% stormwater/48% industrial Facility/Permit Status: Class II/ Major /Active; Renewal County: Chatham County Outfall 001 Drainage Area (mi2): 980 Receiving Stream: Haw River Summer 7Q10 (cfs) 40 (min release) Subbasin: 03-06-07 Winter 7Q10 (cfs): 40 (min release) Stream Classification: WS IV 30Q2 (cfs) 40 (min release) Index No. 16-(42) Average Flow (cfs): 1848 HUC: 03030002 IWC (%): 0.94% 303(d) Listed? No Outfall 002 Drainage Area (min'): - Receiving Stream: Shaddox Creek Summer 7Q10 (cfs) - Subbasin: 03-06-07 Winter 7Q10 (cfs): - Stream Classification: WS IV 30Q2 (cfs) - Index No. 16-43 Average Flow (cfs): - HUC: 03030002 IWC (%): 100% 303(d) Listed? No Miscellaneous State Grid / USGS Quad: E22SE Moncure, NC Region: Raleigh Permit Writer: Ron Berry Date: Revised: 6/11/12 BACKGROUND Performance Fibers manufactures polyester/synthetic fibers using terephthalic acid, ethylene glycol, and fiber finishing lubricants. Two permitted outfalls allow discharge of industrial -based wastewater, one to the Haw River and the second to an unnamed tributary to Shaddox Creek, both classified as WS IV, in the Cape Fear River Basin. This portion of the Haw River is a controlled discharge from Lake Jordan with its confluence in the Cape Fear River. Shaddox Creek confluence is the Haw River. The facility process wastewater discharge is subject to EPA effluent guidelines in 40 CFR 414.30 Subpart C Other Fibers and Subpart I. There are no metal -bearing waste streams or cyanide -bearing waste streams as listed in Part 414. The Permittee has requested that Outfall 001 effluent composite sampler be relocated from off site to the plant site since chlorination is no longer utilized and removes the rational for the current location. This facility is a member of the Upper Cape Fear River Basin Association. The modeling unit is continuing efforts on streams studies and modeling for nutrients and oxygen demanding wastes in this segment of the Cape Fear River for permit development. Fact Sheet NPDES NC0001899 Page 1 of 4 HISTORY 2007 - Outfall 001 TRC, fecal coliform, and designated sample location for chloroform requirements were removed. - Outfall 002 TRC, zinc, and fluoride monitoring were removed. - The 2005 nutrient strategy recommendations were implemented. Outfall 001 TN and TP monitoring reduced to quarterly; a reopener clause for additional monitoring was added. TREATMENT PROCESS The wastewater treatment plant mixing basin collects wastewater from process, non -process, and stormwater where an automatic pH control adjusts the pH by adding sulfuric acid. Sanitary wastewater passes trough a comminutor, a bar screen, and collects in a pump lifting station. The wastewater from the mixing basin and lifting station are discharged into the main aeration basin which uses four surface aerators. A coagulent is added to clarifier influent and the exiting treated wastewater mixes with the conventional water treatment plant treated wastewater, discharging to Outfall 001. If necessary the clarifier discharge can be diverted to the water treatment plant polishing pond. River water is drawn from the Haw River and fills two fire water ponds which overflow to Outfall 002, and supply raw water to the conventional water treatment plant. The backwash wastewater from the water plant is sent to two alum settling ponds and then to the polishing pond. Treated water treatment plant wastewater is discharged from the polishing pond. CURRENT WASTEWATER BALANCE The discharge from Outfall 001 is a combination of treated wastewater from the wastewater treatment facility (94% of the discharge) and from the conventional process water treatment plant (6% of the discharge). The wastewater treatment facility influents consist of process wastewater, non -process wastewater, and sanitary wastewater as shown in Table 1: Table 1: Outfall 001 Waste Treatment Plant Influent Sources Non -process influent (50,600 gpd) % of Influent - evaporation (1) Boiler blowdown 1.1% (2) Softener and demineralizer wastewater 14.9% (3) Cooling tower blowdown 28.7% (4) HVAC/air compressor condensate 11.4% (5) Oil mist air pollution system wastewater 1.7% (6) Oil pretreatment filtered water 0.9% Stormwater (16,000 gpd) 18.3% Process wastewater (7,500 gpd, area stormwater) 8.6% Domestic wastewater (7,900 gpd) 9.0% Water Treatment Plant (4,700 gpd) 5.4% The reported flows from Outfall 001 have decreased from 2006 (See Table 2) to the present approximately 22%. The most recent water balance indicates relatively no change to the volume of process wastewater and sanitary portions since 2007, and is consistent with the discharge history. Table 2: DMR Monthly Flow Averages, MGD 2006 2007 2008 2009 2010 2011e* Annual Average: 0.090 0.085 0.091 0.065 0.075 0.055 Maximum Monthly: 0.105 0.095 0.128 0.076 0.102 0.071 Minimum Monthly: 0.079 0.070 0.069 0.051 0.062 0.048 *not a complete year Fact Sheet NPDES NC0001899 Page 2 of 4 Ot11 002 discharge is a combination of stormwater (52% of total discharge), condensate from HVAC/air compressor/air dryer (1 % of total discharge), and river water that by design overflows continuously from the fire water ponds (47% of total discharge). There is no treatment process associated with this outfall, nor process wastewater sources, nor assigned permitted flow. COMPLIANCE Since 2007 there have been 9 permit limit violations; 1 for BOD, 3 for O&G, and 5 for TSS. The last TSS violation was in May 2011. A total of $145 in fines were assessed and paid. PERMITTING STRATEGY Outfall 001 Projected new BOD and TSS limits were calculated applying 40 CFR 414.31 guidelines, water balance, discharge history, and 1996 wastewater evaluation. The projected BOD and TSS limits are slightly higher but do warrant changing the limits in this permit. The existing BOD and TSS limits and other existing A. (1) limits/requirements will continue in this permit. Data Review Outfall 001 Statistics DMR January 2008 to January 2011 Flow* (MGD) BOD* (lbs/day TSS* (lbs/day) O&G* (lbs/day) pH (S.U.) DO (mg/L Conductivity (µmho/cm) Temperature (°C) Average 0.076 2.10 3.89 1.0 7.25 8.72 996.6 18.27 Maximum 0.13 40.0 5.4 11 8.5 13.9 1610 28.9 Minimum 0.05 > 0.1 1.3 > 0.1 6.5 3.8 436 2.3 montniy average Chronic Toxicity This discharge has consistently passed its chronic test, the A.(3) narrative will be updated. 414.91 Subpart I Review Using the water balance, surface water quality standards, and 414.91 Subpart I factors, new limits were calculated and the more stringent limit applied. No changes were required except for some rounding corrections in special condition A.(8) limits. Subpart I parameters, A.(8), were not detected this permit cycle. The special condition A. (7) requiring increase in monitoring frequency if any Subpart I parameters are detected will continue. Total PAH Review Total PAH annual data showed no detect. It will be removed from this permit and re-evaluated at the next renewal based on Subpart I data. Priority Pollutant Analysis (PPA) One PPA was submitted and the metal data compared to applicable surface water quality standards. All reported values were less than their IWC based limit. No further action is required. The one mercury data value was not conclusive since the more sensitive test method was not previously required. This industry has no known mercury sources associated with its manufacturing process. The permittee will be directed to use test method 1631E for all future mercury analyses. A reopener condition will be added to apply the mercury TMDL if applicable. Reasonable Potential Analysis (RPA) The Division conducted EPA -recommended analyses to determine the reasonable potential for bromoform, chloroform, and dichlorobromomethane toxicants to be discharged based on available data. There was no potential so no further action is required. Outfall 002 Data Review Fact Sheet NPDES NC0001899 Page 3 of 4 The existing A. (2) limits/requirements will continue in this permit Outfall 002 Statistics DMR January 2008 to January 2011 Flow* (MGD) pH (S.U.) Temperature (°C) Average 0.300 _ 7.31 _20.28 Maximum 4.54 8.4 31.3 Minimum 0.03 6.4 5.5 *monthly average Additional Data Review Additional effluent metal data was compared to the IWC based metal limits. The single data value for aluminum exceeded the IWC limit. Will add monthly aluminum monitoring to this permit and evaluate at next renewal. The one mercury data value was not conclusive since the more sensitive test method was not previously required. This industry has no known mercury sources associated with its manufacturing process. The permittee will be directed to use test method 1631E for all future mercury analyses. A reopener condition will be added to apply the mercury TMDL if applicable. Acute Toxicity This discharge is subject to annual acute toxicity monitoring, only results available was in 2007 and it was passed, the A.(4) narrative will be updated. Other Special Condition/Narratives The existing A. (5) Wastewater Treatment Ponds and A. (6) Permit Re -opener: Supplementary Nutrient Monitoring special conditions will continue in this permit. The component list will be updated to include more descriptive equipment narratives. SUMMARY OF PROPOSED CHANGES In keeping with Division permitting strategy the following will be incorporated into the permit: • Outfall 001 Total PAH monitoring in A.(8) will be removed • Outfall 001 Subpart I limits in A.(8) will be corrected. • Outfall 002 Total Aluminum monthly monitoring will be added. • Reopener special condition will be added for mercury TMDL. • A. (3), A. (4), and SUPPLEMENT TO COVER LETTER narratives will be updated. • Cover letter will address Outfall 001 composite sampler relocation. PROPOSED SCHEDULE FOR PERMIT ISSUANCE, Draft Permit to Public Notice: February 29, 2012 Permit Scheduled to Issue: April 2012 NPDES DIVISION CONTACT If you have questions regarding any of the above information or on the attached permit, please contact Ron -y at (9J9 807-6396 or email ron.berry ncdenr.gov. NAME: Z. DATE: 6///I � REGIONAL OFFICE COMMENTS NAME: DATE: SUPERVISOR: DATE: Fact Sheet NPDES NC0001899 Page 4 of.4 Performance Fibers Inc NC0001899 4 wf r HISTORY 1980 - The Allied Fibers facility had two outfalls. Stream classification was C and the current Lake Jordan Reservoir did not exist. - Outfall 001 had assigned mass -based limits for BOD, COD, Oil and Grease, TSS, and TKN. Additional limits for pH, Zinc, and Temperature, and fecal coliform monitoring were also imposed. - Outfall 002 had assigned limits for temperature, zinc, and pH. I985 - Outfall 003 was added for treated wastewater discharging to a UT. Waste load -based limits for BOD, TSS, NH3-N, pH, DO, and fecal coliform were applied. - Outfalls 001 only change was the removal of zinc. - Outfall 002 requirements did not change. 1991 - Based on Raleigh Regional Office recommendation, OutfalI 003 was removed from the permit since its flow combined with the facility wastewater treatment effluent prior to discharging through Outfall 001. - A new waste load allocation (WLA) model was developed because of the new Lake Jordan Reservoir and its control of Haw River flow. - New federal OCPSF guidelines were applied to Outfall 001. - Outfall 001 received new limits per OCPSF guidelines, and for fecal coliform and gross beta particles. Conductivity and PAH monitoring were added. - Outfall 002 received a new limit for fluoride but changed zinc requirements to monitor only. 1992 - The Haw River and Shaddock Creek were reclassified to WS IV. 1994 - Outfall 001 received new limits for acute toxicity and monitoring for TRC. - Outfall 002 received new monitoring requirement for acute toxicity and monitoring for TRC. 1996 - The facility process and non -process waste flows were historically difficult to characterize. A study was conducted to characterize wastewater sources and their contribution to the total BOD loading. Based on that study it was determined that non -process flows contribute a significant BOD load (unlike typical OCPSF facilities) and that an additional allowance should be granted in the permit. - Outfall 001 BOD and TSS limits were revised based on effluent guidelines for OCPSF (40 CFR 414.30), the study non -process wastewater loads, and guidelines for secondary standards for sanitary wastes. - Outfall 001 COD, TKN, and gross beta particle requirements were removed. TN and TP monthly monitoring were added. - Outfall 002 TP monthly monitoring was added. 2000 - The permit was modified to match the expiration date for this subbasin, July 31, 2001. - Ownership changed to Honeywell. - The facility joined the Upper Cape Fear River Basin Association and the permit specific instream monitoring was conditionally waived. 2002 - Outfall 001 monitoring frequency for OCPSF organic parameters changed from quarterly to annually with a conditional provision to increase monitoring to quarterly if a parameter was detected. - Outfall 001 received new requirements for a designated chloroform sample location, a change to chronic toxicity -based limit, and new narrative for conditional waiver of instream sampling. - Outfall 002 fluoride limit and TP monitoring were removed; both fluoride and zinc monitoring were reduced to annually. • 3-7-12 RE Draft permit for Performance Fibers Inc. NC0001899 From: Ruhlman, Carrie Sent: Monday, March 05, 2012 8:36 AM To: Berry, Ron Cc: Kroeger, Steve; Belnick, Tom subject: RE: Draft permit for Performance Fibers, Inc. NC0001899 Ron, Footnote 1 in section A.(1) is incorrect. Performance Fibers is a member of the Upper Cape Fear River Basin Association, not the Lower Cape Fear River Basin Association. Please see that this correction is made. Thank you! Carrie Ruhlman NC Division of water Quality Phone: (919)743-8411 carrie.ruhlman@ncdenr.gov http://portal.ncdenr.org/web/wq/ess/eco/coalition Email correspondence to and from this address may be subject to the North Carolina Public Records Law and may be disclosed to third parties. ??Please consider the environment before printing this e-mail. From: Berry, Ron Sent: Friday, March 02, 2012 3:38 PM To: Pugh, James L.; Ruhlman, Carrie; Kroeger, Steve Subject: Draft permit for Performance Fibers, Inc. NC0001899 As requested see attachment for your copy. Ron Berry ron.berry@ncdenr.gov Engineer I DWQ/Point Source/NPDES Complex Permitting Unit NCDENR Phone: (919) 807-6396 Fax: (919) 807-6495 office: Archdale Building Room 925Y Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed to third parties unless the content is exempt by statute or other regulation. Page 1 • 4 3-19-12 Response draft Permittee NPDES Wastewater Permit - DRAFT - Performance Fibers NC0001899 From: Stewart, Marty [Marty.Stewart@performancefibers.com] Sent: Sunday, March 18, 2012 4:58 PM To: Berry, Ron Subject: NPDES Wastewater Permit - DRAFT - Performance Fibers NC0001899 Mr. Berry, I have received the draft permit NC0001899 for the Performance Fibers New Hill facility. I have reviewed the draft permit and understand the items that have been added or changed. I have no comments or revisions at this time. If you require anything else from me, please let me know. Marty Stewart Disclaimer: This e-mail communication and any attachments may contain confidential and privileged information and is for use by the designated addressee(s) named above only. If you are not the intended addressee, you are hereby notified that you have received this communication in error and that any use or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have received this communication in error, please notify us immediately by replying to this message and deleting it from your computer. Thank you. Page 1 3-12-12 EPA Approval NC0001899 Performance Fibers draft permit From: Pamala Myers [Myers.Pamala@epamail.epa.gov] Sent: Monday, March 12, 2012 10:45 AM To: Berry, Ron Cc: Mark Nuhfer; Belnick, Tom Subject: NC0001899, Performance Fibers draft permit Good Morning Ron, Just a brief note to let you know we received your draft documents on March 2, 2012. My only comments on your draft permit for the Performance Fibers, Inc., Industrial WWTP are that you might want to clarify the reason behind the mercury TMDL reopener clause is because the entire state is listed for mercury impairments. Other than that I have no further comments. Please proceed to issuance at your convenience. Thank you for the opportunity to review this draft permit. Pamala Myers 404.562.9421 myers.pamala@epa.gov Environmental Engineer and Technical Advisor I Pollution Control and Implementation Branch Water Protection Division I Municipal and Industrial NPDES Section U.S. EPA, Region 4 161 Forsyth St. SW I Atlanta, GA 30303 Page 1 NORTH CAROLINA CHATHAM COUNTY The Chatham News AFFIDAVIT OF PUBLICATION Before the undersigned, a Notary Public of said County and State, duly commissioned, qualified, and authorized by law to administer oaths, person- ally appeared Florence Turner first duly sworn, deposes and says: that he (she) is Accounts Receivable Clerk who being (Owner, partner, publisher, or other officer or employee authorized to make this affidavit) of The Chatham News Publishing Co., Inc., engaged in the publication of a newspaper known as, The Chatham News, published, issued, and entered as second class mail in the Town of Siler City, in said County and State; that he (she) is authorized to make this affidavit and sworn statement; that the „vnotice or legal advertisement, a true copy of which is attached hereto, was published in The Chatham News on the following dates: �l o 8S7 a and that the said newspaper in which such notice, paper, document, or legal advertisement was published was, at the time of each and every such publication, a newspaper meeting all of the requirements and qualifications of Section 1-597 of the General Statutes of North Carolina and was a quali- fied newspaper within the meaning of Section 1-597 of the General Statues of North Carolina. This day of • Sworn gland.Abscribed 9aTiore me, this • pUBN>G day of SO 4" T"n Cz--cd-- (Signature of person making affidavit) • eir IARY / Notary Public CLIPPING OF LEGAL ADVERTISEMENT ATTACHED HERETO PUBLIC NOTICE North Carolina Environmental Management Commission/ NPDES Unit 1617 Mail Service Center Raleigh, NC 27699-1617 NPDES NOTICE OF INTENT TO ISSUSE A WASTEWATER PERMIT The North Carolina Environmental Management Commission proposes to issue a NPDES wastewater dis- charge pe:. it to the person(s) listed below. Written comments regarding the pro- posed permit will be accepted until 30 days after the publish date of this notice. The Director of the NC Divi- sion of Water Quality (DWQ) may hold a public hearing should there be a significant degree of public interest. Please mail comments and/or infor- mation requests to DWQ at the above address. Interested persons may visit 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: http://portal.ncdenr. org/web/wq/swp/ps/npd es/calendar, or by calling (919) b07-6304. Performance Fibers, Inc. requested renewal of permit NC0001899 for its facility in Chatham County; this per- mitted discharge is treated industrial wastewater to Shaddox Creek and Haw River, Cape Fear River Basin. M My Commission expires 7 a 0 Date: 9/20/11 , pbrrdb, DMR Data for NPDES Permit NC0001899 Outfall 001 - Performance Fibers Inc 1.00 0.90 ;- 0.80 -- 0.70 - 0.60 - 0.50 - O Flow Rdg ■ Flow Monthly Avg Permitted Flow 0.40 - 0.30 - 0.20 --� 0.10 0.00 6 0o co co 0o co co 00 co 00 0o co 00 a) co co co rn C, rn a o, 0) 0) co 0 0 0 0 0 0 0 0 0 0 0 0 - 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o O O O O 0 0 0 0 ei ei o f • 1 e i ei , .1 m a> c 00 fi > c 9 N Q> c > u g .0 a s> c 00 a a fn o Z o IL') g Q ' Q vvi o Z o LL g a g a' ) o Z o; 40.0 35.0 - 30.0 - 25.0 - n 20.0 • BOD Monthly Avg ❑ BOD Daily Monthly Limit Daily Limit 15.0 - 10.0 5.0 0.0 1J- _C��_ Q _ _n_Q ♦lilil 2.18 00 00 00 CO 00 CO 00 CO CO CO CO CO 01 0, 01 01 01 0) 01 0) 01 01 01 01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o ti .1 c .n fl. > c oo .z > u c .0 `m n > g - 00 c. ;� > ci c .o 01 0 f0 7 0/ 0 0) f0 A 0 01 0 0) 0 0J LL C Q a u O Z LL Q 2 Q H O Z Q LL 0 cm 0 0 0 0 0 0 0 0 0 .. > 0m /1 > U Q ' ' N O ocu Q Z 0 1 f0 25.0 20.0 15.0 10.0 5.0 • TSS Monthly Avg 0 TSS Daily Monthly Avg Limit -Daily Limit -13 ❑ ❑ ❑ • r� orferilo 0 cm •.y ..i ■ ` Chi ❑ 0 . � r®. 0 f f T r❑ ❑ f a f 0 C II co 0o 00 ao 00 0o 00 00 0o 00 00 0o 01 01 01 co 01 co 0) a) a) 01 01 0l 0 0 0 0 0 0 0 0 0 0 O 0 .1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ei .1 e-f .ti ei e-f ei ei ei ei ei ei ei 00 n > b c s > c 00 a > u c a > c 00 a +' > u c c130) f6 O. f0 7 01 o O) 07 R 0. f0 ^ 0 0/ 1.l 0 0) Q7 /0 G. A 7 01 V 0 CU � .LL Q g a fn o z o LL g Q a VI o Z 0 LL g a 2 a fn o Z Date: 9/20/11 , pb:rdb, DMR Data for NPDES Permit NC0001899 Outfall 001 - Performance Fibers Inc • , , Feb-09 .. reo-uy o ) a 1 Mar-09 O Mar-09 - 1 _ 73 Apr-09 • Q° Apr-09 ' ;" 'vo v Q : i> May 09 .: p io May-09 <cz. _ '_.—' w aa 0 Jun-09 - m Jun-09 - s� >> Q Jul-09 p Jul-09 - `' '.°'o a . Aug-09 cro_ .�' Aug-09 •c `` ° Sep-09 re Sep-09 ,oo __ Oct-09 Oct-09 `=" • '' : r , Nov-09 Nov-09 1 Dec-09 K Dec-09 • ilo VI ``Jan-10 azJan-SO <_ =AZ. , 1. Feb-10 .c Feb-10 1 >, Mar-10 Mar-10 i = ,e 1 1 <' ' Apr-10 _� '* Apr-10 - ,,: <;;_�,. 4. r May-10 .. May-10 - <: �� "—' a Jun-10 •• Jun-10 -y'+ 5 Jul-10 , Jul-10 { 1 '` , p Aug-10 , m Aug-10 • € ,cs --*. Sep-10 Sep-10 i 7. �`,, Oct-10 O _3 Oct-10 ` <` `,� Nov-10 Nov-10 � `<` �' . rt Dec-10 Dec-10 00 CO 0 0 c a 0) u_ 00 0 `m CO 0 - Q CO 0 > CO CO 0 c CO 0 ? CO 0 00 7 Q 00 0 O. 0) of CO 0 " O CO 0 > 0 Z CO CT 0 0 b c 0J fo O al 0 .o 0) LL 0, 0 m 0, 0 Q Q 0, 0 > r0 01 0 c 01 0, 0 0 00 ?= Q 01 01 0 0 Q. 0r u N 0 CT01 0 0 > u 0 a z 0 0 .1 c `�° 0 .-, .Q v LL 0 .� L 0 2 0 0 0 0 0 1-1N N 1-1� a-1 . > c= on n m=?= Q 2 Q 0 .-4 a v V1 0 . '' o 0 .1 > 0 Z 0 .1 u v 0 Date: 9/20/11 pb:rdb, 4 ; DMR Data for NPDES Permit NC0001899 Outfall 001 - Performance Fibers Inc 35 30 25 OTemperature Rdg -O O 4 -O- co o0 00 0o 00 00 00 0o 0o op 0o co rn rn 0, rn 0i rn cm 0, rn rn rn rn o 0 0 0 0 0 0 0 0 0 0 0 .-i 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o N .-1 ti ti ti N N ti .-+ ti ti N c m a >, c 00 Q. > u _o ro n >- c 00 a > u c s ro a> c- 00 a > u c IL, 7 al O a1 ro w 3 a, o a, COy m > > y o v LL 2 a 2 a VI o Z QLi_ 2 a 2 ¢ 0, o Z Q LL 2 Q 2 < 0 o Z Q E 0 -0 E 1,800 1,600 1,400 1,200 1,000 800 600 400 200 0 0 0 0 0 0 0 C T = aJ fa Q ,p Li_g a g a 00 6 O Conductivity Rdg O 9 O 6 O O O O O O O O CO 00 CO CO 00 CO 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0� 00 O. �-' > u C al T ^ m C u > u CCL A OD cj > 0) C < {� O Z 0-' LL 2 Q g —�• Q rn O Z Q -t'i LL < 2-, 12 — 10 8 — O J u 6 E 4 2 0 O TN Rdg 4- O s r—r , , O 0 co 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0- 0 4 ? C 00 Q >co L: ? C ha Q- U rer > V C: 9 T C 00 Q V > U C tL 2 Q 2 ' Q ,n 0 Z Q— ,L g Q 2 < ,n o Z Q" LL Q 2-' Q ,n O Z Date: 9/20/11 , pb.rdb, DMR Data for NPDES Permit NC0001899 Outfall 001 - Performance Fibers Inc 1.6 — O 1.4 — 1.2 1.0 E 0.8 — 0.6 0.4 — 0.2 — 0.0 O TP Rdg -Cd 0 O- 00 CO 00 CO CO 00 00 CO CO 00 CO 00 01 0, 41 01 01 01 01 01 O 07 01 01 0 0 0 0 0 0 0 0 0 0 0 0 r+ O O o Q 0 0 o O 9 O 0 0 Q 0 Q 0 O 0 Q 0 O 0 0 0 • .-� r 4 ti ti N N .� N N N ti ti c a a c ao a ;� > c Q" > c ri0 a▪ > u • c 0.c co o. u c -f6 LL • g a g ? Q ▪ o 0 Q 01 `-° u�. 2 Q g= Q v). O z 0 • L g Q 3 Q N O z TGP3B - P/F STATRE 7Day Chr Ceriodaphnia Jan-07 pass =1 Apr-07 pass =1 Jul-07 pass=1 Oct-07 pass = 1 Jan-08 pass=1 Apr-08 pass =1 JuI-08 pass=1 Oct-08 pass =1 Jan-09 pass =1 Apr-09 pass =1 JuI-09 pass =1 Oct-09 pass =1 Jan-10 pass=1 Apr-10 pass = Jul-10 pass =1 OCt-10 pass =1 Date: 9/20/11 DMR Data for NPDES Permit NC0001899 Outfall 002 - Performance Fibers Inc 0.60 0.50 — 0.40 -- O 0.30 0 0 0 0 OQ O 0 0 0 0 00 00 i 40. 0 00 4D 4Di 0.20 o---i yI---- _--i 4DM i -o 00 60 001V110 0 I/ iip 00'011 ■- - 0 0 O si CO o i 0 i III 0.10 — °° -ILOO -9i o- O-0---0o---t-Q0 0 O o f 4-4D•-- 0-048-- 0 of i 4D00 0 0o ao oo,0 a ° o 1- W 08 V N G) -25- 0 00 0 0 Flow Rdg W 1 V O 0 00 0 M Flow Monthly Avg Median -Flow Rdg 0 0 01 i O * ■ 0 0.00 00 00 00 CO CO CO CO CO CO 00 CO 00 01 01 01 01 01 01 01 00 00 01 01 01 0 0 0 0 0 0 0 0 0 0 0 0 a-1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .-1 .� .� .a . .� .� e-1 .ti N .-1 • s .• 6. ▪ L c a - i s 00 a > u c n > 6 no a ▪ > u ro Ii 2 Q Q v1 O Z O °1�' Q Q 1n O Z O - Q- Q vai O Z O 35 *Temperature Rdg 30 0 °-40 ---0 °�0B <eV 25 °�� 0 0O o* 0° °° 0• - - 0- 00 0 0 0 0 O° 00 0 0 20 - 006> 00 ° 0 00 0 d' ▪ 0 0 is O° O� O$ B C so 0 0 0 ,� °o 000 0 9.5 9.0 1 I 1 1 1 1 00 00 CO 00 CO CO 00 CO CO CO 00 CO 01 01 C1 O1 01 01 01 01 01 01 01 01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .-1 a• -I si a-/ .-i ei . -1 ."i r1 ei rl -I 171 6 4 A C 00 6. > u C ? 6 h0 Q > 66.6 1 >..0 ^ OD G. > u `-° ti Q < • v1 O z 0 -f6 LL Q Qco 7 v1 O z O CO ti M fa2 Q 2- Q v1 O Z 8.5 — 8.0 vi 7.5 — 7.0 6.5 — 6.0 5.5 —A— pH Rdg —Limit Range 00 00 00 00 00 o0 0o 00 0o 00 00 0o 01 01 01 01 01 01 01 01 01 01 01 01 0 0 0 0 0 000 00 0 0 .-1 O O O O O O O O O O O O O O O O 0 O o 0 0 O a -I a•-1 a -I .-1 .-I .-1 1-1 r1 a-1 .-1 1-1 a-1 r1 a u c a • a c 00 a > ci 6 �- c 110 0. u > u 0 Ol Q- fo 3 7 0 ▪ 0 CI)OJ A 0. 10 ^ • 3 0) 0 O1 ^ y fo - 0. 10 3 01 0 N ro Q g, < 1.1 O z o IL 2 Q 2 Q,n O z o u_g Q g Q 1n O z Date: 11 /16/11 pip? rdb DMR Data for NC0001899 Performance Fibers, Inc. 0.140 0.120 3. 0.100 i6_ 0.080 0.060 3 0.040 T s 1 0.020 L 0.000 •l 2006 OUTFALL 001 FLOW HISTORY * Monthly Average --Annual Average a $� �q,'76 ®®�nx:c.r r�.re::rrer••:n 0 4 • 4 2007 2008 9 2009 • 2010 2011 Year: 2006 2007 2008 2009 2010 2011p Annual Average, MGD: 0.090 0.085 0.091 0.065 0.075 0.055 Maximum Monthly Average, MGD: 0.105 0.095 0.128 0.076 0.102 0.071 Minimum Monthly Average, MGD: 0.079 0.070 0.069 0.051 0.062 0.046 1/9/2012 Chloroform 1,2 Dichlorobenzene Performance Fibers, Inc )CPSF Flow => 0.0075 MGD NC0001899 nl, _> 0.244 MGD Effluent Monthly Limit Daily Limit EfOuem Characteristics Bases Ibs/day 9 Bases Ibs/day. Acenaphthene OCPSF 0.001 OCPSF 0.004 Acenaphthylene OCPSF _ 0.001 0.001 OCPSF 0.004 0.001 Acrylonitrile OCPSF 0.006 OCPSF 0.015 Anthracene OCPSF 0.001 0.0061 OCPSF 0.004 0.001 Benzene OCPSF 0.002 OCPSF 0.009 Benz ethylhexyl) phthalate 0.002 0.006 OCPSF 0.017 0.006 Carbon Tetrachloride 0.001 OCPSF 0.002 Carbon Tetras 0.001 0.001 OCPSF 0.002 Chlorobenze 0.007 - 0.0009 OCPSF 0.017 0.007 0.001 OCPSF 0.003 0.001 2-Chlorophenol 0.002 OCPSF 0.006 Di-n-butyl phthalate 0.002 0.002 OCPSF 0.004 0.002 1,3-Dichlorobenzene 1,4-Dichlorobenzene 1,1-Dichloroethane 1,2-Dichloroethane 1,1-Dichloroethylene 1,2-trans-Dichloroethylene 2,4-Dichlorophenol 1,2-Dichloropropane 1,3-Dichloropropylene Diethyl phthalate 2,4-Dimethylphenol Dimethyl phthalate 4,6-Dinitro-o-cresol 2,4-Dinitrophenol 2,4-Dinitrotoluene 2,6-Dinitrotoluene Ethylbenzene Fluoranthene Fluorene Hexachlorobenzene Hexachlorobutadlene Hexachloroethane Methyl Chloride Methylene Chloride Naphthalene Nitrobenzene 2-Nitrophenol 4-Nitrophenol OCPSF OCPSF OCPSF CPSF CPSF 1DCPSF OCPSF JOCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF CHRONIC OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF Monthly Average ibs/day Stream classification designated as WS Daily Maximum Ibs/day 0.004 0.004 0.015 0.004 0.009 0.017 0.002 0.002 0.017 0.003 0.006 0.005 OCPSF 0.010 0.004 0.005 0.010 0.002 OCPSF 0.003 0.002 0.003 0.001 OCPSF 0.002 0.0009 0.002 0.001 OCPSF 0.004 0.001 0.004 0.004 OCPSF 0.013 0.004 0.013 0.001 OCPSF 0.002 0.001 0.002 0.001 OCPSF 0.003 0.001 0.002 OCPSF 0.007 0.003 _ 0.002 0.007 0.010 OCPSF 0.014 0.010 0.014 0.002 OCPSF 0.003 0.002 0.005 OCPSF 0.013 0.003 0.005 0.013 0.001 OCPSF 0.002 0.001 0.002 0.001 OCPSF 0.003 0.001 0.003 0.005 OCPSF 0.017 0.005 0.017 0.004 OCPSF 0.008 0.004 0.008 0.007 OCPSF 0.018 0.007 0.018 0.016 OCPSF 0.040 0.016 0.040 0.002 OCPSF 0.007 0.002 0.007 0.002 OCPSF 0.004 0.002 0.004 0.001 OCPSF 0.004 0.001 0.004 0.001 OCPSF 0.002 0.0006 0.002 0.001 OCPSF 0.003 0.001 0.003 0.001 OCPSF 0.003 0.001 0.003 0.005 OCPSF 0.012 0.005 _ 0.012 0.003 OCPSF 0.006 0.003 0.006 0.001 OCPSF 0.004 0.001 0.004 0.002 OCPSF 0.004 0.002 0.004 0.003 OCPSF 0.004 0.003 0.004 0.005 1 OCPSF 0.008 0.005 0.008 Acute Limit N9rL Measurement I Sample Sample Frequency Type Location' Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Annually Annually Annually Annually Annually Annually Annually Annually Annually Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually - Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite Annually Composite I Annually Composite E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E Page 1 of 2 1/9/2012 Effluent Characteristics Phenanthrene Phenol Pyrene Tetrachloroethylene _ Toluene Total Chromium Total Copper Total Cyanide Total Lead Total Nickel Total Zinc 1,2,4-Trichlorobenzene 1,1,1-Trichloroethane aditMonthly Limit Daily Limit ases Ibs/day Bases Ibs/day OCPSF OCPSF OCPSF OCPSF 0.001 0.001 0.002 0.001 OCPSF OCPSF OCPSF OCPSF 0.004 0.002 0.004 0.004 OCPSF 0.002 CHRONIC -10.824 CHRONIC CHRONIC CHRONIC CHRONIC CHRONIC OCPSF OCPSF 1,1,2-Trichloroethane Trichloroethylene Vinyl Chloride Total PAHs Benzo(a)anthracene 3,4-Benzofluoranthene Benzo(k)fluoranthene Benzo(a)pyrene Chrysene Dibenz(a,h)anthracene Indeno(1,2,3-ed)pyrene Total chlorinated benzenes Chlorobenzene_ 2-Chlorophenol 1,2-Dtchtorobenzene 1,3-Dichlorobenzene 1,4-Dichtorobenzene Hexachiorobenzene 1,2,4-Trichiorobenzene Pentachlorobenzene 1,2,4,5-Tetrachlorobenzene OCPSF OCPSF OCPSF CHRONIC OCPSF OCPSF OCPSF OCPSF OCPSF CHRONIC CHRONIC CHRONIC OCPSF OCPSF OCPSF OCPSF OCPSF CHRONIC OCPSF CHRONIC CHRONIC OCPSF 0.005 ACUTE 182.432 1.515 ACUTE 1.303 Monthly Average Daily Maximum Ibslday Ibs/day 0.001 0.0009 0.002 0.001 0.002 10.824 1.515 1.082 ACUTE 3.927 1.082 5.412 ACUTE 6.033 5.412 0.004 0.002 0.004 0.004 0.005 5.412 ACUTE 46.590 5.412 , 10.824 ACUTE 11.960 10.824 0.004 OCPSF 0.009 0.004 0.001 OCPSF 0.003 0.001 0.001 OCPSF 0.001 0.007 0.001 0.001 0.001 0.001 0.001 0.001 0.002 0.005 0.002 0.001 0.001 0.004 OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF OCPSF 0.003 0.003 0.017 0.004 0.004 0.004 0.004 0.004 0.002 0.006 0.010 0.003 0.002 0.002 0 009 0.001 0.001 0.007 0.028 • 0.001 0.009 0.003 0.003 0.003 0.017 0.004 Acute Ltmlt NglL Measurem Frequency Annually Annually Composite Composite E 89649.12 640.35 -1 1929.82 Annually Composite E Annually Composite E Annually Composite E -1- Annually Composite E Annually Composite E -_ Annually 1 Composite E 2964.91 Annually Composite E 22894.74 Annually Composite E 5877.19 Annually L Composites E Annually Composite E Annually Annually Annually Composite Composite Composite E E E 0.001 0.001 0.001 0.001 105.645 0.001 0.002 0.005 0.002 0.001 0.001 0.004 0.110 0.210 0.004 0.004 0.004 0.004 0.002 0.006 0.010 0.003 0 002 0 002 0 009 Subpart I effluent page assessment: 1) Continue to suspend metal monitoring as process has no metal bearing waste streams and no RYA is shown, metals are still part of PPA 2) Add Total PAH limit, is chronic WQS (monthly average) converted to mass limit and assign to monthly average 3) Adjust limits for rounding where applicable 4) Do NOT apply TCB limit or extended 'PCB parameters, Subpart I individual parameter limits more stringent, adjust for CHRONIC where wanc.ued Annually Annually Annually Annually Annually Annually Annually Annually Composite E Composite E Composite Composite Composite Composite Composite Composite Annually Composite Annually Composite Annual Composite E E E E E E E E Annually Composite E Annually _ Composite Annually Composite E Annual Composite E AnnuallyCompositeI E y Composite I E Annually 1 Composite 1 E Annually Composite Page 2 of 2 Peformance Fibers, Inc. REASONABLE POTENTIAL ANALYSIS NC0001899 Qw(MGD)= 0.24 1 Q 10S (cfs) = 32.90 7Q10S (cfs) = 40.00 7Q1OW (cfs) = 40.00 30Q2 (cfs) = 40.00 Avg. Stream Flow, OA (cfs) = 1848.00 Receiving Stream: Haw River WWTP/WTP Class: II IWC ® 1Q1OS = 1.14% IWC ®7Q10S= 0.94% IWC C41 7Q 10W = 0.94% IWC @ 30Q2 = 0.94% IWC @ QA = 0.02% Stream Class: WS IV Outfall 001 Qw = 0.244 MGD CHRONIC TEST CONCENTRATION = 0.94% PARAMETER TYPE (1) STANDARDS & CRITERIA (2) NC WQS / Chronic Applied th FAV / Standard Acute 0 O. REASONABLE POTENTIAL RESULTS ri # Det. Max Pred Cw Allowable Cw RECOMMENDED ACTION Aluminum NC 87 FW(7Q10s) µg/1 1 1 1969.8 Note: n < 9 Default C.V. Limited data set Antimony NC 5.6 WS(7Q10s) µg/I 1 1 276.3 Note: n < 9 Default C.V. Limited data set Copper (AL) Barium Iron (AL) Manganese NC NC NC NC 7 FW(7Q10s) 7.3 1 WS(7Q10s) 1 FW(7Q10s) 200 WS(7QI0s) /41 mg/I mg/1 1 . 1 388.7 Note: n < 9 Default C.V. Limited data set 1 1 0.3 Note: n < 9 Default C.V. Limited data set 1 1 3.9 Note: n <_ 9 Default C.V. Limited data set 1 1 240.6 Note: n <_ 9 Default C.V. Limited data set Acute: NO WQS - Chronic: 9,255.32 No value > Allowable Cw Acute: NO WQS - Chronic: _ 595.74 No value > Allowable Cw Acute: 640.35 - Chronic: 744.68 No value > Allowable Cw Acute: NO WQS - Chronic: 106.38 No value > Allowable Cw I 4- RPA undefined, only one data point, data<chronic - review in next PPA Acute: NO WQS - Chronic: 106.38 No value > Allowable Cw Acute: NO WQS - Chronic: 21,276.60 Molydbenium Mercury NC NC 160 WS(7Q10s) 0.012 FW(7Q10s) µg/1 1 1 I 1414.5 Note: n <_ 9 Default C.V. Limited data set 1 0 1.3 Note: n 5 9 Default C.V Limited data set No value > Allowable Cw Acute: NO WQS - Chronic: 17,021.28 No value > Allowable Cw Acute: NO WQS - Chronic: — —� 1.28 Nickel Sulfates NC NC 25 WS(7Q10s) 261 250 WS(7Q10s) µg/1 mg/1 1 1 113.7 Note: n < 9 Default C.V. Limited data set 1 1 1771.5 Note: n <_ 9 Default C.V. Limited data set No value > Allowable Cw Acute: 22,894.74 - Chronic: 2,659.57 No value > Allowable Cw Zv,3 RPA undefined, only one data point, data<chronic - review in next PPA See chronic Z • ( RPA undefined, only one data point, data<chronic - review in next PPA R- PA undefined, only one data point, data<chronic - review in next PPA RPA undefined, only one data point, data<chronic - review in next PPA R- PA undefined, only one data point, data<chronic - review in next PPA R- PA undefined, only one data point, data<chronic - review in next PPA U- nable to determine, will advise Permittee to use Method 1631E in next PPA See chronic R- PA undefined, only one data point, data<chronic - review in next PPA Acute: NO WQS Chronic: 26,595.74 RPA undefined, only one data point, data<chronic - No value > Allowable Cw review in next PPA Page 1 of 2 2011 RPA 001, rpa 9/30/2011 Peformance Fibers, Inc. NC0001899 REASONABLE POTENTIAL ANALYSIS Outfall 001 Qw = 0.244 MGD Zinc (AL) Bromoform Chloroform Dichlorobromomethane NC NC NC NC 50 FW(7Q10s) 67 4.3 WS(7Q10s) 5.6 WS(7Q10s) 0.4 WS(7Q10s) ILO 1 1 4151.1 Note: n < 9 Default C.V. Limited data set 4 1 59.3 Note: n < 9 Default C.V. Limited data set 4 1 59.3 Note: n < 9 Default C.V. Limited data set 4 1 60.2 Note: n < 9 Default C.V. Limited data set Acute: 5,877.19 Chronic: 5,319.15 No value > Allowable Cw Acute: NO WQS Chronic: 457.45 No value > Allowable Cw Acute: NO WQS Chronic: 595.74 No value > Allowable Cw Acute: NO WQS Chronic: 42.55 No value > Allowable Cw See chronic R- PA undefined, only one data point, data<chronic - T review in next PPA No - RPA, Predicted Max < 50% of Allowbale Cw - No Monitoring required, review in RPA No - RPA, Predicted Max < 50% of Allowbale Cw - No Monitoring required, limited Subpart I RPA for Limited Dataset (n<8 samples) - last two rdgs no detect, review in next PPA Page 2 of 2 9130l2011 ` 2011 RPA 001, rpa Peformance Fibers, Inc. NC0001899 REASONABLE POTENTIAL ANALYSIS Outfall 002 Qw = 0.169i GD Qw (MGD) = 0.17 1Q1OS(cfs)= 0.00 7Q10S (cfs) =. 0.00 7Q10W (cfs) = 0.00 3002 (cfs) = 0.00 Avg. Stream Flow, QA (cfs) = 0.00 Receiving Stream: UT to Shaddox Creek WWTP/WTP Class: II IWC @ 1Q10S = 100.00% !WC @ 7Q10S = 100.00% IWC @ 7Q10W = 100.00% !WC @ 30Q2 = 100.00% !WC @ QA = 100.00% Stream Class: WS IV PARAMETER Aluminum TYPE (1) NC STANDARDS & CRITERIA (2) NC WQS / Chronic Applied /2 FAV / Standard Acute 87 FW(7Q10s) O F z µg/1 REASONABLE POTENTIAL RESULTS ri # Det. Max Pred Cw 1 1 I 1731.8 Note: n <_9 Dettrult C.V. Limited data set Barium Iron (AL) Manganese Mercury NC NC NC NC 1 WS(7Q10s) 1 FW(7Q10s) 200 WS(7Q10s) 0.012 FW(7Q10s) mg/1 mg/1 µg/1 µg/1 1 1 I 0.3 Note: n 59 Default C.V. Limited data set 1 1 3.6 Note: n 59 Default C.V. Limited data set 1 1 355.6 Note: n <_9 Default C.V. Limited data set 1 0 1.3 Note: n <_9 Default C.V. Limited data set Allowable Cw Acute: NO WQS Chronic: 87.00 1 valuei st > Allowable Cw Acute: NO WQS Chr(Tnic: 1.00 No value > Allowable Cw Acute: NO WQS Chronic: 1.00 No value > Allowable Cw Acute: NO WQS Chronic: 200.00 No value > Allowable Cw Sulfates Zinc (AL) NC NC 250 WS(7Q10s) 50 FW(7Q10s) 67 mg/1 µg/1 1 1 + 256.5 Note: n <9 I Default C.V. Limited data sett 1 1 231.4 Note: tt Default C.V. Limited data set Acute: NO WQS Chronic: 0.01 1 valuel s) > Allowable Cw Acute: NO WQS Chronic: 250.00 No value > Allowable Cw Acute: 67.00 Chronic: 50.00 No value > Allowable Cw CHRONIC TEST CONCENTRATION = DEFAULT % = 90 % RECOMMENDED ACTION R- PA undefined, only one data point, data >chronic apply Monthly Monitoring R- PA undefined, only one data point, data<chronic) - review next PPA ----------------- RPA undefined, only one data point, data<chronic review next PPA R- PA undefined, only one data point, data<chronic review next PPA U- nable to determine, will advise Permittee to use Method 1631E in next PPA RPA undefined, only one data point, data<chronic - review next PPA RPA undfined but corrected historical evaluation should have indicated RPA for AL(Cu,Zn,Ag,Fe,CI) - apply Quarterly Monitoring Page 1 of 1 2011 RPA 002, rpa 1/11/2012 NPDES Permit Fact Sheet - • FACILITY => NPDES Permit # => OCPSF Flow => 7Q10s => Average flow => Qp => IWC @ low flow => IWC @ avg. flow => Parameter 1 Acenaphthene 2 Acenaphthylene c 3 Acrylonitrile 4 Anthracene c 5 Benzene c 6 Benzo(a)anthracene (PAH) c 7 3,4-Benzofluoranthene (PAH) c 8 Benzo(k)fluoranthene (PAH) c 9 Benzo(a)pyrene (PAH) c 10 Bis(2-ethylhexyl) phthalate c 11 Carbon Tetrachloride 12 Chlorobenzene c 13 Chloroethane c 14 Chloroform 15 2-Chlorophenol c 16 Chrysene (PAH) 17 Di-n-butyl phthalate 18 1,2-Dichlorobenzene 19 1,3-Dichlorobenzene 20 1,4-Dichlorobenzene 21 1,1-Dichloroethane c 22 1,2-Dichloroethane 23 1,1-Dichloroethylene 24 1,2-trans-Dichloroethylene 25 2,4-Dichlorophenol c 26 1,2-Dichloropropane c 27 1,3-Dichloropropylene 28 Diethyl phthalate 29 2,4-Dimethylphenol 30 Dimethyl phthalate 31 4, 6-D initro-o-cresol 32 2,4-Dinitrophenol c 33 2,4-Dinitrotoluene c 34 2,6-Dinitrotoluene 35 Ethylbenzene 36 Fluoranthene 37 Fluorene c 38 Hexachlorobenzene c 39 Hexachlorobutadiene c 40 Hexachloroethane 41 Methyl Chloride c 42 Methylene Chloride c 43 Naphthalene 44 Nitrobenzene 45 2-Nitrophenol 46 4-Nitrophenol 47 Phenanthrene 48 Phenol 49 Pyrene c 50 Tetrachloroethylene 9/23/2011 Table 1: OCPSF Subpart I Calculations Performance Fibers, Inc NC0001899 0.0075 MGD 40.0 cfs 1,848 cfs 0.24 MGD 0.009 0.94 % IWC @ 1Q10 flow => 0.000 0.02 % Calculates from OCPSF Flow OCPSF OCPSF OCPSF OCPSF Daily Monthly Daily Monthly Maximum Average Maximum Average (pg/L) (pg/L) (Ibs/day) (Ibs/day) 59 22 0.004 0.001 59 22 0.004 0.001 242 96 0.015 0.006 59 22 0.004 0.001 136 37 0.009 0.002 59 22 0.004 0.001 61 23 0.004 0.001 59 22 0.004 0.001 61 23 0.004 0.001 279 103 0.017 0.006 38 18 0.002 0.001 28 15 0.002 0.001 268 104 0.017 0.007 46 21 0.003 0.001 98 31 0.006 0.002 59 22 0.004 0.001 57 27 0.004 0.002 163 77 0.010 0.005 44 31 0.003 0.002 28 15 0.002 0.001 59 22 0.004 0.001 211 68 0.013 0.004 25 16 0.002 0.001 54 21 0.003 0.001 112 39 0.007 0.002 230 153 0.014 0.010 44 29 0.003 0.002 203 81 0.013 0.005 36 18 0.002 0.001 47 19 0.003 0.001 277 78 0.017 0.005 123 71 0.008 0.004 285 113 0.018 0.007 641 255 0.040 0.016 108 32 0.007 0.002 68 25 0.004 0.002 59 22 0.004 0.001 28 15 0.002 0.001 49 20 0.003 0.001 54 21 0.003 0.001 190 86 0.012 0.005 89 40 0.006 0.003 59 22 0.004 0.001 68 27 0.004 0.002 69 41 0.004 0.003 124 72 0.008 0.005 59 22 0.004 0.001 26 15 0.002 0.001 67 25 0.004 0.002 56 22 0.004 0.001 OCPSF Table Federal Criteria or State Standard FC FC FC FC 5S FC FC FC FC FC 5S FC FC SS FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC FC 55 FC FC FC FC FC FC FC FC FC FC SS = inputs 1Q10 = 0.843 x (7Q10s) O'993 1Q10s => 32.86 cfs NPDES Permit No: NCOO 0.011 WQS Table - Chronic Aquatic Life Standard (I1g/L) 60 none none 0.05 none none none none none none none 140 none none none none 9.5 470 390 100 20000 none 5400 none none none 12 1200 320 3400 12 26 none none 97 0.11 46 none none none none none 330 none 8000 750 none none none none Human Health Standard (Ilg/L) none none 0.25 40,000 51 none none none none 2.2 1.6 none 550 170 none 0.018 none none none 190.00 170000 37 7100 10000 none 15 21.000 none none none 280 none 3.4 0.71 none none none 0.0029 18 3.3 96 590.00 none 30.00 none none none 300.0 4,000 3.3 Policy Acute Standards (µg/L) none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none none NPDES Permit Fact Sheet - 9/23/2011 NPDES Permit No: NCO() Table 1: OCPSF Subpart 1 Calculations OCPSF OCPSF OCPSF OCPSF Federal Aquatic Human Daily Monthly Daily Monthly Criteria or Life Health Acute Maximum Average Maximum Average State Standard Standard Standards Parameter (µg/L) (µg/L) (Ibs/day) (Ibs/day) Standard (µg/L) (µg/L) (µg/L) 51 Toluene 80 26 0.005 0.002 5S 11 none none 52 Total Chromium 2770 1110 0.173 0.069 SS 50 none 1022 53 Total Copper- AL 3380 1450 0.211 0.091 SS -AL 7 none 7.3 54 Total Cyanide 1200 420 0.075 0.026 SS 5 none 22.000 55 Total Lead 690 320 0.043 0.020 SS 25 none 33.8 56 Total Nickel 3980 1690 0.249 0.106 SS 88 none 261.000 57 Total Zinc - AL 2610 1050 0.163 0.066 SS -AL 50 none 67 58 1,2,4-Trichlorobenzene 140 68 0.009 0.004 FC 61 none none c 59 1,1,1-Trichloroethane 54 21 0.003 0.001 FC 2500 none none c 60 1,1,2-Trichloroethane 54 21 0.003 0.001 FC none 16 none c 61 Trichloroethylene 54 21 0.003 0.001 FC none 30 none c 62 Vinyl Chloride 268 104 0.017 0.007 SS none 2.4 none c 63 Dibenz(a,h)anthracene (PAH) SS none none c 64 Indeno(1,2,3-ed)pyrene(PAH) 55 none none c 65 Total PAH SS none 0.0311 • 401.17 pH Effluent limitations under continuous monitoring. (a) Where a permittee continuously measures the pH of wastewater pursuant to a requirement or option in a National Pollutant Discharge Elimination System (NPDES) permit issued pursuant to section 402 of the Act, the permittee shall maintain the pH of such wastewater within the range set forth in the applicable effluent limitations guidelines, except excursions from the range are permitted subject to the following limitations: (1) The total time during which the pH values are outside the required range of pH values shall not exceed 7 hours and 26 minutes in any calendar month; and (2) No individual excursion from the range of pH values shall exceed 60 minutes. (b) The Director, as defined in §122.3 of this chapter, may adjust the requirements set forth in paragraph (a) of this section with respect to the length of individual excursions from the range of pH values, if a different period of time is appropriate based upon the treatment system, plant configuration or other technical factors. (c) For purposes of this section, an excursion is an unintentional and temporary incident in which the pH value of discharge wastewater exceeds the range set forth in the applicable effluent limitations guidelines. (Secs. 301, 304, 306 and 501 of the Clean Water Act (the Federal Water Pollution Control Act Amendments of 1972, 33 U.S.C. 1251 et. seq., as amended by the Clean Water Act of 1977, Pub. L. 95-217)) [47 FR 24537, June 4, 1982] Title 40: Protection of Environment PART 414—ORGANIC CHEMICALS. PLASTICS, AND SYNTHETIC FIBERS Subpart C—Other Fibers § 414.30 Applicability; description of the other fibers subcategory. The provisions of this subpart are applicable to the process wastewater discharges resulting from the manufacture of products classified under SIC 2823 cellulosic man-made fibers, except Rayon, and SIC 2824 synthetic organic fibers including those fibers and fiber groups listed below. Product groups are indicated with an asterisk (*). *Acrylic Fibers (85% Polyacrylonitrile) *Cellulose Acetate Fibers *Fluorocarbon (Teflon) Fibers *Modacrylic Fibers *Nylon 6 Fibers Nylon 6 Monofilament *Nylon 66 Fibers Nylon 66 Monofilament *Polyamide Fibers (Quiana) *Polyaramid (Kevlar) Resin -Fibers *Polyaramid (Nomex) Resin -Fibers *Polyester Fibers *Polyethylene Fibers *Polypropylene Fibers *Polyurethane Fibers (Spandex) [52 FR 42568, Nov. 5, 1987, as amended at 57 FR 41844, Sept. 11, 1992] § 414.31 Effluent limitations representing the degree of effluent reduction attainable by the application of the best practicable control technology currently available (BPT) Except as provided in 40 CFR 125.30 through 125.32, and in 40 CFR 414.11(i) for point sources with production in two or more subcategories, any existing point source subject to this subpart must achieve discharges not exceeding the quantity (mass) determined by multiplying the process wastewater flow subject to this subparttimes the concentration listed in the following table. Effluent characteristics BPT effluent limitations' Maximum for any one day Maximum for monthly average BOD5 48 18 TSS 115 36 pH (2) (2) 1AII units except pH are milligrams per liter. 2Within the range of 6.0 to 9.0 at all times. [52 FR 42568, Nov. 5, 1987, as amended at 57 FR 41844, Sept. 11, 1992] § 414.90 Applicability; description of the subcategory of direct discharge point sources that use end -of -pipe biological treatment. The provisions of this subpart are applicable to the process wastewater discharges resulting from the manufacture of the OCPSF products and product groups defined by §414.11 from any point source that uses end -of -pipe biological treatment or installs end -of -pipe biological treatment to comply with BPT effluent limitations. § 414.91 Toxic pollutant effluent limitations and standards for direct discharge point sources that use end -of -pipe biological treatment. (a) Any point source subject to this subpart must achieve discharges not exceeding the quantity (mass) determined by multiplying the process wastewater flow subject to this subpart times the concentrations in the following table. (b) In the case of chromium, copper, lead, nickel, zinc, and total cyanide, the discharge quantity (mass) shall be determined by multiplying the concentrations listed in the following table for these pollutants times the flow from metal -bearing waste streams for the metals and times the flow from cyanide bearing waste streams for total cyanide. The metal -bearing waste streams and cyanide -bearing waste streams are defined as those waste streams listed in Appendix A of this part, plus any additional OCPSF process wastewater streams identified by the permitting authority on a case -by -case basis as metal or cyanide bearing based upon a determination that such streams contain significant amounts of the pollutants identified above. Any such streams designated as metal or cyanide bearing must be treated independently of other metal or cyanide bearing waste streams unless the permitting authority determines that the combination of such streams, prior to treatment, with the Appendix A waste streams will result in substantial reduction of these pollutants. This determination must be based upon a review of relevant engineering, production, and sampling and analysis information. Effluent characteristics Effluent limitations BAT and NSPS1 Maximum for any one day Maximum for any monthly average Acenaphthene 59 22 Acenaphthylene 59 22 Acrylonitrile 242 96 Anthracene 59 22 Benzene 136 37 Benzo(a)anthracene 59 22 3,4-Benzofluoranthene 61 23 Benzo(k)fluoranthene 59 22 Benzo(a)pyrene 61 23 Bis(2-ethylhexyl) phthalate 279 103 Carbon Tetrachloride 38 18 Chlorobenzene 28 15 Chloroethane 268 104 Chloroform 46 21 2-Chlorophenol 98 31 Chrysene 59 22 Di-n-butyl phthalate 57 27 1,2-Dichlorobenzene 163 77 1,3-Dichlorobenzene 44 31 1,4-Dichlorobenzene 28 15 1,1-Dichloroethane 59 22 1,2-Dichloroethane 211 68 1,1-Dichloroethylene 25 16 1,2-trans-Dichloroethylene 54 21 2,4-Dichlorophenol 112 39 1,2-Dichloropropane 230 153 1,3-Dichloropropylene 44 29 Diethyl phthalate 203 81 2,4-Dimethylphenol 36 18 Dimethyl phthalate 47 19 4,6-Dinitro-o-cresol 277 78 2,4-Dinitrophenol 123 71 2,4-Dinitrotoluene 285 113 2,6-Dinitrotoluene 641 255 Ethylbenzene 108 32 Fluoranthene 68 25 Fluorene 59 22, Hexachlorobenzene 28 15 Hexachlorobutadiene 49 20 Hexachloroethane 54 21 Methyl Chloride 190 86 Methylene Chloride 89 40 Naphthalene 59 22 Nitrobenzene 68 27 2-Nitrophenol 69 41 4-Nitrophenol 124 72 Phenanthrene 59 22 Phenol 26 15 Pyrene 67 25 Tetrachloroethylene 56 22 Toluene 80 26 Total Chromium 2,770 1,110 Total Copper 3,380 1,450 Total Cyanide 1,200 420 Total Lead 690 320 Total Nickel 3,980 1,690 Total Zinc2 2,610 1,050 1,2,4-Trichlorobenzene 140 68 1,1,1-Trichloroethane 54 21 1,1,2-Trichloroethane 54 21 Trichloroethylene 54 21 Vinyl Chloride 268 104 1AII units are micrograms per liter. 2Total Zinc for Rayon Fiber Manufacturethat uses the viscose process and Acrylic Fiber Manufacture that uses the zinc chloride/solvent process is 6,796 pg/I and 3,325 pg/I for maximum for any one day and maximum for monthly average, respectively. [52 FR 42568, Nov. 5, 1987, as amended at 58 FR 36892, July 9, 1993] FW Follow up questions on Performance Fiber treatment operation From: Stewart, Marty [Marty.stewart@performancefibers.com] Sent: Monday, October 24, 2011 10:18 AM To: Berry, Ron Subject: FW: Follow up questions on Performance Fiber treatment operation Ron, Please find below the answers to your questions. If you have any more questions, please do not hesitate to contact me. Marty R. Stewart Environmental Engineer marty.stewart@performancefibers.com Performance Fibers, Inc. 338 Pea Ridge Road New Hill, NC 27562 919.545.3154 (office) 336.263.6864 (mobile) From: Berry, Ron [mailto:ron.berry@ncdenr gov] Sent: Wednesday, October 19, 2011 2:25 PM To: Stewart, Marty Subject: Follow up questions on Performance Fiber treatment operation Marty, The marked maps and other details you provide were very informative. I have a few remaining items that need clarification: Water Treatment Plant 1) Does the raw river water from the fire pond go to the contact/mixing tank and then to the filters? If not, what is the function of the contact/mixing tank? If not, what is the source of the filter influent? A.) The raw water from the Fire Ponds goes to the Clarifier first, then the Filters, then the Contact Tank , then the Mixing Tank, and then the Clearwell. B.)There are two tanks: a Contact Tank and a Mixing Tank, and they are after the Filters. The Contact tank is a baffled tank that allows the water to be in contact with the chlorine for increased disinfection. The Mixing Tank is where the final chemicals are added and mixed for pH control and Chloramine Disinfection before the water enters the Clearwell for storage. c.) The Filters influent water comes from the Clarifier. 2) The coagulants are added where? In the raw water inlet pipe in the valve pit before the Clarifier. The coagulant, alum, is mixed with the raw water using an in -line Static Mixer. 3) what is the function of the 20,000 gal clarifier? Removal of the solids 4) Where does the clarifier accumulated solids go? To the Alum Ponds 5) There are two alum settling ponds, what is the influent source for these ponds? How often are these ponds cleaned and how is the solid disposal handle? Backwash from the water plant; Residual sludge land applied approximately every other year 6) Is there solid removal from the polishing pond? Most likely not often but how was the solid disposal handled? No solids removed Wastewater Treatment Plant 7) Potable water needs are being supplied from Chatham county utility. But Page 1 FW Follow up questions on Performance Fiber treatment operation domestic wastewater from plant rest rooms, cafeteria, and custodial sinks still comprise the "sanitary" waste portion indicated on the flow schematic. Is this correct? Correct 8) what type disinfection are used in cooling water? 9) The treated wastewater from the wastewater treatment plant and the effluent from the polishing mix and then proceed to outfall 001. Just a confirmation, outfall 001 flow meter and composite sampler are located after mixing point. correct 10) You had confirmed in a previous discussion that there is only one polishing pond. The application narrative talks about the ability to send the clarifier effluent to the polishing pond. Is this correct? Correct Thank you for your assistance. Ron Ron Berry ron.berry@ncdenr.gov Engineer I DWQ/Point Source/NPDES Complex Permitting Unit NCDENR Phone: (919) 807-6396 Fax: (919) 807-6495 office: Archdale Building Room 925N Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed to third parties unless the content is exempt by statute or other regulation. Disclaimer: This e-mail communication and any attachments may contain confidential and privileged information and is for use by the designated addressee(s) named above only. If you are not the intended addressee, you are hereby notified that you have received this communication in error and that any use or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have received this communication in error, please notify us immediately by replying to this message and deleting it from your computer. Thank you. Page 2 F&g Fofz >Y�F FI)2t Poi-kpS 13 Kg Si eurrp 7° c�.P 2 I 0 (Ai- FALL 001 o°� raA`-a/ tisti (.5 Ko), °,/o F6►./' ivi?) Pj4o 1ojD ).)1 tJ'1 ci-Q44 4,P"I a J3_z ,_ L( 204 2o1 No GAL. ca-A`t F' {2 f juSimhW'T -)4 14t4IL Lum P°/419 >a- er24 2.. -ice' 3 5, C.t Da L A b 1 pfl $"ta li 4� RE Additional information needed for NPDES applicationaaa From: Stewart, Marty [Marty.Stewart@performancefibers.com] Sent: Monday, October 10, 2011 8:01 AM To: Berry, Ron Cc: Stewart, Marty Subject: RE: Additional information needed for NPDES application Attachments: Wastewater Flows.pdf; google view- site Plan #1.docx; google view - Site Plan #2.docx Please find attached a revised water flow diagram for the Performance Fibers Wastewater Permit Renewal Application. After your questions, I met with key players in our Utilities Department to determine if these flows were accurate and if not, use our best engineering knowledge to properly identify the most accurate flow balances at our plant. when I put this application together, I used the best available information at the time, along with guidance from our previous flow diagram from our previous application in 2006. so there are some changes that I now feel more accurately represent water flows on -site. Here is some more information that may answer your earlier questions: The 9,000 GPD from Steam boilers (which had to be re -assessed based on engineering judgment) has about 8% make-up from blow down. The storm water % is pretty comparable to our previous application. It was placed back close to that level in this revised figure since the overflow numbers from the fireponds should have been increased instead (and were in this revised flow diagram). This is justified since we are pulling a constant amount from the Haw River and pulling less in in the process water plant. (This would increase the overflow amount). Cooling demand has gone down for process and cooling towers so we lose less to evaporation. This can also explain the increased amount of wastewater to wwTP from cooling towers. Please note the small decrease in the "process" amount to the WWTP. Going forward, sanitary waste will not be fed by process water treatment, as we are now receiving water from Chatham County for our sanitary water, but it still ends up in our WWTP. Let me know if this helps you going in your review of our application. I will be out of the office until Monday but please contact me if you need more information. I also included the figures you requested clarification on. Have a good week! Marty R. Stewart Environmental Engineer marry.stewart@performancefibers.com Performance Fibers, Inc. 338 Pea Ridge Road New Hill, NC 27562 Page 1 RE Additional information needed for NPDES applicationaaa 919.545.3154 (office) 336.263.6864 (mobile) From: Berry, Ron [mailto:ron.berry@ncdenr.gov] Sent: Thursday, September 29, 2011 4:47 PM To: Stewart, Marty Subject: Additional information needed for NPDES application Mr. Stewart, Completed a much more detail review of the facility process wastewater operation based on the recent application and documented history. Noted several issues that I need further assistance to address. (1) The actual monthly average flow for outfall 002 since April 2008 is 0.169 MGD. The application flow chart indicates 0.154 MGD with about 70% from stormwater. Actual stormwater events should be intermittent and cause the actual reported average flow to be noticeable less. But this is not the case, what is the source of wastewater causing this elevated flow? (2) Noted the required annual acute toxicity for outfall 002 was not been done since 2007, why? (3) Prepared two google earth -based views of the treatment portion of the Performance Fiber operation (see attached). Made best educated guess as to treatment components. Please confirm, correct and/or provide description for items listed including estimated sizes/volumes. If it would be easier to communicate the information in item (3)by providing a plot plan that would certainly be an option. If you have any questions let me know. Ron Berry ron.berry@ncdenr.gov Engineer I DWQ/Point Source/NPDES Complex Permitting unit NCDENR Phone: (919) 807-6396 Fax: (919) 807-6495 office: Archdale Building Room 925N Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed to third parties unless the content is exempt by statute or other regulation. Disclaimer: This e-mail communication and any attachments may contain confidential and privileged information and is for use by the designated addressee(s) named above only. If you are not the intended addressee, you are hereby notified that you have received this communication in error and that any use or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have received this communication in error, please notify us immediately by replying to this message and deleting it from your computer. Page 2 RE Follow up questions on historical data From: Stewart, Marty [Marty.Stewart@performancefibers.com] Sent: Monday, January 16, 2012 11:38 AM To: Berry, Ron Subject: RE: Follow up questions on historical data Attachments: PAH Data 2003-2006.pdf Ron, Here is the data for 2003-2006, with the pollutants analyzed separately, all non -detects. The lab data for 2007 forward is included in the application packet lab data section (OCPSF data from 2007-2010) and were also non -detects. If you require anything from me, please let me know. PLEASE NOTE MY MOBILE NUMBER HAS CHANGED! Marty R. Stewart Environmental Engineer marty.stewart@performancefibers.com Performance Fibers, Inc. 919.545.3154 (office) 919.210.3527 (Mobile) From: Berry, Ron [mailto:ron.berry@ncdenr.gov] Sent: Friday, January 13, 2012 1:29 PM To: Stewart, Marty Subject: RE: Follow up questions on historical data Thanks, that will be great. Ron Berry ron.berry@ncdenr.gov Engineer I DWQ/Point Source/NPDES Complex Permitting Unit NCDENR Phone: (919) 807-6396 Fax: (919) 807-6495 Office: Archdale Building Room 925N Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed to third parties unless the content is exempt by statute or other regulation. From: Stewart, Marty [mailto:Marty.Stewart@performancefibers.com] Sent: Friday, January 13, 2012 12:09 PM To: Berry, Ron Subject: RE: Follow up questions on historical data Mr. Berry, I will locate this data and hope to have a response for you by Monday. Thanks! PLEASE NOTE MY MOBILE NUMBER HAS CHANGED! Marty R. Stewart Environmental Engineer marty.stewart@performancefibers.com Performance Fibers, Inc. Page 1 RE Follow up questions on historical data 919.545.3154 (office) 919.210.3527 (Mobile) From: Berry, Ron [mailto:ron.berry@ncdenr.gov] sent: wednesday, January 11, 2012 8:38 AM To: Stewart, Marty Subject: Follow up questions on historical data Mr. Stewart, we are finalizing the NPDES permit draft for Performance Fibers and need to review the annual PAH monitoring that should have been reported since 2003. can you provide all or any portion of the PAH data from 2003 to present. The PAH value is a calculated value that sums the measured value of: 1) Benzo(a)anthracene 2) Benzo(a)pyrene 3) 3,4-benzofluoranthene 4) Benzo(k)fluoranthene 5) Chrysene 6) Dibenz(a,h)anthracene 7) indeno(1,2,3-ed)pyrene Your assistance in this matter is greatly appreciated. Ron Berry ron.berry@ncdenr.gov Engineer I DWQ/Point Source/NPDES Complex Permitting Unit NCDENR Phone: (919) 807-6396 Fax: (919) 807-6495 Office: Archdale Building Room 925N Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed to third parties unless the content is exempt by statute or other regulation. Disclaimer: This e-mail communication and any attachments may contain confidential and privileged information and is for use by the designated addressee(s) named above only. If you are not the intended addressee, you are hereby notified that you have received this communication in error and that any use or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have received this communication in error, please notify us immediately by replying to this message and deleting it from your computer. Thank you. Disclaimer: This e-mail communication and any attachments may contain confidential and privileged information and is for use by the designated addressee(s) named above only. If you are not the intended addressee, you are hereby notified that you have received this communication in error and that any use or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have received this communication in Page 2 V 1 I 5 J If �. DISCHARGE DISCHARGE NO. 002 (154 GPD) OVERFLOW HAW RIVER 228 4-4 72 C4, u q ,LI'Trd /I!!G tiro, _ 0)(04,41 s2.- L• Gx.)r 12.��da�rh� FIRE PONDS 148 --it- =-- WATER EVAPORATION STEAM ♦ Z I, 2 PROCESS WATER TREATMENT 5 ALUM SETTLING POND S OIL 4.9 r Z P J t-tu0 143 3.> >, 0 J a fit`.! fop I 84 STEAM BOILER 4 PROCESS o.0 - $/ 6'n,-7 i 80 HVAC, AIR COMPRESSOR AND STEAM CONDENSATE SZ°fu STORMWATER 0.5 0 (o 7.0 30t 1,5 t(o;O AIR DRYER 10 16 1,0 • • 1.5 48.5 COOLING TOWERS TW-1,4,5,6 30 OIL MIST AIR POLLUTION CONTROL SYSTEM L.3 0 1.5 4 OIL PRE- TREATMENT 0.75 6.5 POLISHING POND 4.7 1pale, Iat1):11�6,,C, SANITARY CONCENTRATED OIL EMULSION SHIPPED OFF - SITE 6.5 ern/2 • SCHEMATIC OF WATER FLOW PERFORMANCE FIBERS, INC. NEW HILL, CHATHAM COUNTY NORTH CAROLINA NPDES PERMIT NO. NC0001899 (Numbers in Thousands of Gallons) N WASTEWATER TREATMENT PLANT V-0 i 75.3 DISCHARGE 2010 View Performance Fibers, Inca — Water Treatment Plant? (1) Contact Tank/Mixing Tank (to the right) (3) 2 filter (sand) beds (2) Service Water Pumps (4) Clarifier (20,000 gallon capacity) (From Haw ',,River intake To Haw River discharge - Outfall 001 (1) Stormwater Ditch 2010 View Performance Fibers, Inc. 11 (2) Stormwater/Spill Basin (480,000 gallon capacity) (3) Water treatment plant (7)Spill Lagoon (650,000 gallon capacity) (8) Aeration basin (650,000 gallon capacity) (9) Effluent Contact Chamber (5,500 gallon capacity) (13) Alum Settling Pond (300,000 gallon capacity) (14) Alum Settling Pond (500,000 gallon capacity) (15) Fire Pump House (4) Fire Pond (1.2 million gallon capacity) (5) Fire Pond (1.2 million gallon capacity) (6) WWTP Office Building (10) Clarifier (18,500 gallon capacity) (11) Polishing Pond (1,000,000 gallon capacity) (12) Drying bed (20' X 8' X 50') $s 1 62 (16) Process Influent Mixing Chamber (1,200 gallon capacity) (17) Trailer (18) Distance/location between intake and outfall? ^' 4,900 feet DISCHARGE NO. 002 (154 GPD) OVERFLOW HAW RIVER Fgom tf 228 — — — FIRE POND 45 175 WATER TREATMENT 8 214 0!4 0.1 PL +-17 l 20100.' 914,1 c_L,y J 170 5 ALUM SETTLING POND WATER EVAPORATION STEAM OIL 4.9 Z f''►NI�r' 3O j t1+J yli,I' +, 89 STEAM BOILER VJYa 14 HVAC, AIR COMPRESSOR AND STEAM CONDENSATE 4 PROCESS 7.5 107.5 STORMWATER 0.5 AIR DRYER 0 16 -► 1.0 — —0- 69 69.1 COOLING TOWERS TW-1,4,5,6 25.1 i OIL MIST AIR 1.5 POLLUTION CONTROL SYSTEM ♦ 44 l� 1.5 OIL PRE- TREATMENT 0.25 L 0.75 7.9 0.2 4 POLISHING POND I11000140d 9A61 s- SANITARY 7.9 — - 5.45 arloe CONCENTRATED OIL EMULSION SHIPPED OFF- Ir. SITE SCHEMATIC OF WATER FLOW PERFORMANCE FIBERS, INC. NEW HILL, CHATHAM COUNTY NORTH CAROLINA NPDES PERMIT NO. NC0001899 (Numbers in Thousands of Gallons) 4.7 WASTEWATER TREATMENT PLANT 7.3 DISCHARGE NO. 001 (82 GPD) Let WATER BALANCE WASTEWATER OUTFALL 001 PERFORMANCE FIBERS NC0001899 FEB 10, 2012 source per renewal application water balance thousand gallons effluent WWTP effluent outfail +evap boiler bd* 1 1.29% 1.14% demin/softner wastewater* 13 16.82% 14.87% process 7.5 9.70% 8.58% cooling bd 25.1 32.47% 28.70% sanitary wastewater 7.9 10.22% 9.03% condensate 10 12.94% 11.44% stormwater 16 20.70% 1$.30% oil mist/pollution control system 1.5 1.94% 1.72% oil pre-treatment 0.75 0.97% 0.86% evaporation Iosts from WWTP (5.45) -7.05% total effluent from WWTP 77.3 100.00% wtp 4.7 5.37% total effluent to Outfall 82 100.00% total non -process (total WWTP+wtp-sanitary-process-stormwater) 50.6 *percentage provided by ORC, water balance combines as 14,000 GPD 100.00% Performance Fibers, Inc. - NC0001899 Outfall 001 414.31 Subpart C Flow = 0.0075 MGD* Parameter Daily Max Monthly Average mg/Ll Ibs/dayZ mg/Ll Ibs/dayZ BOD5 48 3.0 18 1.1 TSS 115 7.2 36 2.3 pH 6 .0 S.U. - 9.0 S.U. Sanitary Flow = 0.0079 MGD* Parameter Daily Max Monthly Average mg/L3 Ibs/day4 mg/L3 Ibs/day4 BOD5 45 3.0 30 2.0 TSS 45 3.0 30 2.0 pH 6 .0 S.U. - 9.0 S.U. Non -process Flow = 0.0506 MGD* Parameter Daily Max Monthly Average mg/L6 Ibs/day6 mg/L5 Ibs/day6 BOD5 26.90 11.35 17.85 7.53 TSS 2.79 1.18 1.78 0.75 pH 6 .0 S.U. - 9.0 S.U. Water Balance Flow = 0.066 MGD* Parameter Daily Max Monthly Average Current Ibs/day Ibs/day' Current Ibs/day Ibs/day' BOD5 16.7 17.3 10.4 10.6 TSS 10.6 11.3 5.0 5.0 pH 6 .0 S.U. - 9.0 S.U. Ibs/day = Procees + Domestic + Non -process *2011 water balance 1 mg/L = Effluent Guidelines 2lbs/day = 414.31 Subpart C Flow x mg/L x 8.34 *2011 water balance 3 mg/L = Secondary Treatment Standards 4lbs/day = Sanitary Flow x mg/L x 8.34 *2011 water balance s mg/L=Calculated Study Limits Ibs/day (1995 study) _ (8.34 x 0.047 MGD) bibs/day = Calculated Study Limits x mg/L x 8.34 *2011 water balance Calculate factors for non- . Ibs/day = Current permit - Process - Domestic DISCHARGE NO. 002 (154 GPD) OVERFLOW HAW RIVER 228 1 45 FIRE POND 175 POTABLE WATER TREATMENT 170 8 0.1 1 4.9 5 ALUM ► SETTLING POND WATER EVAPORATION STEAM OIL 0.2 89 STEAM BOILER 14 1 4 4 0 HVAC, AIR COMPRESSOR AND STEAM CONDENSATE 107.5 STORMWATER 0.5 AIR DRYER PROCESS 7.5 1 10 16 — — ♦ 69 1.5 69.1 • COOLING TOWERS — — ÷ 44 • TW-1,4,5,6 25.1 OIL MIST AIR POLLUTION CONTROL SYSTEM 1.5 OIL PRE- TREATMENT 1.0 0.75 7.9 POLISHING POND 4.7 SANITARY .9 WASTEWATER — • 5.45 - — — TREATMENT PLANT CONCENTRATED OIL EMULSION 0.25 SHIPPED OFF- L 110 SITE SCHEMATIC OF WATER FLOW PERFORMANCE FIBERS, INC. NEW HILL, CHATHAM COUNTY NORTH CAROLINA NPDES PERMIT NO. NC0001899 (Numbers in Thousands of Gallons) 7.3 DISCHARGE NO. 001 (82 GPD) • Performance 1' Fibers January 26, 2011 Mrs. Dina Sprinkle NC Department of Environment & Natural Resources Division of Water Quality Point Source Branch 1617 Mail Service Center Raleigh, North Carolina 27699-1617 Subject: NPDES Permit Renewal Application Performance Fibers, Inc. New Hill, Chatham County, North Carolina Permit # NC0001899 Dear Mrs. Sprinkle: Performance Fibers Inc. owns and operates a polyester manufacturing facility in New Hill, North Carolina and is requesting renewal of its NPDES Permit (NPDES Permit No. 0001899) per Federal Regulations 40 CFR 122.41, and North Carolina Regulations (15A NCAC 2H.0105(e)). The permit, which expires July 31, 2011, would continue to allow Performance Fibers to discharge water from two outfalls into receiving waters designated as the Haw River and Shaddox Creek in the Cape Fear River Basin. Enclosed are three (3) signed copies of the EPA Application for Permit to Discharge Wastewater for Existing Manufacturing, Commercial, Mining, and Silviculural Operations (FORM 2C) and EPA FORM 1 (General Information). I. Facility Location The Performance Fibers New Hill, North Carolina facility is located near the intersection of Highway 1 and Pea Ridge Road. The facility's location is presented in Item XI attachment to FORM 1. H. Plant Overview Performance Fibers, Inc. manufactures polyester in fiber form at its New Hill, North Carolina facility. Primary raw materials in this manufacturing process include terephthalic acid, ethylene glycol and fiber finish lubricants. A - Outfall 001 Performance Fibers' New Hill, North Carolina facility operates a wastewater treatment facility with the following components and with final discharge through Outfall 001 to the Haw River: Sanitary Flow Bar and Screen Grinder Process Wastewater Bar Screen Neutralization Chamber Aeration Basin Clarifier Sludge Drying Bed Optional Polishing Pond Chlorine Gas Disinfection (Not in Service) Chlorine Contact Chamber (Not in Service) 3 3 8 PEA RIDGE ROAD I NEW HILL, NC 2 7 5 6 2 I T EL 9 1 9 5 4 2 2 2 0 0 www.performancefibers.com Two separate pipelines transport process and sanitary waste to the wastewater treatment plant. Process wastewater comes primarily from non -process cooling tower blowdown with smaller contributions from the following: steam condensate, regenerated water from water softeners, demineralizer blowdown, water 1 2 rinse from polyester parts cleaning operations, stormwater from raw material handling areas, finish oil ' pretreatment (ultrafiltration permeate) and manufacturing building floor drains. Sanitary wastewater comes primarily from plant restrooms, cafeteria and custodial sinks. The plant has a separate sanitary collect nsy tem that flows to alift station. Sanitary waste is blended in a comminutor or the comminutor may be bypassed in the event of amechanical failure and the flow would be directed through a bar screen. From the lift station, the sanitary influent is pumped directly into the aeration bask . % The process wastewater flows into a liftstation adjacent to the sanitary lift station. It is then pumped into a 1,200 gallon neutralization/mixing basin at the north end of the aeration basin. A mixer provides F thorough mixing to keep settable solids in suspension and to aid in the dispersion of pH control chemicals. A pH probe is used to measure influent pH and transmits a signal to the pH analyzer/controllers. The pH - controller regulates the speed of a sulfuric acid pump, which is used to control pH. The mixing basin then discharges through a 6" pipe into the aeration basin. The aeration basin has a capacity of 650,000 gallons and contains four surface aerators to introduce oxygen into the water and provide mixing horsepower. .7 Water from the aeration basin overflows a weir into a 20' diameter clarifier. The clarifier is designed with a surface overflow rate of 440 gallons/ft2/day. A liquid coagulant is added to the water as it flows from the aeration basin to the clarifier to aid in solids settling. The clarifier is equipped with surface and �' bottom sweep arms. The surface sweep arm directs floating solids to a scum pit. The bottom sweep rakesOrel sludge to be recycled or wasted. Sludge pumps remove settled solids from the bottom of the clarifier and either pump the recycled sludge back to the aeration basin or waste it to the sludge drying beds. Clarifier overflow can be valved to a one -million gallon_capacity polishing pond for additional solids removal. Effluent flow is measured before it enters an underground pipeline that discharges directly into the Haw River. B-Outfall 002 Stormwater, steam condensate, air dryer condensate and fire pond overflow discharge through Outfall 002 to Shaddox Creek. The drainage system which reports to Outfall 002 includes a system of baffles and weir designed to contain accidental spills of oil. In an emergency, flow can be contained in a holding pond and pumped to storage or pumped to the process sewer. C- Item V-C Pollutants The following is a list of Item V-C pollutants that are present on the plant site. None of these materials are used as a raw material or intermediate and none of these materials are manufactured as a product or a by-product of the manufacturing process. The list may not be exhaustive, as some commercial products are considered proprietary by the manufacturer and their specific composition is not known to us. In addition, some new materials may be obtained in the future that contain one or more of the listed chemicals and whose composition may not be known to us. Pollutant Use on Site Antimony Lab Reagent Chromium Lab Reagent Copper Lab Reagent Lead Lab Reagent Mercury Lab Reagent, Instrumentation Nickel Lab Reagent Silver Lab Reagent, Electrical Equipment Zinc Lab Reagent Jam) tfw (11/'4 Phenols Lab Reagent Carbon Tetrachloride Lab Reagent Chloroform Lab Reagent Dichlorodifluromethane Lab Reagent, Refrigerant, Leak Checks 1,1,2,2-Tetrachloroethane Lab Reagent Tetrachloroethylene Solvent Titanium Chelate Catalyst Toluene Lab Reagent 1,1,1-Trichloroethane Solvent Trichloroethylene Solvent Phenol Lab Reagent Dichlorobenzne Lab Reagent 1,2,4-Trichlorobenzene Electrical Equipment PCB Electrical Equipment HI. Historical Data Review Historical daily data from the Discharge Monitoring Reports (DMRs) were reviewed for the past four years (January 1, 2007 to December 31, 2010). Annual data from Organic Chemicals, Plastics and Synthetic Fibers (OCPSF) priority pollutants for the past 4 years (2007, 2008, 2009 and 2010) were reviewed. The highest detection limit for these pollutants, (for pollutants that had non -detects) was listed in the Form 2C. Additional sampling events were conducted in December 2010 and January 2011 for data analysis and inclusion in Form 2C. This data can be found in Attachment "Additional Analytical Data". Additional charts showing all data compiled for this application can be found in Attachment `'Additional Application Data". On November 5, 1987, EPA issued regulations establishing effluent limitations for the Organic Chemicals, Plastics and Synthetic Fibers (OCPSF) industrial category. Provisions of Subpart C (414.31) and Subpart I (414.90) Direct Discharge Point Sources That Use End -of -Pipe Biological Treatment are applicable to process wastewater dischargers from the manufacture of polyester fiber and resin. OCPSF effluent guidelines are not expressed in terms of production. No metal -bearing waste streams or cyanide - bearing waste streams listed in Appendix A to Part 414 exist in the manufacture of polyester fibers and resin. A -Flows The average effluent (Outfall 001) from January 2006 to December 2010 is 0.080 MGD (million gallons per day) compared to a permit limit of 0.244 MGD. B-Chronic Toxicity Performance Fibers is required to test the effluent (Outfall 001) for chronic toxicity once per quarter using ceriodaphnia dubia as the test organism. The results are graded on a pass/fail basis. The following table summarizes the results: Pass 1st Quarter, 2007 2nd Quarter, 2007 Pass 3rd Quarter, 2007 Pass 4th Quarter , 2007 Pass 1st Quarter, 2008 Pass 2nd Quarter, 2008 Pass 3rd Quarter, 2008 Pass 4th Quarter , 2008 Pass lst Quarter, 2009 Pass nd 2Quarter, 2009 Pass 3rd Quarter, 2009 Pass 4`h Quarter , 2009 Pass • 1st Quarter, 2010 Pass 2nd Quarter, 2010 Pass 3rd Quarter, 2010 Pass 4d1 Quarter , 2010 Pass IV. Upper Cape Fear River Basin Association Performance Fibers continues its membership in the Upper Cape Fear River Basin Association and renewed signature of membership in May of 2010. Performance Fibers understands that pursuant to the memorandum of agreement between NC DENR and the Upper Cape Fear River Basin Association, that any instream monitoring requirements specified in the new permit will be waived as long as Performance Fibers remains a member of UCFRBA. This agreement should be described in the effluent limitations and monitoring requirements section of the new permit. V. Wastewater Sludge Performance Fibers manages sludge generated from our "wasting sludge" process as follows: Sludge that is wasted from the biological system is pumped to a sand drying bed where the water drains through the sand into a collection system that leads to a sump. The sump is equipped with an automatic level control switch and the water is returned directly to the aeration basin. Once the sludge is dried, it is shoveled off the bed into a metal dumpster and transported to the following landfill: Lule Uwharrie Environmental Landfill �- 0-7 v 500 Landfill Road Li Mt. Gilead, North Carolina 27306 (910) 576-3697 VL Plant Modification (1' There have been no major modifications of the facility since the last permit issuance. Performance Fibers is in the initial investigation stage of altering the type of waste sent to wastewater treatment. Currently, we receive some wastewater from a fmish oil pretreatment process. Changes in the chemical makeup of fmishes used at the plant may allow for this fmish to be sent directly to wastewater treatment, without negative effects to the wastewater treatment plant or the discharged effluent. Performance Fibers understands that any planned change could result in the need to submit for a minor or major permit modification and Performance Fibers would consult with the NPDES Unit prior to such a change. Otherwise, no changes are anticipated at the treatment facility in the next five (5) years. VII. Permit Request Performance Fibers is requesting that the composite sampling site be moved. Currently, our composite sampling site is across Pea Ridge Road, close to the discharge pipe to the Haw River. We believe it would be easier on the Operator in Responsible Charge (ORC) to obtain those samples from the current 001 outfall. Since we have removed chlorination processes, the 001 outfall is below all treatment activities and would be representative of the water discharged back into the Haw River. This was discussed with our regional inspector, Vicki Webb, during her annual compliance inspection of our facility on October 27, 2010. Performance Fibers is most appreciative of the assistance of the NPDES Permit Unit in preparation of this submission package. If we can provide any further information or should you have any questions regarding this submission, please contact me at (919) 545-3154. • Sincerely, .14,(a eJr Marty R. Stewart Environmental Engineer Enclosures: -EPA FORM 1- General Information -EPA FORM 1-Item XI- Topographic Map -EPA FORM 2C-Application for Permit to Discharge Wastewater, Existing Manufacturing, Commercial, Mining and Silvicultural Operations -Water Flow Line Drawing -Upper Cape Fear River Basin Association Membership Confirmation -OCPSF Analytical Results 2007-2010 -Additional Analytical Data -Additional Application Data With Enclosures cc: D. Kanning D. Peterson -W/O Enclosures