NC0000639_Permit (Issuance)_19960412

NPDES DOCUHENT SCANNING COVER SHEET
NPDES Permit:
NC0000639
Sapona Manufacturing Company
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
April 12, 1996
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State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
April 12, 1996
Mr. John Toledano
Sapona Manufacturing Company, Inc.
P.O. Box 128
Cedar Falls, North Carolina 27230
A174TA
1E)EHNR
Subject: NPDES Permit Issuance
Permit No. NC0000639
Sapona Maufacturing
Randolph County
Dear Mr. Toledano:
In accordance with the application for a discharge permit received on October 16, 1995, the Division
is forwarding herewith the subject 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 US Environmental Protection Agency dated December 6, 1983.
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, Post Office Drawer 27447, Raleigh, North Carolina 27611-7447. Unless such demand is
made, this decision shall be final and binding.
Please take notice this permit is not transferable. Part II, E.4. addresses the requirements to be
followed in case of change in ownership or control of this discharge.
This permit does not affect the legal requirements to obtain other permits which may be required by
the Division of Environmental Management or permits required by the Division of Land Resources,
Coastal Area Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Susan Robson at telephone number
[phone], extension 551.
Sincerely,
Original Signed By
David A. Goodrich
A. Preston Howarci, Jr., P.E.
cc: Central Files
Winston-Salem Regional Office
Mr. Roosevelt Childress, EPA
Permits and Engineering Unit
Facility Assessment Unit
Technical Assistance & Certification Group
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Pet [nit No. NC000063c
•
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1,
other lawful standards and regulations promulgated and adopted by the North Carolina
Environmental Management Commission, and the Federal Water Pollution Control Act, as
amended,
Sapona Manufacturing Company, Inc.
is hereby authorized to discharge wastewater from a facility located at
2478 Riverside Drive
Cedar Falls
Randolph County
to receiving waters designated as the Deep River in the Cape Fear River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, III and IV hereof.
This permit shall become effective May 1, 1996
This permit and authorization to discharge shall expire at midnight on April 30, 2001
Signed this day April 12, 1996
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Management Commission

Permit No. NC0000639
SUPPLEMENT TO PERMIT COVER SHEET
Sapona Manufacturing Company, Incorporated
is hereby authorized to:
1. Continue to operate an existing 0.01 MGD treatment system consisting of an aeration basin with
diffused aeration, clarifier with sludge return, and chlorination (Outfall 001), continue to
discharge boiler blowdown, cooling tower blowdown, and air washer wastewater (Outfall 002),
and operate a groundwater remediation system to treat groundwater contaminated with number 2
fuel oil (Outfall 003) located at 2478 Riverside Drive, Cedar Falls, Randolph County (See Part
III of this Permit), and
2. Discharge from said treatment works at the location specified on the attached map into Deep
River which is classified Class C waters in the Cape Fear River Basin.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC0000639
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001 (Domestic Waste). Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics Discharge Limitations Monitoring
Measurement
Monthly Avg,
Flow 0.010 MCA
BOD, 5 day, 20°C 30.0 mg/I
Total Suspended Residue 30.0 mg/I
NH3 as N
Fecal Coliform (geometric mean) 200.0 /100 ml
Total Residual Chlorine
Temperature
Weekly Avg,
Daily Max
45.0 mg/I
45.0 mg/I
400.0 /100 ml
Frequency
Weekly
Weekly
Weekly
2/Month
Weekly
2/Week
Weekly
Requirements
Sample
Tvoe
Instantaneous
Grab
Grab
Grab
Grab
Grab
Grab
*Sample
Location
I or E
E
E
E
E
E
E
* Sample locations: E - Effluent, I - Influent
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC0000639
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 002 (Boiler Blowdown, Cooling Tower Blowdown, and Air Wash Wastewater). Such discharges shall be limited and
monitored by the pennittee as specified below:
Effluent Characteristics
Flow
Temperature
Total Residual Chlorine***
Lbs/day
Discharge Limitations
Units (specIfyi
Monitoring
Measurement
Mon. Avg, Daily Max Mon. Avg, Daily Max, Frequency
Semi-annually
* • • * Semi-annually
Semi-annually
Requirements
Sample
URI
Estimate
Grab
Grab
*Sample
Location
E
E
E
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS (See Part III of this permit).
* Sample Locations: E - Effluent
** 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.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The pennittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III of this Permit).
The pH shall not be less than 6.0 standard units rior greater than 9.0 standard units and shall be monitored semi-annually at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC0000639
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 003. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics
Flow**
Oil and Grease
Xylene
Ethyl benzene
Naphthalene
Lbs/day
Mon. Avg. Daily
Discharge Limitations
Units
Max Mon. Avg, Daily Max. Frequency
Continuous
30.0 mg/I 60.0 mg/I 2/Month
Monitoring
(specify) Measurement
Quarterly
Quarterly
Quarterly
Requirements
Sam lee
Type
Recording
Grab
Grab
Grab
Grab
*Sample
Location
E
E
E
E
E
* Sample location: E - Effluent
** All volumes of wastewater leaving the facility shall be monitored. If continuous flow monitoring is not feasible, then the discharger shall
record the approximate time that discharge began and ended, along with the instantaneous flow at the time of the effluent sampling.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Part III " Permit No. NC0000639
E. The Permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing not
later than ninety (90) days prior to instituting use of any additional biocide used in the treatment
system which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map indicating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the Biocide Worksheet
Form 101 with Supplemental Metals Analysis Worksheet.

FACILITY INFORMATION
Facility
NPDES No.
Design Flow (MGD)
Facility Class
Staff Review and Evaluation
NPDES Wastewater Permit
Sapona Manufacturing, Inc.
NC0000639
0.010
II
STREAM CHARACTERISTICS
Stream Name
Stream Class
Sub -basin
Drainage Area (mi2)
S7Q10 (cfs)
W7Q10 (cfs)
30Q2 (cfs)
IWC (%)
Deep River
C
030609
250
11
N/A
N/A
0.14
Proposed Changes
Parameters Affected
Basis for change(s)
Monitoring frequencies for 002
Flow, Temp., Chlorine
SOP for non -contact cooling H2O
Compliance Schedule: None
Special Condition(s): None
Permits & Engineering Comments:
P&E recommends renewal of NPDES permit with existing limits. The domestic discharge system at
outfall 001 is operating well according to file review, and is in compliance with permit limits. The non -
contact cooling water discharge 002 is not experiencing any problems according to file review. The
monitoring requirements were changed to match the requirements in the general permit for this type of
discharge. Approval for biocide use was issued 2/5/92. The gw remediation system AtoC for outfall 003
was just issued 6/23/95. The only monitoring data for 003 that has been submitted only had readings for
oil and grease recorded at <5 mg/1.
Prepared by: -.0'krA) , syl)-0.._�
Regional Office Evaluation and Recommendations: OK- a!i

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Technician Checklist . _
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Old Permit File Review Erv...,%.,,ost �'°° 003
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Instream Data Review
Clean Map
Stream Classification Check LFI' 1 'C'!
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cc:
Permits and Engineering
Technical Support Branch
Randolph County Health Dept.
Central Files
WSRO
To: Permits and Engineering Unit
Water Quality Section
Attention: Susan Robson
Date: 29 November 1995
NPDES STAFF REPORT AND RECOMMENDATION
County Randolph
Permit No. NC0000639
PART I - GENERAL INFORMATION
1. Facility and Address: Sapona Manufacturing Company
NCSR 2226 - Cedar Falls
P. O. Box 1287
Asheboro, NC 27203
2. Date of Investigation: 28 November 1995
3. Report Prepared by: W. Corey Basinger
Environmental Engineer
4. Persons Contacted and Telephone Number:
* Mr. Archie Johnson, ORC [phone]
* Mr. Walt Sweeney, Q.C. Manager " "
5. Directions to Site: From WSRO, take I-40 east and exit onto
Hwy 220 south. Travel Hwy 220 south to Asheboro and exit
east on Hwy 64/49. Turn left on Loflin Pond Road (NCSR
2222) and proceed to intersection of NCSR 2226. Turn right
on NCSR 2226 and proceed approximately 0.5 miles to the
facility on the right.
6. Discharge Point(s), List for all discharge points:
Latitude: 35° 44' 51" Longitude: 79° 43' 33"
U.S.G.S. Quad No. E-20 NW U.S.G.S. Quad Name Ramseur
7. Site size and expansion area consistent with application?
There is area available if expansion is needed.

8. Topography (relationship to flood plain included): The
facility is located adjacent to the Deep River, the majority
of which lies within the 100 year flood plain.
9. Location of nearest dwelling: There are several Mill owned
homes within 1000 feet, however, none are currently
occupied
10. Receiving stream or affected surface waters: Deep River
a. Classification: Class C
b. River Basin and Subbasin No.: 03-06-09
c. Describe receiving stream features and pertinent
downstream uses: Class C uses; fish and wildlife
propagation, secondary recreation, and agriculture.
Part II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted:
Discharge 001 - 0.01 MGD (Ultimate Design Capacity)
Discharge 002 - Boiler Blowdown, air washer
wastewater, and cooling tower water
Discharge 003 - Groundwater Remediation System
(This is same pipe at 002)
b. What is the current permitted capacity of the Waste
Water Treatment facility?
Discharge 001 - 0.01 MGD
Discharge 002 - see 1(a) above
Discharge 003 - see 1(a) above
c. Actual treatment capacity of the current facility
(current design capacity)?
Discharge 001 - 0.01 MGD
Discharge 002 - see 1(a) above
Discharge 003 - see 1(a) above
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years.
** A-C issued on June 23, 1995 for groundwater
remediation system.
e. Please provide a description of existing or
substantially constructed wastewater treatment
facilities;
* Discharge 001 - Facility consists of a 0.01 MGD
Smith & Loveless Oxigest wastewater treatment system
with aeration basin and diffused aerators, settling
basin with hydraulic skimming and solids return, and
chlorination.

NPDES Permit Staff Report
* Discharge 002 - Existing discharge of boiler
blowdown, air washer water, and cooling tower
wastewater. This discharge also receives storm water
m the paved areas at the plant.
. RoM,
* Discharge 003 - 1.5 gpm groundwater remediation
system consisting of an oil/water separator, four
carbon adsorption units, two surge tanks, and pumps.
f. Please provide a description of proposed wastewater
treatment facilities. N/A
g•
Possible toxic impacts to surface waters: None known
2. Residuals handling and utilization/disposal scheme:
a. If residuals are being land applied, please specify DEM
Permit No.
Residuals Contractor
Telephone No.
b. Residuals stabilization: PSRP PFRP
Other
c. Landfill:
d. Other disposal/utilization scheme (Specify):
* Discharge 001 - Aeration basin is pumped periodically
by contracted septage hauler.
* Discharge 002 - N/A
* Discharge 003'- sludge is removed as hazardous waste.
3. Treatment plant classification (attach completed rating
sheet) . Class II
4. SIC Code (s) : 2252
Primary 02 Secondary
Main Treatment Unit Code: 0 4 0 x 7
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved. (municipals
only) ?N/A
2. Special monitoring or limitations (including toxicity)
requests: None

NPDES Permit Staff Report
3. Alternative Analysis Evaluation: Has the facility evaluated
all of the non -discharge options available. Please provide
regional perspective for each option evaluated. N/A
Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
PART IV - EVALUATION AND RECOMMENDATIONS
Sapona Manufacturing Company has applied for renewal of
NPDES Permit No. NC0000639. A site evaluation was performed on
Tuesday, November 28, 1995 with Mr. Archie Johnson and Mr. Walt
Sweeney present. The system was properly maintained and
operated.
WSRO recommends reissuance of this permit in accordance with
Division guidelines.
Environmental engineer
av,pe.4
ter Quality Regional Supervisor
Olq /4/6/bdrn /9‘r-
Date
Xet, sc,
Date