NC0000752_Permit (Issuance)_20120420

NPDES DOCIMENT !iCANNINO COVER SHEET
NPDES Permit:
NC0000752
Roanoke Rapids Mill WWTP
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 20, 2012
Thus document is printed on reuse paper - igriore any
content on the reNzerse side

• AM
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Charles'Wakild, P. E. Dee Freeman
Govemor Director Secretary
April 20, 2012
Mr. Chi Puryear
Kapstone Kraft Paper Corporation
100 Gaston Rd.
Roanoke Rapids, North Carolina 27870
Subject: Issuance of NPDES
Permit NC0000752
Roanoke Rapids Mill WWTP
Halifax County
Facility Class IV
Dear Mr. Puryear
Division personnel have reviewed and approved your application for renewal of the subject
permit. Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of
Agreement between North Carolina and the U.S. Environmental Protection Agency dated October 15,
2007 (or as subsequently amended).
The following changes have been incorporated into this permit renewal:
• T .irnits for BOD, TSS, Pentachlorophenol, trichlorophenol and TSS limits were increased to reflect
the most recent production data (Outfall 001).
• Outfall 003 was eliminated from the permit.
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
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St Raleigh, North Carolina 27604
Phone: [phone] l FAX: [phone]
Internet www.ncwateraualitv.orq
No na
!laturaiij
Caroli
An Equal Opportunity 1 Affirmative Action Employer

requirements to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources, the Coastal Area Management Act or any other Federal or
Local governmental permit that may be required. If you have any questions concerning this permit,
please contact Sergei Chernikov at telephone number [phone].
Otze,
cc: Central Files
NPDES Files
Raleigh Regional Office / Surface Water Protection Section
Aquatic Toxicology Unit (e-copy)
EPA Region IV (e-copy)
rely,
{Lk
es Wakild P.E.

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
Draft 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 Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
KapStone Kraft Paper Corporation
is hereby authorized to discharge wastewater from a facility located at the
KapStone Kraft Paper Corporation WWTP
100 Gaston Road
Roanoke Rapids
Halifax County
to receiving waters designated as the Roanoke River in the Roanoke 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 June 1, 2012.
This permit and authorization to discharge shall expire at midnight on March 31, 2017.
Signed this day April 20, 2012.
e.64( arles Wakild P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0000752
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.
KapStone Kraft Paper Corporation is hereby authorized to:
1. Continue to operate an existing 28.0 MGD wastewater treatment facility (outfall
001) consisting of the following:
• Mechanical bar screen
• Primary clarifier
• Emergency holding pond
• Sludge lagoon
• Aeration basin
• Three stabilization ponds
2. Continue to discharge non -contact cooling water from the B 85 C evaporator
(outfall 002), and
3. Discharge from said treatment works, located at the KapStone Kraft Paper
Wastewater Treatment Plant, North Roanoke Avenue, Roanoke Rapids, Halifax
County, at the locations specified on the attached map into the Roanoke River
which is classified C waters in the Roanoke River Basin.
2

Kapstone Kraft Paper Corp.- NC0000752
USGS Quad Number: B28NW
Receiving Stream: Roanoke River
Stream Class: C
Subbasin: Roanoke, 03-02-08
Lat.: 36°28'19"
Long.: 77°38'14"

Permit NC0000752
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration,
the Permittee is authorized to discharge from outfall serial number 001 - process water
and stormwater. Such discharges shall be limited and monitored by the Permittee as
specified below:
EF:F U T ` . •
r•t . `:: Cf. �' � �" �;7 �-d
r• r J,� i'
��� '�i�>�'G'
1'c-' yy.'l41,c
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: � #, ,
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u,`I
� ,.fi; -�xx st.;i 'r�^.�,(,�mt
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.:.e �i
ITS ..
'M s5,. tt_c f� ;c��t.
er�''',-'''.�.,iG
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SNIT ItN - IR EN,S,
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;'1 �.. A' k ` h „V�',
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f er 3
��.wK��a.�:����.1M...a..1�VY'%���
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e , .
..::Y: �..a<. .a-. v .,
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� �� .�
;' a
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T�
L' cation1s4
Flow
28.0 MGD
Continuous
Recorder
I or E
BOD, 5 day, 20°C
7,977 Ibs/day
15,953 lbs/day
Dail?
Composite
E
Total Suspended Solids
17,093 lbs/day
34,186 lbs/day
Dail?
Composite
E
Dissolved Oxygen
Dal?
Grab
E, U, D
Temperature
_
Daily's
Grab
E, U, D
Conductivity
Dail?
Grab
E, U, D
NH3 as N
Monthly
Composite
E
Total Nitrogen (NO2+NO3+TKN)
Monthly
Composite
E
Total Phosphorus
Monthly
Composite
E
Chronic Toxicity"
Quarterly
Composite
E
Total Copper's
Quarterly
Composite
E
pH
6.0 - 9.0 standard units
Daily'
Grab
E
Pentachlorophenol4
I
1.65 lbs/day
Weekly
Grab
E
Trichloropheno14
I
1.51 lbs/day
Weekly
Grab
E
Footnotes:
1. Sample locations: E - Effluent, I - Influent, U - Upstream at NC Highway 48 Bridge, D
- Downstream at NC Highway 158. All upstream and downstream samples shall be
collected as grab samples. Stream sampling shall be conducted 3/week during
June, July, August and September and weekly during the remainder of the year.
2. Chronic Toxicity (Ceriodaphnia) P/F at 3.7%; March, June, September and
December; see A. (3), Chronic Toxicity Pass/Fail Permit Limit.
3. Monitoring for metals and the whole effluent toxicity test shall be conducted at the
same time
4. Monitoring for pentachlorophenol and trichlorophenol is not required unless
chlorophenolic containing biocides are used at the facility. If chlorophenolic-
containing biocides are used at the facility, monitoring for pentachlorophenol and
trichlorophenol shall commence immediately for the duration of the use of the
biocides and for a period of not less than two months after discontinuing use of the
biocides.
5. Daily shall mean everyday except Saturdays, Sundays, and legal holidays.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
3

Permit NC0000752
A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration,
the Permittee is authorized to discharge from outfall(s) serial number 002 - non -contact
cooling water. Such discharges shall be limited and monitored by the Permittee as
specified below:
� i � � 1., ar �
.EFFLU, ENT , _
�CHAF , "Y
C ERIST[ S T , , = . �..�
Tt �>'*, ' r3c � c {i X r r�S Y
�� rs ,'C � y
t
_ ,.: �
.e S i .;�, ,y� ,{ t > �xtv^%'P Yd Af/1 if?�`f
K� , fiLii lPT� > r; :. ;:
r ,. . ---,tit;?( tf
, 3 ; ` `°:,,, :11
�. -.. .t .-<t Y �. t4i' �-.��ta:.c.r �
t��. f �,,�S Jyv�. �rjri..'
ti� Y ... . M e
N t•11 ` J , e. ' y'',-A-]�t.�
~n �,. F� tad � f
u.`,.,9_r<[% � . ��-,. �'�.: rc �. ^f
_4. .¢. `>;�u< rot\..i
NITORING REQUIREMENTS
�ti v ^, • ti . `.„
} x { > ' ra y ti f �,
t : � 5:e ::>=> � 4 - 1... ! i..- .
,i "✓ ?
f� onthl - ,r
Average��,
,.nk^.'•r� w -.x.. r� >
, bail ?
,_lazdinuxn
? tms:�..`,�.'uz�,._, �wvx. w'
�I fteasu�r;.ement
/ F
>,.. FregGenc�l �..
r<< .a. ,:,x
r :Sam" Ie ;K
.TYPe
< s..<. f �'x
Sam le<Location
Flow
Semi-annually
Estimate
Effluent
Temperature °C
See note 1
See note 1
Semi-annually
Grab
Effluent
pH
6.0-9.0 standard units2
Semi-annually
Grab
Effluent, Upstream,
Downstream
Footnotes:
1. The temperature of the effluent will be regulated so that the temperature of the receiving
stream does not increase more than 2.8°C (5.05°F) above the natural water temperature and
does not exceed a maximum of 29°C (84.2°F).
2. The pH shall not be less than 6.0 standard units nor more than 9.0 standard units.
In the event that effluent pH shall be recorded outside this range, any value that falls
within the range of pH measured at the upstream and downstream points shall be
considered compliant. Effluent pH shall be sampled on the same days that stream
samples for pH are taken. See Condition A (5.), pH Re -opener.
3. Upstream at NC Highway 48 Bridge, Downstream at NC Highway 158.
There shall be no chromium, zinc or copper added to the treatment system except as
pre -approved additives to biocidal compounds. The permittee shall obtain
authorization from the Division prior to any use of biocide in the cooling water (See
A. (4), Biocide Condition).
There shall be no discharge of floating solids or visible foam in other than trace amounts.
4

Permit NC0000752
A. (3) CHRONIC TOXICITY PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphrda dubia at an effluent concentration of 3. 7 %.
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
March, June, September and December. Effluent sampling for this testing shall be performed at
the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of
the highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the
parameter code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally,
DWQ Form AT-3 (original) is to be sent to the following address:
Attention: 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.
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.
5

Permit NC0000752
A. (4) BIOCIDE CONDITION
The permitted shall not use any biocides except those approved in conjunction with the permit
application. The permitted shall notify the Director in writing at least ninety (90) days prior to
instituting use of any additional biocide in the treatment system, which may be toxic to aquatic life
(other than biocides previously reported to the Division). Such notification shall include completion of
Biocide Worksheet Form 101 and a map indicating the discharge point and receiving stream.
A. (5) pH REOPENER
The Division may re -open this permit to remove pH limitation footnotes at Outfall 002, should new
information indicate water quality problems due to declining pH in this portion of the river.
6

SHERRY AGEE
AFFIDAVIT OF PUBLICATION
STATE OF NORTH CAROLINA)
:SS.
COUNTY OF HALIFAX
North Carolina
Environmental
Management
Commission/
NPDES Unit
1617 Mail Service
Center
Raleigh, NC 27699-
1617
Notice of Intent to
Issue a NPDES
Wastewater Permit
The North Carolina
Environmental
Management
Commission propos-
es to issue a NPDES
wastewater discharge
permit 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 Division of Water
Quality (DWQ) may
hold a public hearing
should there be a sig-
nificant degree of
public interest.
Please mail com-
ments 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 web -
site:
http://portal.ncdenr. or
g/web/wq/swp/ps/npd
es/calendar, or by
calling (919) 807-
6304.
Kapstone Kraft Paper
Corporation request-
ed renewal of NPDES
permit NC0000752
for Roanoke Rapids
Mill in Halifax County,
this permitted facility
discharges treated
process wastewater
and non -contact cool-
ing water to the
Roanoke River,
Roanoke River Basin.
February 15; 2012
12@ETNEN
MAR - 8 2012
DENR-WATEP QUALITY
POINT SOURCE Br.',NCH
being first duly sworn, deposes
and says: That (he) (she) is the Agent to the Publisher of THE
DAILY HERALD newspapers printed and i ublished five days a
week in the County of Halifax, State of North Carolina, and of
general circulation in the cities of Roanoke Rapids, County of
Halifax, State of North Carolina and elsewhere, and thehereto
attached
WASTEWATER PERMIT
was printed and published correctly in the regular and entire issue of said
THE DAILY HERALp5fth
made on the day of
and the last publication thereof was made on the
FEBRUAR_issues that the first was
Y 12
20
15 th
• day of
FEBRUARY 12
20 that said publication
was made on each of the following dates, to wit
02/15/12
Request of
By
NCDENR
The Daily Herald
Subscribed sworn to before me this
20 12
Notary SignatufcY-
LAY of
Notary Public in and for the County of Halifax,State of North Carolina
My Commission Expires:
FEBRUARY

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0000752
Facility Information
Applicant/Facility Name:
KapStone Kraft Paper Corporation /Roanoke Rapids Mill
Applicant Address:
North Roanoke Avenue, Roanoke Rapids, NC 27870
Facility Address:
North Roanoke Avenue, Roanoke Rapids, NC 27870
Permitted Flow
28.0 MGD
Type of Waste:
Industrial (100%)
Facility/Permit Status:
Class IV /Active; Renewal
County:
Halifax County
Miscellaneous
Receiving Stream:
Roanoke River
Regional Office:
Raleigh (RRO)
Stream Classification:
C
State Grid/USGS Quad:
B28NW/Roanoke Rapids
303(d) Listed?
Yes (Hg)
Permit Writer:
Sergei Chernikov, Ph.D.
Subbasin:
03-02-08
Date:
01/10/2012
Index No.
23-(26)
'""
Lat. 36° 28' 19" N Long. 77°_38' 14" W
Drainage Area (mi2):
8,384
7Q 10 (cfs)
1,120
30Q2 (cfs)
1,120
Average Flow (cfs):
2,400
IWC (%):
3.7% o
BACKGROUND
Kapstone Paper Corporation purchased Roanoke Rapids Mill from International Paper in January
2007. KapStone operates an unbleached (Cluster Rule is not applicable) paper mill in
Roanoke Rapids producing high quality unbleached Kraft paper and paperboard. The mill is
integrated including power generation, chemical recovery, pulp production and final paper and
paperboard manufacturing. The site operates a WWTP to treat the wastewaters generated during �
the process. KapStone is permitted to discharge 28.0 MGD of process water through Outfall 001, (4 -1 r i Q J'
non -contact cooling water from the evaporator cooling tower through Outfall 002 and non- otA
C/'
0dh
Process wastewaters are conveyed to the WWTP through a concrete lined open channel. The
WWTP consists of a bar screen, 200 foot diameter primary clarifier, 28 million gallon
emergency pond, 21.5 acre aeration pond with 31 aerators, four stabilization ponds with a total of
370 acres, an effluent defoamer addition system, for solids treatment sludge neutralization tank,
two rotary screen thickeners, two screw presses and a sludge lagoon. The emergency pond is
used to divert process flow in the event they have a power failure, mechanical problems or high
strength waste. The water from the emergency pond is pumped back to the influent channel at a
controlled rate. Condensate collected from the process areas is piped directly to the influent of
the aeration basin. Sludge is landfilled on site under permit WQ0000436.
DMR Data Review/Compliance
Division's records show no limit violations for the past permit cycle, including Whole Effluent
Toxicity limit.
.Fact Sheet
NPDES Ne0000752 Renewal
Pate 1

Stream Monitoring
KapStone monitors upstream and downstream of the discharge for temperature, pH, dissolved
oxygen, BOD and conductivity. The upstream station is located at the bridge on Highway 48, the
downstream station is at the bridge on Highway 158. Dissolved oxygen did not fall below the
state standard of 5 mg/L during the last 3 years (2009 through 2011).
303(d)/Basin Plan
This section of the river is listed on the 303(d) as impaired for fish consumption due to mercury
levels in fish.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA for the permit renewal in 1997. Current limits are based on
guidelines and water quality standards. The current permit includes limits for flow, BOD5, TSS,
pH, pentachlorophenol, and trichlorophenol. Monitoring for pentachlorophenol and
trichlorophenol is not required if the facility doesn't use chlorophenolic-containing biocides.
Based on instream data that the permit holder submitted for the 2001 permit renewal, which
reflect naturally occurring pH at levels occasionally below 6.0 standard units in this portion of
the river, DWQ included a footnote to the pH limit requirements at Outfall 002 and Outfall 003.
(These outfalls discharge non -contact cooling water back into the river a short distance
downstream from where it was drawn.) The footnote states that in the event that the effluent pH
at these outfalls is outside the range of 6.0 — 9.0 standard units, any value that falls within the
range of pH measured at the downstream and upstream points will be considered compliant. It
also requires instream pH to be sampled on the same days that effluent samples are taken. The
footnote will stay in the permit.
Effluent Guidelines
Paper Mill's are regulated under effluent guidelines in 40 CFR 430. Subpart C applies to
unbleached kraft paper production. Attached is the calculation for the proposed limits based
on the most recent production data.
Reasonable Potential Analysis (RPA)
RPA for arsenic, beryllium, chromium, copper, fluoride, lead, mercury, molybdenum, nickel,
silver, and zinc was conducted (please see attached).
SUMMARY OF PROPOSED CHANGES
• Limits for BOD, TSS, Pentachlorophenol, trichlorophenol and TSS limits were increased
to reflect the most recent production data (Outfall 001).
• Outfall 003 was eliminated from the permit.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice:
Permit Scheduled to Issue:
NPDES DIVISION CONTACT
January 17,2012
March 12, 2012
If you have questions regarding any of the above information or on the attached permit, please
contact Sergei Chernikov at [phone].
Fact Sheet
NPDES NC0000752 Renewal
Page 2

NC0000752 KapStone
Outfall 001 EG limits calculations
Effluent Guidelines: 40 CFR 430 Subpart C
Average production:
1271.79 tons/day
2848810 lb/day
2849 k Ib/d
Appendix A
Parameter
EG Daily max
EG Monthly aver
Daily max limit ,
Monthly aver limit
BOD1
5.6
Ib/1000 Ib
2.8
lb/1000 Ib
15953
lb/day
7977
lb/day
TSS'
12
lb/1000 Ib
6
Ib/1000 Ib
34186
lb/day
17093
lb/day
pH1
6to9
Pentachloropheno12
0.00058
lb/1000 Ib
N/A
1.65
lb/day
Trichlorophenol2
0.00053
Ib/1000 Ib
N/A
1.51
lb/day
1. BPT 430.32
2. BAT 430.34
3. BCT 430.33 - same as BPT
Existinct limits
Parameter
Daily max
Ib/d
Monthly aver
Ib/d
BOD
13704
6852
TSS
31152
15576
Pentachlorophenol
1.51
No limit
Trichlorophenol
1.38
No limit
pH
6 -9 SU
Proposed limits
Parameter
Daily max
Monthly aver
Comments
BOD
15,953 Ib/d
7,977 Ib/d
TSS
34,186 lb/d
17,093 Ib/d
Pentachlorophenol
1.65 Ib/d
Trichlorophenol
1.51 Ib/d
NPDES NC0000752
Fact Sheet

Chernikov, Sergei
From: Pamala Myers [[e-mail]]
Sent: Thursday, March 01, 2012 12:57 PM
To: Chernikov, Sergei
Cc: Mark Nuhfer
Subject: Re: final permit FYI
Hello Sergei,
I wanted to be sure to acknowledge we received these docs.
Also, Karrie Jo and I have reviewed Miller Breweries, NC0029980 and KapStone Kraft Paper
NC0000752 and have no comments at this time.
Please forward the final permits after issuance.
Thank you,
Pamala Myers
404.562.9421
mvers.pamala(Eepa.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
From: "Chernikov, Sergei" <[e-mail]>
To: Pamala Myers/R4/USEPA/US@EPA, "Meadows, Susan"
<susan.meadowsOncdenr.gov>
Date: 02/28/2012 12:42 PM
Subject: final permit FYI
Sergei Chernikov, Ph.D.
Environmental Engineer II
Complex Permitting Unit
Phone: [phone], fax [phone]
1617 Mail Service Center
Raleigh, NC 27699-1617
Express mail: 512 North Salisbury St.
Raleigh, NC 27606
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
[attachment "3573 - final cover-2012.docx" deleted by Pamala Myers/R4/USEPA/US] [attachment
"3573-permit-2011.docx" deleted by Pamala Myers/R4/USEPA/US] [attachment "3573-fact sheet-
2011.docx" deleted by Pamala Myers/R4/USEPA/US]
1

A MI
.4 W
KAPSTONE
March 1, 2012
Sergei Chernikov, PhD
Complex NPDES Permitting Unit
Division of Water Quality
1617 Mail Service Center
Raleigh, N.C. 27699- 1617
RE: NPDES Permit NC0000752
Dear Dr. Chemikov:
KAPSTONE
KRAFT PAPER CORPORATION
ADivisionofKAPSTONE PAPER AND PACKAGING CORPORATION
100 Gaston Road Roanoke Rapids, NC 27870
kapstonepaper.com
This letter is in response to the draft NPDES permit NC0000752 that we received from you on
February 15, 2012. After careful review there are no adverse comments. There are a couple of
informational corrections to the draft. On the facility location map (between pages 2 and 3) Outfall
003 is listed even though it has been removed from the permit. On page 6 under A. (5) pH
REOPENER Outfall 003 is referenced again and should be removed.
It should be noted that Kapstone Paper Corporation's Roanoke Rapids mill has no intention of using
biocides containing Pentachlorophenol or Trichlorophenol at this time. If you have any questions,
please feel free to contact me at [phone].
Sincerely,
eXp?„,„__
Thomas C. Puryear
Environmental Engineer III
xc: Anitra Collins
Mike Knudson
Neal Davis
Paul Kinnin
21E@INOWE
MAR - 7 2012
DENR-WATER QUALITY
POINT SOURCE BRANCH

4 Mir
KAPSTONE
September 8, 2011
Mr. Charles Weaver
NC DENR / DWQ / Point Source Branch
1617 Mail Service Center
Raleigh, N.C. 27699- 1617
Attn: Carolyn Bryant
re: Renewal Notice
NPDES Permit No. NC0000752
Roanoke Rapids Mill
Halifax County
Dear Mr. Weaver:
KAPSTONE
KRAFT PAPER CORPORATION
A Division of KAPSTONE PAPER AND PACKAGING CORPORATION
100 Gaston Road Roanoke Rapids, NC 27870
kapstonepaper.com
1';,ll1 1E@CEQ V 12 (1
DU
UUl
SEP 2 7 2011
Gr-rj :WATEIR QUALITY
POINT SOURCE BRANCH
Pursuant to Federal (40 CFR 122.41) and North Carolina (15A NCAC 2H.0105(e) regulations
NPDES permit renewal applications must be submitted at least 180 days prior to the expiration of the
existing permit (March 31, 2012). The Purpose of this correspondence is to request renewal of
NPDES Permit No. 0000752 for the Kapstone Kraft Paper mill located in Roanoke Rapids, North
Carolina. Enclosed you will find the following information (one original and two copies):
• EPA Form 3510-1 (General Information Form)
• Topographic Map of Mill Site and Discharge Points
• Application Form 2C — Wastewater Discharge Information
• Mill Water Balance Diagram
o Wastewater Treatment System Diagram
o Wastewater Treatment System Narrative Description
• Sludge Management Plan Narrative Description
• Results of Priority Pollutant Analysis
• Results of Analysis Required under Part V-B and V-C of Form 2C
Since the last renewal of NPDES permit NC0000752, the only major change to the wastewater
treatment system has been the elimination of discharge No. 003. This discharge consisted of
non -contact cooling water associated with the production of turpentine. The formally directly
discharged non -contact cooling water is presently used in various areas of the mill as a source of
hot water. The re -use of this hot water has reduced the total amount of water withdrawn from
the Roanoke River used in our paper making process.
During the chemical analysis of discharge 002 (non -contact evaporator cooling water), the
presence of Bis(2-ethylhexyl)phthalate (DEHP)was detected at the microgram per liter level.
We have investigated where this material could have entered the waste stream from our process
and cannot find a source. The only explanation for a source of the DEHP was the equipment

used to collect the analytical sample. The temperature of the sample, when collected, was
approximately 120 degrees F. A Nalgene carboy was used to collect the composite sample and
Nalgene tubing was used to connect the sample pump and sample stream to the carboy. A
sample of distilled water was collected using the same sample train and when analyzed the
presence of DEHP was detected. It is possible that the DEHP leached from the carboy and/or
the sample tubing. We collected a grab sample of the cooling water using a stainless steel
container and immediately transferred it to glass bottles. The analysis of the grab sample
showed that the DEHP was not present in the cooling water.
In the same non -contact cooling water sample, from discharge No. 002, the presence of
chloroform was also detected in the microgram per liter level. An investigation of where the
chloroform could have entered the sample was conducted. It was determined that the material
used to clean the sample container prior to collecting the sample could have caused the
chloroform to be present. The discharge was re -sampled using a new sample container and the
results of the analysis showed that no chloroform was detected.
It should be noted that this facility does not manage storm water under our NPDES discharge
permit. The mill has an individual Storm Water permit (NCS000106) that was renewed in 2009
and has an expiration date of July 31, 2014.
If you have any questions regarding the permit renewal application please don't hesitate to call
Mike Knudson at 252-533-6280 or Chris Puryear at 252-533-6237.
, OJOSWA..")--1.--L.---------'
Anitra J. Collins
Mill Manager
xc: Neal Davis
Mike Knudson
Chris Puryear
Paul Kinnin (w/o attachments)

Kapstone
Roanoke Rapids Mill
NPDES Permit Renewal
Wastewater Treatment System Description
The main sewer that brings the wastewater into the treatment facility is a concrete lined
open channel. Along the channel are a composite sampler, pH and conductivity probes,
and a flow meter. The instruments have local readouts at the channel and in the Sludge
Press operators control room. The sludge press operator monitors the operation of the
sludge press and the wastewater facility from this control room. Operation of the sludge
press and wastewater facility can also be monitored from the Lime Kiln operators control
room.
The flow goes through a mechanical bar screen, into a wet well where three lift pumps
carry the flow to a 200 foot diameter primary clarifier. The clarifier has a capacity of 3.8
million gallons. In the event that we have a power failure, mechanical problems or high
strength waste the sludge press operator can divert main sewer flow, by gravity, to the
Surge Pond. The pond is 20.4 acres and holds 28 million gallons of wastewater or about
two days of normal mill wastewater flow. The water from the diversion pond is then
pumped back to the head of the wastewater plant at a rate of 1380 gallons per minute.
The flow from the Primary Clarifier is gravity feed to the aeration pond. Nutrients are
added to the clarified effluent prior to the aeration pond. The aeration pond covers 21.5
acres and has a retention time of four days. There are 31 aerators with a total of 2030
horsepower. The aeration pond also receives approximately 0.8 million gallons per day
from the condensate collection system Hard Pipe Feed Tank (HPFT). (This is not
additional flow to the treatment system but the method of condensate collection and
treatment mandated by the Maximum Achievable Control Technology rules for the Pulp
and Paper industry.) We also have the capability of adding defoamer to the aeration pond
influent flow to prevent excessive foam. The water then cascades down into the first of
four stabilization ponds. There are 370 acres of stabilization ponds with a retention time
of 30-35 days. The ponds and dikes are clay lined and have a capacity of approximately
480 million gallons at a normal operating level of 4 feet.
The final stabilization pond discharge has a bar screen and a composite sampler. Effluent
flow is controlled by an electrically operated butterfly valve at the discharge to the river.
Final effluent flow measurement is accomplished by the use of a Marsh Mc Birney multi -
probe velocity type flow meter. We also have the equipment to feed defoamer to the
effluent for foam control if required.
Sludge from the primary clarifier is pumped to a blend tank where sulfuric acid is added
for pH control and polymer is added to promote thickening. The sludge is then pumped
to one of two rotary screen thickeners and gravity feed to one of two Dupps Andritz
screw presses. The presses are 38 feet long and normally produce a sludge cake of 40 %
solids or greater. These solids are deposited into one of four leak proof 28 foot dump
trailers and hauled to the permitted (WQ0000436) onsite landfill.
July, 2011

Kapstone
Roanoke Rapids Mill
NPDES Permit Renewal
During the treatment process solids accumulate in the first stabilization pond. This pond
is periodically dredged to remove those solids to assure optimum treatment efficiency.
Dredging from the Stabilization ponds are pumped to the old sludge pond where it is
allowed to decant. Leachate from the old sludge pond, and the onsite landfill, flow by
gravity into the aeration pond and treated along with the other wastewater.
July, 2011

September 13, 2011
Kapstone Kraft Paper Corporation
Roanoke Rapids Mill
Sludge Management Plan
The solids that settle to the bottom of the Primary Clarifier are pumped from the center of
the clarifier to a blend tank where sulfuric acid is added to lower the pH and aid the
flocking of the sludge. The sludge is then pumped from the Blend tank to one of two
Rotary Screen Thickeners. While in route to the Rotary Screen Thickeners polymer is
added to flocculate the sludge. Filtrate is released through the screen of the RST and the
solids remain inside and are dumped into a hopper. One of two, 38 foot screw presses
compresses the solids and pushes the filtrate through the screens. The solids are then
dumped into the screw conveyors and conveyed to one of four sealed 28 cubic yard
trailers. The dewatered sludge, which is about 40% solids, is then taken to the mill's
onsite landfill (Permit Number WQ0000436). Periodically the sludge from the sludge
presses are applied to permitted lands under Land Application Permit No. WQ0013516.
All filtrate from the sludge press is returned to the head of the wastewater plant for
treatment.
Whenever it is determined that the ponds need to be cleared of solids. The solids that
accumulate in the ponds are pumped by dredge through 8-10 inch fused plastic pipe to
what is referred to as the Old Sludge Pond. The solids decant in the sludge pond and the
filtrate returns to the Aeration Pond for treatment.

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Roanoke Rapids
Wastewater Treatment Plant
Pulp Mil!
309.5 MG
16 Days Resendon
Roanoke River••,.
Hard pipe
Feed Tank
0.8 MGD
Primary Clarifier
Waodyud
Swrmwaux
Peed
StortRwa r Ditch
i
Site Plan • Roanoke Rapids
Aerators:
4 - 50 hp Air02 aerators_
3 - 75 hp A1r02 aerators
11 - 75 hp high speed surface aerators
13 - 60 hp high speed surface aerators
Total m 2030 hp
Landfill
(26 cres)
Sludge
Dewatering
440

Paper Mill Influent
City
Water
0.26 MGD
Flow
From
River
17.9 MGD
Water in
Wood
Paper Mill
Cold Water Tank 5.8 MGD
Evaporation to Atmosphere
♦ 33 GPM
Water in Paper
8.7 GPM
Paper Mill Effluent 5.8 MGD
263 GPM
i Out
0
Pulp Mill
Influent
Utility
Influent
Out
I
;
;
I
;
;
;' Out
;
Pulpmill
Secondary Blow Heat
Primary Turp Condenser
Secondary Reflux Condenser
Turp Condenser Cooling Water
0.36 MGD
0.22 MGD
0.30 MGD
1.44 MGD
Pulpmill Effluent 2.32 MGD
Condensate Collection
Hard -pipe Feed Tank 0.50 MGD
Rainwater 0.07 MGD
►
Condensate Collection Effluent 0.50 MGD
Non -Contact
Influent
Utility
B Evaporators Surface Condenser 0.92 MGD
C Evaporators Surface Condenser 1.51 MGD
Boiler Water Makeup 0.50 MGD
Slaker Stacks 0.07 MGD
Ash Pond 0.14 MGD
Utility Effluent 3.15 MGD
Non -Contact Water
Surface Condenser Overflow 5.8 MGD
Non -Contact water to River 5.80 MGD
Roanoke Rapids Mill Water Balance
Recycle
Waste
water
Treatment
Flow to River
11.77 MGD
Recycle - • -
Revised August, 2011