NC0002305_Permit (Issuance)_20120803

NPDES DOCUMENT SCANNING COVER SHEET
NC0002305
Guilford Mills WWTP
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
August 3, 2012
Miss document is printed oa reszse paper - ignore any
content on the re nertse wide

ern
MENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Charles Wakild, P.E. Dee Freeman
Governor Director Secretary
August 3, 2012
Mr. Brent Turner
Director of Engineering
Guilford Mills, Inc.
1754 NC Highway 903
Kenansville, NC 28249
Subject: Issuance of Final Permit
NPDES Permit NC0002305
Guilford Mills, Inc.
Duplin County
Class III
Dear Mr. Turner:
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).
Summary of Changes in Final Permit from Existing Permit (No changes from draft)
1) Production based mass limits for BOD, COD, TSS, sulfide, total phenols, and total chromium were
assigned.
2) Total cyanide limits with monthly monitoring were added.
3) Total zinc and total copper quarterly monitoring in conjunction with chronic toxicity test was assigned.
4) Chloride monitoring was removed.
5) Total nitrogen and total phosphorus monitoring was corrected to monthly.
6) Narratives for treatment components, total residual chlorine footnote, and chronic toxicity special
condition were updated.
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.
Page 1 of 2
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
NOne Cai'011ila
7V'atiiraI4i

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 [e-mail].
Sincerely,
Charles Wakild, P.E.
Attachments
Cc: Wilmington Regional Office/Surface Water Protection Section
EPA Region IV/Karrie-Jo Robinson -Shell, P.E. (email)
Environmental Sciences Section/Aquatic Toxicology Unit/Susan Meadows (email)
Paul Bruesch, P.E./Corporate Environmental Manager (email: [e-mail])
Central Files
NPDES File
Page 2 of 2

Permit NC0002305
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
Guilford Mills, Inc.
is hereby authorized to discharge wastewater from outfall located at the
Guilford East Division Wastewater Treatment Plant
1754 NC Highway 903 Kenansville
Duplin County
to receiving waters designated as the Northeast Cape Fear River within 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 September 1, 2012.
This permit and authorization to discharge shall expire at midnight on January 31, 2017.
Signed this day August 3, 2012.
io
harles Wakild, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0002305
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are
hereby revoked, and as of this issuance, any previously issued permit bearing this number is
no longer effective. Therefore, the exclusive authority to operate and discharge from this
facility arises under the permit conditions, requirements, terms, and provisions described
herein.
Guilford Mills, Inc.
is hereby authorized to:
1. Continue discharging 1.5 MGD of treated industrial wastewater from the existing
wastewater treatment facility that includes the following components:
o Mechanical bar screen
o Lint removal screen
o Influent meter with Parshall flume and continuous recording
o Influent transfer pump station
o One (1) 2,000,000 gallon influent equalization basin with three (3) floating
aerators and transfer pumps
o One (1) 2,000,000 gallon aeration basin with eight (8) floating aerators
o Splitter box
o Chemical coagulant and polymer flocculant addition systems.
o Two (2) 55 ft diameter secondary clarifiers with RAS transfer pumps
o Alum/caustic dispensing system
o Flash tank
o One (1) 60 ft diameter tertiary clarifier with RAS transfer pumps
o Effluent pump station
o Chlorination contact tank
o De -chlorination addition
o Effluent flow meter with continuous recording
o Effluent composite sampler
o Sludge thickener tank
o One (1) 1,000,000 gallon sludge digester with one (1) floating aerator
o One (1) 500,000 gallon sludge storage tank with one (1) floating aerator
o One (1) 50,000 gallon filtrate tank with transfer pump
o Sludge drum thickener
o Ten sand sludge -drying beds with liquid recovery pumps
This facility is located at the Guilford East Division Wastewater Treatment Plant, 1754
NC Highway 903, Kenansville in Duplin County.
2. To discharge from said treatment facility through Outfall 001 at a specified location (see
attached map) into the Northeast Cape Fear River, a waterbody classified as C-Swamp waters
within the Cape Fear River Basin.

Guilford Mills, Inc_
FTC0002305
Downstream
N00002305
USGS Quad: G27SE Albertson, NC
Outfall
Latitude: 35° 1' 0.4" N 35° 1' 3" N
Longitude: 77° 50' 46.6" W 77° 51' 38" W
Stream Class: C, Sw
Subbasin: 03-06-22 HUC: 03030007
Receiving Stream: NE Cape Fear River
Facility
North
41141111,1111
Facility Location
Guilford Mills, Inc. NC0002305
Duplin County

Permit NC0002305
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 001. Such discharges shall be limited and monitored by the
Permittee as specified below:
EFFLUENT
CHARACTERISTICS
LIMITS
MONITORING
REQUIREMENTS
Sample
Type
Sample 1
Location
Monthly Average
Daily Maximum
Measurement
Frequency
Flow
Parameter Code 50050
1.5 MGD
Continuous
Recording
Influent or
Effluent
BOD, 5 day, 20°C
Parameter Code QD310
166.8 pounds/day
333.5 pounds/day
3/Week
Composite
Effluent
COD
Parameter Code 00340
2668 pounds/day
5336 pounds/day
3/Week
Composite
Effluent
Total Suspended Solids
Parameter Code QD530
727.1 pounds/day
1454.1 pounds/day
3/Week
Composite
Effluent
pH
Parameter Code 00400
Not less than 6.0 S.U. nor greater than
9.0 S.U.
3/Week
Grab
Effluent
Total Residual Chlorine z
Parameter Code 50060
28 µg/L,
3/Week
Grab
Effluent
Dissolved Oxygen
Parameter Code 00300
Not less than 6.0 mg/L, daily average
3/Week
Grab
Effluent
Dissolved Oxygen, mg/L
(June 1— September 30)
3/Week
Grab
U, D
Dissolved Oxygen, mg/L
(October 1— May 31)
Weekly
Grab
U, D
Temperature, °C
Parameter Code 00010
3/Week
Grab
Effluent
Temperature, °C
(June 1— September 30)
3/Week
Grab
U, D
Temperature, °C
(October 1— May 31)
Weekly
Grab
U, D
Conductivity, µmhos/cm
3/Week
Grab
Effluent
Parameter Code 00094
Conductivity, µmhos/cm
(June 1— September 30)
3/Week
Grab
U, D
Conductivity, µmhos/cm
(October 1— May 31)
Weekly
Grab
U, D
Fecal Coliform
(geometric mean)
Parameter Code 31616
200 / 100 ml
400 / 100 ml
Weekly
Grab
Effluent
Sulfide
Parameter Code 00745
6.7 pounds/day
13.3 pounds/day
Weekly
Grab
Effluent
Total Phenols
Parameter Code 32730
3.3 pounds/day
6.7 pounds/day
Weekly
Grab
Effluent
Total Chromium
Parameter Code 01034
3.3 pounds/day
6.7 pounds/day
Weekly
Composite
Effluent
Oil and Grease
Parameter Code 00556
30.0 mg/L
45.0 mg/L
2/Month
Grab
Effluent
Total Cyanide, µg/L
Parameter Code 00720
(2g/r..i
73 µg/L
Monthly
Composite
Effluent
1,t1,2.v s1-1-0 v tip i lei

Permit NC0002305
(Continued A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS)
EFFLUENT
CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample
Type
Sample 1
Location
Total Nitrogen (TN), mg/L
TN = TKN + (NO2 N+NO3 N)
Parameter Code C0600
Monitor & Report
Monthly
Composite .
Effluent
Total Phosphorus, mg/L
Parameter Code C0665
Monitor & Report
Monthly
Composite
Effluent
MBAS, mg/L
Parameter Code 38260
Quarterly
Grab
Effluent
Total Copper 3, µg/L
Parameter Code 01042
Quarterly
Composite
Effluent
Total Zinc 3, µg/L
Parameter Code 01092
Quarterly
Composite
Effluent
Chronic Toxicity a
Parameter Code TGP3B
Quarterly
Composite
Effluent
Footnotes:
1. U = Upstream in Goshen Swamp at Highway 11 Bridge. D = Downstream in NE Cape Fear River
at Sarecta Bridge.
2. The Division shall consider all effluent Total Residual Chlorine values reported below 50 µg/L to
be in compliance with the permit. However, the Permittee shall continue to record and submit all
values reported by a North Carolina certified laboratory (including field certified), even if these
values fall below 50 µg/L.
3. Measurement must be conducted in conjunction with chronic toxicity test.
4. Chronic Toxicity, Ceriodaphnia dubia, 7 day, P/F at 27%; during January, April, July, and
October. See A (2.).
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER
THAN TRACE AMOUNTS.
A (2.) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 27%.
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.
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.

Permit NC0002305 •
(Continued A. (2) CHRONIC TOXICITY PERMIT LIMIT (Quarterly))
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. If reporting pass/fail
results using the parameter code TGP3B, DWQ Form AT-1 (original) is sent to the below address. If
reporting Chronic Valueresults using the parameter code THP3B, DWQ Form AT-3 (original) is to be
sent to the following address:
NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences 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.
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 all
AT Forms.
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.

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES PERMIT NC0002305
Facility Information
Applicant/Facility
Name:
Guilford Mills, Inc/Guilford East Plant WWTP
Applicant Address:
1754 NC Highway 903; Kenansville, NC 28249
Facility Address:
1754 NC Highway 903; Kenansville, NC 28249
Permitted Flow
1.5 MGD
Type of Waste:
Industrial
Facility/Permit Status:
Class III /Active; Renewal
County:
Duplin County
Miscellaneous
Receiving Stream:
NE Cape Fear
River
Stream Classification:
C, Sw
Subbasin:
03-06-22
Index No.
18-74-(1)
Drainage Area (mi2):
326
HUC:
02030007
Summer 7Q10 (cfs)
6.5
303(d) Listed?.
No
Winter 7Q10 (cfs):
18
Regional Office:
Wilmington
30Q2 (cfs)
-
State Grid / USGS
Quad:
G27SE
Albertson, NC
Average Flow (cfs):
398
Permit Writer:
Ron Berry
IWC (%):
26.4%
Date:
5/8/12
BACKGROUND
Guilford Mills, Inc. manufactures fabrics in its Kenansville facility primarily used in automobile
interiors. Operations include warp knitting, circular knitting, weaving, printing, and dying of
synthetic fabrics. The industrial and domestic wastewater influents combine, are treated by the ,
facility's WWTP, and discharged through Outfall 001 into the NE Cape Fear River, a class C-
Swamp water in the Cape Fear River Basin. 40 CFR 410 Textile Mills Subpart E Knit Fabric
Finishing are applicable.
HISTORY
2008 - Current permit issued. An approved model was available but when compared to effluent
guidelines, the guidelines were more stringent. MBAS and chloride monitoring was
reduced. The annual effluent pollutant scan requirement was removed.
2011 - Advised Permittee to include one effluent pollutant scan with application.
2012 - Permittee provided amended water balance to include water softeners backwash and
more descriptive treatment equipment narrative.
- Permittee provided additional production data to complete a 5 year history and provided
a wastewater treatment narrative.
COMPLIANCE
There were no violations during this permit cycle. The last enforcement action was in 2002.
TREATMENT PROCESS
Wastewater from domestic, industrial and intermittent water softener back wash combined, and
are screened, metered, and collected in the equalization basin. The equalization basin is pumped
Fact Sheet
NPDES NC0002305
Page 1 of 4

to the primary aeration basin. Floating aerators provide aeration. As needed flocculant chemicals
can be added to the flow as it exist the basin. A splitter box directs the wastewater to 2 secondary
clarifiers. The flows recombine, passes through a flash box where additional enhancement
chemicals may be added, and enters the tertiary clarifier. The clarified wastewater is collected
and pumped to the chlorine contact chamber where chlorination followed by dechlorinated
occurs then the treated wastewater passes through the effluent meter and flows by gravity to
Outfall 001. An effluent composite sampler collects samples from a manway.
The removed solids are collected in a gravity thickener, then go to a digestor, and then are
further dewatered via a rotary drum thickener. A sludge holding tank collects the drum solids.
Liquid extracted during the drum dewatering operation is collected a filtrate tank and returned to
the headworks. An approved contractor pumps and hauls the sludge from the holding tank as
needed. As an alternative solids may be diverted from the digestor to drying beds. Captured
liquid is returned to the treatment plant. Dry solids are removed from the beds and transported to
an approved composting operation.
PERMITTING STRATEGY
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on DMR data from January 2010 to December
2011 and from the 1 PPA submitted with the renewal application. Evaluations were conducted
for the detected parameters of antimony, chlorides, total phenolic compounds, chromium,
copper, cyanide, zinc, bromodichloromethane, bromoform, chloroform, and
dibromochloromethane.
Results suggest reasonable potential for the facility to discharge copper, cyanide, and zinc.
Copper and zinc are action level parameters. Copper monitoring will be reduced to quarterly and
zinc quarterly monitoring will be added in conjunction with the toxicity test. Cyanide monthly
monitoring with limits will be added. Total phenols and total chromium had no reasonable
potential but are limited under federal effluent guidelines and limits will be addressed as such.
Chloride had no reasonable potential so chloride monitoring will be removed.
Effluent Guidelines 40 CFR 410 Textile Mills Subpart E Knit Fabric Finishing
Based on 60 consecutive months beginning in January 2007, an average daily production of
66,702.3 lbs/day was determined which represents a 21% reduction from the current permit
production rate. The facility has existing BOD, TSS, and DO allocations from approved models.
Table I list the guideline factors, compare the production -based limits to applicable water quality
and/or assigned allocation. The more stringent limit will be applied.
Table Comuarison of Alicable Effluent Limits
Parameter
40 CFR Part 410 Subpart E
*Factor = lbs/1000 lbs of production
Daily Production =
66702. 3 lbs/day
Applied WQS or Allocation
Flow = 1.5 MGD, IWC = 26.35% or EOP
Section
reference
Daily
Max
Factor*
Monthly
Average
Factor*
Daily
Max
(lbs/day)
Monthly
Average
(lbs/day)
WQS or
Allocation
Monthly
Average
(lbs/day)
Daily
Max
(lbs/day)
BOD
410.52(a)
5
2.5
333.53
166.76
24 mg/L(s)1
300.24
450.36
TSS
410.52(a)
21.8
10.9
1454.17
727.08
Allocation2
1035
2071
COD
410.53(a)
60
30
4002.3
2001.15
Sulfide
410.53(a)
0.2
0.1
13.34
6.67
Phenol
410.53(a)
0.1
0.05
6.67
3.34
No RPA
Fact Sheet
NPDES NC0002305
Page 2 of 4

(Continued Table I: Comparison of Applicable Effluent Limits)
Parameter
40 CFR Part 410 Subpart E
*Factor = lbs/1000 lbs of production
Daily Production =
66702. 3 lbs/day
Applied WQS or Allocation
Flow = 1.5 MGD, IWC = 26.35% or EOP
Section
reference
Daily
Max
Factor*
Monthly
Average
Factor*
Daily
Max
(lbs/day)
Monthly
Average
(lbs/day)
WQS or
. Allocation
Monthly
Average
(lbs/day)
Daily
Max
(lbs/day)
Total
Chromium
410.53(a)
0.1
0.05
6.67
3.34
No RPA
COD
410.52(b)
20
10
1334.1
667.05
pH
410.52(a)
Not less than 6.0 S.U. nor greater than 9.0 S.U.
Footnotes:
1. Approved 2007 model with DO = 5.0 mg/L, BOD monthly average allocation summer = 24
mg/L, winter = 30 mg/L, daily maximum = 1.5 x monthly average allocation.
2. Allocation established in 1977 approved model.
Data review
DMRs were reviewed for the period of January 2010 to December 2011. DMR data is
summarized in Table II below:
Table II: DMR Data Review
Flow*
(MGD)(lb/day)(lb/day)(lb/day)(lb/day)(lb/day)Chromium*
BOD*
TSS*
COD*
Sulfide*
Phenol*
Total
(lb/day)
pH
S.U.
( )
O&G*
mg,,//��
(mg/L)
Fecal
(#/100rm*
(#/100 ml)
Average
0.790
55.32
118.19
660.18
0.657
0.307
0.080
. 7.14
6.95
6.8.
Maximum
0.092
123.6
255.1
1860.3
0.92
0.90
0.09
7.8
13.7
111
Minimum
0.610
23.8
71.7
p
376.0
0.15
0.03
0.06
6.2
5.0
>1
*Based on monthly average
TRC
(µg/L)
DO
(mg/L)
Conductivity
(µmhos/cm)
Temperature
(°C)
Average
25.3
6.82
508.6
21.1
Maximum
32
8.4
1132
30
Minimum
20
6.0
281
10
Whole Effluent Toxicity
The permit requires quarterly chronic testing using ceriodaphnia dubia, at 27% effluent
concentration. Of the 15 quarterly test conducted since January 2008, 13 test passed and 2 failed.
As required the 2 failed tests were followed up with the required consecutive tests, 3 out the 4
follow up tests were passed. Will continue quarterly chronic toxicity testing and update narrative
as needed.
Oil and Grease and MBAS (surfactants)
Oil and Grease limits and MBAS (surfactants) monitoring will continue as concerns remain.
Priority Pollutant Analysis
See RPA Analysis for results.
Fact Sheet
NPDES NC0002305
Page 3 of 4

Lower Cape Fear Nutrient Strategy
A correction will be made to increase monitoring for total nitrogen and total phosphorus to
monthly to coincide with current strategy.
Instream Data Impact
Temperature, Dissolved Oxygen, and Conductivity instream monitoring in the NE Cape Fear
River are required while pH monitoring is voluntary. The January 2010 through December 2011
data was reviewed to determine any impact. There appears to be a positive impact to the DO and
pH. The conductivity indicates the presents of an industrial effluent. Will continue instream
monitoring requirements.
SUMMARY OF PROPOSED CHANGES
In keeping with Division strategies and EPA guideline the following will be incorporated into
the permit:
• New mass -based limits based on Federal Effluent Guideline 40 CFR Part 410 Subpart
E and a production rate of 66,702 pounds/day were calculated for BOD, COD, TSS,
sulfide, phenols, and total chromium. Guideline also defined effluent pH limit range.
• Effluent total zinc quarterly monitoring was added to coincide with toxicity test.
• Effluent total copper monitoring was reduced to quarterly to coincide with toxicity test.
• Effluent total cyanide limits with monthly monitoring was added.
• Effluent chloride monitoring was removed.
• Effluent total nitrogen and total phosphorus monitoring was corrected to monthly.
• Narratives for TRC footnote, component list, and chronic toxicity special condition
were updated.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: May 9, 2012
Permit Scheduled to Issue: June 2012
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please
contact Ron Berry at [phone] or email [e-mail].
NAME:
REGIONAL OFFICE COMMENTS
DATE:
NAME: DATE:
SUPERVISOR: DATE:
Fact Sheet
NPDES NC0002305
Page 4 of 4

Berry, Ron
From: Pamala Myers [[e-mail]]
Sent: Friday, May 18, 2012 1:57 PM
To: Berry, Ron
Subject: Re: Follow Up to Phone Message Guilford Mills, Inc NC0002305
Hi Ron,
Not a problem.
This is your "no comments" documentation as requested.
Pamala Myers
4o4.56z.942I
myers.pamala(6 a pa.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
"Berry, Ron" ---05/18/2012 01:43:32 PM —Pam, Thanks for the information. To be sure I have a document of record
can you please email "No corn
From: "Berry, Ron" <ron.berrvC5?ncdenr.aov>
To: Pamala Myers/R4/USEPA/US@EPA
Date: 05/18/2012 01:43 PM
Subject: Follow Up to Phone Message Guilford Mills, Inc NC0002305
Pam,
Thanks for the information. To be sure I have a document of record can you please email "No comments" in reference to your draft
review. A copy of the email reply is always included with out file documentation.
Thanks, Ron
Ron Berry ron.berrvPncdenr.gov
Engineer I
DWQ/Point Source/NPDES Complex Permitting Unit
NCDENR
Phone: [phone]
Fax: [phone]
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.
1

AFFIDAVIT OF PUBLICATION
STATE OF NORTH CAROLINA
..COUNTY OF SAMPSON
JULES MOLENDA, PUBLISHER, of the Sampson Independent, a newspaper published in
Sampson County, N.C. being duly sworn, says that at the time the attached notice was
published in they SAMPSON INDEPENDENT, said newspaper met all of the requirements
and qualifications prescribed by North Carolina General Statue 11-597; that said newspaper had
a general circulation to actual paid subscribers; and was admitted to the United States mail as
second class matter in Sampson County, N.C.; and further, that the attached notice was
P
hed in e SAMPSON INDEPENDENT on
, 2012.
PUBLIC NOTICE
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 Envir-•
onmental Management
Commission proposes to is-
sue a NPDES wastewater
discharge permit to the
persons) listed below.
• Written comments regarding
the proposed 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
information requests to DWQ
at the above address. In-
terested persons may visit the
DWQ at 512 N. Salisbury
Street, Raleigh, NC to review
information on file. Additional
information on NPDES per-
mits and this notice may be
found on our website: •
http://portal.ncderir.org/weh/wq—
/swp/ps/npdes/calendar, or by
calling [phone],
•
Guilford Mills, Inc. requested
renewal of permit NC0002305
for its treatment facility in
Duplin County; this discharge
is for treated industrial
wastewater to the NE Cape
Fear River, Cape Fear River
Basin.
The Sampson Independent
May,13, 2012.c.
Publisher
Swo . to and subscribed before me this the / fi( day
of 2012_
N • ARY PUBLIC
My commission expires: June 20, 2015

Guilford East Plant WWTP
NC0002305
REASONABLE POTENTIAL ANALYSIS
Qw (MGD) = 1.50
1Q10S(cfs)= 5.41
7Q1 OS (cfs) = 6.50
7Q10W (cfs) = 18.00
30Q2 (cfs) = 6.50
Avg. Stream Flow, QA (cfs) = 398.00
Receiving Stream: NE Cape Fear River
WWTP/WIT Class: Class Ill
IWC ® 1QIOS = 30.06%
IWC @ 7Q1OS = 26.35%
IWC @7Q1OW= 11.44%
IWC @ 30Q2 = 26.35%
IWC @QA= 0.58%
Stream Class: C, Sw
Outfall 001
Qw=1.5MGD.
CHRONIC TEST CONCENTRATION = 26.4%
PARAMETER
TYPE
(1)
STANDARDS & CRITERIA (2)
a
0.
z
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NC WQS /
Chronic
Applied
Standard
�h FAV /
Acute
n# Det. Max Pred Allowable Cw
Cw
Arsenic
Arsenic
C
C
50
10
FW(7Q10s)
HH/WS(Qavg)
ug/L
ug/L
0 0
0 0
N/A
N/A
Acute: NO WQS
Chronic: 189.8
Chronic: 1,724.1
No detect, renewal appliication PPA
'
No deded; renewal application PPA
Beryllium
NC
6.5
FW(7Q10s)
ug/L
0 0
N/A
Acute: NO WQS
Chronic: 24.7
No detect, renewal application PPA
Cadmium
NC
2
FW(7Q10s)
15
ug/L
0 0
N/A
Acute: 49.9
_ ____-___ 7.6 ___
Chronic
No detect, renewal application PPA
No detect, renewal application PPA __—
Chlorides (AL)
NC
230
FW(7Q10s)
mg/L
54 54
,
202
Acute: NO WQS
Chronic: 873
No value > Allowable Cw
NO RPA, continue to monitore quarterly
Total Phenolic Compounds
NC
3.753
A(30Q2)
lb/dy
101 101
2.4
Acute: NO WQS
_ _-_______ ____
Chronic: 14.2
No value > Allowable Cw
_ _ ___ _ ___-_-_____ -
NO RPA, p_ art of effluent guidelines more stringent
Chromium
NC
0.6255
FW(7Q10s)
12.78522
lb/dy
101 101
0.1
Acute: 42.5
_ __ ______ ____
Chronic: 2.4
No value > Allowable Cw
NO RPA, part of effluent guidelines more stringent
_ _ _ _ __-_ _ _ ______ .
NO RPA, part of effiunet guideline
Copper (AL)
NC
7
FW(7Q l Os)
7 .
ug/L
48 48
36
Acute: 24.3
Chronic: 26.6
1 value(s) > Allowable Cw
RP for AL(Cu,Zn,Ag,Fe,CI) - apply Quarterly
Monitoring in conjunction with TOX Test
RP for AL(Cu,Zn,Ag,Fe,CI) - apply Quarterly
Monitoring in conjunction with TOX Test
Cyanide
NC
5
FW(7Q10s)
22
10
ug/L
1 1
Note: n <_ 9
Limited data set
304.1
Default C.V.
Acute: 73.2
Chronic: 19.0
1 value(s) > Allowable Cw
RP for Limited Dataset (n<8) but value > Allowable
Cw - apply Monthly Monitoring with Limit
RP for Limited Dataset (n<8) but value > Allowable
Cw - apply Monthly Monitoring with Limit
Lead
NC
25
FW(7Q10s)
33.8
ug/L
0 0
N/A
Acute: 112.4
_ __ ____ ____—______
Chronic: 94.9
No detect, renewal application PPA
_______________ ___.
No detect, renewal application PPA
2011 RPA-Freshwater, rpa
3/16/2012
Page 1 of 2

. Guilford East Plant WWTP
NC0002305
REASONABLE POTENTIAL ANALYSIS
Outfall 001
Qw=1.5MGD
Mercury
NC
12 FW(7Q10s)
0.5
ng/L
0 0
N/A
Acute: NO WQS
_ ________ ____
Chronic: 45.5
__ ______ ___ __ __
No detect, renewal applicdation PPA
Nickel
NC
88 FW(7Q10s) 261
ug/L
0 0
N/A
Acute: 868.3
_ ___ ____ _ __
Chronic: 334.0
no detect, renewal application PPA
_ ___ ___ ___ ___________.
No detect, renewal application PPA
Selenium
NC
5 FW(7Q10s) 56
ug/L
0 0
N/A
Acute: 186.3
Chronic: 19.0
No detect, renewal application PPA
No dated, renewal application PPA —_-
Silver (AL)
NC
0.06 FW(7Q10s) 1.23
ug/L
0 0
N/A
Acute: 4.092
_
Chronic 0.228
No detect, renewal application PPA
No detect, renewal application PPA
Zinc (AL)
NC
50 FW(7Q10s) 67
ug/L
1 1
Note: a <_ 9
Limited data set
277.E
Default C.V.
Acute: 222.9
Chronic: 189.8
No value > Allowable Cw
Renewal application PPA
Renewall application PPA
Bromodlchloromethane
C
17 HH(Qavg)
µg/L
1 1
Note: n < 9
Limited data set
64.64580
Default C.V.
Acute: NO WQS
_ _ _ _ _ _ _ _ __
..........................................
Chronic: 2931 03448
No value > Allowable Cw
_ _ _ _ _ _ _ _
No RP, Predicted Max <50% of Allowable Cw - No -.
Monitoring required
Bromoform
C
140 HH(Qavg)
µg/l,
1 1
Note: n <_ 9
Limited data set
138.81000
Default C.V.
Acute: NO WQS
_ _ _ _ _ _ _ _ _ _ _
Chronic: 24137.93103
No value > Allowable Cw
•
_- _ _ _ _ _ _
No RP, Predicted Max < 50% of Allowable Cw - No
Monitoring required
Chloroform
C
170 HH(Qavg)
µg/L
1 1
Note: n <_ 9
Limited data set
20.09440
Default C.V.
Acute: NO WQS
_ _ _ _ _ _ _ _ _ _
Chronic: 29310.34483
No value > Allowable Cw
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
No RP, Predicted Max <50% of Allowable Cw - No
Monitoring required
Dibromochloromethane
C
13 HH(Qavg)
µg/L
1 1
Note:*n <_ 9
Limited data set
107.74300
Default C.V.
Acute: NO WQS
_ _ _ _ _ _ _ _ _ _
Chronic: 2241.37931
No value > Allowable Cw
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .
No RP, Predicted Max < 50% of Allowable Cw- No
Monitoring required
Page 2 of 2
2011 RPA-Freshwater, rpa
3/16/2012

Guilford East Plant WWTP REASONABLE POTENTIAL ANALYSIS
NC0002305
Qw (MGD) = 1.50
1Q1OS (cfs) = 5.41
7Q1OS (cfs) = 6.50
7Q10W (cfs) = 18.00
30Q2 (cfs) = 6.50
Avg. Stream Flow, QA (cfs) = 398.00
Receiving Stream: NE Cape Fear River
WWTP/WTP Class: Class III
IWC @ IQ1OS = 30.06%
IWC @ 7Q10S = 26.35%
IWC @ 7QI OW = 11.44%
IWC@30Q2= 26.35%
IWC @ QA = 0.58%
Stream Class: C, Sw
Outfall 001
Qw=1.5MGD
CHRONIC TEST CONCENTRATION = 26.4%
PARAMETER
TYPE
(1)
STANDARDS & CRITERIA (2)
PQL
UNITS
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NC WQS / Applied 'Y2 FAV /
Chronic Standard Acute
Ntu\ Preil
tl # Det. �, Allowable C��
Antimony
NC
640 HH(7QI0s)
ug/L
I I
Note: n <_ 9
Limited data set
3,463.64000
Default C.V.
Acute: NO WQS
_ _ __ _ _ __
Chronic: 2428.84250
No value> Allowable Cw
_ _ _ _ _ _ _ _ _ _ _ _ _
One value ,11 % of WQS, BPJ no RPA , re-evaluate
at next permit renewal
0 0
N/A
Acute:
0 0
N/A
Acute.
Chronic:
--------- -----
U 0
V'!�1
Acute:
Chronic:-----------------
— ---
Page 1 of 1
2011 RPA-Antimony, rpa
7/13/2012

REASONABLE POTENTIAL ANALYSIS
5
Chlorides (AL)
Date Data BDL=1/2DL Results
1 1/6/2010 20.9 20.9 Std Dev.
2 1/20/2010 57.1 57.1 Mean
3 2/3/2010 48.2 48.2 C.V.
4 2/17/2010 23.5 23.5 n
5 3/3/2010 24.5 24.5
6 3/17/2010 52.4 52.4 Mutt Factor =
7 3/31/2010 38.8 38.8 Max. Value
8 4/7/2010 37.8 37.8 Max. Pred Cw
9 4/21/2010 33.7 33.7
10 5/5/2010 22.9 22.9
11 5/19/2010 25.4 25.4
12 6/2/2010 28.9 28.9
13 6/16/2010 31.6 31.6
t
14 6/30/2010 41.6 41.6
15 7/14/2010 91 91
16 8/4/2010 130 130
17 8/18/2010 98.4 98.4
18 9/1/2010 97.5 97.5
19 9/8/2010 68.5 68.5
20 9/22/2010 33.1 33.1
21 10/6/2010 34.1 34.1
22 10/20/2010 45 45
23 11/3/2010 48.6 48.6
24 11/17/2010 70.3 70.3
25 12/1/2010 69.3 69.3
26 12/8/2010 44.1 44.1
27 12/22/2010 39.7 39.7
28 1/5/2011 49.4 49.4
29 1/19/2011 . 37.9 37.9
30 2/2/2011 29.9 29.9
31 2/15/2011 32.8 32.8
32 3/2/2011 35.7 35.7
33 3/16/2011 36.5 36.5
34 3/30/2011 44.7 44.7
35 4/6/2011 36.7 36.7
36 4/20/2011 42.3 42.3
37 5/4/2011 42 42
38 5/18/2011 28 28
39 6/2/2011 55 55
40 6/15/2011 43 43
41 6/29/2011 43 43
42 7/20/2011 46 46
43 8/3/2011 38 38
44 8/17/2011 27 27
45 8/31/2011 29 29
46 9/7/2011 34 34
47 9/21/2011 34 34
48 10/5/2011 31 31
49 10/19/2011 40 40
50 11/2/2011 25 25
51 11/16/2011 33 33
52 11/30/2011 19 19
53 12/7/2011 24 24
54 12/21/2011 22 22
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
USE ONLY
"PASTE SPECIAL-
Values" WITH
"COPY"
COMMAND
21.4470
42.9
0.5001
54
1.6
130.0 mg/L
201.5 mg/L
7
Total Phenolic Compounds
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
Date Data BDL=1/2DL Results
1 1/6/2010 1.1 1.1 Std Dev. 0.3204
2 1/13/2010 1.2 1.2 Mean 0.2973
3 1/20/2010 0.43 0.43 C.V. 1.0779
4 1/27/2010 0.33 0.33 n 101
5 2/3/2010 0.24 0.24
6 2/10/2010 0.78 0.78 Mutt Factor = 1.74
7 2/17/2010 0.51 0.51 Max. Value 1.4 lb/dy
8 2/25/2010 `' 0.4 0.4 Max. Pred Cw 2.4 lb/dy
9 3/3/2010 0.8 0.8
10 3/10/2010 0.28 0.28
11 3/17/2010 0.049 0.049
12 3/25/2010 0.45 0.45
13 3/31/2010 0.071 0.071
14 4/7/2010 0.2 0.2
15 4/14/2010 0.51 0.51
16 4/21/2010 0.3 0.3
17 4/28/2010 I: 0.39 0.39
18 5/5/2010 0.56 0.56
19 5/12/2010 0.11 0.11
20 5/19/2010 0.19 0.19
21 5/26/2010 0.61 0.61
22 6/2/2010 j;' 0.3 0.3
23 6/9/2010 0.11 0.11
24 6/16/2010 0.34 0.34
25 6/23/2010 0.25 0.25
26 6/30/2010 0.12 0.12
27 7/14/2010 1.1 1.1
28 7/21/2010 = 0.2 0.2
29 7/28/2010 1.4 1.4
30 8/4/2010 0.23 0.23
31 8/11/2010 0.4 0.4
32 8/18/2010 0.27 0.27
33 8/25/2010 0.56 0.56
34 9/1/2010 0.34 0.34
35 9/8/2010 0.14 0.14
36 9/15/2010 0.8 0.8
37 9/22/2010 0.53 0.53
38 9/29/2010 0.69 0.69
39 10/6/2010 0.76 0.76
40 10/13/2010 4;c 0.16 0.16
41 10/20/2010 0.052 0.052
42 10/27/2010 0.1 0.1
43 11/3/2010 -i 0.64 0.64
44 11/10/2010 f 1.4 1.4
45 11/17/2010 ?''' 0.41 0.41
46 11/24/2010 0.25 0.25
47 12/1/2010 0.41 0.41
48 12/8/2010 0.15 0.15
49 12/15/2010 0.49 0.49
50 12/22/2010 1.3 1.3
51 1/5/2011 0.21 0.21
52 1/12/2011 0.13 0.13
53 1/19/2011 0.13 0.13
54 1/26/2011 0.74 0.74
55 2/2/2011 0.19 0.19
56 2/9/2011 0.31 0.31
57 2/16/2011 0.41 0.41
58 2/23/2011 0.27 0.27
59 3/2/2011 0.54 0.54
60 3/9/2011 0.3 0.3
61 3/16/2011 0.4 0.4
62 3/23/2011 0.17 0.17
63 3/30/2011 0.19 0.19
64 4/6/2011 0.23 0.23
65 4/13/2011 0.15 0.15
66 4/20/2011 0.22 0.22
67 4/27/2011 0.21 0.21
68 5/4/2011 0.028 0.028
69 5/11/2011 0.033 0.033
2011 RPA-Freshwater, data
- 1 - 3/16/2012

REASONABLE POTENTIAL ANALYSIS
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
70 5/18/2011
71 5/25/2011
72 6/2/2011
73 6/8/2011
74 6/15/2011
75 6/22/2011
76 6/29/2011
77 7/13/2011
78 7/20/2011
79 7/27/2011
80 8/3/2011
81 8/10/2011
82 8/17/2011
83 8/24/2011
84 8/31/2011
85 9/7/2011
86 9/14/2011
87 9/21/2011
88 9/28/2011
89 10/5/2011
90 10/12/2011
91 10/19/2011
92 10/26/2011
93 11/2/2011
94 11/9/2011
95 11/16/2011
96 11/23/2011
97 11/30/2011
98 12/7/2011
99 12/14/2011
100 12/21/2011
101 12/28/2011
102
0.062
0.062
0.029
0.068
0.027
0.031
0.056
0.053
0.068
0.031
0.017
0.032
0.24
0.03
0.033
0.018
0.31
0.053
0.033
0.032
0.038
0.031
0.044
0.1
0.034
0.037
0.036
0.032
0.036
0.038
0.038
0.003
0.062
0.062
0.029
0.068
0.027
0.031
0.056
0.053
0.068
0.031
0.017
0.032
0.24
0.03
0.033
0.018
0.31
0.053
0.033
0.032
0.038
0.031
0.044
0.1
0.034
0.037
0.036
0.032
0.036
0.038
0.038
0.003
2011 RPA-Freshwater, data
- 2 - 3/16/2012

REASONABLE POTENTIAL ANALYSIS
Chromium
Date Data BDL=1/2DL Results
1 1/6/2010 0.078 0.078 Std Dev. 0.0115
2 1/13/2010 0.074 0.074 Mean 0.0801
3 1/20/2010 0.087 0.087 C.V. 0.1430
4 1/27/2010 0.091 0.091 n 101
5 2/3/2010 s 0.075 0.075
6 2/10/2010 r . 0.085 0.085 Mult Factor = 1.09
7 2/17/2010 I., 0.087 0.087 Max. Value 0.1 lb/dy
8 2/25/2010 " 0.086 0.086 Max. Pred Cw 0.1 lb/dy
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
9 3/3/2010 0.086 0.086
10 3/10/2010 0.076 0.076
11 3/17/2010 0.071 0.071
12 3/25/2010 . 0.087 0.087
13 3/31/2010 4 0.073 0.073
14 4/7/2010 0.084 0.084
15 4/14/2010 0.087 0.087
16 4/21/2010 0.089 0.089
17 4/28/2010 0.078 0.078
18 5/5/2010 0.087 0.087
19 5/12/2010 0.073 0.073
20 5/19/2010 0.082 0.082
21 5/26/2010 0.074 0.074
22 6/2/2010 0.073 0.073
23 6/9/2010 0.08 0.08
24 6/16/2010 0.093 0.093
25 6/23/2010 0.078 0.078
26 6/30/2010 0.08 0.08
27 7/14/2010 0.085 0.085
28 7/21/2010 0.077 0.077
29 7/28/2010 0.084 0.084
30 8/4/2010 0.081 0.081
31 8/11/2010 0.079 0.079
32 8/18/2010 0.081 0.081
33 8/25/2010 0.086 0.086
34 9/1/2010 0.075 0.075
35 9/8/2010 0.084 0.084
36 9/15/2010 0.083 0.083
37 9/22/2010 0.084 0.084
38 9/29/2010 0.11 0.11
39 10/6/2010 0.089 0.089
40 10/13/2010 0.072 0.072
41 10/20/2010 0.082 0.082
42 10/27/2010 0.093 0.093
43 11/3/2010 0.091 0.091
44 11/10/2010 0.084 0.084
45 11/17/2010 t: 0.089 0.089
46 11/24/2010 0.082 0.082
47 12/1/2010 0.091 0.091
48 12/8/2010 0.086 0.086
49 12/15/2010 i 0.087 0.087
50 12/22/2010 0.077 0.077
51 1/5/2011 0.086 0.086
52 1/12/2011 0.077 0.077
53 1 / 19/2011 0.091 0.091
54 1/26/2011 0.089 0.089
55 2/2/2011 0.087 0.087
56 2/9/2011 0.067 0.067
57 2/16/2011 0.078 0.078
58 2/23/2011 0.077 0.077
59 3/2/2011 0.088 0.088
60 3/9/2011 0.073 0.073
61 3/16/2011 0.083 0.083
62 3/23/2011 0.073 0.073
63 3/30/2011 0.08 0.08
64 4/6/2011 0.08 0.08
65 4/13/2011 0.081 0.081
66 4/20/2011 0.061 0.061
67 4/27/2011 0.081 0.081
68 5/4/2011 0.069 0.069
69 5/11/2011 0.083 0.083
Date
1 1/13/2010
2 1/27/2010
3 2/10/2010
4 2/25/2010
5 3/10/2010
6 3/25/2010
7 4/14/2010
8 4/28/2010
9 5/12/2010
10 5/26/2010
11 6/9/2010
12 6/23/2010
13 7/21/2010
14 7/28/2010
15 8/11/2010
16 8/25/2010
17 9/15/2010
18 9/29/2010
19 10/13/2010
20 10/27/2010
21 11/10/2010
22 11/24/2010
23 12/15/2010
24 12/22/2010
25 1/12/2011
26 1/26/2011
27 2/9/2011
28 2/23/2011
29 3/9/2011
30 3/23/2011
31 4/13/2011
32 4/27/2011
33 5/11/2011
34 5/25/2011
35 6/8/2011
36 6/22/2011
37 7/13/2011
38 7/27/2011
39 8/10/2011
40 8/24/2011
41 9/14/2011
42 9/28/2011
43 10/12/2011
44 10/26/2011
45 11/9/2011
46 11/23/2011
47 12/14/2011
48 12/28/2011
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
Data
Copper (AL)
BDL=1/2DL Results
10 10 Std Dev. 2.6497
10 10 Mean 10.5208
10 10 C.V. 0.2519
10 10 n 48
10 10
10 10 Mult Factor = 1.28
10 10 Max. Value 28.0 ug/L
10 10 Max. Pred Cw 35.8 ug/L
10 10
10 10
10 10
10 10
10 10
11 11
10 10
11 11
10 10
10 10
10 10
10 10
10 10
10 10
10 10
28 28
14 14
10 10
10 10
10 10
10 10
10 10
10 10
11 11
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
10 10
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
-1-
2011 RPA-Freshwater, data
3/16/2012

REASONABLE POTENTIAL ANALYSIS
70 5/18/2011 0.078 0.078
71 5/25/2011 0.078 0.078
72 6/2/2011 0.072 0.072
73 6/8/2011 0.075 0.075
74 6/15/2011 0.067 0.067
75 6/22/2011 0.078 0.078
76 6/29/2011 0.08 0.08
77 7/13/2011 0.076 0.076
78 7/20/2011 0.075 0.075
79 7/27/2011 0.078 0.078
80 8/3/2011 0.083 0.083
81 8/10/2011 0.08 0.08
82 8/17/2011 0.074 0.074
83 8/24/2011 0.075 0.075
84 8/31/2011 0.083 0.083
85 9/7/2011 0.03 0.03
86 9/14/2011 0.079 0.079
87 9/21/2011 0.067 0.067
88 9/28/2011 0.083 0.083
89 10/5/2011 0.079 0.079
90 10/12/2011 0.094 0.094
91 10/19/2011 0.078 0.078
92 10/26/2011 0.088 0.088
93 11/2/2011 0.074 0.074
94 11/9/2011 0.085 0.085
95 11/16/2011 0.092 0.092
96 11/23/2011 0.09 0.09
97 11/30/2011 0.081 0.081
98 12R/2011 0.091 0.091
99 12/14/2011 0.096 0.096
100 12/21/2011 0.075 0.075
101 12/28/2011 0.009 0.009
102
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
2011 RPA-Freshwater, data
- 2 - 3/16/2012

REASONABLE POTENTIAL ANALYSIS
10
Cyanide
1
2
3
4
5
6
7
8
9
10
Date Data BDL=1/2DL Results
6/23/2011 23 23 Std Dev.
Mean
C.V. (default)
n
Mult Factor =
Max. Value
Max. Pred Cw
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
N/A
23.00
0.6000
1
13.22
23.0 ug/L
304.1 ug/L
18
Zinc (AL)
1
2
3
4
5
6
7
8
9
10
Date Data
6/23/2011
BDL=1/2DL Results
21 21 Std Dev. N/A
Mean
C.V. (default)
n
Mult Factor =
Max. Value
Max. Pred Cw
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
21.0000
0.6000
1
13.22
21.0 ug/L
277.6 ug/L
2011 RPA-Freshwater, data
- 1 - 3/16/2012

REASONABLE POTENTIAL ANALYSIS
19
Bromodichloromethane
1
2
3
4
5
6
7
8
9
10
Date Data
6/23/2011'
4.89 4.89
BDL=1/2DL Results
Std Dev.
Mean
C.V. (default)
n
Mult Factor =
Max. Value
Max. Pred Cw
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
N/A
4.8900
0.6000
1
13.22
4.890000 pg/L
64.645800 pg/L
20
Bromoform
Date Data
1 6/23/2011
2
3
4
5
6
7
8
9
10
10.5 10.5
BDL=1/2DL Results
Std Dev.
Mean
C.V. (default)
n
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
N/A
10.5000
0.6000
1
Mult Factor = 13.22
Max. Value 10.500000 pg/L
Max. Pred Cw 138.810000 pg/L
2011 RPA-Freshwater, data
- 1 - 3/16/2012

REASONABLE POTENTIAL ANALYSIS
21
Chloroform
Date Data BDL=1/2DL
1 6/23/2011
2
3
4
5
6
7
8
9
10
1.52 1.52
Results
Std Dev. N/A
Mean 1.5200
C.V. (default) 0.6000
n 1
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
Mult Factor = 13.22
Max. Value 1.520000 pg/L
Max. Pred Cw 20.094400 pg/L
22
Dibromochloromethane
1
2
3
4
5
6
7
8
9
10
Date Data BDL=1/2DL Results
6/23/2011 ?T 8.15 8.15 Std Dev. N/A
USE ONLY
"PASTE
SPECIAL -
Values" WITH
"COPY"
Mean 8.1500
C.V. (default) 0.6000
n 1
MultFactor = 13.22
Max. Value 8.150000 pg/L
Max. Pred Cw 107.74300 pg/L
2011 RPA-Freshwater, data
- 1 - 3/16/2012

3,500,000
3,000,000
2,500,000
2,000,000
— 1,500,000
1,000,000
500,000
0
GUILFORD MILLS PRODUCTION
Monthly Production —Annual Average Production 5 YR Average Production
C ..Q " L >` C — OD Q. > V L T C OA 0. 4.., > U
co cv ro Q. co O ? 7 a) O O O v fl. co a) u O a)
gag, Q�nozo,�gag, <v,ozo
C -
co CD
ra
>`C— 0.00_+- > u
g Qcnozo
. rti n .
NIV\i"\
\\*
C i" T C O0 Cl. +' > U C ..O " i T C
ro a� O co O cn o o a) fd ucu Q as O cn o O a
a zoo g a z
2007 2008 2009 2010 2011
30.43333 = days/month (1,626 days _ 60 months)
Current: 2,554,270 lbs/month 83,930.0 lbs/day
Renewal: 2,010,802 lbs/month 66,072.3 lbs/day
Date: 4/13/12
pb: rdb

Guilford Mils, Inc. -Guilford East Plant
NPDES Permit Number NC0002305
Production Data 2007 through 2011
report prepared by: Paul Bruesch, 4/9/12
Count Date Production
No. MM/YY (packed Ibs)
1 Jan-07 3,031,803
2 Feb-07 2,322,061
3 Mar-07 2,386,793
4 Apr-07 3,033,471
5 May-07 2,738,362
6 Jun-07 2,950,549
7 Jul-07 2,275,512
8 Aug-07 2,510,007
9 Sep-07 3,091,370
10 Oct-07 3,189,290
11 Nov-07 2,957,248
12 Dec-07 2,501,508
13 Jan-08 2,928,232
14 Feb-08 2,701,115
15 Mar-08 2,676,602
16 Apr-08 2,946,325
17 May-08 1,925,294
18 Jun-08 2,525,453
19 Jul-08 1,643,409
20 Aug-08 2,161,526
21 Sep-08 2,140,010
22 Oct-08 2,261,568
23 Nov-08 1,371,205
24 Dec-08 1,003,865
25 Jan-09 674,215
26 Feb-09 849,960
27 Mar-09 955,144
28 Apr-09 1,161,273
29 May-09 925,029
30 Jun-09 1,086,276
31 Jul-09 1,102,452
32 Aug-09 1,498,391
33 Sep-09 1,869,340
34 Oct-09 2,069,110
35 Nov-09 1,698,562
36 Dec-09 1,522,139
37 Jan-10 1,714,464
38 Feb-10 1,876,725
39 Mar-10 2,039,238
40 Apr-10 1,876,343
41 May-10 1,879,307
42 Jun-10 2,078,146
43 Jul-10 1,618,126
44 Aug-10 2,187,525
45 Sep-10 2,182,335
46 Oct-10 2,058,381
47 Nov-10 1,916,314
48 Dec-10 1,835,041
H:\documents1 ENVIR REPORT FILES1Guittord Eas0NPDES Permit Renewal-20111Production Data by Month Packed Pounds 2007-2011
Production Data 2007-2011
Printed: 04ro9/2012 5:55 PM
Page 1 of 2

Guilford Mils, Inc. -Guilford East Plant
NPDES Permit Number NC0002305
Production Data 2007 through 2011
report prepared by: Paul Bruesch, 4/9/12
Count Date Production
No. MM/YY (packed Ibs)
49 Jan-11 1,887,835
50 Feb-11 1,766,835
51 Mar-11 2,236,526
52 Apr-11 1,838,225
53 May-11 1,879,307
54 Jun-11 2,078,146
55 Jul-11 1,618,126
56 Aug-11 1,887,331
57 Sep-11 1,958,280
58 Oct-11 2,183,486
59 Nov-11 1,941,865
60 Dec-11 1,426,018
Total 120,648,394
Maximum 3,189,290
Minimum 674,215
Average 2,010,807
number months 60
number days 1,826
Average Production
lb/month
lb/day
2,010,807
66,073
3,500,000
3,000,000
2,500,000
2,000,000
1,500,000
1,000,000
500,000
0
Production
,6‘ 6 6‘ ,c;1/4 Q% Os 00 0% O°5 °5 O°5 P. ,+�0 ,�O ,�O ,�O ,�\ ,�\ �'� ,�'�
aP ii" �J 0Z`" �' V9 # oc � e•PQ� �J\ 06" i 4 �J`" per'` ���" QQv •�•V p6`"
H: docurnents%ENVIR REPORT FILES1Guitlord East1NPDES Permit Renewal-20111Production Data by Month Packed Pounds 2007-2011
Production Data 2007-2011
Printed: 04 092012 555 PM
Page 2 of 2

Title 40: Protection of Environment
PART 410—TEXTILE MILLS POINT SOURCE CATEGORY
Subpart E—Knit Fabric Finishing Subcategory
§ 410.50 Applicability; description of the knit fabric finishing subcategory.
The provisions of this subpart are applicable to process wastewater discharges resulting from the following types of
textile mills: knit fabric finishers, which may include any or all of the following unit operations: Bleaching, mercerizing,
dyeing, printing, resin treatment, water proofing, flame proofing, soil repellency application and a special finish
application.
410.51 Specialized definitions.
In addition to the definitions set forth in 40 CFR part 401 and §410.01 of this part, the following definitions apply to
this subpart:
(a) The term simple manufacturing operation shall mean all the following unit processes: desizing, fiber preparation
and dyeing.
(b) The term complex manufacturing operation shall mean "simple" unit processes (desizing, fiber preparation and
dyeing) plus any additional manufacturing operations such as printing, water proofing, or applying stain resistance or
other functional fabric finishes.
(c) For NSPS (§410.55) the term hosiery products shall mean the internal subdivision of the knit fabric finishing
subcategory for facilities that are engaged primarily in dyeing or finishing hosiery of any type.
§ 410.52 Effluent limitations representing the degree of effluent reduction attainable by the
application of the best practicable control technology currently available (BPT).
(a) Except as provided in 40 CFR 125.30 through 125.32, any existing point source subject to this subpart must
achieve the following effluent limitations representing the degree of effluent reduction attainable by the application of
the best practicable control technology currently available (BPT):
Pollutant or pollutant
property
BPT limitations
Maximum for any 1
day
Average of daily values for 30
consecutive days
Kg/kkg (or pounds per 1,000 lb) of product
BOD 5
5.0
2.5
COD
60.0
30.0
TSS
21.8
10.9
Sulfide
0.20
0.10
Phenols
0.10
0.05
Total chromium
0.10
0.05
pH
(1)
(1)
'Within the range 6.0 to 9.0 at all times.

(b) Except as provided in paragraph (d) of this section for commission finishing operations, the following limitations
establish the quantity or quality of pollutants or pollutant properties, controlled by this section and attributable to the
finishing of knit fabrics through simple manufacturing operations employing a natural and synthetic fiber or through
complex manufacturing operations employing a synthetic fiber, which may be discharged by a point source subject to
the provisions of this subpart, in addition to the discharge allowed by paragraph (a) of this section.
Pollutant or pollutant
property
BPT limitations
Maximum for any 1
Average of daily values for 30
consecutive days
day
Kg/kkg (or pounds per 1,000 lb) of product
COD
20.0
10.0
§ 410.53 Effluent limitations representing the degree of effluent reduction attainable by the
application of the best available technology economically achievable (BAT).
(a) Except as provided in 40 CFR 125.30 through 125.32, any existing point source subject to this subpart must
achieve the following effluent limitations representing the degree of effluent reduction attainable by the application of
the best available technology economically achievable (BAT):
Pollutant or pollutant
property
BAT limitations
Maximum for any 1
day
Average of daily values for 30
consecutive days
Kg/kkg (or pounds per 1,000 lb) of product
COD
60.0
30.0
Sulfide
0.20
0.10
Phenols
0.10
0.05
Total Chromium
0.10
0.05

Date: 4/13/12
Pb: rdb
Guildford Mills
NC0002305
ow =
1.5 MGD
Production, lbs/day = 66702.3
IWC 7Q10s =
66.7023 1000 lbs/day IWC 1Q10s =
IWC 30Q2 =
Part 410 Subpart E
26.35%
30.06%
26.35%
EG factors lb/1000 lb
Calculated Limits
WQS Limits
Parameter
Daily Max
Monthly
Average
Daily Max
(lbs/day)
Monthly Avg
(lbs/day)
Acute or
Daily
(lbs/day)
Chronic or
Monthly
(lbs/day)
BOD 410.52(a)
5
2.5
333.5
166.8
450.36
300.24
TSS 410.52(a)
21.8
10.9
1454.1
727.1
2071
1035
COD 410.53(a)
60
30
4002.1
2001.1
Sulfide 410.53(a)
0.2
0.1
13.3
6.7
Phenol 410.53(a)
0.1
0.05
6.7
3.3
Total chromium 410.53(a)
0.1
0.05
6.7
3.3
COD 410.52(b)
20
10
1334.0
667.0
Total mass -based limits
New Permit Limits
Parameter
Daily Max
(lbs/day)
Monthly Avg
(lbs/day)
BOD
333.5
166.8
TSS
1454.1
727.1
COD
5336.2
2668.1
Sulfide
13.3
6.7
Phenol
6.7
3.3
Total chromium
6.7
3.3
EG more stringent than 2007 approved model BOD, 24 mg/L summer/30 mg/L winter
EG more stringent than allocation established 1977
No RPA for WQS, apply EG limits
No RPA for WQS, apply EG limits
Limits based on 410 Subpart E
Limits based on 410 Subpart E
Limits based on 410 Subpart E
Limits based on 410 Subpart E
Limits based on 410 Subpart E
Limits based on 410 Subpart E

Google Earth Guilford Mill NC0002305
Headworks: 35° 1 3 N
O• Y-
Outfall: 35° 1'
3
J 2012 Goggle
Image USDA Farm Service Agency
77° 51' 38" W
77°50'56.9"W

3-28-12 RE
From:
Sent:
To:
Cc:
Need additional information on treatment equipment and source of water for plant
Paul Bruesch [[e-mail]]
Wednesday, March 28, 2012 11:04 AM
Berry, Ron
Keith
westb
rook; Brent Turner; Carl D. Squires
Subject: RE: Need additional information on treatment equipment and source of
water for plant
Ron,
Here is additional information to complete our reply to your request:
The total water used for a regeneration cycle on the water softeners is 4,500 gals.
We regenerate one
(1) softener per day, five (5) days per week (Monday -Friday).
Can you give us any more information on when the new NPDES permit will be issued?
will you be
sending a draft permit before the final permit is issued?
Regards,
Paul
From: Paul Bruesch
Sent: Tuesday, March 27, 2012 12:19 PM
To: Berry Ron ([e-mail])
cc: Keith westbrook; Brent Turner
subject: RE: Need addtional information
for plant
Ron
on treatment equipment and source of water
Please see below for the information requested. we will
information about the
backwash volume from the water softeners shortly.
Regards,
Paul
PAUL R. BRUESCH, P.E. Corporate Environmental Manager
Guilford North America
1754 NC 903
Kenansville, NC 28349
tel [phone]
www.guilfordtextiles.com
forward additional
From: Berry, Ron [mailto:[e-mail]]
sent: Wednesday, March 21, 2012 1:48 PM
To: Paul Bruesch
subject: Need addtional information on treatment equipment and source of water for
plant
Paul,
Starting to put a draft permit together for the Guilford Mills facility and have a
few questions. I used
the application Process Flow Diagram as a reference.
1) what is the volume capacity of the influent equalization basin?
Page 1

Guilford Mills, Inc. — Guilford East Plant
NPDES Permit No. NC0002305
Description of Wastewater Treatment Plant Operations
The facility is an activated sludge -type wastewater treatment plant permitted to discharge a
maximum daily average flow of 1.5 million gallons of treated wastewater.
Influent consists of combined industrial wastewater from textile manufacturing plant
operations and domestic sewage that enters the headworks. The headworks consists of a
bar screen and optional mechanical lint screens.
After screening, influent flows by gravity into an equalization basin. The contents of the
equalization basin are mixed and aerated. The level of the equalization basin is adjusted as
needed to control flow through the rest of the process.
Equalized influent is pumped into the aeration basin. Return activated sludge settled from
the clarifiers is also pumped to the aeration basin where it is mixed with equalized influent to
become "mixed liquor". Floating aerators are used to add oxygen to the process, which is
known as the activated sludge process. A fixed level is maintained in the aeration basin.
Mixed liquor leaves the aeration basin and flows by gravity to a splitter box. Some mixed
liquor is removed before reaching the splitter box to maintain sludge age; this is known as
waste activated sludge or WAS.
The splitter box divides the flow equally to each of the two secondary clarifiers. The clarifiers
slow the flow velocity to allow the biosolids to settle which are then pumped back to the
aeration basin. The solids pumped back are called return activated sludge or RAS. The
clarified liquid overflows the weirs of the clarifiers and flows by gravity through piping to the
tertiary clarifier. Treatment chemicals may be injected into the flow in this section of piping
which contains a static mixer (flash mixing). Treatment chemicals may be added at other
points in the process.
The tertiary clarifier again slows the velocity of the flow to allow the remaining biosolids to
settle which are pumped to a gravity thickener. The clarified wastewater overflows to an
effluent pump station where it is pumped to the chlorination contact chamber. Liquid chlorine
is added as the effluent flows into to the contact chamber. After the required contact time
dechlorination chemicals are added. The effluent flows over a weir where the flow is
measured and recorded. The effluent then flows by gravity to the outfall on the Northeast
Cape Fear River. Effluent is sampled from a manhole in the outfall line.
Biosolids (solids) that are wasted from the process are pumped into in a gravity thickener,
digested in an aerobic digester then further thickened in a rotary drum thickener which
discharges into a sludge holding tank. Filtrate from the rotary drum thickener and clear water
overflowing the weir from the gravity thickener flows into a filtrate tank from which it is
pumped back to the headworks. Periodically a contractor pumps liquid sludge from the
holding tank hauling it off to be land applied to agricultural fields at agronomic rates under
Land Application of Residuals Permit No. WQ0018107.
Solids may be applied to sand drying beds instead of being processed by the rotary drum
thickener. Once dried, cake solids are removed from the drying beds and transported to a
permitted composting operation. Filtrate from the sand drying beds is pumped back to the
treatment process.
C:1Documents and Settings1Ron_BerrylLocal Settings1Temporary tntemet Files1Content.Outlook1B4MZ39V4120120423-Description of WWTP Operations.docPage
1 of 1

4-27-12 RE Staff Report for Guilford Mills NC0002305
like a Google Earth view from above.
As far as permit, here are a few comments:
* Please require reporting of parameter concentrations (mg/L) for items having
lbs/day
limits so we can potentially calculate/confirm the mass loading. All mass loading
permits should do this.
* Can we require fecal 3x/week to match TRC or would drop TRC
fecal?
to match weekly
* They have had a few tox failures, should we require any other parameters of
concern or
known toxicants to be monitored?
* system Description: Assume 1st pump station listed is to transfer from EQ
to aeration,
the square aeration basin is actually their sludge digester (thus item is repeated),
sludge
thickener is a rotary sludge thickener, the alum/caustic system is inactive &
replaced by
coagulant, the effluent pump station is actually an internal lift station for
hydraulics to
feed chlorination system prior to gravity discharge (been the location of most
bypasses
when power is lost and until hydraulics equalize).
* FYI -- Effluent is foamy before being pump to chlorination and ORC indicated
it is in
outfall manhole where sampling tube is located. Misters present before pumping to
chlorination, but have not seen them operating past 2 inspections. My guess is it
foams
up again after falling from contact chamber into outfall line. Thoughts?
Dean Hunkele, senior Environmental Specialist
Wilmington Regional office
Division of Water Quality, Surface water Protection section
http://www.ncwaterquality.org/
Direct Phone:
Main Phone:
Fax:
Address:
[phone]
[phone]
[phone]
127 Cardinal Drive Ext
Wilmington, NC 28405-3845
To report a SSO, WWTP Bypass, or Spill after hours, holidays, or weekends
call The NC Division of Emergency Management @ 1-800-858-0368
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.
Page 2

4-27-12 RE Staff Report for Guilford Mills NC0002305
From: Berry, Ron
Sent: Friday, April 27, 2012 11:05 AM
To: Hunkele, Dean
Subject: RE: Staff Report for Guilford Mills NC0002305
Dean,
There are Google earth views of all the permitted facility accessible through BIMS.
For further clarity
on equipment I have had several conversations with Permittee representative and
recently obtained
an updated description of the treatment process operation. There are several
equipment
items/functions which are used only when needed. Is foam a problem at the point of
discharge?
There is a foam compliance narrative associated with the outfall.
The monitoring frequency for TRC and fecal coliform are different because TRC is a
toxicant, fecal
coliform is an imposed treatment standard because of the domestic influent. There is
no justification
to change monitoring frequencies.
It is up to the ESS/Toxicology Unit to initiate any toxicity -based changes in
permits. In which case we
will receive a notification from ESS, none have been received. Copies of the draft
and final permit are
sent to ESs. The history of toxicity tests will be stated in the fact sheet.
The permit mass -based reporting is consistent with industrial permits requirements.
The Regions can
certainly request that the permittee provide the bases for any calculated value.
I will be sending you a pre -public notice draft and fact sheet to review shortly.
Thanks for the
information.
Ron
Ron Berry [e-mail]
Engineer I
DWQ/Point Source/NPDES Complex Permitting Unit
NCDENR
Phone: [phone]
Fax: [phone]
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.
From: Hunkele, Dean
Sent: Thursday, April 05, 2012 4:41 PM
To: Berry, Ron
Subject: Staff Report for Guilford Mills NC0002305
Importance: High
Ron,
Please find the attached inspection report from my visit 2 weeks ago. Facility
address has been
updated in BIMS. Would be nice if we could get a plan view of treatment units/flow
schematics
Page 1

3-28-12 RE Need additional information on treatment equipment and source of water for plant
From: Berry, Ron
Sent: Wednesday, March 28, 2012 12:20 PM
To: 'Paul Bruesch'
subject: RE: Need additional information on treatment equipment and source of
water for plant
Paul,
As the permittee you should always be sent a draft permit for review and comment»a
minimum of 30
days before any final permit can be issued. Depending on your or others comments,
additional time to
respond to comments may occur or the response will be done in conjunction with the
final permit
cover letter. Best guess is your draft permit should be issued in next 30 days.
Ron
Ron Berry [e-mail]
Engineer i
DWQ/Point Source/NPDES Complex Permitting Unit
NCDENR
Phone: [phone]
Fax: [phone]
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.
From: Paul Bruesch [mailto:[e-mail]]
Sent: Wednesday, March 28, 2012 11:04 AM
To: Berry, Ron
Cc: Keith Westbrook; Brent Turner; Carl D. Squires
Subject: RE: Need additional information on treatment equipment and source of water
for plant
Ron,
Here is additional information to complete our reply to your request:
The total water used for a regeneration cycle on the water softeners is 4,500 gals.
we regenerate one
(1) softener per day, five (5) days per week (Monday -Friday).
Can you give us any more information on when the new NPDES permit will be issued?
will you be
sending a draft permit before the final permit is issued?
Regards,
Paul
From: Paul Bruesch
Sent: Tuesday, March 27, 2012 12:19 PM
To: Berry Ron ([e-mail])
Cc: Keith Westbrook; Brent Turner
Subject: RE: Need addtional information on treatment equipment and source of water
for plant
Ron,
Page 1

3-28-12 RE Need additional information on treatment equipment and source of water for plant
Please see below for the information requested. we will forward additional
information about the
backwash volume from the water softeners shortly.
Regards,
Paul
PAUL R. BRUESCH, P.E. Corporate Environmental Manager
Guilford North America
1754 NC 903
Kenansville, NC 28349
tel [phone]
www.guilfordtextiles.com
From: Berry, Ron [mailto:[e-mail]]
sent: Wednesday, March 21, 2012 1:48 PM
To: Paul Bruesch
Subject: Need addtional information on treatment equipment and source of water for
plant
Paul,
starting to put a draft permit together for the Guilford Mills facility and have a
few questions. I used
the application Process Flow Diagram as a reference.
1) what is the volume capacity of the influent equalization basin?
2.0 million gallons
2) what is the diameter of the tertiary clarifiers
60-feet
3) What is the volume capacity of the sludge digestor basin?
1.0 million gallons
4) What is the volume capacity of the sludge holding tank?
0.5 million gallons
5) what is the volume capacity of the filtrate tank?
50,000 gallons
6) what chemical is used for dechlorination and where is it added?
sodium bisulfite is added to one of the baffled sections of the 0.5
MG Chlorine Contact
chamber, in before the final effluent weir.
7) where is the effluent composite sample point located?
At manhole #MH-1, in the treated effluent discharge line, located
directly in front of the
chlorination building. This is the first available sampling point downstream from
the final effluent
weir.
water?
Also, what is this facility source for plant water and drinking
The only source of water is groundwater pumped from three (3) wells.
water withdrawal from
these wells is permitted under CCPCUA Permit #Cu3094, validthrough 8/31/14.
If the facility uses any water treatment process (sand filter, softeners,
demineralizer, other ion
exchange, reverse osmosis, etc.) that generate waste streams that are either an
influent to the
existingwastewater treatment system or discharged elsewhere then we need a
description, estimate
of flow in gpd, and point of discharge. in some cases water is obtained from the
Page 2

3-28-12 RE Need additional information on treatment equipment and source of water for plant
local utility so if true in
this case just state the utility name.
The only water treatment process that generates a waste stream is from two (2) water
softeners.
Backwash water from the softeners flows into an industrial drain pipe that flows to
the treatment
plant influent.
Process Description: (2) two conventional water softeners are used to treat the ..
plant process water.
One of the two softeners is regenerated daily, five days a week. we have requested
information on
the design backwash volume from the equipment manufacturer, which we will forward
upon receipt.
There no water or sewer connections to any public utility.
Thank you for your assistance,
Ron
Ron Berry [e-mail]
Engineer I
DWQ/Point Source/NPDES Complex Permitting Unit
NCDENR
Phone: [phone]
Fax: [phone]
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 3

GUILFORD MILLS, INC NC0002305
CONVERTED MASS -BASED VALUES TO CONCENTRATION -BASED VALUES
Compared Values to Secondaratment Standard Limits
90 ---
80 -
70 ------
60 ---
50
op
40
143
• TSS Monthly D TSS Daily Cal -Monthly Avg Limit
0•
30 -
20 -
10 -�
a
Ec
Daily Limit
u
u
A O. ^
_
- �1-
■ -ki.— 1�i J

bate:3/15/12
pb: rdb
DMR Data fro NC0002305 Guilford East Plant VVVVTP
TGP3B - P/F STATRE 7Day Chr Ceriodaphnia
mm/dd/yy Pass/Fail ChV Passing ChV = or > 27%
4/14/2008 Pass 73.50%
7/21/2008 Pass >100%
10/2/2008 Pass >100%
1/21/2009 Pass 73.50%
4/13/2009 Fail 19.10%
5/25/2009 pass 100% Follow up test
6/15/2009 Pass 100% Follow up test
7/20/2009 Pass >100%
10/10/2009 Pass >100%
1/25/10 Pass >100%
4/12/10 Pass 73.50%
7/19/10 Pass 73.50%
10/11/10 Pass 38.20%
1/17/11 Fail 19.10%
2/14I11 Fail <6.75% Follow up test
3/28/11 Pass >100% Follow up test
4/11/11 Pass 38.20%
7/18/11 Pass 73.50%
10/17/11 Pass
Total 15 test
Passed 13
Failed 2
Follow up ChV test resulted 3 passing and 1 failure

��►�.r"� 1�E }T yo big NT" 1- OOO 2.3O5-
3//q/z_
40
30
O Upstream
Temperature Impact
X Downstream Effluent
0
0
C
CO
38
3
Q 0 0
a,
1 1 1 1 1 1 1 1 1 1
0 0 O O 0 el O 0 0 0 0
g ¢ E - ¢ In 0 z a
e-I
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10
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e-1 el
L el el
o a,
z a
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10 —
8 —
6 X-
44
2
0 Upstream
DO Impact
X Downstream —Effluent
9
0 r 1 i r e 1 r 1 , 1
0 0 0 0 0 0 0 0 0 0 0 0 .-I .-I ei ei ei e-I -I ei ei v-1
ei e1 e-Il rl r1 el ei el e-1 e♦ el el el el ei el ei l el ei e l 4-1 ei e�
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LL g a 2 ¢ In o z a ,,. a 2 a Ir, o z a
8.0
7.5
7.0
V)
6.5
6.0
0
c
11s
800
pH Impact
O Upstream X Downstream —Effluent
700 —
600 —
g 500 1
400
t
300 —
200 — - - - -R-
100-- 0-
X
O
1 1 1 1 1 1 1 . , 1 1 1 1 1
O O 0 0 0 0 0 0 0 0 0 e 4 ei ei e'4 '-I u-I el ei ei el ei ei
el el eel ei ei el el I-1 e1 ei ei ei a -I el e-1 I-1 ei el I-1 el el ei ei
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 /
U. 2 a 2- a I) 0 z 0; U. 2 a E; < v 0 z o
Conductivity Impact
0 Upstream X Downstream
Effluent
X
sz_?0<
X
X X
O
0 i , 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 o ei e-I e♦ e-1 ei ei e'I e-1 e-1 e-I e-I el
ei el el el el e l ' ei ei ei el e-1 ei ei e� e-I fi e-I ei ei el ei el ei el
1 1 / 1 1 1 —1..11o 1 1 u 1 1 1 1 1 1 1 1 1
g a g a v 0 z o 1° LL g a 2; a v 0 z° o

AUTOMOTIVE I SPECIALTY
Mrs. Dina Sprinkle
NCDENR/ DWQ/ Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
[phone]
Subject: Application for Renewal of:
NPDES Permit No. NC0002305
Guilford Mills, Inc. -Guilford East Plant
Duplin County, North Carolina
1754 NC Hwy 903
Kenansville. NC 28349. USA
T [phone] F [phone]
date: August 3, 2011
Dear Mrs. Sprinkle:
Enclosed please find one signed original and two copies of a completed application for renewal of subject NPDES
permit.
The application consists of EPA Forms 3510-1, 3510-2C and attachments as noted on the forms. Per checklist
received 6/16/11, a description of the sludge management plan and a Priority Pollutant Analysis (PPA) are
included. This application is being submitted at least 180 days prior to the January 31, 2012 expiration date.
Since issuance of the last permit there have been no changes to the treatment process.
If you have any questions or need additional information, please call me at [phone].
Sincerel
Paul R. Bruesch, P.
Corporate Environmental Manager
cc: Brent Turner
Gilbert O'Neal, ATE&E
l(12.kA5
LC
H:ldocuments1 ENVIR REPORT FILES1Guilford East1NPDES Permit Renewal-20111Cover Letter NPDES Renewal APP 02AUG11.doc
ISO TS 1654E ; ISO 140v 1 i ISO 17025

Sludge Management Plan
Guilford Mills, Inc. -Guilford East Plant
NPDES Permit No. NC0002305
Date: July 29, 2011
This plan has been prepared for attachment to the NPDES permit renewal
application, per checklist received by email from Charles Weaver on June 16,
2011.
This document is a narrative description of the sludge management plan for the
facility to describe how sludge (or other solids) generated during wastewater
treatment are handled and disposed.
Sludge (biosolids) is generated during the normal course of operation of the
wastewater treatment plant. By design, some sludge, called activated sludge, is
maintained within the treatment plant. Excess sludge is removed from the
system, or wasted, to maintain the desired mean cell residence time (MCRT) or
sludge age.
The largest volume of sludge is removed as a thickened liquid and a smaller
volume is removed as a dried solid, or cake.
After settling in the clarifiers, most of the sludge is removed (wasted), digested,
thickened and stored as a liquid in a sludge holding tank. On a scheduled basis,
the contents of the sludge holding tank is pumped and hauled by a licensed
contractor to various agricultural fields, all approved for land application at
agronomic rates under permit WQ0018107.
Sand drying beds provide an alternate method of sludge handling. After drying to
a cake under atmospheric conditions, these solids are transported to McGill
Environmental Systems, Rose Hill, NC for composting. McGill holds EPA ID or
RCRA permit No. NCD986231793.
A small amount of solids are removed from the influent bar screen. These solids
are bagged for disposal in a sanitary landfill.
Signed:
Brent urner, Director of En
date: c/z/�/
l

Guilford Mills -East Plant
NPDES Permit NC0002305
Summary of Effluent Aquatic Toxicity Reports 2007-2010
Reference: EPA Form 2C, VII. BIOLOGICAL TOXICITY TESTING DATA
date prepared: August 2, 2011
No.
Sample 1
Sample 2
Pass/Fail
ChV
1
01/22/07
01/25/07
PASS
73.5%
2
04/16/07
04/19/07
PASS
38.2%
3
07/23/07
07/26/07
PASS
73.5%
4
10/08/07
10/11/08
PASS
>100%
5
01 /21 /08
01/24/08
PASS
>100%
6
04/14/08
04/17/08
PASS
73.5%
7
07/21/08
07/24/08
PASS
>100%
8
09/29/08
10/02/08
PASS
>100%
9
01 /21 /09
01/25/09
PASS
73.5%
10
04/13/09
04/16/09
FAIL
19.1%
11
05/25/09
05/28/09
PASS
100.0%
12
06/15/09
06/18/09
PASS
100.0%
13
07/20/09
07/23/09
PASS
>100%
14
10/19/09
10/22/09
PASS
>100%
15
01/25/10
01/28/10
PASS
>100%
16
04/12/10
04/15/10
PASS
73.5%
17
07/19/10
07/22/10
PASS
73.5%
18
10/11/10
10/14/10
PASS
38.2%
19
01/17/11
01/19/11
FAIL
19.1%
20
02/14/11
02/16/11
FAIL
<6.75%
21
03/28/11
03/30/11
PASS
>100%
22
04/11/11
04/11/11
PASS
38.2%
23
07/18/11
07/20/11
PASS
73.5%
H: documents% ENVIR REPORT FILES1Guilford EastINPDES Permit Renewal-2O111Semmary of Effluent Aquatic Toxicity Reports JAN07-JUL11
Sheet1
Printed: 08/02/2011 11:31 AM
Page 1 of 1

Guilford Mils, Inc. -Guilford East Plant
NPDES Permit Number NC0002305
Production Data January 2008 through May 2011
Cow Date Production
MM/YY (packed Ibs)
1 Jan-08 2,928,232
2 Feb-08 2,701,115
3 Mar-08 2,676,602
4 Apr-08 2,946,325
5 May-08 1,925,294
6 Jun-08 2,525,453
7 Jul-08 1,643,409
8 Aug-08 2,161,526
9 Sep-08 2,140,010
10 Oct-08 2,261,568
11 Nov-08 1,371,205
12 Dec-08 1,003,865
13 Jan-09 674,215
14 Feb-09 849,960
15 Mar-09 955,144
16 Apr-09 1,161,273
17 May-09 925,029
18 Jun-09 1,086,276
19 Jul-09 1,102,452
20 Aug-09 1,498,391
21 Sep-09 1,869,340
22 Oct-09 2,069,110
23 Nov-09 1,698,562
24 Dec-09 1,522,139
25 Jan-10 1,714,464
26 Feb-10 1,876,725
27 Mar-10 2,039,238
28 Apr-10 1,876,343
29 May-10 1,879,307
30 Jun-10 2,078,146
31 Jul-10 1,618,126
32 Aug-10 2,187,525
33 Sep-10 2,182,335
34 Oct-10 2,058,381
35 Nov-10 1,916,314
36 Dec-10 1,835,041
37 Jan-11 1,887,835
38 Feb-11 1,766,835
39 Mar-11 2,236,526
40 Apr-11 1,838,225
Total 72,687, 861
Maximum 2,946,325
Minimum 674,215
Average 1,817,197
number months 40
number days 1,216
Average Production
lb/month 1,817,197
lb/day
59,776
3,500,000
3,000.000
2,500,000
2.000,000
1,500,000
1,000,030
500,000
0
Production
1\GLE-FP1Pbrueschtdocuments\_ENVIR REPORT FILES\Gullford EastWPDES Permit Renewal-2011\GE Water Pumped vs Packed Pounds JUNI I
Production Data thru 2008-Apr11
Printed: 06f09/2011 4:09 PM
Page 1 of 1

Guilford Mills, Inc. -Guilford East Plant NPDES Permit No. 0002305
EPA Form 3510-2C (8-90) Sections II-B. Flows, Sources of Pollution and Treatment Technologies
Outfall No. 001
Note: treatment descriptions and codes from Table 2C-1 found in instructions for Form 2C
date: August 1, 2011
2. OPERATION(S) CONTRIBUTING FLOW
3. TREATMENT
a. OPERATION
b. AVG FLOW (MGD)
a. DESCRIPTION
b. CODES
Headworks--including a bar screen, Parshall flume, and mechanical lint removal system
832,540
screening
1-T
Flow -equalization basin with three (3) floating aerators
919,000
stabilizing pond
3-G
Transfer pump station, equalization basin to aeration basin
919,000
n/a
n/a
Aeration basin, 2.0 MG volume with eleven (11) floating aerators
1,495,000
activated sludge
3-A
aerated lagoons
3-B
Splitter box (influent to secondary clarifiers)
1,420,000
n/a
n/a
Two secondary clarifiers (55-foot diameter x 14-ft. deep) with RAS pumping station (combined
flow is shown)
1,420,000
sedimentation (settling)
1-U
chemical conditioning
5-E
Sludge return pumps (RAS)
576,000
n/a
n/a
Tertiary clarifier
844,000
sedimentation (settling)
1-U
Gravity thickener
96,600
gravity thickening
5-C
Sludge Digester with four (4) floating aerators
44,800
aerobic digestion
5-A
Rotary drum thickener
44,800
no code listed
Sludge storage basin with one (1) floating aerator
11,200
n/a
n/a
Land Application of liquid biosolids
4.073 MG/year
land application
5-P
Twelve (12) sand sludge -drying beds (with return filtrate to aeration basin), 85 tons dried sludge
hauled to McGill Environmental Systems in 2010 for composting
60
9,000 sq. ft. surface area,
total
5-H
Effluent pump station
822,400
n/a
n/a
Chlorination! de -chlorination facility
822,400
disinfection (chlorine)
2-F
dechlorination
2-E
Effluent sampler and recording flow meter
822,400
n/a
n/a
Outfall
822,400
discharge to surface water
4-A
Notes:
1) data above is based on total flow of 300,192,583 gallons final effluent for 2010, average of 0.822455 MGD for 365 days, rounded to 822,400 GPD for calcs..
2) influent flow for each individual operation listed is shown in table above
3) the above flows are shown on accompanying process flow diagram
H:ldocumentsl_ENVIR REPORT FILES1Guilford EastlNPDES Permit Renewal-20111Table of Flows -Sources of Pollution and Treatment Technologies 29JUL11
2010 table
Printed: 08/01/2011 6:31 PM
Page 1 of 1