NC0000078_Renewal Application_20000303

NPDES DOCUMENT SCANNING COVER SHEET
NC0000078
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File
- Historical
Renewal Application
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
March 3, 2000
This document is printed on reuse paper - igriore any
content on the reYerse side

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Application for Renewal
Permit N00000018
Ecusta Division
P. H. Glatfelter C
P. O. Box 200
Pisgah Forest NC 28768
omuanv

Mcusta a division of P. I-1. GLATFELTER CO.
P.O. BOX 200 . PISGAH FOREST, NORTH CAROLINA 28768-0200
TELEPHONE [phone]
D. MIKE CODY
Director, Environmental Affairs
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
February 28, 2000
Mr. Charles H. Weaver, Jr.
NC DENR/Water Quality/NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Renewal of NPDES Permit No. NC0000078
Dear Mr.: Weaver:
On August 31 2000, the above subject permit for the Ecusta Division of P. H. Glatfelter
Company expires. In preparation for this, we are submitting this renewal application and
two copies. This application consists of:
1. This letter requesting a renewal of our existing NPDES permit.
2. The completed application form C for;
A. Outfall 001 which includes:
♦ Present Operating Status
• Potential Facility Changes
• Schematic of wastewater flow
• Location Map
• Production data for the last three years
♦ Priority Pollutant Analysis
• Dioxin Analysis for both the influent and effluent of the Waste
Treatment Plant
B. Outfall 002 which includes:
• Potential Facility Changes
• Schematic of wastewater flow
• Location Map
C. Outfall 003 which includes:
• Potential Facility Changes
• Schematic of wastewater flow
• Location Map
3. Written documentation showing the authority delegated to the Authorized
representative.
4. A narrative description of the sludge management plan for the Ecusta.

In anticipation of this renewal, the following requests are respectfully submitted for your
review.
1. In 1999 new rules were approved for the grade classification of Waste Treatment
Plants. The Ecusta Facility waste treatment plant was reclassified from a grade IV
plant to a Grade III plant. After further review of the new regulations we would like to
request that our treatment plant be reclassified as a grade II facility, and that the
required laboratory testing be reduced to a level commensurate with a Grade II
Treatment facility.
2. That the effluent limitations and monitoring requirements for Summer and Winter be
adjusted to the following time frame:
• Summer May 1 to November 30
• Winter December 1 to April 31
nie i Ca <..,; fry - ..,/ AGRvn
This request is based on, the changes in weather patterns resulting in turn over of
lakes and ASB systems in Western North Carolina form late March to the first weeks in
April. There is adequate river flow and assimilative capacity in April to handle the load.'•--p
In November, warmer temperatures and lower river flows are affecting the assimilative TR%c -,-r
capacity of the river and extending the summer season.
3. That Part V, Dioxin Monitoring, be eliminated from the permit. The production of this De-
mill is made from elemental chlorine free (ECF) purchased pulp, chlorine free flax £ rfY�• _�
pulp, or flax pulp that is bleached with chlorine. The data submitted to the DEHNR Gam,-z6c,,�
over the last ten years has shown that flax pulp bleached with chlorine does not
produce detectable amounts of PCDD or PCDF compounds.
P. H. Glatfelter appreciates the opportunity to submit this information. Throughout our
history, we have been committed to acting responsibly with respect to the environment.
We have always complied with environmental laws and regulations and we have made
extensive efforts to minimize environmental impact. Our Corporate Environmental Policy
and our commitment to ISO 14001 certification indicates our dedication to minimize the
environmental impact of our operations and to use our natural resources wisely. We are
committed to working with you to develop a permit that accomplishes our common
objective of protecting our resources.
If further information is desired, please call me at [phone].
Sincerely,
7/?(A
D. Mike Cody
Director, Environmental Affairs

Printed Name erson Signing
ignature of Applicant or authorized Agent
NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
SECTION 1. APPLICATION AND FACILITY DESCRIPTION
Unless otherwise specified on this form all items are to be completed if an item is not applicable indicate NA'.
1. Applicant and facility producing discharge
This applies to the person, agency, firm, municipality, or any other entity that owns or is responsible for the permitted facility. This may or may not
be the same name as the facility or activity producing the discharge. Enter the name of the applicant as it is officially or legally referred to; do not
use colloquial names as a substitute for the official name.
Name ECUSTA, division of P. H. Glatfelter Company
Mailing address of applicant:
Street address One Ecusta Road
City Pisgah Forest
State North Carolina
County Transylvania
lip Code 28742-0200
Telephone Number ( 828 ) 877-2'147 Fax Number ( 828 ) 277-73RS
e-mail address [e-mail]
2. Mailing address of applicant's Authorized Agent / Representative:
Complete this section if an outside consulting firm/ engineering firm will act on behalf of the applicant / pennittee
Street address P. 0 . Box 200
City Pisgah Forest County Transylvania
State North Carolina Zip Code 28768-0200
Telephone Number ( 828 ) 877-2'347 Fax Number ( 828 ) 877-2'385
e-mail address [e-mail]
3. Facility Location:
Street address One Ecusta Road
City Pi shah Fnrpgt County Transylvania
State North Carolina Zip Code 7R7F,R—fl200
Telephone Number ( 828) 877-2347 Fax Number ( 828 ) 877-2385
4. Nature of Business: Manufacturer of bleached kraft, lightweight papers & fine papers
State the nature of the business conducted at the plant or operating facility
I certify that I am familiar with the information contained in this application and that to the best of my knowledge and belief such
information is true, complete, and accurate.
D. M. Cody Director. Environmental Affairs
Title
Application Signed
North Carolina General Statue 143-215.6 (b)(2) provides that Any person who knowingly makes any false statement representation, or certification in any application, record, report, plan, or other
document files or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowingy
renders inaccurate any recorr8ng or monitoring device or method required to be operated or maintained under Article 21 or regulation of the Environmental Management Commission implementing
that Article, shall be guilty of a misdemeanor punishable by a line not to exceed $10,000. or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by
a fine or not mare Than 510,000 or imprisonment not more than 5 years, or both, for a similar offense.)
1 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
SECTION I1. BASIC DISCHARGE DESCRIPTION
Complete this section for each discharge from the facility to surface waters.
SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE REQUIRED EVEN IF SEVERAL DISCHARGES ORIGINATE IN THE SAME FACIUTY.
All values for an existing discharge should be representative of the twelve previous months of operation. If this is a proposed discharge, values should
reflect best engineering estimates.
1. Outfall Number 001 and Type Wastewater Treatment Plant Effluent
Give the nature of the discharge (process water, non -contact cooling water, etc.)
2. Discharge To End Date: NA
If the discharge is scheduled to be discontinued within the next 5 years, give the date (or best estimate) the discharge will end.
3. Discharge Receiving Stream Name: French Broad
Give the name of the waterway (at the point of discharge) by which it is usually designated on published maps of the area. If the discharge is to
an unnamed tributary, so state and give the name of the first body of water fed by that tributary which is named on the map, e.g., UT to McIntire
Creek, where McIntire Creek is the first water way that is named on the map and is reached by the discharge.
4. Discharge Type and Occurrence
a. • • Check whether the discharge is continuous or intermittent. If the discharge is intermittent, describe the frequency of discharge
® Continuous Intermittent Frequency:
b. Enter the average number of days per week (during periods of discharge) this discharge occurs.
3 65 days per week
5. Water Treatment Additives
Complete the table below if this outfall:
• discharges cooling andlor steam water generation
• water treatment additives are used (any conditioner, inhibitor, or algicide)
• does not have whole -effluent toxicity testing required
Additive
Manufacturer
Quantity
(pounds added per million
gallons of water treated)
Chemical Composition
(active ingredient(s))
Ant ifoam
Nalco 7564
0.81
Aqueous blend of
fatty alcohol
Alkanolamine salt
2 of 4

NPDES Application,Form - Standard Form C
Major Manufacturing or Commercial Facilities
OUTFALL NUMBER 00
6. Wastewater Characteristics
Check the box beside each constituent present in the effluent (discharge water).
This determination is to be based on actual analytical data or best estimate (for proposed discharges).
Parameter
Present .
Parameter
Present
Color —
00080
X
Copper 01042
Ammonia
00610
X
Iron 01045•
Organic nitrogen
00605
X
Lead 01051
•
Nitrate
00620
Magnesium 00927
Nitrite
00615
Manganese 01055
Phosphorus
00665
x
Mercury 71900
Sulfate
00945
Molybdenum 01062
Sulfide •
00745
Nickel 01067
Sulfite
00740
Selenium . 01147
Bromide
71870
Silver 01077
Chloride
00940
x
Potassium - 00937
Cyanide
00720
Sodium 00929
Fluoride
00951
Thallium 01059
Aluminum
01105
X
Titanium 01152
Antimony
01097
X
Tin 01102
Arsenic
01002
Zinc 01092
Beryllium
01012
Algicides* 74051
Barium
01007
x
Chlorinated organic compounds*
74052
Boron
01022
Pesticides* 74053
Cadmium
01027
Oil and grease 00550
Calcium
00916
•
Phenols 32730
Cobalt
01037
Surfactants 38260
Chromium
01034
Chloride 50060
2<
Fecal coliform
74055
Radioactivity 74050
3of4

4
NPDES Application Form — Standard Form C
Major Manufacturing or Commercial Facilities
7. Supplemental Documentation
Submit the following information appended at the end of this application form. All sheets should be approximately letter size with
margins suitable for filing and binding. All pages should include facility location and permit number (if available):
Present Operating Status: Provide a narrative description of installed wastewater treatment components
at the facility. Include sizes & capacities for each component.
Potential Facility Changes: Provide a narrative description of any planned upgrades / expansions /
repairs planned for the facility during the next five years. Do not include tasks associated with routine
operation & maintenance.
Schematic of wastewater flow: Provide a line drawing of water flow through the facility. The schematic
should show flow volumes at all points in the treatment process. Specific treatment components should
be identified.
Id Location map: Submit a map showing the location of each outfall. The usual meridian arrow showing
north as well as the map scale must be shown. On all maps of rivers, the direction of the current is to be
indicted by an arrow. All outfalls should be identified with the outfall number(s) used in Section II of this
application. A copy of the relevant portion of a USGS topographic map is preferred.
Production Data: Submit the last 3 years' production data for the facility. Where applicable, use units
specified in the appropriate subpart of 40 CFR.
Priority Pollutant Analysis: Industrial facilities classified as Primary Industries (see Appendix A to Title 40
of the Code of Federal Regulations, Part 122) must submit a Priority Pollutant Analysis (PPA) in
accordance with 40 CFR Part 122.21. If the PPA is not completed within one week of the due date for
the permit application, submit the application package without the PPA. Submit the PPA as soon as.
possible after it is completed.
1;‘,
4 of 4

Present Operating Status of the Waste Water Treatment Plant.
Ecusta Division of P. H. Glatfelter
A. Water Treatment Waste Collection Facilities
Waste from the Water Treatment Plant (Filter Plant) consists of grit from the baffle chambers, alum
sludge from the settling basins, and backwash from the sand filters. These wastes flow by gravity to the
wet well of the Water Treatment Waste Pumping Station which is equipped with three centrifugal lift
pumps. Each pump is rated at 5,000 GPM at 30 feet of head and is driven by a 50-HP motor. A series of
level switches automatically controls the operation of the pumps. A manually controlled selector switch is
located at the Water Treatment Plant to select any of the three pumps as the lead pump. This provision
insures that pump usage is distributed among the pumps.
A 1/3-HP submersible sump pump is located in the lift station dry well and is automatically
controlled by a level switch. In addition, a high level alarm is installed in the dry well to notify the water
plant operator of flooding in the pump pit. A drain line is installed on the lift pumps discharge header to
prevent freezing of trapped water when pumps are not operating. A timer controlled solenoid valve open
long enough to drain the portion of the discharge line that is above ground near the Storage Reservoir.
The water treatment waste is pumped to a previously existing 800,000 gallons concrete basin that
serves as a Storage Reservoir. Its purpose is to dampen surges to the Primary Clarifiers and enable better
control of flow through the Grit Chamber. Flow enters the Storage Reservoir through five diffuser lines
designed to flush deposited solids from the reservoir floor. A high level switch is installed in the reservoir
to activate an audible and visible alarm on the control panel at the Water Treatment Plant and warn of
potential overflow.
The Grit Chamber is located adjacent to the Storage Reservoir and receives flow by gravity at a rate
controlled by a manually operated valve. The Grit Chamber removes the heavier solids from the water
treatment waste to avoid overloading the Primary Waste Treatment Facilities. Solids that settle to the
bottom of the chamber are collected by mechanical grit removal equipment and are transferred to a grit
conveyor, which carries them to a storage pad. The grit removal equipment is provided with dual speed
drive and is timer controlled; the grit conveyor operates in conjunction with the grit removal mechanism.
Grit is periodically trucked from the storage pad to the sludge landfill for disposal. Grit Chamber effluent
flows by gravity to the East Process Sewer, intersecting at Manhole P-16. See Drawing G 8005-C(EX) 40
B. Primary Waste Treatment Facilities
• .GRIT CHAMBER
The grit chamber is a channel with a widened cross section to slow down the flow permitting settling
and removal of a depressed, coarse particulate matter which could damage mechanical equipment.
The 54" influent pipe from the junction manhole discharges directly upstream of the grit chamber.
The channel has been designed so that the velocity of the -waste will allow heavy grit to settle to the
bottom of the channel while lighter, suspended solids will pass through to be removed in the
clarifiers.
Whenever the grit builds up in the bottom of the channel to a depth of about 2 feet, stop logs should
be inserted to isolate the grit chamber and bypass the flow around it. After dewatering the channel
with portable pumps, the grit is removed manually with the assistance of the jib crane. The grit
chamber has been designed to readily receive the addition of permanent mechanical grit removal

equipment should it be required in the future by continuous heavy grit loads. Because the mechanical
bar screen will also be out of service during this operation, the emergency bar screen in the junction
manhole should be used.
• MECHANICAL BAR SCREEN
After the grit chamber, the raw wastes flow through the mechanical bar screen where large objects
and debris are caught on the bars and prevented from reaching the pumps following the wet well.
The screen consists of 3/8"x2 1/2" vertical bars spaced to provide 1" clear openings. Rakes spaced 5
ft. apart on chains, travel at about 7 fpm up the parallel bars. The rakes lift materials on the bars up
into a two cu. yd. container compatible with mill refuse trucking equipment. The screen has two basic
modes of operation: manual and automatic. For manual, operation, the operator pushes the "Hand"
button on the clarifier control panel located in the lab in the operating building. The red "Run" light
will be on constantly, signifying the rakes are running continuously for automatic operation the
operator pushes "Auto". The "Auto" light will be on continuously but the "Run" light will be on only
when the rakes are running. The time periods that the rakes are on and off for automatic mode are
adjustable at a timer at the screen. This bar screen may also be controlled from a local "key" switch at
the bar screen. The switches are marked bar screen and have a hand and auto switch. Bar screen will
normally be in hand position. The bar screen is protected from heavy load by a shear pin located on
the drive of the screen motor.
• WET WELL
The raw waste flow from the paper mill enters the wet well downstream of the mechanical bar screen.
From the wet well with the aid of level controls, the raw waste flow is Lifted into the clarifiers by the
main lift pumps. The wet well consists of two chambers connected by a 48" by 48" sluice gate, located
between No. 2 and No. 3 main lift pumps. This sluice gate may be operated from a crank type
operator on a floor stand just east of No. 1 sludge pump on the second floor of the operating building.
This sluice gate is normally open". Normally, the waste flow passes through the grit chamber and the
mechanical bar screen before entering the wet well. When the grit chamber is bypassed, the raw waste
will enter the wet well through stop log No. 1. When the mechanical screen is bypassed, the waste
flow will enter the wet well through stop log No. 1 or No. 3. (See stop log location sketch of the grit
and screen chamber.) The two inlets of the wet well provides a mean to isolate one of its two
chambers with the 48"x48" sluice gate closed and with proper arrangement of stop logs. In this
manner, one of the wet well chamber can be entered for repairing pump suction piping, cleaning wet
well, etc. while the waste plant is kept in operation. Inside the wet well, the waste flow is lifted
through a 30-inch suction pipe into each main lift pumps. There are four (4) 30-inch suction pipes
installed, each equipped with an anti -vortex fitting, located at 3.5 ft. from the bottom of the wet well.
The construction of this fitting forces the waste flow to come upward through its bottom part into the
30-inch suction pipe. The three main lift pumps use three of these four suction pipes. The fourth
suction pipe is provided for the future fourth pump.
The wet well is equipped with two level transmitters, one for each wet well chamber. They are located
on the north wall of the main lift pump room in the basement of the operating building. They are set
at two ft. above the bottom of the wet well. The operator simply closes the gate valve provided and
removes the differential pressure cell. Meanwhile, the system continues to operate using the other
transmitter. Use of the alternate transmitter is also required when one chamber of the wet well is
dewatered for cleaning, etc. (The water level in the wet well should normally be kept at 8-ft. depth
from the bottom of wet well. It shall never let the water level drop below 5 ft. or rise above 12 ft.

When water level drops below 5 ft., air may be sucked into the main lift pump to cause serious
damages, such as losing prime or causing vibration in pumps. Operation above 12-ft. water depth
would cause immediate, back flow into Davidson River with the loss of a working pump. Otherwise,
the wastewater will start to back flow into the Davidson River when water level reaches 14-ft. depth
(6 ft. above the normal 8-ft. depth)
• MAIN LIFT PUMPS
Three main lift pumps are provided to lift the wastewater from the wet well to the influent
distribution chamber. These pumps are controlled by signals from level sensing devices located in the
wet well. Each pump has a capacity of 13,300 gpm at 26 feet and is driven by a 125 hp, 600-rpm
motor. The pumps are centrifugal mixed flow type.
The pumps and control system are designed with one pump running on variable speed, two other
pumps on constant speed and has provision of adding a fourth constant speed pump in the future.
The pump control system is designed to maintain a constant wet well level by varying the speed of
one pump and by starting or stopping the other two constant speed pumps.
When the first pump starts or is operating at a minimum speed, a wet well level above the set point
elevation will cause the pump speed to increase until either the wet well level returns to the set point
or until the pump is operating at full speed. After a set period of time (0 to 5 minutes adjustable), after
the first pump is operating at full speed and the wet well level does not lower to the set point, the
second pump will start at constant speed and the first pump will adjust its speed so that the set point
elevation is maintained. When the variable speed pump reaches its full speed with the second pump
first pump will adjust its speed so that the set point elevation is maintained. When the variable speed
pump reaches its full speed with the second pump operating at constant speed and the wet well level
continues to stay above the set point, the third pump will start at constant speed an the first pump
will again adjust its speed to match the incoming flow. The pump sequence operates in reverse order
when the inflow decreases.
When the variable speed controller is inoperable due to malfunction, the pump control system is
designed to operate all three pumps at constant speed automatically through the set point controller.
The pumps would be turned on and off sequentially as dictated by the water level.
The pump control system is provided with a manually operated pump sequence selection switch
mounted on the instrument panel with the selected lead pump to be operated on variable speed and
the lag pump or pumps on constant speed. The lead pump should be alternated on a regular schedule
to equalize wear on the pumps and motors .
• DISTRIBUTION BOX
The distribution box is essentially several manholes combined into one common walled structure. The
influent manhole receives the waste flow from the main lift pumps through a 48" pipe. With the
sluice gates provided, the flow to each clarifier can be controlled. Also provided is a slide gate,
opening directly to the effluent manhole which can be used to bypass the clarifiers. The scum
manholes receive the scum skimmed from the clarifiers. The pipe from the scum boxes to the
manholes may need to be cleaned occasionally due to the nature of the scum. The effluent manhole
receives the clarified waste stream from the effluent troughs in the clarifiers. The manhole has a
sluice gate which always remains open to the secondary waste treatment facilities.

• SLUDGE PUMPS PRIMARY CLARIFERS
Three duplex plunger pumps are provided to pump sludge from the clarifier sludge wells to the
dewatering devices. They also pump scum to the dewatering devices or to a truck loading connection.
The pumps have eleven stroke length positions available. Power is supplied by a 7-1/2 hp constant
speed motor, gear reducer and variable speed belt drive. The belt drive should be used to make routine
adjustments over its 3 to 1 range. The maximum output of each pump is 145 gpm at 35 psi.
Under normal operating conditions one pump should be running for each operating centrifuge. The
optimum pumping rate will be determined during the first several months of operation and will
remain more or less constant thereafter. Care should be taken not to draw the sludge level too low in
the clarifiers resulting in dilute sludge feed to the dewatering devices.
When in "automatic" mode, these pumps are interlocked with both the sludge conveyors and the
dewatering devices. To start the pumps, both the conveyor and dewatering devices must be running.
Also, in the event of a malfunction causing a shutdown of either the conveyor or dewatering devices,
the pumps are also shut down. Three duplex plunger pumps are provided to pump sludge from the
clarifier sludge wells to the dewatering devices. They also pump scum to the dewatering devices or to
a truck loading connection. The maximum output of each pump is 145 gpm at 35 psi.
Under normal operating conditions one pump is running for each dewatering unit. When in
"automatic" mode, these pumps are interlocked with both the sludge conveyors and the sludge
dewatering equipment.
• Sludge Dewatering
One two -meter Andritz belt press accomplishes sludge dewatering. Two Bird Centrifuges are used as
back up when the belt press is out of service or the load to the primary clarifiers exceeds the belt press
capacity The basic adjustments can be set to achieve a drier filter cake at the expense of some solids
recovery, or to achieve a somewhat wetter cake with fewer solids lost. It is possible to produce a drier
cake by increasing the speed and/or decreasing pool depth. Operation is basically unattended after
manual start
• SLUDGE CONVEYORS
The sludge conveyors are 24 inches wide, smooth belt conveyors designed to run at 50 feet per
minute. The horizontal conveyor receives dewatered sludge through rubberized chutes attached to the
sludge hoppers. The horizontal conveyor when operated in the forward direction transfers the sludge
to the inclined conveyor. The inclined conveyor discharges directly onto the sludge pad.
The conveyors are interlocked with the sludge pumps as described above. The horizontal conveyor is
interlocked with the inclined conveyor except when operating in reverse.
C. Secondary Waste Treatment Facilities
Effluent from the Primary Clarifiers flows to the Aerated Stabilization Basin (ASB) by the Flow
Diversion Structure and the 60-inch diameter pipeline. Primary effluent enters the ASB through four

submerged diffuser lines. In addition, leachate from the sludge landfills enters the ASB by gravity
drainage.
The ASB, which has a surface area of approximately 75 acres and provided 11.2 days of detention
(water surface elevation 2111.5 feet, 30 MGD waste flow), is designed to remove soluble organic material
by biological action. Biological removal is accomplished by microorganisms, which consume the waste as
a food source and require sufficient dissolved oxygen to survive and reproduce. Ten 75-HP floating
surface aerators and one 75 HP down draft mixer are provided to maintain adequate dissolved oxygen and
mixing. The aerators are located so that approximately 9 days of detention time is in active aeration and
the area southeast of the midfeather is a quiescent zone having 2.2 days detention. This area provides an
opportunity for additional settling of solids prior to discharge of the wastewater.
Discharge from the ASB is regulated by the Effluent Control Structure, which collects the treated
wastewater at the water surface and is equipped with a surface baffle to prevent discharge of floating
material. A slide gate serves as a discharge control weir and can be used to vary the water level in the
basin, if desired. A sluice gate is provided to drain the ASB to the French Broad River, should this be
required.
Treated wastewater flows by gravity from the Effluent Control Structure through the Final Effluent
Parshall Flume and is discharged via an open ditch to the French Broad River. A foam corral is
constructed in the open ditch to eliminate foam in the discharge as required by the NPDES Permit.
The Parshall flume is used to measure the flow of treated effluent and is also the location of the
Final Effluent Monitoring Station. Instrumentation is provided to monitor and record pH, dissolved
oxygen, temperature, and flow. An automatic sampler collects a continuous, flow proportional, composite
sample to be analyzed in the laboratory. Defoamer is injected at the Parshall Flume for foam control if
needed.
The Aerator Maintenance Facility is a dock -like structure located within the ASB on the northwest
bank of the midfeather. It enables aerator repairs to be accomplished with the least inconvenience. A
pontoon work boat provides access to aerators for periodic inspections; scheduled gear reducer oil
changes, and minor maintenance while aerators are in place in the basin. For major repairs, an aerator
may be towed to the maintenance facility by the workboat. The Aerator Maintenance Facility is equipped
with a hoist and trolley for lifting the motor or gearbox and for easy loading andunloading of equipment
and supplies. The necessary electrical connections are provided for welding and running an aerator motor
at the maintenance facility.

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1. The Ecusta Mill is in a transition from the production of lightweight cigarette paper to fine printing
papers. The amount of production listed in this application reflects our capacity, which is constrained
by the amount of lightweight paper we produce. The need for cigarette paper is declining while the
demand for fine printing papers is high. Based on production practices, market projections, committed
growth, and utilization of our current facility for fine printing papers the following production rates
could be obtained at our facility over the next five years.
Pulp Production
342,365 pounds /day
Paper Production
890,000 pounds / day
The production of this mill will continue to be made from elemental chlorine free (ECF) purchased
wood pulp, chlorine free flax pulp, or flax pulp that is bleached with chlorine.
Also there is possibilities of pulping other non -wood species such as cotton.
2. A 10,000-gallon spill collection system will be installed in the Evaporator Area.

Non -Contact
Cooling Water
3.262 MGD
Discharge
No. 003
Davidson
River 1.272 MGD
Schematic of Water Flow
Discharge
No. 002
Davidson
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• Pumpingit

Production Data
P. H. Glatfelter
Ecusta Mill
January
February
March
April
May
June
July
August
September
October
November
December
1997 1998 1999
lbs. lbs. lbs.
22,998,098 21,613,113 19,387,822
20,836,446 19,329,594 21,316,967
23,243,329 23,106,644 24,888,074
19,352,744 21,798,259 21,350,696
22,805,607 23,296,905 23,535,357
20,934,435 22,041,858 21,660,486
19,011,509 22,399,148 16,340,878
20,617,355 22,485,948 22,391,086
21,929,727 18,958,390 21,228,268
24,448,986 20,303,906 23,259,529
22,350,216 17,780,220 21,344,652
17,113,778 14,874,220 19,032,381
Monthly Average 21,303,519 20,665,684 21,311,350
Daily Average
January
February
March
April
May
June
July
August
September
October
November
December
Monthly Average
Daily Average
Total Production
Monthly Average
Daily Average
700,390 679,420 700,647
1997
CEH TCF
lbs. lbs.
2,360,250
2,378,449
2,423,357
2,189,161
2,079,226
1,476, 872
1,582,327
2,476,822
2,477,341
2,667,063
2,903,570
2,357,807
604,800
48,000
264,000
379,200
1,094,400
585,391
1,126,072
729,800
479,327
561,700
385,400
688,800
1997 1998 1999
Tons Tons Tons
11,499.0 10,806.6 9,693.9
10,418.2 9,664.8 10,658.5
11,621.7 11,553.3 12,444.0
9,676.4 10, 899.1 10, 675.3
11,402.8 11,648.5 11,767.7
10,467.2 11,020.9 10,830.2
9,505.8 11,199.6 8,170.4
10,308.7 11,243.0 11,195.5
10,964.9 9,479.2 10,614.1
12,224.5 10,152.0 11,629.8
11,175.1 8,890.1 10,672.3
8,556.9 7,437.1 9,516.2
10,651.8 10,332.8 10,655.7
350.2 339.7 350.3
1998 1999
CEH TCF CEH TCF
lbs. lbs. lbs. lbs.
2,868,437 351,092 1,524,464 1,475,309
2,206,578 497,200 1,893,132 880,610
1,776,200 926,700 2,023,823 719,391
1,919,161 775,771 2,266,426 967,049
2,453,073 678,050 1,906,565 1,322,355
2,104,038 953,728 2,619,154 549,205
2,083,862 849,147 1,835,289 207,445
2,911,043 485,176 1,867,797 1,292,991
1,733,828 1,077,851 2,687,170 192,974
1,965,546 1,234,346 1,964,545 988,671
2,009,185 1,185,739 1,907,003 1,021,132
1,387,436 797,954 2,227,256 0
2,281,020 578,908 2,118,199 817,730 2,060,219 801,428
74,992 19,033 69,639 26,884 67,733 26,348
2,859,928
94,025
2,935,928
96,524
2,861,646
94,082
CEH - Chlorine, Caustic, Hypochlorite
TCF - Totally Chlorine Free

Annual Pollutant Analysis Monitoring Requirement
Reporting Form A
(Revised June 1990)
I. Facility Information:
NPDES Permit No: NGOOOOOiS Discharge (Pipe) No: 00 t Year. gGAO
Facility Name: G Gc S - Cote. Class:_ ll_ County: 16r t/s y L Fi t t-'`/a--
Person(s) Collecting Samples: 3cis o" ova vv.: p 1 s
Page 1 of 9
Status of facility wastewater treatment operation on day of sampling: typical: _.2L. Yes No
If no, explain briefly:
Analytical Laboratory: Pa .c e- Nv\a.V '
II. Sampling:
24 hr composite for main sample / grab sample for purgeable fraction
Date Sampled: (composite sample) Corresponding sample taken for toxicity testing:
Sampling begun (date, time): ' , (o 0-� V41'. B6 'iNM Yes
Sampling finished (date, time): 1-- /7 /0c? 4Z 35 Rtn No
Date and time sampled (grab sample):
Instructions
The purpose of this document and the accompanying memo is to standardize the sampling, analysis and reporting procedures to be used
for the Annual Pollutant Analysis Monitoring (APAM) Requirement as described in the permit.
Sampling
1 - Take a 24-hour composite sample from the final effluent during mid -week (Wednesday through Friday). Collect a grab sample for the volatile
organic fraction when collection of the 24hour composite sample is completed. Follow any other sampling instructions provided by the laboratory
performing the analysis.
2 - indicate in the space provided at the top of this page whether a corresponding sample for toxicity testing was taken.
3 - Make note of any unusual wastewater treatment operating conditions occurring on the day of sampling in the space provided on the form.
Analysis
4 - Analyze the effluent for pollutants listed on the APAM form, Including those to be identified and approximately quantified under the 10
significant peaks rule, using appropriate EPA -approved methods for each of the analytic fractions. Other analytical methods can be substituted
only with prior, written approval of the Director of the Division of Environmental Management (DEM). Read and distribute to the laboratory
performing the analysis the accompanying memo (Tedder, October 1990) clarifying analytical requirements.
5 - Identify chemicals to be analyzed for according to the 10 significant peaks rule (as described In Item 2 of the Annual Pollutant Analysis
Monitoring Requirement in the permit) using a GC/MS library search. Tentative identification Is all that Is required; confirmation by standard
injection is not necessary. Estimate the concentration of each based on an intemal standard having the c . est retention time.
Reporting
6 - Quantitation Limit Targets that should be met are listed on this Revised APAM Reporting Form A. Report the use of any higher quantita-
tion limit and an explanation as to why the listed quantitation limit target could not be met. Examples of acceptable reasons for not meeting
a quantitation limit target could be high background concentrations In a sample, or the necessity for sample fraction dilution to bring a chemical
to within a quantifiable concentration. List any quantitatlon limit dlffertent (whether higher or lower) from the target In the column provided
for this purpose.
7 - If a chemical is found to be below the quantitation limit, report the concentration detected as less than (or '<') the quantitation limit
in the appropriate space. Provide a concentration estimate for chemicals detected in concentrations greater than the detection limit and less
than the quantitation limit. Enter the detection limit in parentheses beside the estimate. Chemicals detected in concentrations above the quan-
titation limits must be quantified. Quantitation limit and detection limit are defined in the accompanying memo (Tedder, October 1990). Enter
the total number of peaks detected in each analytic fraction in the appropriate space on this Revised APAM Form A. Report all concentrations
In units of micrograms per liter (ug/1) and metals as total recoverable metal. If no peaks to be identified under the 10 significant peaks rule
are observed, enter "none" In the space provided for "other" compounds in each appropriate analytic fraction section. Provide the concentra-
tion estimate and retention time for "unknowns" as well as for "significant peaks" for which a structural assignment can be made.
8 - If "significant peaks" are found, provide probable molecular weight, library match probability, retention time, Identification basis, and
MS scan number for each. In addition, list intemal standards and their retention times.
9 - In the section labeled "Organic Analytical Information" (p. 9), Include for each organic fraction the method, extraction technique, GC
operating conditions, and surrogate recovery. Report the size of the GC/MS library being utilized in the appropriate space.
10 - Use copies of thls Annual Pollutant Analysis Monitoring Revised Form A to report the results of the analysis. Both the analytical laboratory
representative and the facility operator in responsible charge should sign completed forms (last page).
11 - Mail two completed copies of the form (and the laboratory report, If submitted to the facility on a different form) to: ATTN: Central Files,
Division of Environmental Management, NC DEHNR, P.O. Box 27687, Raleigh, NC 27611. Mail the APAM form separately from Discharge Monitoring
Reports.

A. Purgeable (Volatile Organic) Fraction, EPA Method 624 Page 2 of 9
Number of chemicals detected in Fraction o
Fraction STORET Number 84085
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit*
Concentration
• Detected
GC/MS
Confirmation?
1. Pollutants to be analyzed for:
(ug/L)
(ug/L)
(ug/L)
Yes
No
34210
Acrolein
100
100
<100
X
34215
Acrylonitrile
100
100
<100 '
X
34030
Benzene
5
5
<5
X
32101
Bromodichloromethane
5
5 _
<5
X
32104
Bromoform
5
5
<5
X
34413
Bromomethane
10
10
<10
X
32102
Carbon tetrachloride
5
5
<5
X
34301
Chlorobenzene
6
6
<6
X
34311
Chloroethane
10
10
<10
X
34576
2-Chloroethyl vinyl ether
10
10
<10
X
32106
Chloroform
5
5
<5
X
34418
Chloromethane
10
10
<10
X
32105
Dibromochloromethane
5
5
<5
X
34496
1,1-Dichloroethane
5
5
<5
X
34531
1,2-Dichloroethane
5
5
<5
X
34501
1,1-Dichloroethylene
5
5
<5
X
34546
trans-1,2-Dichloroethylene
5
5
<5
X
34541
1,2-Dichloropropane
6
6
<6
X
34704
cis-1,3-Dichloropropene
5
5
<5
X
34699
trans-1,3-Dichloropropene
5
5
<5
X
34371
Ethylbenzene
8
8
<8
X
34423
Methylene chloride
5
5
<5
X
34516
1,1,2,2-Tetrachloroethane
7
7
<7
X
34475
Tetrachloroethylene
5
5
<5
X
34010
Toluene
6
6
<6
X
34506
1,1,1-Trichloroethane
5
5 •
<5
X
34511
1,1,2-Trichloroethane
5
5
<5
X
39180
Trichloroethylene
5
5
<5
X
34488
Trichlorofluoromethane
10
10
<10
X
39175
Vinyl chloride
10
10
<10
X
If difference from quantitation limit target
NA = Not Analyzed

2. Other purgables (up to 10 highest peaks)
Page 3 of 9
Compound
Prob
Mole.
Wt.
Est.
Conc.
(ug/L)
Lib. Match
Prob.
(%)
Retention
Time (RT)
(Min)
Identification Basis
Scan
Number
Lib.
Match
Manual
Interpret.
RT
none
Complete only if non -target compounds are present:
Internal Standard
Retention
Time (RT)
(Min)
Pentafluorobenzene
0
1,4-Difluorobenzene
0
Chlorobenzene-d5
0
0
0

B. Acid Extractable Fraction, EPA Method 8270 Page 4 of 9
Number of chemicals detected in Fraction 0
Fraction STORET Number 45582
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit*
Concentration
Detected
GC/MS
Confirmation?
1. Pollutants to be analyzed for:
(ug/L)
(ug/L)
(ug/L)
Yes
No
34452
4-Chloro-3-methylphenol
10
10
<10
X
34586
2-Chlorophenol
10
10
<10
X
34601
2,4-Dichlorophenol
10
10
<10
X
34606
2,4-Dimethylphenol
10
10
<10
X
34616
2,4-Dinitrophenol
50
50
<50
_ X
34657
2-Methyl-4,6-dinitrophenol
50
50
<50
X
34591
2-Nitrophenol
10
10
<10
X
34646
4-Nitrophenol
50
50
<50
X
39032
Pentachlorophenol
50
50
<50
X
34694
Phenol
10
10
<10
X
34621
2,4,6-Trichlorophenol
10
10
<10
X
* If difference from quantitation limit target

2. Other acid extractables (up to 10 highest peaks)
Page 5 of 9
Compound
Prob
Mole.
Wt.
Est.
Conc.
(ug/L)
Lib. Match
Prob.
(%)
Retention
Time (RT)
(Min)
Identification Basis
Scan
Number
Lib.
Match
Manual
Interpret.
RT
unknown
10
13.682
x
1623
unknown
37
15.332
x
1869
unknown
•
45
15.802
x
1939
unknown
86
17.292
x
2161
unknown
'
85
17.654
x
•
2215
unknown
81
18.989
x
2414
unknown
45
19.439
x
2481
unknown
85
20.553
x
2647
Complete only if non -target compounds are present:
Internal Standard
Retention
Time (RT)
(Min)
1,4-Dichlorobenzene-d4
5.78
Napthalene-d8
7.33
Acenapthene-d10
10.26
Phenanthrene-d10
13.1
Chrysene-d12
18.46
Perylene-d12
21.17

l
C. Base/Neutral Fraction, EPA Method 8270 Page 6 of 9
Number of chemicals detected in Fraction 0
Fraction STORET Number 45583
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit*
Concentration
Detected
GC/MS
Confirmation?
1. Pollutants to be analyzed for:
(ug/L)
(ug/L)
(ug/L)
Yes
No
3405
Acenaphthene
10
10
<10
X
34200
Acenaphthylene
10
10
<10
X
34220
Anthracene
10
10
<10
X
39120
Benzidine
50
50
<50
X
34526
Benzo (a) anthracene
10
10
<10
X
34247
Benzo (a) pyrene
10
10
<10
X
34230
Benzo(b)fluoranthene
10
10
<10
X
34521
Benzo (ghi) perylene
10
10
_
<10
X
34242
Benzo(k)fluoranthene
10
10
<10
X
34278
Bis(2-chloroethoxy)methane
10
10
<10
X
34273
Bis(2-chloroethyl)ether
10
10
<10
X
34283
Bis(2-chloroisopropyl) ether
10
10
<10
X
39100
Bis(2-ethylhexyl) phthalate
10
10
<10
X
34636
4-Bromophenyl phenyl ether
10
10
<10
X
34292
Butyl benzyl phthalate
10
10
<10
X
34581
2-Chloronaphthalene .
10
10
<10
X
34641
4-Chlorophenyl phenyl ether
10
10
<10
X
34320
Chrysene
10
10
<10
X
34556
Dibenzo (a,h) anthracene
10
10
<10
X ,
34536
1,2-Dichlorobenzene
10
10
<10
X
34566
1,3-Dichlorobenzene
10
10
<10
X
34571
1,4-Dichlorobenzene
10
10
<10
X
34631
3,3-Dichlorobenzidine
20
20
<20
X
34336
Diethyl phthalate
10
10
<10
X
34341
Dimethyl phthalate
10
10 _
<10
X
39110
Di-n-butyl phthatate
10
10
<10
X
34611
2,4-Dinitrotoluene
10
10
<10
X
34626
2,6-Dinitrotoluene
10
10
<10
X
34596
Di-n-octyl phthalate
10
10
<10
X
34346
1,2-Diphenylhydrazine
10
10
<10
X
34376
Fluoranthene
10
10
<10
X
34381
Fluorene
10
10
<10
X
39700
Hexachlorobenzene
10
10
<10
X
34391
Hexachlorobutadiene
10
10
<10
X
34386
Hexachlorocyclopentadiene
10
10
<10
X
34396
Hexachloroethane
10
10
<10
X
34403
Indeno(1,2,3-cd) pyrene
10
10
<10
X
34408
Isophorone
10
10
<10
X
34696
Naphthalene
10
10
<10
X
34447
Nitrobenzene
10
10
<10
X
34438
N-nitrosodimethylamine
10
10
<10
X
34428
N-nitroso-di-n-propylamine
10
10
<10
X
34433
N-nitrosodiphenylamine
10
10
<10
X
34461
Phenanthrene
10
10
<10
X
34469
Pyrene •
10
10
<10
X
34551
1,2,4-Trichlorobenzene
10
10
<10
X
If difference from quantitation limit target

2. Other base/neutrals (up to 10 highest peaks)
Page 7 of 9
Compound
Prob
Mole.
Wt.
Est.
Conc.
(ug/L)
Lib. Match
Prob.
(%)
Retention
Time (RT)
(Min)
Identification Basis
Scan
Number
Lib.
Match
Manual
Interpret.
RT
None
Complete only if non -target compounds are present:
Internal Standard
Retention
Time (RT)
(Min)
1,4-Dichlorobenzene-d4
5.78
Napthalene-d8
7.33
Acenapthene-d10
10.26
Phenanthrene-d10
13.1
Chrysene-d12
18.46
Perylene-d12
21.17

D. Organochlorine/Organophosphorus Pesticides and PCBs Page 8 of 9
Number of chemicals detected in Fraction 0
Fraction STORET Number 00188
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit*
Concentration
Detected
Confirmation?
Dual Column GC/MS
1. Pollutants to be analyzed for: (ug/L)
Organochlorine Pesticides/PCBs: EPA Method 8080
(ug/L)
(ug/L)
Yes
No
Yes
No
39330
Aldrin
0.05
0.05
<0.05
X
39337
Alpha-BHC
0.05
0.05
<0.05
X
39338
Beta-BHC •
0.05
0.05
<0.05
X
34259
Delta-BHC
0.1
0.1
<0.1
X
39340
Gamma-BHC (Lindane)
0.05
0.05
<0.05
X
39350
Chlordane
0.2
0.2
<0.2
X
39310
4,4'-DDD
0.1
0.1
<0.1
X
39320
4,4'-DDE
0.1
0.1
<0.1 •
X
39300
4,4'-DDT
0.1
0.1
<0.1
X
39380
Dieldrin
0.02
0.02
<0.02
X
34361
Endosulfan I (alpha)
0.1
0.1
<0.1
X
34356
Endosulfan II (beta)
0.1
0.1
<0.1
X
34351
Endosulfan sulfate
0.7
0.7
<0.7
X
39390
Endrin
0.06
0.06
<0.06
X
34366
Endrin aldehyde
0.2
0.2
<0.2
X
39410
Heptachlor
0.05
0.05
<0.05
X
39420
Heptachlor epoxide
0.8
0.8
<0.8
X
39480
Methoxychlor
0.5
0.5
<0.5
X
39755
Mirex
0.2
0.2
<0.2
X
39400
Toxaphene
2.4
2.4
<2.4
X
34671
PCB 1016
0.5
1.0
<1.0
X
39488
PCB 1221
0.5
1.0
<1.0
X
39492
PCB 1232
0.5
1.0
<1.0
X
39496
PCB 1242
0.5
1.0
<1.0
X
39500
PCB 1248
0.5
1.0
<1.0
X
39504
PCB 1254
1
1.0
<1.0
X
39508
PCB 1260
1
1.0
<1.0
X
Organophosphorus Pesticides: EPA Method 8140
39560
Demeton
2.5
2.5
<2.5
X
39540
Parathion (ethyl)
0.6
0.6
<0.6
X
E. Herbicides, EPA Method 8150
Number of chemicals detected in Fraction 0
Fraction STORET Number 00148
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit*
Concentration
Detected ,
Confirmation?
1. Pollutants to be analyzed for:
(ug/L)
(ug/L)
(ug/L)
Yes
No
39730
2,4-D
12
12
<12
X
39045
Silvex
2
2
<2.0
X
39740
2,4,5-T
2
2
<2.0
X
* If difference from quantitation limit target

Organic Analytical Information
Page 9 of 9
Organic Fraction
Method
Extraction
GC Operating Conditions
Column Description .
Surrogate Spikes
Batch
Continuous
Length X ID, Film Thickness,
Column Type, Carrier Gas & Flow
Rate, Temperature Program
Compound
Recovery
%
Purgeable
624
X
J&W DB-624, 60 m x 0.25 mm ID
DBFM
107%
Helium, 1 mUmin
Toluene-d8
104%
4 min @ 40 C, to 220 C CO 8 C/min, 4.5 min
BFB
108%
Acid Extractable
8270
X
J&W DB5-MS, 30 m x 0.25 mm id
2-FP
41 %
Helium,1.0 mUmin, 1.75 min € 40 C, to 130 C
Phenol-d6
34%
35 C/min, to 330 C @ 12 Clmin, 7 min
2,4,6-TBP
77%
Base/Neutral Extractable
8270
X
J&W DB5-MS, 30 m x 0.25 mm id
NitroBenz-d5
58%
Helium,1.0 mUmin, 1.75 min @ 40 C, to 130 C
2-FBP
57%
35 C/min, to 330 C @ 12 C/min, 7 min
Terphenyl-d14
56%
GC/MS Library size (number of reference spectra): Method.624 - 40,000 Method 625 - 75,000
F. Metals and Other Chemicals
Number of Metals and Other Chemicals (as listed below) detected in Sample 2
Fraction STORET Number 78240
STORET Compound
Number
Quantitation
Limit Target
Quantitation
Limit'
Concentration
Detected
1. Pollutants to be analyzed for:
(ug/L)
(ug/L)
(ug/L)
1104
Aluminum
50
100
290
1097
Antimony
50
50
<50 .
1002
Arsenic
10
10
<10
1012
Beryllium
25
25
<25
1027
Cadmium
2
2
<2
1034
Chromium
5
5
<5
1042
Copper
2
2
<2
1051
Lead
10
10
<10
71900
Mercury
0.2
_
0.2
<0.2
1067
Nickel
10
10
<10
1147
Selenium
5
5
<5
1077
Silver
5
5
<5
1092
Zinc
10
10
<10
2. Other inorganics:
1077
Barium
500
500
<500
940
Chloride
1ti00
1000
20000
720
Cyanide
20
20
<20
951
Fluoride
100
100
<100
• If difference from quantitation limit target
Analytical Laboratory
Facility Operator
I certify that this
Signed:
Representative:
/'/
� (. (itr�� Z .4.4.LSigned:
(ORC):
complete
Date: /
•
cAli 2066
in Responsible Charge
report is accurate and
to the best
of my knowledge.
Date:

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
SECTION 11. BASIC DISCHARGE DESCRIPTION
Complete this section for each discharge from the facility to surface waters.
SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE REQUIRED EVEN IF SEVERAL DISCHARGES ORIGINATE IN THE SAME FACILITY.
All values for an existing discharge should be representative of the twelve previous months of operation. If this is a proposed discharge, values should
reflect best engineering estimates.
. (2tr....• 4.
1. Outfall Number 002 and Type Non -contact cooling water
Give the nature of the discharge (process water, non -contact cooling water, etc.)
2. Discharge To End Date: NA
If the discharge is scheduled to be discontinued within the next 5 years, give the date (or best estimate) the discharge will end.
3. Discharge Receiving Stream Name: Davidson River
Give the name of the waterway (at the point of discharge) by which it is usually designated on published maps of the area. If the discharge is to
an unnamed tributary, so state and give the name of the first body of water fed by that tributary which is named on the map, e.g., UT to Mclntire
Creek, where Mclntire Creek is the first water way that is named on the map and is reached by the discharge.
4. Discharge Type and Occurrence
a. Check whether the discharge is continuous or intermittent. If the discharge is intermittent, describe the frequency of discharge
© Continuous Intermittent Frequency:
b. Enter the average number of days per week (during periods of discharge) this discharge occurs.
365 days per week
5. Water Treatment Additives
Complete the table below if this curia:
• discharges cooling and/or steam water generation
• water treatment additives are used (any conditioner, inhibitor, or algicide)
• does not have whole -effluent toxicity testing required
Additive
Manufacturer
Quantity
(pounds added per million
gallons of water treated)
Chemical Composition
(active ingredient(s))
Cationic Coagulant
Nalco 8158
1.25
Polyaluminum
. Chloride
2 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
SECTION I. APPLICATION AND FACILITY DESCRIPTION
Unless otherwise specified on this form a!1 items are to be completed. If an item is not applicable indicate 'NA'.
1. Applicant and facility producing discharge
This applies to the person, agency, firm, municipality, or any other entity that owns or is responsible for the permitted facility. This may or may not
be the same name as the facility or activity producing the discharge. Enter the name of the applicant as it is officially or legally referred to; do not
use colloquial names as a substitute for the official name.
Name ECUSTA, division of P. H. Glatfelter Company
Mailing address of applicant:
Street address One Ecusta Road
City Pisgah Forest
State North Carolina
County Transylvania
Zip Code
28742-0200
Telephone Number ( 828 ) 877-2347 Fax Number ( 828 ) S77-7189
e-mail address [e-mail]
2. Mailing address of applicant's Authorized Agent / Representative:
Complete this section if an outside consulting firm/ engineering firm will act on behalf of the applicant 1 permittee
Street address
P. 0. Box 200
City Pisgah Forest County Transylvania
State North Carolina Zip Code 28768-0200
Telephone Number ( 828 ) 877-2347 Fax Number ( 828 ) $77-23S
e-mail address [e-mail]
3. Facility Location:
Street address 0ne Ecusta Road
City Pi shah Forest County
State North Carolina Zip Code 2R7�R—(l90O
Telephone Number ( 828) 877-2347 Fax Number ( 828 ) 877-2385
4. Nature of Business: Manufacturer of bleached kraft, lightweight papers & fine papers
Transylvania
State the nature of the business conducted at the plant or operating facility
I certify that I am familiar with the information contained in this application and that to the best of my knowledge and belief such
information is true, complete, and accurate.
D. M. Cody
Printed Name at Person Signing
SignatureatApplIcant or Auth• zed Agent
Director, Environmental Affairs
Title
o
Date Application Signed
North Carolina General Statue 143.215.E (b)(2) provides that: Any person who knowingly makes any false statement representation, or certification in any application, record. report, pla
n, or other
document files ar required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowing),
renders inaccurate any recanting ar monitoring device or method required to be operated or maintained under Article 21 or regulations al the Environmental Management Commission implementing
That Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $10,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by
a fine or not mare than $10,000 or imprisonment not more than 5 years, or both, for a similar offense.)
1 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
OUTFALL NUMBER Ot 2
6. Wastewater Characteristics
Check the box beside each constituent present In the effluent (discharge water).
This determination is to be based on actual analytical data or best estimate (for proposed discharges).
Parameter
Present
Parameter
Present
Color +'
00080
Copper 01042
-.
Ammonia
00610
Iron ' 01045
•
Organic nitrogen
00605
Lead 01051
Nitrate
00620
'
Magnesium 00927 ,
Nitrite
00615
Manganese • 01055
Phosphorus
00665
Mercury 71900
Sulfate
;
00945
Molybdenum 01062
Sulfide
00745
Nickel 01067
Sulfite
00740
Selenium . 01147
Bromide
71870
Silver 01077
Chloride
00940
Potassium - 00937
Cyanide
00720
Sodium 00929
Fluoride
00951
Thallium 01059
Aluminum
01105
Titanium 01152
Antimony
01097
Tin 01102
Arsenic
01002
Zinc 01092
Beryllium
01012
Afgicides* 74051
Barium
01007
Chlorinated organic compounds* 74052
Boron
01022
•
Pesticides* 74053
Cadmium
01027
.
.0i1 and grease 00550
Calcium
00916
•
-
Phenols 32730
Cobalt
01037
Surfactants 38260
Chromium
01034
Chloride 50060
Fecal coliform
74055
Radioactivity 74050
3 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
7. Supplemental Documentation
Submit the following information appended at the end of this application form. All sheets should be approximately letter size with
margins suitable for filing and binding. All pages should include facility location and permit number (if available).
1$. Present Operating Status: Provide a narrative description of installed wastewater treatment components
at the facility. Include sizes & capacities for each component.
XS Potential Facility Changes: Provide a narrative description of any planned upgrades / expansions /
repairs planned for the facility during the next five years. Do not include tasks associated with routine
operation. & maintenance.
Xi Schematic of wastewater flow: Provide a line drawing of water flow through the facility. The schematic
should show flow volumes at all points in the treatment process. Specific treatment components should
be identified.
i Location map: Submit a map showing the location of each outfall. The usual meridian arrow showing
north as well as the map scale must be shown. On all maps of avers, the direction of the current is to be
indicted by an arrow. All outfalls should be identified with the outfall number(s) used in Section II of this
application. A copy of the relevant portion of a USGS topographic map is preferred.
O Production Data: Submit the last 3 years' production data for the facility. Where applicable, use units
specified in the appropriate subpart of 40 CFR.
I Priority Pollutant Analysis: Industrial facilities classified as Primary Industries (see Appendix A to Title 40
of the Code of Federal Regulations, Part 122) must submit a Priority Pollutant Analysis (PPA) in
accordance with 40 CFR Part 122.21. If the PPA is not completed within one week of the due date for
the permit application, submit the application package without the PPA. Submit the PPA as soon as.
possible after it is completed.
4 of 4

Present Operating Status of Uutfall 002
This discharge receives non -contact cooling water generated during the manufacture of fine paper and
storm water.

� FJ• .fti; .;
Arp.
iY:/J //.i::rrr r:'rr.'Jfr':::,;• "•
"} �`Jf ii xrfiy
. J '
�� �
it .Jf , r>1J f .J' f r JJ:ry :rr.{.1/.... f':. is •3f� '•'•r
.viiilir"rf.$iSSi i''i'r }!:'"'•;::.:ii v�r. rr...... ";•fif: i
7
There arc no planned upgrades, expansions, or repairs that would affect outfall 002

Discharge
No. 003
Davidson
River 1.272 MGD
Schematic of Water Flow
Boiler Feed Water
0.9 MGD
Potable Water
0.082 MGD
Leachate
Landfill
0.012 MGD
Primary
Treatment
17.188 MGD
Process
Water
16.206 MGD
Secodary
Treatment
ASB
MGD
Discharge 001
French Broad
River
17.2 MGD

1.
NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
SECTION 1. APPLICATION AND FACILITY DESCRIPTION
Unless otherwise specified on This form all items are to be completed. If an item is not applicable indicate 'NA'.
Applicant and facility producing discharge
This applies to the person, agency, firm, municipality, or any other entity that owns or is responsible for the permitted facility. This may or may not
be the same name as the facility or activity producing the discharge. Enter the name of the applicant as it is officially or legally referred to; do not
use colloquial names as a substitute for the official name.
Name ECUSTA, division of P. H. Glatfelter Company
Mailing address of applicant:
Street address One Ecusta Road
City Pisgah Forest
State North Carolina
County
Zip Code
Transylvania
28742-0200
Telephone Number ( 828 ) 877-2347 Fax Number ( 828 ) R77-7'3R5
e-mail address [e-mail]
2. Mailing address of applicant's Authorized Agent / Representative:
Complete this section if an outside consulting firm) engineering firm will act on behalf of the applicant / permittee
Street address P . 0 . Box 200
City Pisgah Forest County Transylvania
State North Carolina Zip Code 28768-0200
Telephone Number ( 828 ) 877-2347 Fax Number ( 828 ) 877-2385
e-mail address [e-mail]
3. Facility Location:
Street address one Ecusta Road
City P; sgh Fnregt County Transylvania
State North Carolina Zip Code ?R7fiR-09n0
Telephone Number ( 828) 877-2347 Fax Number ( 828 ) 877-2385
4. Nature of Business: Manufacturer of bleached kraft, lightweight papers & fine papers
State the nature of the business conducted at the plant or operating facility
I certify that I am familiar with the information contained in this application and that to the best of my knowledge and belief such
information is true, complete, and accurate.
D. M. Cody
Printed Name of Person Signing
Signature of scant or Authorized . ent
Director, Enviroranental Affairs
Title
,;?,,,6-57 4f) /
ate Applic on Signed
North Carolina General Statue 143-215.6 (b)(2) provides that Any person who knowingly makes any false statement representation, or certification in any application, record, report, plan, or other
document files or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowingly
renders inaccurate any recording or monitoring device or method required to be operated or maintained under Article 21 or regulations of the Environmental Management Commission implementing
that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed 510,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by
a fine or not more than $10,000 or imprisonment not more than 5 years, or both, for a similar offense.)
1 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
SECTION H. BASIC DISCHARGE DESCRIPTION
Complete this section for each discharge from the facility to surface waters.
SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE REQUIRED EVEN IF SEVERAL DISCHARGES ORIGINATE IN THE SAME FACILITY.
All values for an existing discharge should be representative of the twelve previous months of operation. If this is a proposed discharge, values should
reflect best engineering estimates.
1. Outfall Number 003 and Type Non —contact cooling water
Give the nature of the discharge (process water, non -contact cooling water, etc.)
2. Discharge To End Date:
If the discharge is scheduled to be discontinued within the next 5 years, give the date (or best estimate) the discharge will end.
NA
3. Discharge Receiving Stream Name: Davidson River
Give the name of the waterway (at the point of discharge) by which it is usually designated on published maps of the area. If the discharge is to
an unnamed tributary, so state and give the name of the first body of water fed by that tributary which is named on the map, e.g., UT to McIntire
Creek, where McIntire Creek is the first water way that is named on the map and is reached by the discharge.
4. Discharge Type and Occurrence
a. - - Check whether the discharge is continuous or intermittent. If the discharge is intermittent, describe the frequency of discharge
El Continuous Intermittent Frequency:
b. Enter the average number of days per week (during periods of discharge) this discharge occurs.
365 days per week
5. Water Treatment Additives
Complete the table below if this outfall:
• discharges cooling and/or steam water generation
• water treatment additives are used (any conditioner, inhibitor, or algicide)
• does not have whole -effluent toxicity testing required
Additive
Manufacturer
Quantity
(pounds added per million
gallons of water treated)
Chemical Composition
(active ingredient(s))
Cationic Coagulant
Nalco 8158
1.25
Polyaluminum Chlox
ide
2 of 4

NPDES Application Form - Standard Form C
Major Manufacturing or Commercial Facilities
OUTFALL NUMBER Cl-)
6. Wastewater Characteristics
Check the box beside each constituent present in the effluent (discharge water).
This determination is to be based on actual analytical data or best estimate (for proposed discharges).
Parameter
Present .
Parameter
Present
Color —
00080
Copper 01042
Ammonia
00610
Iron ' 01045
•
Organic nitrogen
00605
Lead 01051
Nitrate
00620
•
Magnesium 00927 ,
Nitrite
00615
•
Manganese • 01055
Phosphorus
-Sulfate
00665
Mercury 71900
00945
Molybdenum 01062
Sulfide •
. 00745
Nickel 01067
Sulfite
00740
Selenium . 01147
Bromide
71870
Silver 01077
Chloride
00940
Potassium 00937
Cyanide
00720
Sodium 00929
Fluoride
00951
Thallium 01059
Aluminum
01105
Titanium 01152
Antimony
01097
Tin 01102
Arsenic
01002
Zinc 01092
Beryllium
01012
Algicides* 74051
Barium
01007
Chlorinated organic compounds* 74052
Boron
01022
Pesticides* 74053
Cadmium
01027
.0i1 and grease 00550
Calcium
00916
•
Phenols 32730
Cobalt
01037
Surfactants 38260
Chromium
01034
Chloride 50060
Fecal coliform
74055
Radioactivity 74050
3 of 4

NPDES Application Form — Standard Form C
Major Manufacturing or Commercial Facilities
7. Supplemental Documentation
Submit the following information appended at the end of this application form. All sheets should be approximately letter size with
margins suitable for filing and binding. All pages should include facility location and permit number (if available).
`a Present Operating Status: Provide a narrative description of installed wastewater treatment components
at the facility. Include sizes & capacities for each component.
Al Potential Facility Changes: Provide a narrative description of any planned upgrades / expansions /
repairs planned for the facility during the next five years. Do not include tasks associated with routine
operation & maintenance.
:81 Schematic of wastewater flow: Provide a line drawing of water flow through the facility. The schematic
should show flow volumes at all points in the treatment process. Specific treatment components should
be identified.
Location map: Submit a map showing the location of each outfall. The usual meridian arrow showing
north as well as the map scale must be shown. On all maps of rivers, the direction of the current is to be
indicted by an arrow. All outfalls should be identified with the outfall number(s) used in Section II of this
application. A copy of the relevant portion of a USGS topographic map is preferred.
C3 Production Data: Submit the last 3 years' production data for the facility. Where applicable, use units
specified in the appropriate subpart of 40 CFR.
Priority Pollutant Analysis: Industrial facilities classified as Primary Industries (see Appendix A to Title 40
of the Code of Federal Regulations, _Part 122) must submit a Priority Pollutant Analysis (PPA) in
accordance with 40 CFR Part 122.21. If the PPA is not completed within one week of the due date for
the permit application, submit the application package without the PPA. Submit the PPA as soon as.
possible after it is completed.
4 of 4

Present Operating Status of Outfall 003
This discharge receives non -contact cooling water generated during the manufacture of fine paper and
storm water.

•stir r. j Apr •Y
'A' r -�liyr •'r:f` yr'�� r 'r'��r
�7 f . f�fY rirofpx�
.7' •
vJ�n !u�„!?.',ry%:.''<:5'rirr::r: •r:>rrrr::::::: ,�;:'::':•,;::::v .::...:• ,•t..!f'
iiF f%lr:
+•iJ:i
'.�ks��'_:'W. _ _.=r�iiirre r ...r :f tff.. "•/,�.' _ __ __ __� ..._
i:1;�4` �: 3 ,.".u�;,•.' .' �r' xrr jv i'i.•:•.:•r.Gr :.:i':'.:r>:<i <r:'•rr':%:.,}{:X..
ri:..v�rr:..r�.r�:::.::.Yr.Gr.G:: /..::,•. :•:,:::::: u::.r.� r..:: .. ..
There are no planned upgrades, expansions, or repairs that would affect outfall 003

Schematic of Water Flow
I
Boiler Feed Water
0.9 MGD
Discharge
No. 002
Davidson
River 1.99 MGD
I
Potable Water
0.082 MGD
Leachate
Landfill
0.012 MGD
Primary
Treatment
17.188 MGD
i
Process
Water
16.206 MGD
Secodary
Treatment
ASB
MGD
Discharge 001
French Broad
River
17.2 MGD

311CCUsta a division of P. H. GLATFELTER CO.
P.O. BOX 200 . PISGAH FOREST, NORTH CAROLINA 28768-0200
TELEPHONE [phone]
R. J. GUSSMAN
Director, Environmental Affairs
Tel. [phone]
Fax [phone]
June 7, 1999
Mr. T. Stevens, Director
Division of Water Quality
Department of Environment and Natural Resources
P. O. Box 29535
Raleigh, NC '27626-0535
Dear Mr. Stevens:
Subject: Signature Authority
Attached is a written authorization effective July 12, .1999 appointing
Mr. D. M. Cody, Director of the Environmental Affairs Department of the
Ecusta Division of the P. H. Glatfelter Company, as a duly authorized
representative to sign and certify all reports and other information
requested by you as your representative. This delegation is made by
Mr. R. S. Lawrence, Vice President and General Manager of the Ecusta
Division.
Sincerely,
R. J. Gussman, Director
Environmental Affairs
RJG:ls
Enclosure
cc: F. Westall
C. L. Missimer
D. M. Cody

INTER -OFFICE MEMO
ECUSTA
a division of P.S. Glatfelter Company
To: D. M. Cody
From: R. S. Lawrence
Subject: SIGNATORY REQUIREMENTS
Date: April23, 1999
Copy to:
By this memo, you as Environmental Affairs Director as of July 12, 1999, are
appointed as a duly authorized representative to sign and certify all reports and
information required to be submitted to the Department of Environmental and
Natural Resources or other regulatory agency.
Vice President and General Manager
RSL:ls

Operating Plan for Sludge Landfill
Attached is the approved operating plan for the Sludge Landfill. (Permit No. WQ0013419) P. H. Glatfelter
owns and operates this mono -fill using a contractor to haul and place the sludge.

OPERATING PLAN
FOR
SLUDGE LANDFILL
ECUSTA
(A DIVISION OF P.H. GLATFELTER, CO.)
PISGAH FOREST, NORTH CAROLINA
December 1993
CRRIN
: SEAL :
No.17543
crw�• � o ;
,,?FNT WV55,.
.,.nun►►`
f. RMT, INC. — GREENVILLE, SC
or C. Jones P.E.
ject Engineer
R`Rent Nilsson, P.E.
Senior Geotechnical Engineer
100 VERDAE BOULEVARD - 29607-3825
INC. 100
Box 16778 — 29606-6778
803/281.0030 — 803/281-0288 FAX

LANDFILL OPERATING PLAN DECEMBER 1993
P.H. GLATFELTER CO. - PISGAH FOREST, NC SECTION 1
Section 1
INTRODUCTION
1.1 General Information
This Site Operating Plan (SOP) describes the filling sequences and procedures for de -watered primary
sludge placement in the landfill operated at the P. H. Glatfelter-Ecusta Division (Ecusta) site located in
Pisgah Forest, North Carolina. This plan outlines the daily operations as well as a contingency
operating plan for abnormal conditions. The facility is currently operated by an independent contractor
to Ecusta. Ecusta personnel supervise the performance of the contractor.
1.2 Overview
The overall sludge landfill SOP has been developed around four integral components: a spine dike that
extends the length of the landfill, finger dikes that extend out from the spine dike, surface drainage, and
sludge placement. Each lift of the landfill will be operated and developed in a similar manner.
The waste route within the landfill will utilize the existing east -west spine dike and the finger dikes that
extend to the north and south of the spine dike. These dikes will be maintained as necessary to
provide a stable access road for the sludge hauling vehicles.
Sludge will be placed so that surface drainage is encouraged to flow to the north and south sides of the
landfill along the finger dikes. Surface drainage will be routed to the lower portion of the landfill through
surface water channels, constructed and maintained on either side of the landfill. Surface water from
the landfill will be removed to the mill wastewater treatment system through the existing drains at the
lower, northwest end of the landfill and along the existing dam.
I:1W P181816070P. PI.Nlcdf93
1-1

LANDFILL OPERATING PLAN DECEMBER 1993
P.H. GLATFELTER CO. - PISGAH FOREST, NC SECTION 2
Section 2
LANDFILL DEVELOPMENT
2.1 initial Site Development
Because stability of the sludge is highly dependent upon drainage, the sludge landfill must be prepared
initially to manage surface storm water runoff. This will be accomplished by excavating and
constructing channels on the north and south sides of the spine dike as shown in Figure 2-1. Due to
the steep slope of the landfill grade, erosion protection must be included in the channel. In addition,
runoff from the sludge is expected to contain a high concentration of suspended sludge fibers. A series
of silt fences will be placed and maintained in the side drainage channels to assist in removing the
suspended fibers before they enter the drainage system at the lower end of the landfill.
During operation of the sludge landfill, these silt fences will be inspected after each storm event and
replaced or cleaned as necessary. Experience has found that runoff from the landfill can deposit
suspended fibers on filter materials in the drainage system which can form a low permeability cake. If
left unchecked, this low permeability cake could partially or completely impede water flow. Therefore,
regular replacement or cleaning of the silt fence should occur to ensure a minimum of 75 percent of the
area of the individual silt fences are clear and free -draining. This may require that the silt fence be
replaced or cleaned as often as after each storm event. Inspection of the silt fences will also include
the existing drainage structures to ensure that maximum flow capacity is maintained.
2.2 General Daily Operations
The landfill will be developed in lifts 2 to 4 feet in thickness. Each lift will be built up until it becomes
necessary to modify the access dikes. The filling sequence and general operations will be similar for
each lift of the landfill. The following aspects of daily operations are critical to effective development of
the site:
Compacting the sludge to maximize sludge storage and the capacity of the landfill. (A
unit weight of 20 pounds per cubic foot [pcf] is typical of unit weights found in the test
cell).
Removing trapped surface water by placing additional waste materials, ditching,
pumping, or using other appropriate methods to prevent saturation of in -place sludge.
I AW P 18181607OP. P L W cdf 93
2-1

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the outcome of initial observations. The number and location of the monitoring devices will be
determined in the field by the geotechnical engineer. It is anticipated that readings of the
settlement plates and survey monuments will be taken immediately after construction and
thereafter at 6 month intervals or as determined by the geotechnical engineer.
i
RMT, Inc.
PR. Glatfelter
November 1996

LANDFILL OPERATING PLAN
P.H. GLATFELTER CO. - PISGAH FOREST, NC
DECEMBER 1993
SECTION 2
Maintaining the drainage channels on the north and south sides of the landfill and the
associated silt fences.
Placing the sludge to encourage drainage to the side channels. (This includes sloping
the surface of the sludge toward the channels and angling the leading edge of waste
downslope.)
Daily operations are summarized in Table 2-1.
TABLE 2-1
DAILY SLUDGE PLACEMENT OPERATIONS
• Promote surface drainage by sloping the sludge surface to the landfill sides (north
and south).
• Construct finger dikes off the spine dike as necessary for sludge placement.
• Maintain side drainage channels, drainage structures, and silt fences.
• Remove trapped or ponded surface water by placing additional waste materials,
ditching, pumping, or using other appropriate methods to prevent saturation of in -
place sludge.
• Place sludge in 6 to 8 inch lifts.
• Compact sludge during placement by successive passes of the dozer.
• Raise and maintain spine dike as required for placement of the sludge. to flee'
• Construct a new spine dike as necessary for access to the landfill surface.
2.2.1 Access Roads
The existing access road from the dam on the west side of the landfill will be used as an
all-weather access road. The existing spine dike, the existing finger dike, and any new finger
dikes will be maintained as all-weather access roads when they are needed for sludge
placement. As the elevation of the sludge rises in the landfill, the spine and finger dikes will be
raised to facilitate access to the higher elevations by placing a layer of biaxial geogrid over the
existing spine dike. The geogrid should extend a minimum of 4 feet beyond either edge of the
I:1W P18181607OP. PLNlcdf 93
2-3

EXISTING ROAD
2210
2200
2190
ENSTING GRADE
EXISTING SUJDGE.LANDFEL
r-0 HIGH X 15' WIDE DKE
TYPICAL EACH UFT
LFTS Z-4LIFTS
PERNETER DRAINAGE DITCH • • -
WEI, EROSION CONTROL FABRIC
ANCHORED IN ACCORDANCE WITH
THE MANUIRCTUREFTS
RECOMMENDATONEL(TYPCAL)
TYPICAL SECTION THROUGH SUIDGE LANDFILL
1•=50' NORM Ti.tOPVERT.:
5
2220
2210
22LNO
2190
NOTElk
.T..;7-4EitSIDESLOPESSIICIA99/41Eal
2.B.EV�4OWNA5F��OMY
AND ARE Nor WENDED FOR CONSTRUCTION PURPOSES.
3. SECTION IS TAKEN LOOKIIII WET..
..ialaGUIRE2T.1
= AINIARFNIEIV3110.) , .
OdidlOVEINEFL3993
_ProPtIceetellYt
• • -
-ECUSik DRIISION
PISGAH FOREST, ILC.

LANDFILL OPERATING PLAN
P.H. GLATFELTER CO. - PISGAH FOREST, NC
DECEMBER 1993
SECTION 2
existing underlying dike. Then clean sand with 2 (horizontal): 1 (vertical) sideslopes should be
placed. The top of the new dike should be a minimum of 10 feet wide and at least 2 feet thick.
This layer of sand should be protected from traffic wear and erosion by placing 6 inches of clay
or gravel over it (refer to Figure 2-2). Natural clays containing gravel found in the area would
be acceptable for this purpose.
As the elevation of sludge approaches that of the dikes, runoff from the upslope portion of the
landfill may have a tendency to flow over and along the dike, creating the potential for erosion.
This condition will be monitored by the operator and remedied as it occurs by placing more
clean sand on the dike to raise the top elevation or by using other appropriate methods in order
to prevent the dike itself from becoming a drainage path.
2.2.2 Sludge Placement
The sludge material will be placed by back dumping in or near the active cell. The sludge will
then be spread by a dozer into lifts approximately 6 to 8 inches thick. The process of the dozer
spreading the lifts is the only compaction required. However, in order to minimize the number
of passes required to achieve compaction, the ground pressure produced by the equipment
may be optimized. The operator in the field will monitor this process since too much pressure
could cause displacement rather than consolidation of the uncompacted sludge.
Sludge will be placed such that the waste surface slopes toward the north and south perimeter
drainage channels. The landfill will be operated by placing the sludge on the downhill slope of
the landfill and working upward. The leading edge of the sludge should be angled to
encourage runoff along it and the downhill slope. (The opposite sloping would force ponding
next to the spine dike. Refer to Figure 2-3.) Also, the sludge placement will be balanced on
either side of the spine or finger dike. This will provide stability to the dike by providing equal
loading on the dike.
2.2.3 Finger Dikes
Finger dikes will be constructed to extend north and south from the spine dike. These dikes
will be constructed as described in Section 2.2.1. These dikes will be oriented downhill away
from the spine dike. These dikes will also be raised as the sludge increases in elevation. The
1:1W P18181607OP. PLNlcd193
2-4

DIKE
DRAINAGE BLANKE1 _ 5'
TEX-NET TN 3002/1120
1a1V1,
OR EQUAL
2
EXISTING GRADE
5'
DIKE SECTION
--6" THICK STONE
WEARING COURSE
(AS REQUIRED)
2
1
CAt ✓.J
2' THICK CLEAN SAND
FIGURE 2-2
IOWor. APPROVED BY: V.C.J.
DATE: DECEMBER 1993
JOB NO: 816.07
ECUSTA DIVISION
PISGAH FOREST, N.C.

GRADE TO DRAIN
SLUDGE PLACEMENT
z
SLUDGE PLACEMENT
w
a.
0
J
V)
PLAN - SLUDGE PLACEMENT
GRADE TO DRAIN
4'
FIGURE 2-3
me. APPROVED BY: V.C.J.
DATE: DECEMBER 1993
AIM JOB NO: 816.07
ECUSTA DIVISION
PISGAH FOREST, N.C.

LANDFILL OPERATING PLAN DECEMBER 1993
P.H. GLATFELTER CO. - PISGAH FOREST, NC SECTION 2
number and length of the individual finger dikes will be determined in the field by the operator
for convenience and efficiency of sludge placement.
2.3 Construction of Successive Lifts
As the surface of the compacted sludge rises to the level of the access dike, the operator will build up
the access dikes. This will be accomplished by first raising the spine dike, and then constructing finger
dikes as necessary (See Section 2.2.1). A concept of the final cross-section is illustrated in Figure 2-1.
The maximum elevation will be limited in some areas by clearance requirements under the existing
power lines. The slopes indicated on the cross-section are estimated and may be less than what can
be achieved in the field. Important features in Figure 2-1 are as follows:
• The spine dike is constructed on top of the previous spine dike.
• The surface slope is toward the sides (north and south).
• There are drainage channels along the sides of the landfill that require maintenance
and reconstruction as the lifts are created.
I :1W P18181607OP. PL W cdf 93
2-7

Spill Prevention and Control Plan
Permit WQ003419
Primary Sludge Monofill
This Spill Prevention and Control Plan (SPCP) only applies to the residuals (primary
sludge) generated at the primary wastewater treatment plant of the P.H. Glatfelter
Company at Pisgah Forest. It covers the residual storage area at the primary wastewater
treatment plant, residual transportation and the residual disposal area.
Residual Storage Area (Sludge Pad)
This area is located adjacent to the primary wastewater treatment plant. Even though it
can accumulate up to three days of residuals, normally all residuals are removed daily.
All drainage from this area enters the process wastewater treatment plant. After trucks
are loaded with the residuals, any residuals outside the truck are removed. If the
residuals can become airborne, a controlling cover is placed over the residuals.
Residual Transportation (Haul Trucks)
All residuals are transported by truck approximately two miles from the Residual Storage
Area at the wastewater treatment plant to the disposal area. This transportation occurs on
both private and public roads. If any residual falls from the truck to the ground or road
surface, it is the responsibility of the transporter to remove it and clean the area. There is
minimal hazard from these residuals since they are classified as a Class B pathogen and
are non -hazardous according to the TCLP analysis.
Sludge Spill Prevention & Control Plan
It is the responsibility of the transporter to maintain compliance with all applicable
county, state and federal regulations. The current Residual Transportation Contractor is
M&M Grading Contractors, Inc. of Route 1, Box 381, Lake Toxaway NC.
Residual Disposal Area (Sludge Landfill)
The Residual Disposal Area is located on Company -owned land and public access is
restricted. All residuals will be disposed of in the area described in the existing permit
WQ0013419. The method of disposal will follow the operating procedure contained in
the November 1996 "Interim Operating Plan for Sludge Landfill" with amendments.
Any disposal of residuals outside of the permitted area will be removed by the operating
contractor. It is the responsibility of the Residual Transportation Contractor to place all
transported residuals in the permitted area. It is the responsibility of the Residual
Disposal Area Contractor, also M&M Grading Contractors, Inc., to ensure that the
residuals placed in this landfill are placed in such a manner as to ensure compliance with
the 1996 Operating Plan.

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INC.
INTERIM OPERATING PLAN
FOR
SLUDGE LANDFILL
P.H. GLATFELTER COMPANY
ECUSTA DIVISION
PISGAH FOREST, NORTH CAROLINA
November 1996
1(62,9,k;
,���p��ntr��►i
7.,614
E Ken
t nt Nilsson, P.E.
No. 1T5 3 !Senior Geotechnical Engineer
.,�f�`°••••a-••' c� RMT, INC. — GREENVILLE, SC
Sharon Y. rleski
Project Geotechnical Engineer
{
100 VERDAE BOULEVARD - 29607-3825
P.O. Box 16778 - 29606-6778
864/281-0030 - 864/281-0288 FAX
I: \ WP\8\820I202.DOC\CDI56
01996 RMT, Inc.
All Rightc Reserved

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Section
Introduction
1.1 General Information
This Interim Operating Plan describes the construction and filling sequence for vertical
expansion of the P. H. Glatfelter sludge landfill in Pisgah Forest, North Carolina. The facility is
used exclusively for the disposal of dewatered primary sludge generated at the Ecusta Mill.
The landfill is currently operated by an independent contractor to P. El:Glatfelter. P. H.
Glatfelter staff supervise the performance of the contractor.
•
1.2 Overview
The existing landfill site covers an area of about 16 acres. It is located in a long, deep ravine
adjacent to the easternmost portion of the mill Aerated Stabilization Basin (ASB). The landfill
was created by building an earthen retention dam across the mouth of the ravine. This dam is
about 70 feet high in the center of the ravine. Sludge leachate and contact runoff are
transported by gravity flow to a culvert that runs down the interior face and through the dam
into the ASB.
Dewatered sludge, composed primarily of cellulose fiber and calcium carbonate, generated by
production of pulp and paper is disposed of in the landfill Sludge is hauled to the landfill in
trucks. It is end -dumped from the trucks into the landfill from staging areas located along the
upper perimeter road on the north side of the landfill. When the sludge is fresh it can be
shaped and bladed with a low -ground -pressure bulldozer. After a period of a few days,
however, the sludge weakens and the working face will slough. The sludge is allowed to
migrate down slope toward the dam. Existing conditions are shown on Drawing S-1618-E1.
The design of the proposed sludge landfill modifications is based upon providing additional.
freeboard at the existing dam and improving surface and subsurface drainage of the sludge.
Improved sludge drainage will enhance its stability and allow it to be more easily shaped to
final closure contours. The modifications will assist in significantly extending the life of the
landfill.
Operation of the landfill will include the vertical expansion of the existing dam using geogrid
reinforcement, granular drainage blankets,' geotextiles, and imported earth fill. The interior
access road will also be upgraded. In addition to expanding the dam and upgrading the
interior access road, operations will address waste placement and monitoring. The first stage
RMT, Inc.
IAWP\8\8W120 .noc\cnF96
1
P.H. Glatfelter
November 1996

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of vertical expansion will be 10 feet above the sludge surface. The performance of the first
stage of vertical expansion will be monitored and evaluated prior to the additional vertical
expansion. This will be done not only to confirm that the waste material and drainage system
are performing as predicted, but also to provide information. for making modifications to the
design that will enhance the performance of future stages of vertical expansion. The operating
plan may also be modified depending on the evaluation of the first stage of the dike expansion.
RMT, Inc. 2 P.H. Glatfelter
lAWMI Aami2z.voc1ca7'3s November 1996

� Section 2
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Vertical Expansion of Existing Dam.
The first stage of vertical expansion will include raising the dam on the south side of the site.
To create a more uniform platform on which to construct the vertical expansion, the area
adjacent to the existing dam will be filled in with sludge as shown on Drawing S-1618-E2. The
sludge used to fill in the area adjacent to the dam will be end -dumped from the interior access
road and pushed toward the dam to the base grade of the first expansion dike. Therefore, the
first step will be to upgrade the interior access road as indicated on Drawing S-1618-E1 with a
6-inch layer of crushed stone.
A stable working surface on top of the sludge adjacent to the existing dam will be constructed
of synthetic geogrid and freely draining granular fill. The geogrid will provide accessibility for
construction of the granular fill drainage layer. Tensar BX 1200 biaxial geogrid reinforcement
will be rolled out from the dam across the sludge. The geogrid will extend 15 feet beyond the.
footprint area of the new dike and drainage layer as indicated on the drawings. The geogrid
will be overlapped approximately 3 feet along the common edge and where anchored into the
edge of the dam. It will be anchored at least 5 feet into the dam as shown on Drawing
S-1618-E2.
The freely draining granular fill will be end -dumped onto the top of the dam. It will be pushed
on to the adjacent geogrid by means of a low -ground -pressure bulldozer (D-4 Caterpillar with
36-inch wide tracks). Equipment will not bear directly on the geogrid itself. The granular fill
will be spread out over the geogrid in lifts at least 1.0 foot thick, but no more than 3 feet thick
The thickness required to distribute the load of the bulldozer will be governed by the strength
of the underlying sludge. It will be pushed out over the geogrid in intermittent sections or
finger dikes extending perpendicular from the dam. This construction technique has been
utilized as an effective way to minimize the mud wave effect, often associated with this type of
construction. Once the intermittent, granular fill, finger dikes have been placed, granular fill
can be spread out over the geogrid between the granular finger dikes. These recommendations
are based on RMT's previous experience with building on sludge.
The freely draining granular Layer will be at least 2 feet thick. It wall function as drainage layer
to convey leachate and contact runoff. It will be hydraulically connected to the drainage
blanket that will extend up the interior side slope of the new dike and the existing leachate
collection drainage system. This reinforced layer will also provide accessibility and a relatively
RMT, Inc.. 3 P.H. Glatfelter
L`WP`8`8207OC`mE96 November 1996

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firm working surface for construction of the initial lift of new dike construction on the sludge
surface.
Prior to construction of the new dike, a layer of geotextile will be placed over the freely -
draining granular drainage layer. This will prevent fine-grained soil used in the construction
of the new dike from migrating into the drainage layer and dogging it.
The new dike will extend 10 feet above the sludge surface. This dike will have 3 (horizontal) :
1 (vertical) interior and exterior side slopes. It will have a minimum crest width of .15 feet. The
borrow source, located on P. H. Glatfelter's former property across Ecusta Road from the mill,
is suitable for use as fill for dike construction. However, oversized (> 3 inches) pieces of rock
that do not break downwith conventional construction equipment will have to be removed
prior to compaction. If the percentage of fine-grained material falls below 30 percent, the soil
may have to be blended with soil containing more fine-grained soil or an alternate borrow area
maybe used.
The new dike will be constructed by placing successive horizontal layers for the full width of
the fill. Each lift will have a loose depth of 8 inches or less and be compacted with appropriate
compaction equipment. Each lift of soil will be compacted to at least 95 percent of the Standard
Proctor (ASTM D 698) maximum dry density at ± 3 percent of the optimum moisture content
Each lift will be constructed at least 2 feet beyond the slope line and cut back to line and grade
after completion. Each layer shall be spread uniformly on a prepared surface, i.e., a soil surface
that has been moistened and aerated as necessary to maintain the specified moisture content
and scarified, or otherwise broken up in such a manner that the fill .will bond with the surface
on which it is being placed.
Qualified geotechnical personnel will monitor the placement and test the compaction of the
new dike fill soil to verify that the recommended compaction has been attained.
It is anticipated that the expansion dike will undergo settlement on the order of 3 to 5 feet.
This settlement may cause tension cracking at the "hinge" connection where the new dike is
connected to the existing dam. Cracks at this location should be repaired to remove any
preferential pathway for the flow of leachate. The soil at that location may be restored by
removal to the granular layer and then recompacting.
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RMT, Inc. 4
k\ WAS\s201202.DOCIGD796
P.H. Glatfelter
November 1996

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Section 3
Leachate Collection System
Leachate will be collected within the granular drainage layer. This layer will convey the
leachate to the 48-inch diameter perforated corrugated metal pipe connected to the 48-inch
diameter reinforced concrete pipe where it will flow down the interior face and through the
existing dam into the ASB. Storm water that comes in contact with the waste will also be
treated as leachate and handled in the same manner. As the waste consolidates and dewaters
under the surcharge, the freely draining granular fill will also function as a drainage layer for
the existing waste beneath the new dike. It will also convey leachate from additional sludge
and contact runoff. It will be important that uninterrupted drainage be provided from the
sludge surface to the granular drainage layer. Storm water flowing off the surface should be
able to exit directly into the drainage layer without having to pass through a layer of sludge or
other material. This may require periodic maintenance of the drainage blanket to remove any
solids that have been deposited. Typically, maintenance would include scarifying the surface
of the granular drainage blanket with the teeth of a backhoe bucket or similar equipment.
RMT, Inc. 5 P.H. Glatfelter
kwuvooncopomas96 November 1996

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Section 4.
Daily Operations
Proper daily operations are necessary to maximize surface water removaL The daily
operations critical in managing the development of the site are summarized in Table 1.
Table 1
Daily Sludge Placement Operations
1.
Continue to place sludge from the uphill end of the landfill (north side).
2.
Compact sludge during placement by successive passes of the dozer.
3.
Promote surface drainage by sloping the sludge surface to the landfill sides and
angling the leading edge of water downslope. •
4.
To avoid obstruction of the drainage layer, sludge or waste material should not
be dumped into the landfill from the newly constructed dike.
5.
If the granular drainage blanket along the newly constructed dike becomes
dogged or covered with sludge, take immediate action to remove the material
dogging the drainage blanket and restore the freely draining property of the
drainage blanket.
6.
Maintain side drainage channels and drainage structures.
7.
Remove trapped or ponded surface water by placing additional waste
materials, ditching, pumping, or using other appropriate methods to prevent
saturation of in -place sludge.
4.1 Waste Placement
Placement of the sludge is to be accomplished by end -dumping from the upper (north) end of
the landfill. The sludge will be allowed to migrate toward the newly constructed dike as the
sludge undergoes drainage and consolidation. The operator will continue to shape the sludge
to promote efficient drainage.
4.2 Monitoring'
The new dikes and the existing dam will be monitored to evaluate the performance of the
vertical expansion. Monitoring will include periodic visual inspections and the use of
settlement plates and survey monumentsthat will be used to track any lateral or vertical
displacements. This monitoring may be later upgraded to include the use of slope
inclinometers or other devices to assist in evaluating the dike performance, depending upon
i
RMT, Inc.
P.H. GlatfeIter
November 1996

400
•
ROVN No. 2 ASH LANDFILL
last
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VERTICAL EXPANSION
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1°ai MAqP PPP POPP
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SLUDGE LANDFILL
VERTICAL EXPANSIIH
PISGAH rOREST, NORTH CAROL INA
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041.11 II.
16-
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NOTE 5> x2lBil
x21812 1
NOTES
%
I. EXISTING TOPOGRAPHY OTFORNATOIN VAS TAKEN
FROM A SURVEY PREPARED BY HA8PION, HINTZ t
ASSOCIATES. INC. AND PROVIDED BY ECUSTA DIVISION
JANUARY, 1995.
2. ELEVATIONS SHOW ARE IN FEET AND ARE BASED Di
MEAN SEA LEVEL <MSL) DATUM.
3. LOCATION OF NEW PIPING SHALL BE DETERMINED IN
THE FIELDPIPE SHALL BE FOUNDED IN EARTH FILL
OR NATURAL GROUND.
4. ALL CORRUGATED METAL PEPE ICMP) SHALL BE 16 GA
WITH REROLLEO ENDS AND ANNULAR CON4tCTING
BANDS CONFORMING TO MSHTO M-36. PERFORATIONS
(UNLESS NOTED OTHERWISE) SHALL LE 3/8 • DIA. ..
6' DC., E.W. ALL PIPE SHALL BE ASPHALT COATED.
5. FILTER FABRIC SURROUNDING THE EXISTING DRAINAGE
STRUCTN
FILTER BL SWILL BE REMOVED AND THE STONE
FILTER BLANKET REST[RED.
6. REMOVE SEGMENTS OF EXISTING 48' DIA. CONCRETE
PIPE TO DRAIN POMO VATER ADJACENT TO DAM.
REPLACE WITH 48' DIA. PERFORATED CHP. AND
SURROUND WITH CRUSHED STONE.
f
0 50 100 150 200
N 3500
DETAIL A
p
-�..r= --;
, ,, ."+r
LEGEND
i
'
NEW EXIST.
��i 1
/
DIP O
CONTOUR
SPOT ELEV. X 21872
^^'�
TREE LINE
ROAD 11
GRAVEL/
STONE i0
1111111�
���, /��
�r `
It�\
1��11,
,��'
,10
�,:lik`
•1`�
1 '
/
L7 218L9
X • �'
NEW BITCH, CLEAN A" it �
REOUIRED TO
CONTINLOUS FLOW i • NTREE �•
A0
y /
SLUDGE
SCALE. l' . 50'
_
P.H. GLATFELTER-ECUSTA MILL
LANDFILL DRAINAGE SYSTEM RESTORATION
SITE/PIPING PLAN
FIGURE 1
1•3'
��.' /
'Itr
/ 91( /7ALL WEATHER ROAD
Drown By. MDV
Approved Byi RKN
Eta te.SEPTEMBER 1996
pro.). No.. 82012.02
R-739-83

F9/18lle: t<:\cad\civil \ecusta\8201202c\nlsc.det
/96
r12' (NIN.) ND 57 CRUSHED STONE 2'-0'
2
PERFORATED
EXIST. Imo_ '
�. •
12' DIA. RUT
CORRUGATED METAL PIPE WELL GRADED GRANOLA•
GRADE
SEE NOTE 4 ON rm. Il2'(M1N)
MATERIAL (ASTM C-33H
'?'\' C,'?, Y' \�,\,�l),@,'�,;i U'",c °i,'p.'"iF,\;�
\�.,./:k ., IA' �.ra u. L
SECTION 0
COMPACTED 114 YE THOROUGHLY
'-6' tMIN> III 57 CRUSHED STONE COMPACTED IN LAYERS
NOT EXCEEDING 6'
NTS
MY
s
a MIN.
1/4 ' THK. PERFER D
ALUMINUM PLATE
6'
12' DIA FULLY PERFORATE:
CORRUGATED METAL PIPE
SCE NOTE 4 ON FIG I BEDDING
FUTURE N1S
SLUDGE
4:' ,a APPROVED FILL MATERIAL
EXIST! COMPACTED TO 957. OF
SLUDGE --^ �` STANDARD PROCTOR MAX. DRY DENSITY
EXSTN RAT.
• �,\,,
- _- SLOPE AS REQUIRED TO
`
\
Q r MAINTAIN STABILITY OF
\�\�w�^
r A� = ?'S' TRENCH SIDEWALL OR
TO
PROVIDE SHEETING
`Y INSURE SAFETY OF PERSONNEL
EXIST
GRADE SECTION © =;i
AND PROTECT ADJACENT
NTS
NENEIy
_
�
STRUCTURES
SEE BEDDING DETAIL
12' 5MI CRUSHEDVERSiX SffHQQgT EXACT LOCATION TO BE TRENCH
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'''' r'' SECTIONS AND DETAILS
Drown By: NOV
Mk SECTION
Approved By:RKN
VIEFF NTS
Da te+SEPTEMBER 1996
ProJ No., 82012.02
R-739-B4

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