NC0004405_Permit (Issuance)_20040716

NPDES DOCUHENT SCANNING COVER SHEET
NC0004405
l:.
NPDES Permit:
Document Type:,^
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Correspondence
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
July 16, 2004
This document is printed on reuse paper - igxore airy
content on the reYerse side

�C'AN A TE94
`r,
irwv�—{
Arthur Toompas
Corporate Environmental Manager
Cone Textile Group
2420 Fairview Street
Greensboro, North Carolina 27405
Dear Mr. Toompas:
Michael F. Easley
Governor
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
July 16, 2004
Subject: Issuance of NPDES Permit
Permit No. NC0004405
Cliffside Plant WWTP
Rutherford County
Division personnel have reviewed and approved your application for renewal of the
subject permit. Accordingly, we are forwarding the attached NPDES discharge permit. This
permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1
and the Memorandum of Agreement between North Carolina and the U.S. Environmental
Protection Agency dated May 9, 1994 (or as subsequently amended).
If any parts, measurement frequencies or sampling requirements contained in this
permit are unacceptable to you, you have the right to an adjudicatory hearing upon written
request within thirty (30) days following receipt of this letter. This request must be in the form
of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and
filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh, North
Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The
Division may require modification or revocation and reissuance of the permit. This permit
does not affect the legal requirements to obtain other permits which may be required by the
Division of Water Quality or permits required by the Division of Land Resources, the Coastal
Area Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Teresa Rodriguez at
telephone number [phone], extension 553.
Sincerely
ORIGINAL SIGNED BY
Tom Belnick
Alan W. Klimek, P.E.
Cc: NPDES Files
U.S. EPA Region 4
Asheville Regional Office
Aquatic Toxicology Unit
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Visit us on the INTERNET © www.enr.state.nc.us

Permit NC0004405
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
Cone Mills Corporation
is hereby authorized to discharge wastewater from a facility located at the
Cliffside Plant
US Highway 221-A and NCSR 1003
Cliffside
Rutherford County
to receiving waters designated as Second Broad River in the Broad River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set
forth in Parts I, II, III and IV hereof.
This permit shall become effective September 1, 2004.
This permit and authorization to discharge shall expire at midnight on July 31, 2008.
Signed this day July 16, 2004.
ORIGINAL SIGNED BY
Tom Belnick
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0004405
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
Cone Mills Corporation
is hereby authorized to:
1. Continue to operate an existing 1.75 MGD wastewater treatment plant consisting of:
• Pump station and bar screen
• Extended aeration basin
• Dual final clarification
• Aqua disk filter
• Chlorination, effluent reaeration, and dechlorination
• Sludge storage tank
The facility is located at the US Highway 221-A and NCSR 1003, Cliffside, Rutherford
County.
2. Discharge wastewater from said treatment works at the location specified on the
attached map into the Second Broad River which is classified C waters in the Broad
River Basin.

35° 13' 59" N
81°45'59"W
Broad River
03-08-02

Permit NC0004405
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until expiration, the
Permittee is authorized to discharge from outfall 001. Such discharges shall be limited and monitored
by the Permittee as specified below:
E 'FI U T
CHARACTE R/ST CS
Limits
11 onite g tequ lreknentS
Monthly
e 'i
= Daily
1Vleasuremeat
picequ Frequency
e
Sample Type
Sample.:
Locattionl
Flow
1.75 MGD
Continuous
Recording
I or E
BOD, 5-day (20°C)
1,080 lbs/day
2,460 lbs/day
3/Week
Composite
E
COD
13,576 lbs/day
31,746 lbs/day
3/Week
Composite
E
Total Suspended Solids
2,745 lbs/day
6,329 lbs/day
3/Week
Composite
E
Fecal Coliform (geometric
mean)
200/100 ml
400/100 ml
3/Week
Grab
E
Total Residual Chlorine
28 jag/L
3/Week
Grab
E
Temperature
3/Week
Grab
E
Total Nitrogen
Quarterly
Composite
E
Total Phosphorus
Quarterly
Composite
E
pH3
3/Week
Grab
E
Sulfide
22.8 Ibs/day
52.8 lbs/day
Weekly
Grab
E
Phenols
28.1 lbs/day
45 lbs/day
Weekly
Grab
E
Total Chromium
28.1 lbs/day
45 lbs/day
Weekly
Composite
E
Total Copper
2/Month
Composite
E
Total Zinc
2/Month
Composite
E
Chronic Toxicity4 •
Quarterly
Composite
E
Notes:
1. Sample Locations: E- Effluent, I- Influent
2. For a given wastewater sample, TN = TKN + NO3-N + NO2-N, where TN is total nitrogen, TKN is total
Kjeldahl Nitrogen, and NO3-N and NO2-N are nitrate and nitrite nitrogen, respectively.
3. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4. Chronic toxicity (Ceriodaphnia) P/F at 4.2 %; January, April, July and October.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0004405
A. (2.) CHRONIC TOXICITY PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 4.2 %.
The permit holder shall perform at a minimum, quarterlu monitoring using test procedures outlined in
the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. Effluent sampling for this testing shall be performed at the NPDES
permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter
code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT-3
(original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later
than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate
signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name, permit number, pipe number, county, and the month/year of the
report with the notation of "No Flow" in the comment area of the form. The report shall be submitted
to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
monitoring will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-
opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls,
shall constitute an invalid test and will require immediate follow-up testing to be completed no later
than the last day of the month following the month of the initial monitoring.

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0004405
Facility Information
Applicant/Facility Name:
Cone Mills Corp.— Cliffside Plant
Applicant Address:
2420 Fairview Street, Greensboro, NC 27405
Facility Address: i
272 Old Main Street, Cliffside, NC 28024
Permitted Flow (MGD):
1.75
Type of Waste:
97 % Industrial, 3% Domestic
Facility Classification:
III
Permit Status:
Renewal
County:
Rutherford
Miscellaneous
Receiving Stream:
Second Broad River
Regional Office:
ARO
Stream Classification:
C
State Grid / USGS Quad:
Chesnee
303(d) Listed?
No
Permit Writer:
Teresa Rodriguez
Basin/Subbasin:
030802
Date:
5/3/04
Drainage Area (mi2):
219.6
.. 4 . _. .
=`'i
81 ° 45' 59" W
. ' "
= ° @ ,. �'
BF
Lat. 35° 13' 59" N Long.
Summer 7Q10 (cfs)
62.1
Winter 7Q10 (cfs):
91.2
30Q2 (cfs)
Average Flow (cfs):
312
IWC (%):
4.2
Summary: Cone Mills Corp. is a specialty textile manufacturer. The Cliffside Plant manufactures denims and
jacquards fabrics. The manufacturing operations include yarn manufacturing, slashing, dyeing and weaving.
The Packaging and Dyehouse operations are no longer in use.
Facility Description: Domestic waste from 105 residential and commercial connections (approximately
52,500 gpd) is treated at the Cone Mills WWTP. All process wastewaters from the manufacturing process go
to the wastewater treatment plant. The WWTP is located approximately 1.5 miles from the manufacturing site.
The treatment system consists of a pump station and bar screen, extended aeration basin with 13 mechanical
aerators, two final clarifiers, three Aqua Disk Filters, tablet chlorination and dechiorination and post -aeration
tank. A color removal system is installed but not in use because it caused toxicity problems in the effluent.
Basin Plan: The area in the Second Broad River were the discharge is located was not sampled for the
current basin plan report. In general the Second Broad River is classified as Good -Fair in this sub -basin.
DMR Review: DMR data was reviewed for the period of January 2002 to December 2003. Average flow was
0.465 MGD. BOD averaged 31.53 Ibs/day, COD averaged 439.19 Ibs/day, and TSS averaged 174.56 Ibs/day.
Chronic Toxicity test (Ceriodaphnia) is performed at 4.2 % on a quarterly basis. They had failures in January
and February of 2000 and January 2001. These failures were attributed to a polymer used for color removal.
They stopped using the polymer and haven't had any more failures on toxicity.
Pollutant Scan: A pollutant scan was submitted with the permit application. The following parameters were
detected in concentrations less than designated criteria or allowable concentrations: bromodichloromethane,
chloroform, and bis(2-ethylexyl) phthalate.
Fact Sheet
NPDES NC0004405
Renewal
Page 1

Reasonable Potential Analysis: Reasonable potential analysis was performed for the following parameters:
Parameter
Maximum
Predicted
(pg/I)
Allowable
concentration
(pg/I)
1/2 FAV
(pg/I)
Comments
Arsenic
1195 pg/I
N/A
Results for the past two years
were < 10 pg/I. Eliminate
monitoring.
Total Chromium
10.5 pg/I
1195 pg/I
N/A
Change to production based limit
Copper
58.1 pg/I
167pg/I
7 pg/I
Continue monitoring 2/mth
Mercury
0.3 pg/I
N/A
Results for the past two years
were < 0.2 pg/l. Eliminate
monitoring.
Nickel
18.6 pg/I
2103 pg/I
261 pg/I
Eliminate monitoring
Zinc
665 pg/I
1195 pg/I
67 pg/I
Continue monitoring 2/mth
Chlorides
1372800 pg/I
5495622 pg/I
N/A.
Eliminate monitoring
PERMITTING STRATEGY/LIMITS DEVELOPMENT
Federal guidelines were used to calculate permit limits for BOD, COD, TSS, sulfides, chromium and phenol.
The applicable effluent guidelines are 40 CFR 410 Subpart D — Woven Fabric Finishing Subcategory for
finishing of denim and jaquards and Subpart G — Stock and Yarn Finishing Subcategory for yarn preparation
and dyeing. See the attached spreadsheet with the limits calculations. Long term production was estimated
as 255841 Ibs/day based on production for 2001 — 2003. Calculated limits were higher than actual limits. The
facility is meeting the current limits. The limits will remain as in the previous permit except for phenol.
When the permit was renewed in 1991 a classification of WS-III was used for the discharge location. The limit
for Phenol was calculated using the standard of 1 pg/I for WS waters. The actual classification of the Second
Broad River at the discharge location is C. The discharge is 1/2 mile downstream from the former water supply
for Cone Mills, which has been transferred to the Sanitary District and is not in use any more, although the WS
classification remains for that segment of the river. The limit of 23 pg/I for phenol is not applicable since the
classification at the discharge location is not WS-III. The proposed limits for phenol are 28.1 Ibs/day as a
monthly average and 45 Ibs/day as a daily maximum. These limits were calculated using the applicable
effluent guidelines. (See attached calculations)
The previous permit had a limit for Total Chromium of 1.2 mg/I based on water quality standards. A
reasonable potential analysis predicts a maximum concentration of 0.0105 mg/I. There is no reasonable
potential to exceed the water quality limit. The proposed limits of 28.1 Ibs/day as a monthly average and 45
Ibs/day as a daily maximum are based on production figures and effluent guidelines. (See attached
calculations)
SUMMARY OF PROPOSED CHANGES
• The classification at the discharge location was corrected. The previous permit had a
classification of WS-III. The correct classification is C.
• As a result of the correction in classification the phenol limits were changed to 28.1 Ibs/day for the
monthly average and 45 Ibs/day for the daily maximum as per effluent guidelines. Previous limit
no longer applies because it was based on a WS classification.
• Modify the Total Chromium limit to 28.1 Ibs/day for monthly average and 45 Ibs/day for daily
maximum as per effluent guidelines.
• Eliminate monitoring for Arsenic, Nickel, Mercury and Chlorides. These parameters didn't show
reasonable potential.
Fact Sheet
NPDES NC0004405
Renewal
Page 2

PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice:
Permit Scheduled to Issue:
NPDES DIVISION CONTACT
May 12, 2004
June 18, 2004
If you have questions regarding any of the above information or on the attached permit, please contact Teresa
Rodriguez at 919) 733-5083 ext. 553.
NAME: (,t4— % DATE: 6-1/4
REGIONAL OFFICE COMMENTS
NAME: DATE:
SUPERVISOR: DATE:
Fact Sheet
NPDES NC0004405
Renewal
Page 3

PUBLIC NOTICE
STATE of NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
COMMISSION/NPDES UNIT
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT TO ISSUE
A NPDES WASTEWATER PERMIT
On the basis of thorough staff review and
application of NC General Statute 145.21, Public
taw_92-500 and other lawful _standardsand.
regulations, the North Carolina Environmental
Management Commission proposes to issue a
National Pollutant Discharge Elimination System
(NPDES) wastewater discharge permit to the
person(s) listed below effective 45 days from the
publish date of this notice.
Written comments regarding the proposed
permit will be accepted until 30 days after the
publish date of this notice. All comments
received prior to that date are considered in the
final determinations regarding the proposed
permit. The Director of the NC Division of Water
Quality may decide to hold a public meeting for
the proposed permit should the Division receive
a significant degree of public interest.
Copies of the draft permit and other supporting
information on file used to determine conditions
present in the draft permit are available
upon request and payment of the costs of
reproduction. Mail comments and/or requests
for information to the NC Division of Water
Quality at the above address or call Ms. Valery
Stephens at [phone], extension 520_
Please include the NPDES permit number
(attached) in any communication. Interested
persons may also visit the Division of Water
Quality at 512 N Salisbury Street Raleigh, NC
27604-1148 between the hours of 8:00 a.m. and
5:00 p.m to review information on file.
Cone Mills Corporation, Permit No. NC0004405,
has applied for renewal of its permit discharging
to the Second Broad River in the Broad River
dssw-d61-rlar3nntars are water quality limited;
LI
U U
JUlN 1 0 2004 .,11
D_r,3 - ,�,.; ;t QUALITY
POINT SUigiCE EN ;'H
FFIDAVIT OF PUBLICATION
I
1 STATE OF NORTH CAROLINA
1
RUTHERFORD COUNTY
undersigned, a Notary Public of said County and State,
nissioned, qualified, and authorized by law to administer
sonally appeared
Susie Sisk
I first duly sworn, deposes and says: that they are
,Iassified Advertising Representitive
iartner, publisher, or other officer or employee authorized to
S affidavit) of THE DAILY COURIER, a newspaper
1, issued and entered as second class mail In the town of
CITY, In said County and State; that they are authorized to
affidavit and sworn statement; that the notice or other legal
ment, a true copy of which is attached hereto, was published
IAILY COURIER on the following dates:
May 18, 2004
said newspaper in which such notice, paper, document, or
ertisement was published was, at the time of each and every
)lication, a newspaper meeting all of the requirements and
tions of Section 1-597 of the General Statutes of North
and was a qualified newspaper within the meaning of Section
the General Statutes of North Carolina.
I0th day of June, 2004.
Susie Sisk, Classified Advertising Representitive
Sworn to and subscribed before me this the 10th day of June, 2004.
(Heather D. diodes, f b 'f�ubh rj',
• \e.,
My commission expires: August 21, ?Q43
Do: •:. ' _
- _- .0 Lv ot
III

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
REGION 4
ATLANTA FEDERAL CENTER61 FORSYTH STREET
rr� r_
ATLANTA, GEORGIA 30303-8960 r� 1J L5
MAY 2 0 2004
MAY 2 5 2004
Ms. Teresa Rodriguez
North Carolina Department of Environment and
Natural Resources
Division of Water Quality
NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
•
SUBJ: Draft NPDES Permit
Cone Mills (Cliffside Plant) - NPDES No. NC0004405
Dear Ms. Rodriguez:
In accordance with the EPA/NCDENR MOA, we have completed review of the draft permit
referenced above and have no comments. We request that we be afforded an additional review
opportunity only if significant changes are made to the draft permit prior to issuance, or if significant
comments objecting to the draft permit are received. Otherwise, please send us one copy of the final
permit when issued.
If you have any questions, please call me at [phone].
Sincerely,
Marshall Hyatt, Environmental Scientist
Permits, Grants, and Technical Assistance Branch
Water Management Division
Internet Address (URL) • http://www.epa.gov
Recycled/Recyclable • Printed with Vegetable OH Based Inks on Recycled Paper (Minimum 30% Postconsumer}

REASONABLE POTENTIAL ANALYSIS
Cone Mills Corp. - Cliffside Plant WWTP
NC0004405
Time Period 2001-2003
Ow (MGD) 1.75
7Q10S (cfs) 62.1
7010W (cfs) 91.2
30Q2 (cfs) 0
Avg. Stream Flow, QA (cfs) 312
Rec'ving Stream Second Broad River
WWTP Class III
IWC (%) ® 7010S 4.1851
0 7Q10W 2.8883
0 3002 WA
® OA 0.8619
Stream Class C
Outfall 001
Ow =1.75 MCD
PARAMETER
TYPE
(1)
STANDARDS &
CRITERIA (2)
P0L
Units
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NCHYOS/ SSFAV/
Clocale Aetna
n IDot AlaProdcb AllosvtbloCW
Arsenic
NC
50
ug/L
0 0
Acute: N/A 'All
N/A _ ._ _-----------------------.—_—.—.—._
Chronic: 1,195
the results were less than detection (< 10 or < S ugll)
Beryllium
C
6.5
ug/L
0 0
N/A
Acute: N/A
Chronic: - #VALUE!_
—_ -------—_—_.—•—•—•_ -------------
Cadmium
NC
2 15
ug/L
0 0
Acute: 15
N/A
Chr—onic: ---48-------
1
-------------------- ---
Chromium
NC
50 1.022
ug/L
67 1
Acute: 1.022
10.5ni_-_ _---------------•—•—•---------•---
Chroc: 1,195
Copper
NC
7 AL 7.3
ug/L
73 1
Acute: 7
58.1 1 _ __ __.—
Chronic: 167
Continue monitoring
___ —_—_—_—_____ ___ _—_—_—.—.—._
Chtorlde
NC
230000
ug/L
9 9
Note: n<12
Limited data
Acute: N/A
1372800.0 _ _
Chroni_c: 5,495_,62_2-----------------------------•---
set
Eliminate monotortng
Ftuorlde
NC
1,800
ug/L
0 0
N/A
Acute: NIA
[Etz,.1,7._4:66ir—
--------•---•---_—.—.—.—•—
Lead
NC
25 N 33.8
ug/L
0 0
Acute: 34
WA _ -_ _—•—.—•—_—_—.—_—_—•—_-----------_—
Chronic: 597
Mercury
NC
0.012
0.0002
ug/L
0 0
Acute: N/A
WA __ _nic: -_ _ _•—•—•—•-------------------•---•—
Chro0.3
-All samples were < 0.2
—
Molybdenum
A
3,500
ug/L
0 0
WA
Acute: N/A
__ _
Chronic: 406,081
_•-------------------------•-----
Nickel
NC
88 261
ug/L
9 1
Note: nc12
Limited data
Acute: 261
18.6 i _ __ __—•-------------.—_—_—_—•—•—.—_—__
Chronic: 2,103
set
Etimilnate monotoring
Phenols
ug/L
163 36
' Acute: N/A
40.3 __ _ _---------------•---•-------------
1 Chronic: WA
1
Selenlum
NC
5.0 56
ug/L
0 0
N/A
Acute: 56
- C _ -_ _---•-----------------------------
hronic: 119
Silver
NC
0.06 Al. 123
ug/L
0 0
WA
Acute: 1
_ -- __--------•—•—•—•—•---•-------------
Chronic: - 1
Zinc
NC
50 AL 67
ug/L
73 73
665.0
Acute: 67
_ -_ _—•---•—_—_---_—_—_-------------_—
Chronic: 1,195
Continue monitootng
'Legend:
C = Carcinogenic
NC = Non -carcinogenic
A = Aesthetic
Freshwater Discharge
cone mills rpa.xis, rpa
5/10/2004

REASONABLE POTENTIAL ANALYSIS
4
5
11
Chromium
Copper
Date Data BDL=1/2DL Results
< 5 2.5 Std Dev. 0.8969
< 5 2.5 Mean 2.3306
c 5 2.5 C.V. 0.3848
< 5 2.5 n 67
< 5 2.5
< 5 2.5 Mutt Factor = 1.3600
< 5 2.5 Max. Value 7.7 ug/L
< 5 2.5 Max. Pred Cw 10.5 ug/L
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
c 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
< 5 2.5
5.4 2.7
< 5 2.5
< 5 2.5
7.3 3.7
4 2.0
3.6 1.8
2.8 1.4
3.2 1.6
4.2 2.1
3.7 1.9
4.4 2.2
3.4 1.7
3.6 1.8
7.2 3.6
3.6 1.8
2.1 1.1
< 0.2 0.1
4.6 2.3
4.6 2.3
3.4 1.7
3.7 1.9
3.8 1.9
3.6 1.8
< 0.2 0.1
3.9 2.0
3.1 1.6
6 3.0
6 3.0
3 1.5
4 2.0
3.9 2.0
6.5 3.3
3.1 1.6
5 2.5
4.8 2.4
-! 7.7 7.7
Date Data BDL=1/2DL Results
1 45 22.5 Std Dev. 6.1933
2 43 21.5 Mean 11.2397
3 28 14.0 C.V. 0.5510
4 31 15.5 n 73
5 32 16.0
6 23 11.5 Mult Factor = 1.4900
7 29 14.5 Max. Value 39.0 ug/L
8 11 5.5 Max. Pred Cw 58.1 ug/L
9 15 7.5
10 16 8.0
11 12 6.0
12 12 6.0
13 10 5.0
14 11 5.5
15 15 7.5
16 12 6.0
17 13 6.5
18 12 6.0
19 8 4.0
20 9.6 4.8
21 9.9 5.0
22 15 7.5
23 11 5.5
24 12 6.0
25 12 6.0
26 20 10.0
27 16 8.0
28 15 7.5
29 29 14.5
30 19 9.5
31 16 8.0
32 < 2 1.0
33 14 7.0
34 26 13.0
35 26 13.0
36 23 11.5
37 21 10.5
38 22 11.0
39 18 9.0
40 21 10.5
41 18 9.0
42 21 10.5
43 2.5 1.3
44 23 11.5
45 17 8.5
46 18 9.0
47 21 10.5
48 19 9.5
49 19 9.5
50 23 11.5
51 24 12.0
52 24 12.0
53 48 24.0
54 32 16.0
55 19 9.5
56 23 11.5
57 29 14.5
58 31 15.5
59 24 12.0
60 23 11.5
61 27 13.5
62 35 17.5
63 50 25.0
64 32 16.0
65 21 10.5
66 26 13.0
67 28 14.0
68 25 12.5
69 6 3.0
70 33 16.5
71 30 15.0
72 56 28.0
73 El 39.000 39.000
cone mills rpa.xls, data
-1 - 5/7/2004

REASONABLE POTENTIAL ANALYSIS
Nickel
Date Data BDL=1/2DL Results
7 7.0 Std Dev. 1.5000
5 2.5 Mean 3.0000
5 2.5 C.V. 0.5000
5 2.5 n 9
5 2.5
< 5 2.5 Mult Factor = 2.6600
5 2.5 Max. Value 7.0 ug/L
5 2.5 Max. Pred Cw 18.6 ug/L
< 5 2.5
cone mills rpa.xls, data
2 5/7/2004

REASONABLE POTENTIAL ANALYSIS
12
15
Phenols
Zinc
Date Data BDL=1/2DL Results Date Data BDL=1/2DL Results
1 < 5 2.5 Sid Dev. 4.6063 1 180 180.0 Std Dev. 76.4229
2 < 5 2.5 Mean 4.3147 2 170 170.0 Mean 200.3699
3 < 5 2.5 C.V. 1.0676 3 130 130.0 C.V. 0.3814
4 < 5 2.5 n 163 4 140 140.0 n 73
5 9 9.0 5 190 190.0
6 c 5 2.5 Mult Factor = 1.4400 6 110 110.0 Mult Factor = 1.3300
7 < 5 2.5 Max. Value 28.0 ug/L 7 150 150.0 Max. Value 500.0 ug/L
8 5 5.0 Max. Pred Cw 40.3 ug/L 8 140 140.0 Max. Pred Cw 665.0 ug/L
9 9 9.0 9 140 140.0
10 < 5 2.5 10 140 140.0
11 < 5 2.5 11 120 120.0
12 19 19.0 12 130 130.0
13 < 5 2.5 13 73 73.0
14 5 5.0 14 110 110.0
15 c 5 2.5 15 67 67.0
16 < 5 2.5 16 180 180.0
17 6 6.0 17 150 150.0
18 < 5 2.5 18 210 210.0
19 < 5 2.5 19 170 170.0
20 5 5.0 20 160 160.0
21 14 14.0 21 200 200.0
22 < 5 2.5 22 310 310.0
23 12 12.0 23 240 240.0
24 < 5 2.5 24 230 230.0
25 < 5 2.5 25 120 120.0
26 8 8.0 26 380 380.0
27 < 5 2.5 27 170 170.0
28 < 5 2.5 28 170 170.0
29 < 5 2.5 29 360 360.0
30 < 5 2.5 30 270 270.0
31 8 8.0 31 230 230.0
32 < 5 2.5 32 170 170.0
33 < 5 2.5 33 180 180.0
34 12 12.0 34 240 240.0
35 < 5 2.5 35 190 190.0
36 22 22.0 36 220 220.0
37 < 5 2.5 37 220 220.0
38 < 5 2.5 38 230 230.0
39 < 5 2.5 39 180 180.0
40 < 5 2.5 40 150 150.0
41 < 5 2.5 41 230 230.0
42 < 5 2.5 42 260 260.0
43 < 5 2.5 43 44 44.0
44 < 5 2.5 44 240 240.0
45 < 5 2.5 45 230 230.0
46 < 5 2.5 46 240 240.0
47 < 5 2.5 47 270 270.0
48 < 5 2.5 48 210 210.0
49 6 6.0 49 160 160.0
50 < 5 2.5 50 210 210.0
51 < 5 2.5 51 150 150.0
52 < 5 2.5 52 180 180.0
53 < 5 2.5 53 290 290.0
54 < 5 2.5 54 230 230.0
55 < 5 2.5 55 160 160.0
56 < 5 2.5 56 200 200.0
57 < 5 2.5 57 210 210.0
58 < 5 2.5 58 220 220.0
59 < 5 2.5 59 220 220.0
60 < 5 2.5 60 170 170.0
61 < 5 2.5 61 170 170.0
62 < 5 2.5 62 290 290.0
63 < 5 2.5 63 410 410.0
64 < 5 2.5 64 210 210.0
65 < 5 2.5 65 63 63.0
66 < 5 2.5 66 220 220.0
67 14 14.0 67 120 120.0
68 < 5 2.5 68 230 230.0
69 < 5 2.5 69 280 280.0
70 < 5 2.5 70 270 270.0
71 < 5 2.5 71 200 200.0
72 < 5 2.5 72 500 500.0
73 28 28.0 73 220 220.0
74 < 5 2.5 74
75 < 5 2.5 75
cone mills rpa.xls, data
76 < 5 2.5 7 j . 5/7/2004

REASONABLE POTENTIAL ANALYSIS
77 < 5 2.5
78 < 5 2.5
79 < 5 2.5
80 < 5 2.5
81 < 5 2.5
82 < 5 2.5
83 < 5 2.5
84 < 5 2.5
85 < 5 2.5
86 5 5.0
87 < 5 2.5
88 < 5 2.5
89 5 5.0
90 < 5 2.5
91 < 5 2.5
92 < 5 2.5
93 < 5 2.5
94 < 5 2.5
95 < 5 2.5
96 5 5.0
97 5 5.0
98 9 9.0
99 <' 5 2.5
100 < 5 2.5
101 < 5 2.5
102 < 5 2.5
103 5 5.0
104 6 6.0
105 5 5.0
106 7 7.0
107 6 6.0
108 < 5 2.5
109 < 5 2.5
110 < 5 2.5
111 < 5 2.5
112 < 5 2.5
113 5 5.0
114 < 5 2.5
115 < 5 2.5
116 < 5 2.5
117 7 7.0
118 < 5 2.5
119 < 5 2.5
120 < 5 2.5
121 < 5 2.5
122 < 5 2.5
123 < 5 2.5
124 < 5 2.5
125 < 5 2.5
126 < 5 2.5
127 < 5 2.5
128 < 5 2.5
129 < 5 2.5
130 < 5 2.5
131 < 5 2.5
132 < 5 2.5
133 < 5 2.5
134 < 5 2.5
135 < 5 2.5
136 < 5 2.5
137 < 5 2.5
138 < 5 2.5
139 < 5 2.5
140 < 5 2.5
141 < 5 2.5
142 < 5 2.5
143 < 5 2.5
144 < 5 2.5
145 <° 5 2.5
146 " 10 10.0
147 5 2.5
148 <J 5 2.5
149 <; 5 2.5
150 < 5 2.5
151 <° 5 2.5
152 <'. 5 2.5
153 < 5 2.5
154 io 10.0
155 23 23.0
156 27 27.0
157 < 5 2.5
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
-2-
cone mills rpa.xls, data
5/7/2004

REASONABLE POTENTIAL ANALYSIS
158 s.a 5.8
159 : is 18.0
160 13 13.0
161 < io 5.0
162 . < io 5.0
163 rz 22.0
158
159
160
161
162
163
cone mills rpa.xls, data
- 3 - 5/7/2004

' Facility
Permit No.
Sanitary flow loads:
Domestic Flow:
Cone Mills
NC0004405
0.052IMGD
Parameter
Standard (mg/I)
Mthly ave Daily max
Load (Ib/day)
Mthly ave Daily max
BOD
30
45
13.01
19.52
TSS
30
45
13.01
19.52
Production Information
Effluent Guideline section:
Production units as per EG
Average Production
Daily maximum
410 Subparts D and G
Ib
Ib/1000 Ib
255841
255.841
255841
255.841
Effl Guideline Part
BPT or BAT
Parameter
Guideline limit
Daily max Mthly ave
Allowable Load (Ib/d)
Daily max Mthly ave
G - Stock and Yarn
Finishing 410.72 BPT
BOD
6.8
3.4
1739.72
869.86
TSS
17.4
8.7
4451.63
2225.82
G - Stock and Yarn
Finishing 410.73 BAT
COD
84.6
42.3
21644.15
10822.07
=Sulfide
0.24
0.12
61.40
30.70
Phenol
0.12
0.06
30.70
15.35
Chromium
0.12
0.06
30.70
15.35
D- Wooven Fabric
Finishing 410.40(a)BPT
_Total
BOD
6.6
3.3
1688.55
844.28
TSS
17.8
8.9
4553.97
2276.98
410.40 (b)
COD
20
10
5116.82
2558.41
410.43 BAT
COD
60
30
15350.46
7675.23
Sulfide
0.2
0.1
51.17
25.58
Phenols
0.1
0.05
25.58
12.79
Total Chromium
0.1
0.05
25.58
12.79
Limits
Parameter
Daily max (Ib/d)
Mthly ave
(Ib/d)
BOD
3447.79
1727.15
TSS
9025.12
4515.81
COD
42111.43
21055.71
Sulfides
112.6
56.3
Phenols
56.3
28.1
Tot Chromium
56.3
28.1
Previous Limits
Parameter
Daily max
(Ib/d)
Mthly ave
(Ib/d)
BOD
2460.00
1080.00
TSS
6329.00
2745.00
COD
31746
13576
Sulfides
52.80
22.80
Phenols
23 ug/l
Tot Chromium 1.2 mg/I

Name of Stream Description Curr. Class Date Prop. Class Basin Stream Index #
Roberson Creek From source to Second
(Robinson Creek) Broad River
Heaveners Creek
Hunting Creek
Forest Lake
Buck Branch
From source to Roberson
Creek
From source to Roberson
Creek
Entire lake and connecting WS-V
stream to Second Broad River
From source to Second
Broad River
Big Spring Branch From source to Second
Broad River
McMurray Branch
Webbs Branch
Puzzle Creek
Morrow Creek
Copper Mine
Branch
From source to Big Spring
Branch
From source to Second
Broad River
From source to Second
Broad River
From source to Second
Broad River
From source to Morrow Creek
Holland Creek From source to Second
Broad River
Second Broad From a point 0.6 mile
River upstream of Webbs Creek to a
point 0.5 mile upstream of
Cone Mills Water Supply
Intake
Webbs Creek
Webbs Creek
WS-V 08/03/92
WS-V 08/03/92
WS-V 08/03/92
08/03/92
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-V 08/01/98
WS-IV 08/01/98
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
Broad
9-41-14
9-41-14-1
9-41-14-2
9-41-15
9-41-16
9-41-17
9-41-17-1
9-41-18
9-41-19
9-41-20
9-41-20-1
9-41-21
9-41-(21.5)
From source to a point 0.3 WS-V 08/01/98 Broad 9-41-22-(1)
mile upstream of mouth
From a point 0.3 mile WS-IV 08/01/98 Broad 9-41-22-(2)
upstream of mouth to
Second Broad River
Hog Pen Branch From source to Second WS-IV 08/03/92
Broad River
Hills Creek From source to Rutherford WS-V 08/01/98
County SR 1982
Hills Creek From Rutherford County SR WS-IV 08/01/98
1982 to Second Broad River
Second Broad From a point 0.5 mile
River upstream of Cone Mills Water
Supply Intake to Cone
Mills Water Supply Intake
WS-IV;CA 08/03/92
Broad
Broad
Broad
Broad
9-41-23
9-41-24-(1)
9-41-24-(2)
9-41-(24.3)
Page 6 of 7

Name of Stream Description
Curr. Class Date
Prop. Class Basin Stream Index #
Second Broad
River
From Cone Mills Water Supply C 08/03/92 Broad 9-41-(24.7)
Intake to Broad River
Riddles Creek From source to Second C 08/03/92 Broad 9-41-25
Broad River
Page 7 of 7

CONE TEXTILE
GROUP
A DIVISION OF CONE MILLS CORPORATION
May 3, 2004
Ms. Teresa Rodriguez
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: Cone Offside Production Data
Dear Ms. Rodriguez:
We have gone through our files to provide the available data on pounds of production at our plants in
Rutherford County that discharge to the wastewater treatment plant. We have yarn manufacturing,
slashing, dyeing and weaving processes at the plants. The production figures are as follows:
Year Monthly Average Daily Maximum
2000 6,968,195 . 1'6'41' 278,000
2001 5,701,975 1."-ik;lt,` ,. 228,000
2002 5,549,624 : a ' 222,000
2003 4,098,865 Jj 1};k'r\ ' 164,000
Ov-ell CL-All'ie-d r 4A-ErrN
LIzLh�
Jl �
These are based on at least 25 days per month with a maximum of 30 days per month. During good demand
which we are receiving at this time we run 30 days per month. For 2004 our daily maximum is 186,000
pounds per day. Our monthly average is expected to be 4,464,000 pounds.
Please call me at 336-230-7216 with any questions.
Sincerely,
at
Arthur Toompas
f t'
White Oak Plant 2420 Fairview Street Greensboro NC 27405 tel [phone] fax [phone]

SOC PRIORITY PROJECT: No
IF YES, SOC NUMBER
TO: NPDES UNIT
WATER QUALITY SECTION
ATTENTION: Charles Weaver
DATE: May 6, 2003
NPDES STAFF REPORT AND RECOMMENDATION
Rutherford COUNTY
PERMIT NUMBER NC0004405
PART I - GENERAL INFORMATION
MAY 1 2 2003
1. Facility and Address: 2420 Fairview Street
Mailing: Greensboro, North Carolina 27405
2. Date of Investigation: January 14, 2003
3. Report Prepared By: Roger Edwards
4. Persons Contacted and Telephone Number: Mike Gibert 828-657-5375
Arthur Toompas 336-230-7216
5. Directions to Site: Highway 221A to NCSR 1003 turn left, approximately
0.1 turn right on NCSR 1975, stay right at first driveway and follow
to WWTP.
6. Discharge Point(s), List for all discharge points:
Latitude: 35° 13' 59" Longitude: 81° 45' 59"
Attach a USGS map extract and indicate treatment facility site and
discharge point on map.
U.S.G.S. Quad No. U.S.G.S. Quad Name Chesnee SC
7. Site size and expansion area consistent with application?
X Yes No If No, explain:
-1-

8. Topography (relationship to flood plain included): Graded hillside
above 2nd Broad River
9. Location of nearest dwelling: approximately 0.5 miles
10. Receiving stream or affected surface waters:
a. Classification: C
b. River Basin and Subbasin No.: Broad River 030802
c. Describe receiving stream features and pertinent downstream
uses: Wildlife propagation, agriculture, and recreation
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted 1.75 MGD (Ultimate
Design Capacity)
b. What is the current permitted capacity of the Wastewater
Treatment facility? 1.75 MGD
c. Actual treatment capacity of the current facility (current
design capacity 1.75 MGD
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two years:
N/A
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: Screening, influent
pH adjustment, aeration basin, dual secondary clarifiers, color
removal system (chemical feed -coagulation & flocculation,
filtration) disinfection and dechlorination.
f. Please provide a description of proposed wastewater treatment
facilities: N/A
g. Possible toxic impacts to surface waters: Textile dyeing
operation possible metals, salts, sulfides. Historically no on
going toxicity problems
h. Pretreatment Program (POTWs only): N/A
in development
should be required
approved
not needed
-2-

2. Residuals handling and utilization/disposal scheme:
a. If residuals are being land applied, please specify DWQ Permit
Number WQ0002379
Residuals Contractor Synagro Southeast
Telephone Number 336-766-0328
b. Residuals stabilization: PSRP X PFRP OTHER
C. Landfill:
d. Other disposal/utilization scheme (Specify):
3. Treatment plant classification (attach completed rating sheet):
4. SIC Codes(s): 2261, 2262, 2211, 2212
Primary 55 Secondary 02, 14
Main Treatment Unit Code: 05003
PART III - OTHER PERTINENT INFORMATION N/A
1. Is this facility being constructed with Construction Grant Funds or
are any public monies involved. (municipals only)?
2. Special monitoring or limitations (including toxicity) requests:
3. Important SOC, JOC, or Compliance Schedule dates: (Please indicate)
Date
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Alternative Analysis Evaluation: Has the facility evaluated all of
the non -discharge options available. Please provide regional
perspective for each option evaluated.
Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
-3-

5. Other Special Items:
PART IV - EVALUATION AND RECOMMENDATIONS
Proceed with renewal of permit NC0004405
Signature of Report Preparer
Z -tc:d
ater Quality Regional Supervisor
-03
Date
-4-

Second Broad River, Cliffside
Subject: Second Broad River, Cliffside
Date: Fri, 11 Jan 2002 14:39:42 -0500
From: Jim Mead <[e-mail]>
To: Edwards <[e-mail]>
CC: Nowell <[e-mail]>, "Yonts, Woody" <[e-mail]>,
"Rayno, Don" <[e-mail]>,
"Sutherland, John" <[e-mail]>
Roger,
This is in response to our phone conversation regarding Cone Mills at
Cliffside in Rutherford County.
First I checked our water system files to see if they had registered the
withdrawal and what kinds of amounts had been reported:
- In 1991 they reported an average daily use of 0.79 mgd with a maximum
daily use of 1.292 mgd, with water coming from the Second Broad River.
This water was used at three textile facilities (weave, Haynes and yarn
plants), plus a very small amount for residential and commercial use
(.016 mgd) .
- More recently, the 1999 updated water use registration indicated that
Cone Mills was purchasing 1.115 mgd from the Duke Power water system
that also serves Spindale and Rutherfordton, with water coming from the
Broad River (not Second Broad). This amount was listed as going only to
the weave and Haynes plants. The yarn plant is not listed, and neither
are the commercial or residential uses. Perhaps the yarn plant has shut
down.
- The Public Water Supply Section in DEH lists a "Cliffside Sanitary
District" in their 1998 data and I suspect that the residential and
commercial uses are now handled by that entity. The Cliffside Sanitary
District does not have a Local Water Supply plan on file with us, and I
don't know if the water is still coming from the Second Broad, is being
purchased from the Duke Power system, or is from another source.
- In terms of WWTP discharge info, our water use registration info from
1999 indicates an average discharge from Cone Mills of .556 mgd with a
max. of 1.05 mgd
Now, to get at your question about what re -activation of the Cone Mills
intake to a withdrawal of 1.0 mgd means for the downstream 7Q10:
- The withdrawal takes place upstream of the dam at Cliffside, and the
WWTP discharge occurs downstream of the dam. A USGS gage was located in
between the intake and outfall, but was de -activated in late 1996
following rating curve problems after a large sediment slug was released
from the dam.
- I used a drainage area of 220 square miles for both the WWTP outfall
and the de -activated gage (#02151000, Second Broad River at Cliffside).
The stream flow records for this gage are influenced by the upstream
Cliffside dam and intake, and exhibit diurnal fluctuation as well as
some regulation at low flows.
- Using USGS Water Supply Paper 2403, I estimated the "natural" 7Q10 at
220 square miles as 66.8 cfs. This is based on a combination of the
regression formula and partial record gage data near Bostic (drainage of
164 sq mi) that are listed in WSP 2403.
- Then I determined the 7Q10 from the Cliffside gage data as 61.6 cfs.
I used a period of record from 7/1/1925 through 9/30 1988. Later
records are available through 9/30/1996, but I wanted to reduce the
effect of upstream withdrawals and discharges from Spindale and Forest
City that have grown in recent years. However, do note that this 7Q10
of 61.6 cfs does reflect any flow modifications from the Cliffside
intake and dam upstream.
- Then, as a worst case scenario I assumed the Cliffside gage records
through 1988 were "natural", and manipulated them for upstream
withdrawals and discharges. I assumed a constant 8.0 mgd withdrawal by
1 of 2 1/15/02 9:30 AM

•
Second Broad River, Cliffside
Forest City, a constant 1 mgd withdrawal by Cone Mills, and WWTP
discharges of 3.37 mgd by Forest City and 1.83 mgd by Spindale. When
all of this is factored in, the resulting 7Q10 at the Cone Mills outfall
(220 square miles) is 56.2 cfs.
- The 7Q10 used by DWQ in the NPDES permit for Cone Mills is 62.1 cfs.
It is important to note that the reduced 7Q10 of 56.2 cfs is an absolute
worst case scenario. Note that the estimated natural 7Q10 of 66.8 cfs
is higher than the gage record 7Q10 of 61.6 cfs. This suggests that the
gage record may already reflect some flow modifications from upstream
users. Therefore, reducing the gage record flows by the Cone Mills and
Forest City withdrawals may constitute "double counting" to some unknown
extent, and the reduced 7Q10 might not be quite as low as 56.2 cfs.
In any case, it is fair to say that a reasonable estimate of the 7Q10 at
the Cone Mills outfall is between 61.6 and 56.2 cfs after upstream
withdrawals and discharges are factored in. This is not terribly
different from the 62.1 cfs used in determining the NPDES permit
conditions, and its significance would depend on the sensitivity of the
waste load model and how tight the effluent limits are.
One other thing to keep in mind with respect to flows at the Cone Mills
outfall. The Cliffside dam has operated as a small hydro project and
may still be operated as one. Before it was de -activated, the
downstream USGS gage showed large daily fluctuations in flow during
certain periods. The overall effect on daily average flows may not have
been as extreme, but instantaneous flows varied widely within a day. I
don't know if this sort of within -day stream flow variation is a concern
for waste load assimilation and effluent limits. If so, you may want to
ask Cone Mills if they still plan to operate the small hydro plant in
this manner. The hydro is not presently licensed by the Federal Energy
Regulatory Commission (FERC), but there is a possibility that FERC would
require it to become licensed (and attach operating conditions) if we
bring downstream flow and water quality concerns to their attention.
Let me know if you any further questions. I can be reached by email or
call 919/715-5428.
Jim Mead
2 of 2 1/15/02 9:30 AM

JAN.24.2003 9:16AM CONE MILLS ENG. 336 379 6793 NO.954 P.1/1
CONE Tuggig
GROUP
al A DIVISION OF CONE {MILS CORPORATION
January 24, 2003
Mr. Charles II, Weaver
NPDES Unit
NCDENR
1617 Mail Service Center
Raleigh, NC 27699-1617
Re: Renewal NPDES PermitNC0004405
Rutherford County
Dear M. Weaver:
We received the permit application for the renewal of the permit for plant in Rutherford County. The
completed application will be returned as soon as we receive the data from the laboratory on the tenting of
pollutants required in the Form 2C Application Please call me at 336-230-7216 with any questions,
Sincerely,
a
Arthur J. Toompas
White Oak Plant 2420 Fairview Street Greensboro NC 27405 tel 336.230,7000 fax [phone]

CONE TEXTILE
GROUP
9 A DIVISION OF CONE MILLS CORPORATION
March 14, 2003
Mrs. Valery Stephens
NC DENR/ Water Quality / Point �:ource Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Re: NPI.!ES Pern:il Number NC 0004405
Rutherford County
Dear Mrs. Stephens:
We are requesting the renewal of the above mentioned permit. The plant has made very few
changes. The chlorine system was changed from ton cylinders of chlorine to sodium hypochlorite tablets
and the sulfur dioxide ton cylinders for dechlorination was replaced with sulfite tablets. Biosolids are still
land applied for beneficial reuse as a soil conditioner and a fertilizer supplement.
It is requested that mercury requirements be removed from the permit since there is no mercury in
the effluent. It is also requested that sulfide testing be eliininated or reduced to quarterly since it is not
present in the effluent. These tests add cost to the operation without adding value and do not help protect
the environment since they arc not present.
The priority pollutant dn.t is provid'•r.d on the original laboratory APAM. We feel that the
wastewater iteatment ='. nit is w.::.i, perated aid well maintained and will continue to perform within its
design capacity at 1.75, •.'�.GD.1i tr .:e are any questions or if additional information is needed please call
me at (336)-230-7216.
S.ncere_
Arthur J. Toompas
Corporate Environmental Manager
Enclosures
White Oak Plant 2420 Fairview Street Greensboro NC 27405 tel [phone] fax [phone]

2-.500, oOD GAL.
SLUDGE SiGE.TA1lKS
COLOR R MOVA L ?&TURN :LUP&E
IN PLUEN T
DEi16U . 1;75 MGD
HAM
-_ 0.75145D
(FROM YAM- F-5 )_ GL IF? -
SP RRu.I ANr PD -
Vit:LAGB)
LUD6E
LOADING _ I
S'riITIoN
E47uAL1ZA7101t P3143114 AT
C1.1FFSlPE WEAVE PLANT
13AR
..SGRN
RA PI D
MIXER.
AERATION ,SAsiJ
(AfEc1�,4 NI GAL Af124ToR)
ANAL .
C.LAK1F1ElZ
-.'D1 vgR5IaN ex
ANAL
GLARJF1 R
w ,v
r
RETV R14 S1.uDGE
Pu Air Bt.pG.
A 4Ta R
GL2
5TG E.
502
5TGE.
001 PI5CNAJGE
0.74 MGD
AGI D TANK
PaLY/Y R /DP/T/o/
AQUA
DISK
FIGTM now
CDLOQ REMOVAL
_RETURN SLUDGE
P.UM-P ST,4TION
__ S E T QF S.T. WRTERTEOW
GC.TFESTD W5T6W,4TFR -TR?ATMcNT PLAN_.
-Dr G R74 ( o. oo!
-DATE : 5 1.4 -$:

LOCATION /0i4?
Co,v� 41 /L15
i/404(TO/OG�4PH/C 0/4-
A'f/145 / c.///f5/,04'=" /Z1 PZ,1#T
C1/ s/95 ifrnitli4VT2W Te7717NT�,.�//T
0,0,v7Y - 6--
III A199 8' SCALE :'/ '=2dD' PG /o,t/

LINE DRAWING
RAW
MATERIALS
10,000 GPD
SOLID WASTE
4,000 GPD
FIBER
PREPARATION
BLUE RIVER
i90,000 GPD
45,000 GPD
15.000
GPD
40,000 GPD
GRIT
SEPARATOR
STORMWATER
36,000 GPD
1 45,000 GPD
DYEING
20,000
GPD
40,000 GPD
NEUTRAL—
IZATION
TANK
MUNICIPAL
WATER SUPPLY
I
30,000 GPD
10,000
WASHING GPD
LOSS
34,000 GPD
MAX: 20,000 GPD
WASTE
TREATMENT
PLANT . 1
6,000 GPD
40,000 GPD
• BLUE RIVER
10,000 GPO
COOLING WATER
DRYING
10,000 GPD
WASTE
TREATMENT
PLANT AL 2
OUTFALL 002
50.000 GPD
70,000 GPD + STORMWATER
OUTFALL 001
SCHEMATIC OF WATER FLOW
BROWN MILLS. INC.
CITY. COUNTY. STATE
TO ATMOSPHERE
5,000 GPD
TO PRODUCT
5,000 GPD
FIGURE 2C•1