NC0004405_Permit (Issuance)_19990111

NPDES DOCYNENT 5CANNINC COVER SHEET
NPDES Permit:
NC0004405
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:
January 11, 1999
This document is printed on reuse paper - ignore nary
content on the reverse side

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
January 11, 1999
Mr. Jeffrey S. Wells, P.E.
Environmental Engineer
Cone Mills Corporation
3101 North Elm Street
Greensboro, North Carolina 27415-6540
DENR
Subject: Issuance of NPDES Permit
Permit No. NC0004405
Cliffside WWTP
Rutherford County
Dear Mr. Wells:
This letter is to inform you that the Division has finalized its review and the comment period is
now closed for NPDES permit NC0004405. A final copy of the permit is attached to this letter for your
records.
The following note has been included in the final permit in response to your comment letter
dated November 23, 1998:
➢ The 0.3 µg/1 limit for Mercury will become effective one year from the effective date of the
permit. The facility is still required to monitor for Mercury. If no elevated levels are
detected over a one-year period, the facility can petition to have the limit removed and the
monitoring frequency reduced to 2/month.
The following list has been included to outline the changes that were addressed in the draft
permit. These changes remain unchanged in the final permit:
➢ The permit expiration date has been changed. The permit renewal will expire on July 31,
2003. The expiration dates have been revised so that an equal number of permit renewals
will come in at any one time. This change will allow the Division to issue permits more
efficiently.
> Total Nitrogen and Total Phosphorus monitoring was included in the permit renewal. This
is a requirement of the North Carolina Administrative Code Section 2B.0500. It is a
requirement for facilities that discharge 50,000 GPD or more.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Issuance of NPDES Permit
Permit No. NC0004405
Cliffside WWTP
Page 2 of 2
➢ The monitoring frequency for Sulfide has been revised from 3/week to weekly. Past
monitoring data indicates that a reduction in monitoring is warranted.
➢ The monitoring frequency for Fecal Coliform has been revised from weekly to 3/week as
per the requirements outlined in the North Carolina Administrative Code Section 15 A
NCAC 2B.0500.
➢ The monitoring frequency for Arsenic and Nickel has been revised from Monthly to
Quarterly as per the results of the reasonable potential analysis.
➢ The monitoring frequency for Copper and Zinc has been revised from Monthly to 2/Month
as per current standard operating procedures for Class III facilities.
➢ The limits for BOD, COD, TSS, and Sulfide were revised using current production data
and applicable CFR guidelines.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty
(30) days following receipt of this letter. This request must be in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of
Administrative Hearings, Post Office Drawer 27447, Raleigh, North Carolina 27611-7447. Unless such
demand is made, this decision shall be final and binding.
Please be advised that this permit is not transferable. Part II, E.4. addresses the requirements to
be followed in case of change in ownership or control of this discharge. In addition, this permit does not
affect the legal requirement to obtain other permits which may be required by the Division of Water
Quality or permits required by the Division of Land Resources, Coastal Area Management Act or any
other Federal or Local governmental permit that may be required.
In closing, I would like to state that it is the Division's ultimate goal to provide quality service to
the public. Please take a moment to review the procedures you followed in applying for this permit
renewal in addition to the Division's response to your project needs. If we can improve our service to
you in any manner, please bring it to our attention. We appreciate your cooperation during the renewal
process and we look forward to working with you in the future.
If we can be of further assistance to you or if you would like to suggest any improvements we
can make to strengthen our customer service efforts, please do not hesitate to contact Jeff Myhra of my
staff at [phone], extension 597.
Sincerely,
Original Signed By
payid A. QQodrich
A. Freston Howard, Jr., P.E.
cc: Central Files
Mr. Roosevelt Childress, EPA
Asheville Regional Office / Roger Edwards
Point Source Compliance Enforcement Unit
Aquatic Toxicology Unit
NPDES Unit / Permit file

Permit No. 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 provision of North Carolina General Statute 143-215.1, other lawful standards and
d
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.
The permit shall become effective February 1, 1999
This permit and the authorization to discharge shall expire at midnight on July 31, 2003
Signed this day January 11, 1999
Original Signed By
David P. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

SUPPLEMENT TO PERMIT COVER SHEET
Cone Mills Corporation
is hereby authorized to:
Permit No. NC004405
1. Continue to operate an existing 1.75 MGD wastewater treatment plant consisting of biological
treatment using extended aeration activated sludge, dual final clarification, color removal,
chlorination, effluent reaeration, dechlorination, sludge storage with sludge land application
located at the Cliffside Plant, US Highway 221-A and NCSR 1003, Cliffside, Rutherford
County (See Part III of this permit), and
2. Discharge from said treatment works at the location specified on the attached map into the
Second Broad River which is classified Class WS-III waters in the Broad River Basin.

a
1 170 000! FEET (N. C.) • 130
r.
211
Latitude: 35°13' 59"
Longitude: 81° 45' 59"
USGS Quad #: G11NE
River Basin #: Broad
Receiving Stream:.Second Broad River
Stream Class: C
n0.B•.
.-h :Coo7Er o•
• •-7/aAS
• Q
r
81.45'
-J5' 15.
3900
O
550 000 FEET
IN. C.)
3898
Cones Mills, Corporation
Cliffside Plant
NC0004405
Discharge Point:
Latitude: 35°13'59"
Longitude: 81°45'59"
ItfaZell
�
Cone Mills
Cliffside Plant
NC00004405
Rutherford County

A.(1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0004405
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall
serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
CHARACTERISTIC S `
EFFLUENT.
„
, T
'
, ; LIMITS
MONITORING REQUIREMENTS
MonthlyWeeklyDaily
,
' Average
Average
Maximum
Measurement ,
Frequency
Sample ;
Type
Sample •
Location'
•
Flow
1.75 MGD
Continuous
Recorder
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 Ibs/day
3 / Week
Composite
E
Total Suspended Solids
2,745 lbs/day
6,329 Ibs/day
3 / Week
Composite
E
Fecal Coliform (geometric mean)
J
200 / 100 ml
400 / 100 ml
3 / Week
Grab
E
Total Residual Chlorine
28 µg/I
3 / Week
Grab
E
Temperature
3 / Week
Grab
E
Total Nitrogen (NO, + NO, + TKN)
Quarterly
Composite
E
Total Phosphorus
Quarterly
Composite
E
Chronic Toxicity2
Quarterly
Composite .
E
PH3
3 / Week
Grab
E
Chromium
1.2 mg/I
Weekly
Composite
E
Sulfides
22.8 lbs/day
52.8 Ibs/day
Weekly
Grab
E
Phenols
23 µg/l
Weekly
Grab
E
Mercury,
0.3 µg/l
Weekly
Composite
E
Copper
2 / Month
Composite
E
Zinc
2 / Month
Composite
E
Nickel
Quarterly
Composite
E
Arsenic
Quarterly
Composite
E
Chlorides
Quarterly
Composite
E
otes:
Sample locations: I — Influent, E — Effluent.
2 Chronic Toxicity (Ceriodaphnia) P/F at 4.2%; January, April, July, and October; See special condition A.(3). on the Supplement to Effluent
Limitations and Monitoring Requirements Page.
3 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4 The limit for Mercury will become effective one year from the effective date of the permit. The facility is still required to monitor for Mercury.
If no hits are detected over a one-year period, the facility can petition to have the limit removed from the permit.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Special permit conditions are listed on the Supplement to Effluent Limitations and Monitoring Requirements page.

Permit No. NC0004405
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A.(2). Chronic Toxicity Pass/Fail Permit Limit (Qrtrly)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in
the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised November
1995, or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction or
significant mortality is 4.2% (defined as treatment two in the procedure document). The permit
holder shall perform quarterly monitoring using this procedure to establish compliance with the
permit condition. 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.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the month in which it was performed, using the
parameter code TGP3B. Additionally, DWQ Form AT-1 (original) is to be sent to the following
address:
Attention: Environmental Sciences Branch
North Carolina Division of Water Quality
4401 Reedy Creek Road
Raleigh, North Carolina 27607
Test data shall be complete and accurate and include all supporting chemical/physical
measurements performed in association with the toxicity tests, as well as all dose/response data.
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 any single quarterly monitoring indicate a failure to meet specified limits, then monthly
monitoring will begin immediately until such time that a single test is passed. Upon passing, this
monthly test requirement will revert to quarterly in the months specified above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
then monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing, this monthly test requirement will revert to quarterly in the months specified
above.

Permit No. NC0004405
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS (Continued)
SPECIAL CONDITIONS
Should any test data from this monitoringrequirement 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.

State of North Carolina \_\
wand Nat 11r1;°71V/YA
Departmral Resources
nt of ment � t T''
� •
Division of Water Quality V` 1 4
James B. Hunt, Jr., Governor 1/Z 1 iV/DEHNR
Wayne McDevitt, SecretaryIIIIA. Preston Howard, Jr., P.E., Director
October 27, 1998
MEMORANDUM
To: Hornlean Chen
Division of Environmental Health
From: Kim Murphy
Subject: Review of DRAFT PERMITS
Cliffside WWTP
Rutherford County
NC0004405
Please indicate below your agency's position or viewpoint on the DRAFT permit and,
return this form by 12/04/98. If you have any questions on the draft permit, please,
contact Jeff Myhra at 919/733-5083 ext. 597.
RESPONSE:
This agency has reviewed the draft permit and determined that the proposed
discharge will not be sufficiently close to any existing or know proposed
public water supply intake so as to create an adverse effect on water quality.
We concur with the issuance of this permit provided the facility is operated
and maintained properly, the stated effluent limits are met prior to discharge,
and the discharge does not contravene the designated water quality standards.
Concurs with issuance of the above permit, provided the following conditions {' '
are met: •
Opposes the issuance of the above permit, based on reasons stated below, or
attached:
Signed ri✓a � � ' — /1-Y-0 Date: /2-/-f'9g
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

4,1110
November 23, 1998
Mr. Jeff Myhra
NPDES Unit
NCDENR - DWQ
P.O. Box 29535
Raleigh, N.C. 27626-0535
Dear Mr. Myhra:
E
We have reviewed the Draft NPDES Permit No. NC0004405 for our Cliffside
Wastewater Treatment Plant in Rutherford County. We are requesting a review of
the proposed limit of 0.3 ug/l on mercury.
Mercury is not used in our manufacturing processes at the Rutherford County
facilities. We propose to continue monitoring monthly for mercury without a limit.
Please call me at (336)-379-6579 with any questions.
Sincerely,
Jeffrey S. Wells, P.E.
Environmental Engineer
Cc: Mr. Mike Gibert
Mr. Alan Daeke
Mr. Scott Bland
Mr. Arthur Toompas
ve„.
oceeilfvfl,1
ert-to-
;e4A:./,60,,
)ft
c931:\,,v
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fl
OLt
^:?
cl1
P.O. Box 26540
CONE MILLS CORPORATION
310t NORTH ELM STREET
FAX: 9c0.379.6793
GRI:P.NSBORO, NC 27.1.15-654o

PUBLIC NOTICE
State of North Carolina
Environmental
Management Commission
Post Office Box 29535
Raleigh, NC 27626-0535
NOTIFICATION OF
INTENT TO ISSUE A
STATE NPDES PERMIT
On the basis of thorough
staff review and applica-
tion of Article 21 of Chap-
ter 143, General Statutes
of North Carolina, Public
Law 92-500 and other law-
ful standards and regula-
tions, the North Carolina
Environmental Manage-
ment Commission propos-
es to issue a permit to dis-
charge to the persons list-
ed below effective
12/21/98 and subject to
special conditions.
Persons wishing to com-
ment upon or object to the
proposed determinations
are invited to submit same
in writing to the above ad-
dress no later than
12/4/98. All comments re-
ceived prior to that date
will be considered in the
formulation of final deter-
minations regarding the
proposed permit. A public
meeting may be held
where the Director of the
Division of Environmental
Management finds a sig-
nificant degree of public in-
terest in a proposed per-
mit.
A copy of the draft permit
is available by writing or
calling the Division of Envi-
ronmental Management,
P.O. Box 29535, Raleigh,
North Carolina 27626-
0535, [phone].
The application and other •
information may be in-
spected at these locations
during normal office hours.
Copies of the information
on file are available upon
request and payment of
the costs of reproduction.
All such comments or re-
quests regarding a pro-
posed permit should make
reference to the NPDES
permit number listed be-
low.
Date 10/27/98
David A. Goodrich
for A. Preston Howard, Jr.,
P.E. Director
Division of Environmental
Management
Public notice of intent to is-
sue a State NPDES permit
to the following:
1. NPDES No. NC
0004405. Cone Mills Cor-
poration, has applied for a
permit renewal for a facility
located at a site at the in-
jo-
AFFIDAVIT OF PUBLICATION o
W
W
ow
STATE OF NORTH CAROLINA
RUTHERFORD COUNTY
00
0'
N
O
Before the undersigned, a Notary Public of said County and
State, duly commissioned, qualified, and authorized by law to
administer oaths, personally appeared
Betty Brooks
who being first duly sworn, deposes and says: that they are
Classified Advertising Manager
(Owner, partner, publisher, or other officer or employee authorized
to make this affidavit) of THE DAILY COURIER, a newspaper
published, issued and entered as second class mail In the town
of FOREST CITY, in said County and State; that they are
authorized to make this affidavit and sworn statement; that the
notice or other legal advertisement, a true copy of which is
attached hereto, was published in THE DAILY COURIER on the
following dates:
November 3, 1998
and that said newspaper in which such notice, paper, document,
or legal advertisement was published was, at the time of each and
every such publication, a newspaper meeting all of the requirements
and qualifications of Section 1-597 of the General Statutes of North
Carolina and was a qualified newspaper within the meaning of Section
1-597 of the General Statutes of North Carolina.
This 4th day of November, 1998.
tersection of US Highway
221-A and NCSR 1003,
Cliffside, Rutherford Coun-
ty. The facility discharges
1.750 MGD of treated do-
mestic and industrial
wastewater from an outfall
into Second Broad River, a
Class WA -III stream in the
Broad River Basin which
has a 7Q10 flow of 62.1
cfs.
2. NPDES No.
NC0083275. Dan River,
Inc., PO Box 217, Spin -
dale, NC 28160 has ap-
plied for a permit renewal
for an existing facility lo-
cated at the Harris Facility
NCSR 1111, south of
Rutherfordton in Ruther-
ford County. The facility is
permitted to discharge
0.91 MGD of treated do -
tic nd industrial
mes
wastewater from 1 outfall
into the Broad River, a
Class C stream in the
Broad River Basin which
has a 7Q10 flow of 186.0
cfs. No parameters are
water quality limited, but
this discharge may affect
future allocations.
3. NPDES No.
NC0005088. Duke Power
Company, Wachovia Cen-
ter, P.O. Box 1007, Char-
lotte, NC 28201-1007 has
applied for a permit renew-
al for a facility located at
Cliffside Steam Station, off
NCSR 1002, South of Cliff -
side, Rutherford County.
The facility discharges a
variable amount of treated
domestic and industrial
wastewater from one out-
let' into Broad River, . a
Gass C stream in the
4J11 f: "
Adve Ising Manager)
me this
Notary Public)
ry 12, 2001
DWQ BUDGET OFFICE

SOC PRIORITY PROJECT: Yes No X
IF YES, SOC NUMBER
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Jeff Myhra
DATE: June 17, 1998
NPDES STAFF REPORT AND RECOMMENDATION
Rutherford County
PERMIT NUMBER NC0004405
PART I - GENERAL INFORMATION
1. Facility and Address: Cone Mills Corporation-Cliffside
Mailing: 3101 North Elm Street
Greensboro, NC 27415
2. Date of Investigation: December 16, 1997
3. Report Prepared By: Roy Davis
4. Persons Contacted and Telephone Number: Mike Gilbert, ORC
1-828-657-5375
5. Directions to Site: In Rutherford County, follow U.S. Highway 221-A
south from Forest City. Enter the unincorporated village of
Cliffside. Turn left on NCSR 1003. Almost immediately turn left
onto NCSR 1975. The wastewater treatment plant site is directly
ahead.
6. Discharge Point(s), List for all discharge points:
Latitude: 35 °13 '57 " S Longitude: 81 °46 '00
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, S.C.
7. Site size and expansion area consistent with application?
_X_ Yes No If No, explain:
8. Topography (relationship to flood plain included):
Graded hillside considerable distance above Second Broad River.
-1-

9. Location of nearest dwelling: Approximately 1/2 mile from wwtp.
10. Receiving stream or affected surface waters: Second Broad River
a. Classification:"C"
b. River Basin and Subbasin No.:9-41
c. Describe receiving stream features and pertinent downstream
uses: Fish and wildlife propagation.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted MGD (Ultimate
Design Capacity) 1.75
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:
None
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: Partial flow
equalization, screening, ph adjustment when needed, mechanical
aeration, dual final clarification, color removal, effluent
chlorination and dechlorination and sludge storage tanks.
f. Please provide a description of proposed wastewater treatment
facilities: None
g. Possible toxic impacts to surface waters: None known or
suspected. Effluent chlorine is dissipated by the addition of
S02.This is a textile dyeing and finishing operation therefor
metals and salts are present in effluent but historically not
in toxic concentrations.
h. Pretreatment Program (POTWs only):
Not Applicable
in development approved
should be required not needed
-2-

2. Residuals handling and utilization/disposal scheme: Land Application
a. If residuals are being land applied, please specify DWQ Permit
Number WQ0002379
Residuals Contractor: Environmental Waste Recycling
Telephone Number 1-336-998-8184
b. Residuals stabilization: PERP. X PFRP OTHER
C. Landfill: Not utilized.
d. Other disposal/utilization scheme (Specify): None
3. Treatment plant classification (attach completed rating sheet): III
4. SIC Codes(s): 2261,2262,2211 and 2212
Primary 55 Secondary 02,14
Main Treatment Unit Code: 05003
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or
are any public monies involved. (municipals only)? No.
2. Special monitoring or limitations (including toxicity) requests:
3. Important SOC, JOC, or Compliance Schedule dates: (Please indicate)
None. 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:
5. Other Special Items:
-3-

PART IV - EVALUATION AND RECOMMENDATIONS
The wastewater treatment plant serving the Cone Mills-Cliffside
complex has an excellent compliance record and protects Water Quality
standards in the receiving stream. The Asheville Regional Office
recommends that the Division proceed with renewal of NPDES Permit No.
NC0004405.
Signature of R ort Pre
parer
parer
Water Quality Regional Supervisor
Date
Sr
-4-

RATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
Name of Facility: CON ` t uo-S C© KC' — C ;.--11 T F. —
Owner or Contact Person: A RYFlt, fs Jv l oor i fi S
Mailing Address: S / 0 / A/ . Ek or., STD 61kEE tffo Ro , %'C '9:71#-LS
County: RoTHERFo0-2 Telephone: 3'�— 37 9 �n..4
Present Classification: New Facility Existing Facility
NPDES Per. No. NC00o4'to 5 Nondisc. Per. No.WQ — Health Dept.Per No.
Rated by: Roy X AaliS Telephone :c - ..51-4Ao$Date: �o
Reviewed by: Health Dept.
- I t, . - {rru,dRegional Office
I Central Office
ORC: Tni 1KE- &IL BE RI- Grade: a:+L
Check Classification(s): Subsurface Spra Irrigation
Wastewater Classification: (Circle One) I it IV
8
Telephone:
Telephone: •2_$'-Za'/-0$r
Telephone:
Telephone: ec857-53?-5"
Land Application
Total Points:
JN-PLANT PROCESSES AND RELATED CONTROL EQUIPMENT WHICH ARE AN INTEGRAL PART OF INDUSTRIAL PRODUCTION SHALL NOT BE
CONSIDERED WASTE TREATMENT FOR THE PURPOSE OF CLASSIFICATION. ALSO SEPTIC TANK SYSTEMS CONSISTING ONLY OF SEPTIC TAW
AND GRAVITY NITRIFICATION LINES ARE EXEMPT FROM CLASSIFICATION.
SUBSURFACE CLASSIFICATION
(check all units that apply)
1. septic tanks
2. pump tanks
3. siphon or pump -dosing systems
4. sand filters
5. grease trap/interceptor
6. oil/water separators
7. gravity subsurface treatment and disposal:
8. pressure subsurface treatment and disposal:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SPRAY IRRIGATION CLASSIFICATION
(check all units that apply)
preliminary treatment (definition no. 32 )
lagoons
septic tanks
pump tanks
pumps
sand filters
grease trap/interceptor
oil/water separators
disinfection
chemical addition for nutrient/algae control
spray irrigation of wastewater
In addition to the above classifications, pretreatment of wastewater In excess of these components shell
be rated using the point rating system and will require an operator with an appropriate dual certification.
LAND APPLICATION/RESIDUALS CLASSIFICATION (Applies only to permit holder)
1. Land application of biosolids, residuals or contaminated soils on a designated site.
WASTEWATER TREATMENT FACILITY CLASSIFICATION
The following systems shall be assigned a Class I classification gnlesi the flow is of a significant quantity or the technology is unusually
complex, to require consideration by the Commission on a case -by -case basis: (Check if Appropriate)
1. OiUwater Separator Systems consisting only of physical separation, pumps and disposal;
2. Septic Tank/Sand Filter Systems consisting only of septic tanks, dosing apparatus, pumps,sand filters, disinfection
and direct discharge;
3. Lagoon Systems consisting only of preliminary treatment, lagoons, pumps, disinfection, necessary chemical treatment for
algae or nutrient control, and direct discharge;
4. Closed -loop Recycle Systems;
5. Groundwater Remediation Systems consisting only of oil/water separators, pumps, air -stripping, carbon adsorption, disinfection
and dispo l;
6. Aquaculture operations with discharge to surface waters;
7. Water Plant sludge handling and back -wash water treatment;
8. Seafood processing consisting of screening and disposal.
9. Single-family discharging systems, with the exception of Aerobic Treatment Units, will be classified if permitted after July 1,
1993 or 11 upon inspection by the Division, it is found that the system is not being adequately operated or maintained. Such
systems will be notified of the classification or reclassification by the Commission, in writing.

The following scale is used for rating wastewater treatment facilities: (circle appropriate points) '
ITEM POINTS
(1) Industrial Pretreatment Units or Industrial Pretreatment Program (see definition No. 33) 4
(2) DESIGN FLOW OF PLANT IN gpd [not applicable to non -contaminated cooling waters, sludge handling facilities for
water purification plants, totally dosed cycle systems(see definition No. 11), and facilities consisting only of hem
(4)(d) or Items (4)(d) and (11)(d))
0 - 20,000 1
20,001 - 50,000 2
50,001 - 100.000 .3
100,001 - 250,000 4
250,001 - 500,000 5
500,001 - 1,000,000
1,000,001 - 2,000,000
2,000,001 (and up) rate 1 point additional for each 200,000 gpd capacity up to a maximum of 3
Design Flow (gpd)
(3) PRELIMINARY UNiTSrPROCESSES (see definition No.32)
(a) Bar Screens
or
(b) Mechanical Screens. Static Screens or Comminuting Devices 2
(c) Grit Removal 1
or
(d) Mechanical or Aerated Grit Removal 2
(e) Fbw Measuring Device 1
or
(() Instrumented Flow Measurement CC2)
(g) Preaeratlon
(h) Influent Flow Equalization <-)
(i) Grease or Oil Separators - Gravity
Mechanical
Dissolved Air Flotation 8
(J) Prechtorination .5
(4) PRIMARY TREATMENTLRIfiS/PROCESSES
(a) Septic Tank (see definition No. 43) 2
(b) Imhoff Tank .5
(c) Primary Clarifiers -55
(d) Settling Ponds or Settling Tanks for Inorganic Non-toxlc Materials (sludge handling facilities for water
purification plants, sand. gravel, stone. and other mining operations except recreational activities such as gem
or gold mining) 2
(5) SECONDARY TREATMENTLNfTS'PROCESSES
(a) Carbonaceous Stage
(t) Aeration -High Purity Oxygen System 20
Diffused Air System
Mechanical Air System (fixed. floating or rotor)9±5
Separate Sludge Reaeratlon .3
(It) Tridding Filter
High Rate 7
Standard Rate .5
Packed Tower 5
(ill) Biological Aerated Filter or Aerated Biological Fitter 10
(iv) Aerated Lagoons 10
(v) Rotating Biological Contactors 10
(vi) Sand Filters -intermittent biological 2
Recirculating biological .3
(vil) Stabilization Lagoons
(vili) Clarifier
(Ix) Single stage system for combined carbonaceous removal of BOD and nitrogenous removal by
nitrification (see definition No. 12)(Poinis for this Item have to be in addition to items
(5)(a)(I) through (5)(a)(v1i1),
utilizing the extended aeration process (see deflnhion No.3a) 2
utilizing other than the extended aeration process 8
(x) Nutrient additions to enhance BOD removal 5
(xi) Biological Culture ('Super Bugs')addition 5
(6) Nitrogenous Stage
(I) Aeration - High Purhy Oxygen System 20
Diffused Air System 10
Mechanical Air System (fixed, floating or rotor) .8
Separate Sludge Reaeratlon .3
(II) Trickling Fitter -High Rate 7
Standard Rate .5
Packed Tower .5
(III) Biological Aerated Filter or Aerated Biological Filter 10
(iv) Rotating Biological Contactors 10
(v) Sand Fitter- Intermittent biological 2
Recirculating biological .3
(vl) Clarifier
(6) TERTIARY OR ADVANCED TREATMENT UNF S/PROCESSES
(a) Activated Carbon Beds -
without carbon regeneration •5
with carbon regeneration 15
(b) Powdered or Granular Activated Carbon Feed -
without carbon regeneration .5
with carbon regeneration 15
(c) Air stripping .5
(d) Denitrfflcallon Process 10
(e) Electrodialysts 5
(1) Foam Separation .5
(g) Ion Exchange 5
(h) Lard Application of Treated Effluent (see definition No. 22b) (not applicable for sand. gravel. stone
and other similar mining operations) by high rate Infiltration
(I) Microscreens \y�
()) Phosphorous Removal by Biological Processes (See definition No. 26)
(k) Polishing Ponds - without aeration 2
with aeration .5
.5

(I) Post Aeration - cascade 0
diffused or mechanical
(m) Reverse Osmosis
(n) Sand or Mixed -Media Filters - low rate 2
high rate 5
(o) Treatment processes for removal o1 metal or cyanide 15
(p) treatment processes for removal of toxic materials other than metal or cyanide 15
(7) SLUDGE TREATMENT
(a) Sludge Digestion Tank - Heated (anaerobic) 10
Aerobic
Unhealed (anaerobic) 3
(b) Sludge Stabilization (chemical or thermal) 5
(c) Sludge Drying Beds - Gravity 2
Vacuum Assisted 5
(d) Sludge Elutriatlon .5
(e) Sludge Conditioner (chemical or thermal) 5
(f) Sludge Thickener (gravity) .5
(g) Dissolved Air Flotation Unit [not applicable to a unit rated as (3)(i)) 8
(h) Sludge Gas Utilization (including gas storage) 2
(I) Sludge Holding Tank - Aerated .5
Non -aerated
2
(j) Sludge Incinerator (not including activated carbon regeneration) 10
(k) Vacuum Filter, Centrifuge. or Filter Press or other similar dewatering devices 10
RESIDUALS UTILIZATION/DISPOSAL (including incinerated ash)
(a) Lagoons 2
(b) Land Application (surface and subsurface) (see definition 22a)
by contracting to a land application operator or landfill operator who holds the land application permit
or landfill permit
(c) Dedicated Landfill(burlal) by the permillee of the wastewater treatment facility
(9) DISt FECiirN
(a) Chlorination
(b) Dechlorination
(c) Ozone .5
(d) Radiation .5
(1 0) CHEMICAL ADDITION SYSTEM(S) ( see definition No. 9) [not applicable to chemical additions rated as item (3)(j),
(5)(a)(xi), (6)(a), (6)(b). (7)(b), (7)(e). (9a), (9)(b) or (9)(c) 5 points each:
List 5 0 2.
Por_Yr4—..1. IL._
(8)
(1 1) MISCELLANEOUS UNrTS/PROCESSFS
(a) Holding Ponds, Holding Tanks or Settling Ponds for Organic or Toxic Materials including wastes from mining
operations containing nitrogen or phosphorus compounds In amounts significantly greater than Is common
for domestic wastewater
4
(b) Effluent Flow Equalization (not applicable to storage basins which are inherent In land application systems) 2
(c) Sume Discharge (not applicable to storage basins Inherent in land application systems) 5
(e) Stand -By Power Supply
(f) Thermal Pollution Control Device 3
TOTAL POINTS
®1P
f4i
.5
.5
cip
CLASSIFICATION
Class I 5-25 Points
CI.ss II 26-50 Points
C4ess . 51-65 Points
66-Up Points
Facilities having a rating of one through four points. Inclusive, do not require a certified operator.
Facilities having an activated sludge process will be assigned a minimum classification of Class II.
Facilities having treatment processes for the removal of metal or cyanide will be assigned a minimum classification of Class II.
Facilities having treatment processes for the biological removal of phosphorus will be assigned a minimum classification of Class III.
.0004 DEFINITIONS
The following definitions shall apply throughout This Subchapter.
(1) Activated Carbon Beds. A physicaVchemicai method for reducing soluble organic material from wastewater effluent; The column -type beds used in this
method will have a flow rate varying from two to eight gallons per minute per square foot and may be either upflow or downflow carbon beds. Carbon may or
may not be regenerated on the wastewater treatment plant site;
(2) Aerated Lagoons. A basin in which all solids are maintained in suspension and by which biological oxidation or organic matter is reduced through artificially
accelerated transfer of oxygen on a flow -through basis;
(3) Aeration. A process of bringing about Intimate contact between air or high purity oxygen in a liquid by spraying, agitation or diffusion;(3a) Extended
Aeration. An activated sludge process utilizing a minimum hydraulic detention time of 18 hours.
(4) Agriculturally managed site. Any site on which a crop is produced, managed, and harvested (Crop Includes grasses, grains. trees, etc.);
(5) Air Stripping. A process by which the ammonium Ion is first converted to dissolved ammonia (pH adjustment) with the ammonia then released to the
atmosphere by physical means; or other similar processes which remove petroleum products such as benzene, toluene, and xylene;
(6) Carbon Regeneration. The regeneration of exhausted carbon by the use of a furnace to provide extremely high temperatures which volatilize and oxidize the
absorbed Impurities;
(7) Carbonaceous Stage. A stage of wastewater treatment designed to achieve 'secondary' effluent limits;
(8) Centrifuge. A mechanical device In which centrifugal force Is used to separate solids from liquids or to separate liquids of different densi;las;
(9) Chemical Addition Systems- The addition of chemical(s) to wastewater at an application point for purposes of improving solids removal, pH adjustment.
alkalinity control, etc.; the capability to experiment with different chemicals and difierent application points to achieve a specific result will be considered one
system; the capability to add chemical(s) to dual units will be rated as one system; capability to add a chemical at a different application points for different
purposes will result In the systems being rated as separate systems;
(10) Chemical Sludge Conditioning. The addition of a chemical compound such as lime, ferric chloride, or a polymer to wet sludge to coalesce the mass prior to
Its application to a dewatering device;
(11) Closed Cycle Systems. Use of holding ponds or holding tanks for containment of wastewater containing Inorganic, non -toxic materials from sand, gravel,
crushed stone or other similar operations. Such systems shall carry a maximum of two points regardless of pumping facilities or any other appurtenances;
(12) Combined Removal of Carbonaceous BOD and Nitrogenous Removal by Nitrification- A single stage system required to achieve permit effluent limits on BOD
and ammonia nitrogen within the same biological reactor,
(13) Dechlorination. The partial or complete reduction of residual chlorine In a liquid by any chemical or physical process;
(14) Denitritication Process. The conversion o1 nitrate -nitrogen to nitrogen gas;

•
(15) Etectrodiatysls. Process for removing ionized salts from water through the use of ion -selective Ion -exchange membranes;
(16) Fitter Press. A process operated mechanically for partially dewatering sludge;
(17) Foam Separation. The planned frothing of wastewater or wastewater effluent as a means of removing excessive amounts of detergent materials through
the introduction of air in the form of fine bubbles; also called foam fractionation;
(18) Grit Removal. The process of removing grit and other heavy mineral matter from wastewater;
(19) Imhoff Tank. A deep two story wastewater tank consisting of an upper sedimentation chamber and a lower sludge digestion chamber.
(20) instrumented Flow Measurement. A device which Indicates and records rate of flow;
(21) ion Exchange. A chemical process in which ions from two different molecules are exchanged;
(22) Land application:
(a) Sludge Disposal. A final sludge disposal method by which wet sludge may be applied to land either by spraying on the surface or by subsurface injection
(i.e., chisel plow); [not applicable for types of sludge described In (11) of this Rule);
(b) Treated Effluent. The process of spraying treated wastewater onto a land area or other methods of application of wastewater onto a land area as a
means of final disposal or treatment;
(23) Microscreen. A low speed, continuously back -washed, rotating drum fitter operating under gravity conditions as a polishing method for removing
suspended solids from effluent;
(24) Nitrification Process. The biochemical conversion of unoxidized nitrogen (ammonia and organic nitrogen) to oxidized nitrogen (usually nitrate);
(25) Nitrogenous Stage. A separate stage of wastewater treatment designed for the specific purpose of converting ammonia nitrogen to nitrate nitrogen;
(26) Phosphate Removal, Biological. The removal of phosphorus from wastewater by an oxic/anoxic process designed to enhance luxury uptake of phosphorus
by the microorganisms;
(27) Polishing Pond. A holding pond following secondary treatment with sufficient detention time to allow settling of finely suspended solids;
(28) Post Aeration. Aeration following conventional secondary treatment units to increase effluent D.O. or for any other purpose;
(29) Post Aeration. (Cascade) A polishing method by which dissolved oxygen is added to the effluent by a nonmechanical, gravity means of flowing down a
series of steps or weirs; The flow occurring across the steps or weirs moves in a fairly thin layer and the operation of the cascade requires no operator
adjustment; thus, zero points are assigned even though this is an essential step to meeting the limits of the discharge permit;
(30) Powdered to Granular Activated Carbon Feed. A biophysical carbon process that utilizes biological activity and organic absorption by using powdered or
granular activated carbon; Virgin or regenerated carbon is feed controlled into the system;
(31) Preaeration. A tank constructed to provide aeration prior to primary treatment;
(32) Preliminary Units. Unit operations in the treatment process, such as screening and comminution, that prepare the liquor for subsequent major operations;
(33) Industrial Pretreatment.
(a) Pre-treatment Unit, Industrial. The conditioning of a waste at its source before discharge, to remove or to neutralize substances injurious to sewers and
treatment processes or to effect a partial reduction in Toad on the treatment process which is operated by the same governing body as the wastewater
treatment plant being rated;
b) Pre-treatment Program, Industrial - must be a State or EPA required program to receive points on the rating sheet;
(34) Primary Clarifiers. The first settling tanks through which wastewater is passed In a treatment works for the purpose of removing settleable and suspended
solids and BOD which is associated with the solids;
(35) Pumps. All influent, effluent and in -plant pumps;
(36) Radiation. Disinfection or sterilization process utilizing devices emitting ultraviolet or gamma rays;
(37) Reverse Osmosis. A treatment process In which a heavy contaminated liquid Is pressurized through a membrane forming nearly pure liquid free from
suspended solids;
(38) Rotating Biological Contractors. A fixed biological growth process in which wastewater flows through tanks in which a series of partially submerged circular
surfaces are rotated;
(39) Sand Filters:
(a) Intermittent Biological. Flttratton of effluent following septic tanks. lagoons. or some other treatment process In which further biodecomposttton is
expected to produce desired effluents; Hydraulic loading rates on these fitters are computed to gpd/ac and have a resulting low gpm/sf (less than one);
b) Recirculating biological - the same type of sand fitter as defined in Subparagraph (39) (a) of this Rule with the added capability to recycle effluent back
through the sand fitter,
(40) Sand or Mixed -Media Filters. A polishing process by which effluent limits are achieved through a further reduction of suspended solids;
(a) tow rate — gravity, hydraulically loaded filter with loading rates In the one to three gpm/sf range;
(b) high rate — a pressure. hydraulically loaded titter with loading rates in the five gpmisf range; At any rate. the loading rate wits exceed three gprrvsf;
(41) Secondary Clarifiers. A tank which follows the biological unit of treatment plant and which has the purpose of removing sludges associated with the
biological treatment units;
(42) Separate Sludge Reaeration. A part of the contact stabilization process where the activated sludge is transferred to a tank and aerated before returning it
to the contact basin;
(43) Septic Tank. A single -story settling tank in which settled sludge is in contact with the wastewater flowing through the tank; shall not be applicable for
septic tank systems serving single family residences having capacity of 2.000 gallons or less which discharge to a nitrification field;
(44) Sludge Digestion. The process by which organic or volatile matter and sludge is gasified. liquefied. mineralized or converted into more stable organic matter
through the activity of living organisms, which Includes aerated holding tanks;
(45) Sludge Drying Beds. An area comprising natural or artfficial layers of porous materials upon which digested sewage sludge Is dried by drainage and
evaporation;
(46) Sludge Elutriation. A process of sludge conditioning to which certain constituents are removed by successive washings with fresh water or plant effluent;
(47) Sludge Gas Utilization. The process of using sewage gas for the purpose of heating buildings, driving engines. etc.;
(48) Sludge Holding Tank (Aerated and Nonaerated). A tank utilized for small wastewater treatment plants not containing a digester In which sludge may be
kept fresh. and supernatant withdrawn prior to a drying method (i.e. sludge drying beds); This may be done by adding a small amount of air simply to keep the
sludge fresh. but not necessarily an amount that would be required to achieve stabilization of organic matter. A nonaerated tank would simply be used to
decant sludge prior to dewatering and would not allow long periods (several days of detention) without resulting odor problems;
(49) Sludge Incinerators. A furnace designed to bum sludge and to remove all moisture and combustible materials and reduce the sludge to a sterile ash;
(50) Sludge Stabilization (Chemical or Thermal). A process to make treated sludge less odorous and putrescrble, and to reduce the pathogenic organism
content; This may be clone by pH adjustment. chlorine dosing. or by heat treatment;
(51) Sludge Thickener. A type of sedimentation tank In which the sludge Is permitted to settle and thicken through agitation and gravity;
(52) Stabilization Lagoon. A type of oxidation lagoon in which biological oxidation of organic matter Is effected by natural transfer of oxygen to the water from
air (not a polishing pond);
(53) Stand -By Power Supply. On site or portable electrical generating equipment;
(54) Static Screens. A stationary screen designed to remove solids, including non -biodegradable particulate (ftoatabte solids, suspended solids and BOD
reduction) from municipal and industrial wastewater treatment systems;
(55) Tertiary Treatment. A stage of treatment following secondary which is primarily for the purpose of effluent polishing; A settling lagoon or sand or coal fitter
might be employed for this purpose;
(56) Thermal Pollution Control Device. A device providing for the transfer of heat from a fluid flowing in tubes to another fluid outside the tubes. or vice versa;
or other means of regulating liquid temperatures;
(57) Thermal Sludge Conditioner. A conditioning process by which heat Is added for a protracted period of time to improve the dewaterability of sludge by the
solubilizing and hydrauliztng of the smaller and more highly hydrated sludge particles;
(58) Toxic Materials. Those wastes or combinations of wastes. including disease -causing agents which atter discharge and upon exposure. Ingestion. Inhalation
or assimilation into any organism, either directly from the environment or indirectly by ingestion through food chains, will cause death, disease, behavioral
abnormalities. cancer. genetic mutations. physiological malfunctions (including maHunctions to reproduction) or physical deformations, in such organisms or their
offspring; Toxic materials include, by way of illustration and not limitation: lead, cadmium, chromium. mercury, vanadium, arsenic. zinc, ortho-nitro-chlorobenzene
(ONCE). polychlorinated biphenyls (PCBs) and dtchlorodiphenyl trtchloroethane (DDT); and any other materials that have or may hereafter be determined to have
toxic properties;
(59) Trickling Fitter. A biological treatment unit consisting of a material such as broken stone or rock over which wastewater is distributed; A high rate trickling
filter is one which operated at between 10 and 30 mgd per acre. A low rate trickling fitter Is one which is designed to operate at one to four mgd per acre;
(60) Trickling Fitter (Packed Tower). A plug flow type of operation In which wastewater flows down through successive layers of media or filtrate material; Organic
material is removed continually by the active biological fixed growth In each successive layer. This method may produce 'secondary' quality effluent, or may be
adapted to produce a nitrified effluent;
(61) Vacuum Fitter. Centrtiuges. or Fitter Presses. Devices which are designed to remove excess water from either digested or undigested sludge prior to disposal
or further treatment.

FACT SHEET FOR NPDES PERMIT DEVELOPMENT
�`z •. f �� 1 & "-
r: �
t 2z. njj' f IP y t
Faci�i�y�Znfo�mato .� � _.r..
°"4f t e 6 1 j i..,i .2 +;•`�s'.
S, F-_...
` ..' �-..
Facility TTame , :
Cone Mills (NC0004405)
YPermitte : k low• j,
1.75 MUD
County ; ; { _ ,
t,
Rutherford
Facility (''lass .
III
Regional- Oi ice. ,
Asheville
Facility/
(i e: Ne
Existing
xermit Status
Modification,
. x Renewal)
Existing
. rUS(. S opo Quad z
,E r
' ` ' ` "' ' �
} N # rfd,..2.. } r
.
`` r
Chesnee
.i .
, -
_ , 2
�t Ch ti szi
. ..., ream ara�cter�s c
.ecevnStream:
Second Broad River
IStrealiV .1 sstxcation
: -
C
Winter 7Q.i U (cfs)
..._
91.2
~SFubbasu
4 i t�t;hr Y w '] � .a..
�:
03-08-02
30Q2 � 9; ),:,2' r 2.
... �'^ic4: 7fjt :.tt 22 �.,:
�'
P
_....
N/A
.,:'^4
'D rains 1 ' Area m 2 _
219.6
1pAverage Plow C. :
312
SSummer Q., U i(cfs) _..
62.1
ilW C (/o);'
� .
4.2
Changes Incorporated into Permit Renewal
Proposed C hanges
Parameter Af ec�ted
r-:
-... 3as* for change s
Permit Cover Page
The expiration date has been
changed to July 31, 2003
NPDES Unit revised the
expiration dates for certain
permits to keep a more
manageable number of
permits in-house for review.
Supplement to Permit Cover
Sheet
Revised treatment plant
description
Revised as per application and,
Region staff report.
Effluent Limitations Page
Added '1•N and '1'P monitoring
Required for facilities that
discharge 50,000 GPD or
more. Requirement of
Administrative Code Section
2B.0500.
Effluent Limitations Page
Revised limits for BOD,
COD, TSS, and Sulfide
Revised using CFR guidelines
and production rates reported
in application. See notes
below.
Effluent Limitations Page
Revised monitoring frequency
for Sulfide from 3 / week to
weekly.
Facility requested reduction in
monitoring. Past data
indicates some elevated
levels, but no violations.
Effluent Limitations Page
Revised Fecal Coliform
monitoring requirement from
weekly to 3 / Week.
Requirement of
Administrative Code Section
2B.0500.
Effluent Limitations Page
Revised monitoring frequency
for Arsenic and Nickel from
Monthly to Quarterly.
Revised as per results of
reasonable potential analysis.
Effluent Limitations Page
Added limit of 0.3 mg/1 for
mercury.
Reasonable potential analysis
results determined that a limit
was necessary.
Effluent Limitations Page
Revised monitoring frequency
for Cooper, and Zinc from
Monthly to 2 / Month.
As per current SOP for Class
three facilities.
Page 1
Version: January 5, 1999

Facility Notes for Cone Mills Corrporation Cliffside Plant (NC0004405)
MEMORANDUM
TO: File
FROM: Jeff Myhra
DATE: July 16, 1998
SUBJECT: Permit file review for Cliffside Plant (NC0004405)
Facility Information:
Qw = 1.75 MGD
Second Broad River
03-08-02
Stream Class:
Second Broad River
C
9-41-(24.7)
8-3-92
• The Cliffside Plant is dedicated to denim manufacturing with operations that include yarn
manufacturing, dyeing, slashing, weaving, finishing and sanforizing. These processes are
performed on cotton fibers with water based treatments. Conventional textile processing
is performed. The Plant produces a Jacquard woven material using man-made fibers.
Sanitary waste also makes up a portion of the discharge.
• Facility is classified as a categorical industry. 40 CFR Part 410 "Textile Mills Point
Source" applies to the facility operations. The following subparts are applicable:
- Subpart D " Woven Fabric Finishing Subcategory" applies because the
facility operations include woven fabric dyeing.
Subpart G " Stock and Yam Finishing Subcategory" applies because the
facility operations include yarn dyeing and finishing.
Subpart H "Non -woven Manufacturing Subcategory" applies because the
facility manufactures non -woven synthetic textile products by mechanical,
thermal, and/or adhesive bonding procedures.
• The following limits are applicable to facility operations:

Cliffside Plants 1 and II: The Cliffside Plants are dedicated to denim manufacturing, with
operations that include yarn manufacturing, dyeing, slashing, weaving, finishing, and sandorizing.
These processes are performed on cotton fibers with water -based treatments. Maximum
production capacity for both plants equals 220,000 lbs/day (this value was used to calculate daily
maximum limits). The monthly average production rate (average of daily maximum production
over a 3-year period) for both plants is 190,000 lbs/day (this value was used to calculate monthy
average limits).
Subpart G -
410.72 (a)
(BPT Limits)
Monthly
Average
(lbs/1 000
lbs)
Monthly
Average
Limit
(lbs)
Daily
Max
(lbs/1 000
lbs)
Daily Max
Limit
(lbs)
BOD5
3.4
646
6.8
1,496
COD
42.3
8,037
84.6
18,612
'1'SS
8.7
1,653
17.4
3,828
Sulfide
0.12
22.8
0.24
52.8
Phenol
0.06
11.4
0.12
26.4
Total Chromium
0.06
11.4
0.12
26.4
PH
6-9
6-9
6-9
6-9
TOTALS FOR CLIFFSIDE PLANTS
Pollutant
Monthly
Average
Limit
(lbs)
Daily
Maximum
Limit
(lbs)
BOD5
646
1,496
COD
8,037
18,612
'1'SS
1,653
3,828
SuIfide
22.88
Phenol
11.4
26.4
Total Chromium
11.4
26.4
PH
6-9
6-5

Haynes Plant: This plant produces greigTmaterial from cotton fibers. Maximum production was
estimated to be 120,000 lbs/day (this value was used to calculate daily maximum limits). The
monthly average production rate (average of daily maximum production over a 3-year period) for
this plant was estimated to be 105,000 lbs/day (this value was used to calculate mouthy average
limits).
Subpart D -
410.42 (a)
(BPT Limits)
Monthly
Average
(lbs/1000
lbs)
Monthly
Average
Limit
(lbs)
Daily
Max
(lbs/1000
lbs)
Daily Max
Limit
(lbs)
BOD5
3.3
346.5
6.6
792
COD
30.0
3,150
60.0
7,200
'1'SS
8.9
934.5
17.8
2,136
Sulfide
0.10
10.5
0.20
24
Phenol
0.05
5.25
0.10
12
lotal Chromium
0.05
5.25
0.10
12
PH
6-9
6-9
6-9
6-9
Subpart 1) -
410.42 (c)
(BPT Limits)
Monthly
Average
(lbs/1000
lbs)
Monthly
Average
Limit
(lbs)
Daily
Max
(lbs/1000
lbs)
Daily Max
Limit
(lbs)
COD
20.0
2,100 40.0
4,800
Subpart D -
410.43 (a)
(BAT Limits)
Limits are the same as specified in Subpart D - 410.42 (a).
TOTALS FOR HAYNES PLANT
Pollutant
Monthly
Average
Limit
(lbs)
Daily
Maximum
Limit
(lbs)
BOD5
346.5
792
COD
5,250
12,000
TSS
934.5
2,136
Sulfide
10.5
24
Phenol
5.25
12
Total Chromium
5.25
12
PH
6-9
6-9

Packaging and llyehouse: Phis process is classified as a new source therefore NSPS apply. .
Production was estimated to be 20,000 lbs/day. No monthly average production values were
supplied here so 20,000 lbs/day was used for both monthly average and daily maximum limits.
Subpart G -
410.75
(NSPS Limits)
Monthly
Average
(lbs/100
0lbs)
Monthly
Average
Limit
(lbs)
Daily
Max
(lbs/10001
bs)
Daily
Max
Limit
(lbs)
BOD5
1.9
38
3.6
72
COD
21.9
43.8
33.9
678
TSS
4.4
88
9.8
196
Sulfide
0.12
2.4
0.24
4.8
Phenols
0.06
1.2
0.12
2.4
'Total Chromium
0.06
1.2
0.12
2.4
PH
6-9
6-9
6-9
6-9
TOTALS FOR PACKAGING AND DYEHOUSE PLANT
Pollutant
Monthly
Average
Limit
(lbs)
Daily
Maximum
Limit
(lbs)
BUDS
38
72
COD
43.8
678
TSS
88
196
Sulfide
2.4
4.8
Phenols
1.2
2.4
Total Chromium
1.2
2.4
PH
6-9
6-9

Jacquard Plant: "1'his plant produces synthetic fibers and produces a jacquard woven material.
This plant began operations in 1995. Water use includes slashing, boiler, and air conditioning
equipment. Production was estimated to be 30,000 lbs/day (this value was used to calculate daily
maximum limits). The monthly average production rate (average of daily maximum production
over a 3-year period) for this plant was estimate to be 25,000 lbs/day (this value was used to
calculate monthy average limits)
Subpart H -
410.85
(NSPS Limits)
Monthly
Average
(lbs/100
0lbs)
Monthly
Average
Limit
(lbs)
Daily
Max
(lbs/10001
bs)
Daily
Max
Limit
(lbs)
BUDS
1.4
35
2.6
78
CUD
9.8
245
15.2
456
TSS
2.2
55
4.9
147
Sulfide
0.023
0.575
0.046
1.38
Phenols
0.0I 1
0.275
0.023
0.69
Total Chromium
0.011
0.275
0.023
0.69
pH
6-9
6-9
6-9
6-9
TOTALS FOR JACQUARD PLANT
Pollutant
Monthly
Average
Limit
(lbs)
Daily
Maximum
Limit
(lbs)
BUDS
35
78
COD
245
456
'1'SS
55
147
Sulfide
0.575
1.38
Phenols
0.275
0.0
'Total Chromium
0.275
0.69
pH
6-9
6-9
Secondary Limits: Sanitary wastewater flow was estimated to be 58,000 gallons/day.
Monthly
Average
(mg/1)
Monthly
Average
Limit
(mg/1)
Daily
Max
(mg/1)
Daily
Max
Limit
(mg/I)
BUDS
30.0
14.51
45.0
21.77
TSS
30.0
14.51
45.0
21.77

BOD5
1,080
2,459.8
COD
13,575.8
31,746
TSS
2,745
6,328.8
Sulfide
36.3
82.9
Phenols
18.1
41.5
Total Chromium
18.1
41.5
pH
6-9
6-9
• Staff report was prepared by Roy Davis on June 17, 1998.
Region commented that since this is a textile dyeing and finishing operation
some metals and salts are present in the effluent but historically not in toxic
concentrations.
Facility is rated Class III.
In general, the region commented that this facility has an excellent compliance
record and protects water quality standards in the receiving stream. The
Asheville Regional office recommends that the Division proceed with
renewal.
No special basinwide management strategies apply
1 eire-rvr!'wy+-,
�a:l vMay
y/ s As (/. 7s. A & /g. 3y G •/ fr /C)
eote
Cr r. 6.7 60 4 d2. / Cf1
/2 aoli
itletta„t oe_e444.„1/
0...1 I
64,14,4a
oeOZ30,
�1 id, :
enyou
(2.7c 4-
(s-e.et /e)
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��'•1 �s� Gz ��/1
tAil‹ ,144$44_5 1/.4.4

4v{iv(C/44,:ait
Facility Name =
Cone Mills
Parameter =
Chromium
NPDES # =
NC0004405
Standard =
50
pg/I
Qw (MGD) =
1.75
7Q1Os (cfs)=
62.1
n
BDL=1/2DL
tual Data
/WC (%) =
4.20
Jan-98
10
< 20
Jan-98
10
< 20
FINAL RESULTS
Jan-98
10
< 20
Chromium
Jan-98
10
< 20
Max. Pred Cw
176
Dec-97
10
< 20
Allowable Cw
1190.5
Dec-97
10
< 20
Nickel
Dec-97
10
< 20
Max. Pred Cw
112.5
Dec-97
10
< 20
Allowable Cw
595.2
Dec-97
10
< 20
Arsenic
Nov-97
10
< 20
Max. Pred Cw
10
Nov-97
10
< 20
Allowable Cw
1190.5
Nov-97
10
< 20
Le- .
Nov-97
10
< 20
-:.. Pred Cw
0.0
Oct-97
10
< 20
Allo , = ble Cw
0.0
Oct-97
10
< 20
Mercury
Oct-97
10
< 20
Max. Pred Cw
349.52
Oct-97
10
< 20
Allowable Cw
0.3
Sep-97
10
< 20
Sep-97
10
< 20
Sep-97
10
< 20
Sep-97
10
< 20
Aug-97
80
80
Aug-97
10
< 20
Aug-97
10
< 20
Aug-97
10
< 20
Jul-97
2.5
< 5
Jul-97
2.5
< 5
Jul-97
2.5
< 5
Jul-97
2.5
< 5
Jul-97
2.5
< 5
Jun-97
2.5
< 5
Jun-97
2.5
< 5
Jun-97
2.5
< 5
Jun-97
2.5
< 5

Cary North WWTP
May-97
2.5
<
5
May-97
2.5
<
5
May-97
2.5
<
5
May-97
2.5
<
5
Apr-97
2.5
<
5
Apr-97
2.5
<
5
Apr-97
2.5
<
5
Apr-97
2.5
<
5
Apr-97
2.5
<
5
Mar-97
2.5
<
5
Mar-97
2.5
<
5
Mar-97
2.5
<
5
Mar-97
2.5
<
5
Feb-97
2.5
<
5
Feb-97
17
17
Feb-97
2.5
<
5
Feb-97
2.5
<
5
Jan-97
2.5
<
5
Jan-97
2.5
<
5
Jan-97
2.5
<
5
Jan-97
2.5
<
5

Cary North VW TP
1
Parameter =
Nickel
Standard =
25
pg/I
RESULTS
n
DL=1/2Ddual
Data
RESULTS
Std Dev.
44.547727
Jan-98
25
< 50
Std Dev.
11.67
Mean
48.5
Dec-97
25
< 50
Mean
12.88
C.V.
0.9185098
Nov-97
25
< 50
C.V.
0.906
N =55
Oct-97
25
< 50
N = 13
Sep-97
25
< 50
Mutt Factor
2.2
Aug-97
25
< 50
Mult Factor
4.5
Max. Value
80
pg/I
JuI-97
2.5
< 5
Max. Value
25
pg/
Max. Pred
C 176
pg/I
Jun-97
2.5
< 5
Max. Pred C
112.5
pg/
Allowable C
1190.5
pg/I
May-97
2.5
< 5
Allowable C
595.2
pg/
Apr-97
2.5
< 5
Mar-97
2.5
< 5
Feb-97
2.5
< 5
Jan-97
2.5
< 5

Cary North WWTP
Parameter =
Arsenic
Standard =
50
fag/1
n
DL=1/2DLtual
Data
RESULTS
Jan-98
2.5
< 5
Std Dev.
0.97
Dec-97
2.5
< 5
Mean
2.346
Nov-97
2.5
< 5
C.V.
0.412
Oct-97
2.5
< 5
N = 13
Sep-97
2.5
< 5
Aug-97
2.5
< 5
Mult Factor
2
Jul-97
3
3
Max. Value
5
pg/
Jun-97
1.5
< 3
Max. Pred
C 10
pg/
May-97
5
5
Allowable C1190.5
fag/
Apr-97
1.5
4 3
Mar-97
1.5
< 3
Feb-97
1.5
c 3
Jan-97
1.5
i_ 3

Cary North VVWTP
Parameter=
Mercury
Standard =
0.012
pg/I
n
DL=1/2DLtual
Data
RESULTS
Jan-98
0.4
0.4
Std Dev.
7.048
0.25
< 0.5
Mean
2.65
0.1
< 0.2
C.V.
2.66
0.25
< 0.5
n=13
0.25
< 0.5
4.5
4.5
Mult Factor)
13.6
25.7
25.7
Max. Value
25.7
Ng/
2.5
<5
Max. Pred
C 349.5
Ng/
0.1
< 0.2
Allowable G
0.3
pg/
0.1
< 0.2
0.1
< 0.2
0.1
< 0.2
0.1
< 0.2
I
,/`/ /y a �1
With
Jrd4
$-f' `" r �) ``' its °"
1:0
a) U yrt L
41 c)b
Ctlwv"1"

NC0004405
Facility: Cone Mills
Discharge to: Second Broad River
Stream class and index #: WS-III
Residual Chlorine
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (UG/L)
IWC (%)
Allowable Conc. (ug/l)
Fecal Limit
Ratio of 22.9 :1
62.1
1.75
2.7125
17.0
0
4.19
406.20
Ammonia as NH3
(summer)
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL (MG/L)
IWC (%)
Allowable Concentration (mgll)
Ammonia as NH3
(winter)
7Q10 (CFS)
200/100m1 DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL (MG/L)
IWC (%)
Allowable Concentration (mg/I)
62.1
1.75
2.7125
1.0
0.22
4.19
18.86
minimum = 2
91.2
1.75
2.7125
1.8
0.22
2.89
54.92
minimum = 4

CNE
June 2, 1998
Mr. Charles H. Weaver, Jr.
NPDES Unit
NCDENR - DWQ
P.O. Box 29535
Raleigh, N.C. 27626-0535
Re: NPDES Permit No. NC0004405
Rutherford County
Dear Mr. Weaver:
/tZ /00
60
p yNRA-
\-0-0g02
JUG 0 5 1598
POINT SOURCE BRANCH
We are requesting the renewal of the above mentioned permit. There have
been several additions to the wastewater treatment plant since the last permit
renewal. First, a 500,000-gallon sludge storage tank was added in 1992. Second, an
Aqua Disk Color Removal system was started -up in early 1995. The addition
included a flocculator with polymer addition, three Aqua Disk units with controls, a
wood beam building, a return sludge pump station, and a 500,000-gallon sludge
storage tank. Total sludge storage capacity is 1,000,000 gallons.
There have also been some changes in the production facilities at Cliffside. A
new indigo dye rope range was added at the Cliffside plant in 1996. In 1995 the
Cone Jacquard weave plant was started -up. The jacquard plant processes synthetic
fibers and produces a jacquard woven fabric. Water use includes slashing, boiler, and
air-conditioning equipment.
P.O. Box 2654o
CONE MILLS CORPORATION
310I NORTH ELM STREET
FAX: [phone]
GREENSBORO, NC 27415-654o

Iiia��•7ifj T i
ii J
Mr. Charles H. Weaver, Jr.
Page 2
June 2, 1998
Also, we are requesting that sulfides be eliminated from our new permit or that
monitoring be significantly reduced. Current requirements are a grab sample three
times per week with a monthly average limit of 36.5 lbs/day. Values reported for
August thru December 1997 averaged below 1.0 lbs/day. January thru July 1997
values averaged less than 12.0 lbs/day.
Enclosed is a check for $300.00 for the permit renewal fee, Standard Form C,
and our sludge management plan. The priority pollutant analysis will be forwarded
to you directly from the lab. We feel that the waste water treatment plant is well
operated, well maintained and will continue to perform within its design capacity at
1.75 MGD. If there are any questions or if additional information is needed please
call me at (336)-379-6579.
Sincerely,
Jeffrey S. Wells, P.E.
Environmental Engineer
Enclosures
Cc: Mr. Roger Edwards - Asheville Regional Office
P.O. Box 2654o
CONE MILLS CORPORATION
3101 NORTH ELM STREET
FAX: [phone]
GREENSBORO, NC 27415-6S4o

2- 500, 000 6AL.
(5LUP6E SiGE. TA14K5
CaLeR REMOVAL RETURN :$L000E
INFLUENT
DI:516N-: 1:75 MGD
MGR
(FROM HAYII.E5)._CLIFF-
.'1D RRN- ANTAW --
VtLLAGE)
LUP6E
t4Aa/NG
entriam
,113
Z
04
8AR
- 3GR�N
RAPID
MIXER
AERATION 0AIIN
__(-A'IECHA tildAL f} RAVI )
RETtRN SLuDGe
PUMP 6I.Pc .
AE1r4TOR
C Lz CONTACT
REAEMTIO.N.TANK _.
SO2
ST6E.
oo l PI scwA GE.
0.74 MGD
EQUALIZATION 0,43114 AT
CLIFs1'e W FAvE RANT
D
Sit=uQla
aarP TANK
POLyMERADDiTio/c Y
AQUA
DISK
FILTR4 710N
1"-
PIOC471
COLOR.-. REMOVAL
_RETURN _ S.LU DGE
PUMP-- STATION
_5CHEMA_T_f.0 _O_F_WA.S2EWAT_ER_.E_tDW
GC1FF31DEIWA5TE6YA7'ER 7R?ATMENi PLANT .
D f5 CHAR GE E+7r,4 L 14o. 001
DATE: 5-14-48:

CLIFFSIDE WWTP
SLUDGE MANAGEMENT PLAN
The sludge holding system at the Cliffside Wastewater Treatment Plant consist of two five
hundred thousand gallon sludge storage tanks. Sludge is wasted into these tanks periodically to
maintain a MLSS in the aeration basin of 5000 to 6000 mg/1. This sludge is aerobically digested
for a minimum of thirty days. Next the sludge is thickened by decanting supernatant from the
tanks into the aeration basin. After the tanks are full and at the desired three percent solids range
Environmental Waste Recycling(EWR) is called to schedule the land application of these
biosolids.
The current permit (see attachment) is effective from May 30, 1996 to June 30 1999 and
provides for the application of approximately 180 dry tons per year of sludge from the Cliffside
WWTP to approximately 597.2 acres of land in Rutherford and Cleveland Counties. All
monitoring and testing is performed by EWR and is kept on file by Cone.

2-.Soo, 00o GAL.
SLUDGE 5TGE. TA;4K5
COLOR 1ZEMOVA L RETURN :SLUDGE.
INFLUENT
DE.516K s' 1:75 MGD
.FRo 1141FS).GL1Fi=.
ANT-4Ft
EQUALIZATION- A5114 ,4T
CLr i17E VWE4vE PtANr
'ALL
SLuP6 c
LOADING
.1•PiTIoN
JP
5AR i-
C - w 7
a
RAPID
MtxFR.
AERATIOIJ ,5As14
(MMEcI-IANIGAL A- RAToQ.-
7 t ()
FINAL .
GL'AKIFIcE-IZ
w
0
RETVRts! 5LuPGE
PUMP' E ;'iG.
AEl4TaR
c o-luuvn
po)
LZ Coi rAcT
REAERATIQN TANK..
.3)1
VI4G-R51DN iff;X
FINAL
cLAR1FIE
GL2
5TGE..
LVX6tk
.
001 DISCHARGE
0.74 MGD h"
.SvLfuzlc
Aef D TANK
AquA
D 15 K FL OCCULATD;
FU6TP4 TfO� 3)
kit
COLo2 2EMoVAL
_RETURN SLUDGE
PUMP STATION
( .J FF5P 45TM4TEER R?ATM ENT PLA JT
1715c,HARGE-5ctz14L No. co►
_ U�,