NC0006254_Renewal (Application)_20230622

ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
David Hallock
Blue Ridge Tissue Corporation
PO Box 99
Patterson, NC 28661
Subject: Permit Renewal
Application No. NC0006254
Patterson Mill
Caldwell County
Dear Permiee:
NORTH CAROLINA
Environmental Quality
June 22, 2023
The Water Quality Permitting Section acknowledges the June 16, 2023 receipt of your permit renewal application and
supporting documentation. Your application will be assigned to a permit writer within the Section's NPDES WW permitting
branch. Per G.S. 150E-3 your current permit does not expire until permit decision on the application is made.
Continuation of the current permit is contingent on timely and sufficient application for renewal of the current permit. The
permit writer will contact you if additional information is required to complete your permit renewal. Please respond in a
timely manner to requests for additional information necessary to allow a complete review of the application and renewal
of the permit.
Information regarding the status of your renewal application can be found online using the Department of Environmental
Quality's Environmental Application Tracker at:
https•//deg nc gov/permits-regulations/permit-guidance/environmental-application-tracker
If you have any additional questions about the permit, please contact the primary reviewer of the application using the
links available within the Application Tracker.
ec: WQPS Laserfiche File w/application
Sincerely,
Wren Thedford
Administrative Assistant
Water Quality Permitting Section
North Carolina Department of Environmental Quality I Division of Water Resources
AsheWlle Regional Office 1 2090 US. Nlgl w y 70 1 Smnnanok North Carolina 28778
82&2%.4500

NPS
May 4, 2023
3303 Spirit Way
Green Bay, WI 54304
800-558-5066
f 920-983-9291
www.npsholdinas.com
Division of Water Resources
Water Quality Permitting Section-NPDES
1617 Mail Service Center Laserfiche
Raleigh, NC 27699
RE: Permit Renewal Application for NC0006254
Please find enclosed our completed NPDES permit renewal application with
attachments in support of our renewal request.
Following the previous application submitted on July 26, 2019, the following
changes are noted:
1. Installation of a water treatment process consisting of a DAF clarifier,
gravity table, and screw press. This effort is with the intention of
replacing the flow to the open fiber traps. One of the two fiber traps has
been closed. Flow to the existing fiber trap is only used as an
emergency backup during process disruptions.
2. The three year daily average production has dropped to 24.4 tons from
26.1 tons.
3. The three year daily average discharge has increased from 241,500 GPD
to 276,000 GPD.
4. The effluent defoamer has changed from Fennotech 1725 to Combat
504.
Please contact me regarding any questions at my office phone [phone], cell
phone [phone] or email at [e-mail].
Sincerely,
David Cunningham
Process Engineer
NPS Holdings
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NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number INCO006254
Please print or type.
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
NPS Holdings LLC
Patterson Mill
1427 Yadkin River Road
Lenoir
NC / 28645
828 757 7536
[e-mail]
2. Location of facility producing discharge:
Check here if same as above CKX
Street Address or State Road
City
State / Zip Code
County
Caldwell
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name NPS Holdings LLC
Mailing Address 1427 Yadkin River Road
City Lenoir
State / Zip Code NC / 28645
Telephone Number 828 757 7536
Fax Number
4. Ownership Status:
Federal ❑ State ❑ Private NX Public ❑
Page 1 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
5. Standard Industrial Classification (SIC) code(s): 2621
6. Number of employees: 68
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space prot4ded is not sufficient attach a
separate sheet of paper with the system description.
Attachment A: Description of Wastewater treatment.
Attachment B: Wastewater treatment flow diagram
Attachment C: Description of the manufacturing process that generates wastewaters
8. Is facility covered under federal effluent limitation guidelines? S
Yes ❑
If yes, specify the category?
9. Principal product(s) produced: Tissue & Towel
Principal raw material(s) consumed: Recycled pre consumer fiber waste such as boxes,
plates, tissue, and towels.
Briefly describe the manufacturing process(es):
Attachment C
Page 2 of 5 C-MI 10108

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
/List snerifir amounts rnnsiimed nn.d/nr units nfnrnrlurtinn ni)er the Tn.ct throo nonrcl
Product Produced or Raw Material
Consumed
AVERAGE
Product Produced or Raw Material
Consumed
PEAK
per Day
24.4 tons
44.2 tons
per Month
742 tons
881 tons
per Year
T9,531 tons
9,259 tons
• Data based on last three years. (2020-2022)
11. Frequency of discharge: Continuous 29 x Intermittent ❑
If intermittent:
Days per week discharge occurs: 7 Duration: 24 hours
12. Types of wastewater discharged to surface waters only
Discharge
Flow
GALLONS PER DAY
Sanitary - monthly average
Utility water, etc. - monthly average
Process water - monthly average
264,000
Stormwater - monthly average
Other - monthly average
Explain: Backflush of river water filter
12,000
Monthly Average
276,000
total discharge (all types)
• Data based on last three years. (2020-2022)
13. Number of separate discharge points: 2 Outfall Identification number(s) # 1 and #2
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Yadkin River
Page 3 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data [for new or proposed discharges]
Provide data for the parameters listed. Temperature and pH shall be grab amples, for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly
average. If only one analysis is reported, report as daily maximum.
NOTE: Permittees requesting renewal should complete the table ONLY for the parameters
currentlu monitored. Summarize the oast 3 nears of effluent data -
Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
456
173
lbs/day
Chemical Oxygen Demand (COD)
628
398
lbs/day
Total Organic Carbon
Total Suspended Solids
315
125
lbs/day
Ammonia as N
Temperature (Summer) (Apr -Sept)
26
16.8
Deg C
Temperature (Winter) (Oct -Mar)
25
15.0
Deg C
pH
8.2
7.3
Fecal Coliform (If sanitary waste is
present)
Total Residual Chlorine (if chlorine is
used)
"Data based on last three years. (2u2u-2U22)
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable
Type Permit Number Type Permit Number
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES NC0006254 Dredge or fill (Section 404 or CWA)
PSD (CAA) Other WQ0011532
Non -attainment program (CAA)
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Combat 504: Effluent defoamer, 39 lbs/day
Boiler treatment BG-822 Alkalinity Control, 2.4 lbs/day
Boiler treatment BC-621 Scale Control, 2.2 lbs/day
Boiler treatment OP 928 Oxygen Control, 5.4 lbs/day
Boiler treatment SR 222 Corrosion Control, 3.4 lbs/day
Page 4 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Avid Cunni h ess En ; Aetr
Printed name of Person SignL14 Title
Signature of Applicant Date
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 5 of 5 C-MI 10/08

5/4/23
Attachment A
Description of Wastewater Treatment
3303 Spirit Way
Green Bay, WI 54304
800-558-5066
i 920-983-9291
www.npscoro.com
Wastewater is pumped from the effluent pit located at the tissue machine to the
Shaker Screen in our water treatment area. Screened wastewater is pumped to our
Dissolved Air Flotation where fibers are separated from the wastewater. Fibers are
concentrated in a Gravity Table and screw press before dropping into dumpsters to be
waste hauled. Clarified water is pumped to the Aeration Basin. Effluent from the
Aeration Basin is sent to a settling pond (polishing pond) before discharging to the
Yadkin River.
Attachment B
Wastewater treatment flow diagram
Shaker Screen DAF Clarifier Aeration Basin Settling Pond
850,000gal 600,000 gal Effluent to Yadkin River
Gravity Table &
• Screw Press Solids collected in clumpsters and waste hauled
• Fiber traps had fed Aeration Basin previously and is only used as a backup system.
Attachment C
Description of manufacturing process that generates waste waters
Recycled fiber (brown boxes, white plates, etc.) are ground in a pulper to separate the
fibers and dilute the stock to a pumpable consistency of 5%. This thick stock is
pumped to the tissue machine where it passes through a refiner for further fiber
development before being diluted to .1 %. This thin stock is distributed across a —9'
wide forming wire at —1,000 fpm whereby the forming sheet is dewatered prior to
contacting a heated forming drum called a Yankee. All water extracted during the
drying process is recycled except for tank overflows. The sheet is continuously
pulled from the Yankee drum and formed into the tissue/towel roll at a moisture
content of about 5%.
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