NC0083275_Permit Issuance_19981221

State of North Carolina
Department of Environment
and Natural Resources A
�Division of Water Quality
�-...ice•
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary NCDENR
A. Preston Howard, Jr., P.E., Director
December 21, 1998
Mr. Gregory Boozer
Vice President, Manufacturing
Dan River Incorporated
P.O. Box 261
Danville, Virginia 24543
Subject: NPDES Permit Issuance
Permit Number: NCO083275
Dan River Inc. -Harris Facility
Rutherford County
Dear Mr. Boozer:
In accordance with the application for discharge permit received on April 27, 1998, the Division
is forwarding herewith the subject state - NPDES permit. This permit is issued pursuant to the
requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between North Carolina and the U.S. Environmental Protection Agency dated December 6, 1983.
As reflected in the Draft Permit sent for your review on November 4, 1998, limits for cfrtain
parameters have changed. These limits are based on the production numbers that were reported
by the Dan River facility and based on guidance provided by the EPA.
For this permit period, the Division has changed the limits for Sulfide, Phenol, and Total
Chromium. Based on the effluent data reported in the Harris facility's DMRs monitortAg for
Lead, MBAS, Zinc and Copper, have been reduced to Quarterly.
There are two other changes that you should note in this final permit. The change in the
expiration date is due to a change in the 030802 basin schedule and will effect all dischargers in
this subbasin. The toxicity test has been changed from Acute Pass/Fail at 75% to Chronic
Pass/Fail at 0.75% in accordance with the October 1996 memo by Steve Tedder, Section Chief.
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 a demand is made, this permit shall be final and binding.
Please take notice that this permit is not transferable. Part II, EA. addresses the requirements to
be followed in case of change in ownership or control of this discharge.
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
83275 cov Itr

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, Coastal
Area Management Act, or any other Federal or Local governmental permits may be required.
If you have any questions or need additional information, please contact Mr. Steven D. Pellei,
telephone number [phone], extension 516.
Sincerely,
Original Signed By
David k Goodrich
A. Preston Howard, Jr., P.E.
cc: Central Files
Mr. Roosevelt Childress, EPA
Asheville Regional Office, Water Quality
NPDES Unit, Permit File 4
Point Source Compliance/Enforcement Unit

Permit No. NCO083275
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 Water Quality Commission, and the
Federal Water Pollution Control Act, as amended,
Dan River Incorporated
is hereby authorized to discharge wastewater from a facility located at
Harris Facility
on NCSR I I I I
south of Rutherfordton
Rutherford County
to receiving waters designated as the Broad River in the Broad River Basin
in accordance with the discharge limitations, monitoring requirements, and other conditions set forth in
Parts I, II, III, and IV hereof.
This 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 December 21,1998.
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By the Authority of the Environmental Management Commission

Permit No. NC0083275 ;
SUPPLEMENT TO PERMIT COVER SHEET
Dan River Incorporated
is hereby authorized to:
1. Continue to operate an existing 0.91 MGD wastewater treatment facility consisting of three
static bar screens, an equalization/neutralization basin, dual aeration basins with fine bubble
diffusers, two final clarifiers, a Parshall flume effluent meter, sludge digester, sludge holding
tank, and standby generator located at the Harris Facility on NCSR 1111, south of
Rutherfordton, Rutherford County, and
2. Discharge wastewater from said treatment works at the location specified on the attached map
into the Broad River which is classified C waters in the Broad River Basin

ROAD CLASSIFICATION
PRIMARY HIGHWAY LIGHT Ty
ROAD HARDOR
HARD SURFACE IMPROVED SURFACE
SECONDARY HIGHWAY
HARDSURFACE =301111111=1 UNIMPROVEDROAD
ide 35°12'23" Longitude 81053'15"
# G1 1 NW Sub -basin 030802
im Class C
Class 55 16
no Stream
Q 0.91 MGD
SCALE 1:24 000
0 m. 11, FEET
xww000�.a� KILOMETER
CONTOUR INTERVAL 5 FEET
QUAD LOCATION
Dan River Incorporated
• NCO083275
Rutherford County

A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0083275
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
ont y
Average
Weekly
Average
Daily
Maximum
e asurement
Frequency
Sample
Type
Sample
Location*
Flow
ontinuous
ecor ing
or
ay,
s ay
s ay
ee y
omposi e
s ay
s ay
ee y
omposi e
Total uspen a esi ue
s ay
s ay
Weekly
omposi e
u i e
7.0 lbs/day
s ay
ee y
Grab
Phenols
3.5 lbs/day
s ay
Weekly
Grab
Total Cromium
s ay
8.2 lbs/day
ee y
omposi e
i and urease
mg
mg
Weekly
ra
empera ure
ee y
ra
pH
3[Week
Gr5b
Total Nitrogen 2+ 3+
emi-annua y
omposi e
otal Phosphorus
semi-annually
Composite
Conductivity
Monthly
omposi e
Copper
ua ery
omposi e
Lead
Quarterly
omposi e
Zinc
ua ery
omposi e
IVIBAS
ua ery
omposi e
Chronic Toxicity2
IQuarterly
Composi e
Notes:
* Sample locations: E - Effluent, I - Influent
1 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
2 Chronic Toxicity (Ceriodaphnia) P/F at 0.75%; March, June, September and December, See Part I, Condition A(2).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Part I Permit No. NCO083275
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 0.75% (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 March, June, September, and December. 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.
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.
QCL P/F Version 9196

PUBLICNorth
AFFIDAVIT OF PUBLICATION o
State of North Carolina
Environmental W
Management Commission L CV
Post Office Box 29535 _
Raleigh, NC 27626-0535 STATE OF NORTH CAROLINA UJ
v
NOTIFICATION OF UJ O
INTENT TO ISSUE A LK Z
STATE NPDES PERMIT RUTHERFORD COUNTY
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 I
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.'
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 wastewater from 1 outfalll
221-A and NCSR 1003, into the Broad River, .a
Cliffside, Rutherford Coun- Class C stream in the
ty. The facility discharges Broad River Basin which
1.750 MGD of treated do- has a 7Q10 flow of 186.0
mastic and industrial cts. No parameters are
wastewater from an outfall water quality limited, but
into Second Broad River, a this discharge may affect
Class WA -III stream in the future allocations.
Broad River Basin which
Date 10/27/98 has a 7Of0 flow of 62.1
cis.
David A. Goodrich
for A. Preston Howard, Jr.,
P.E. Director .2. NPDES No.
Division of Environmental NC0083275. Dan River,
Management Inc., PO Box 217, Spin -
Public notice of intent to is- dale, NC 28160 has ap-
plied for a permit renewal
sue a State NPDES permit for an existing facility lo-
to the following: cated at the Harris Facility
1. NPDES No. NC NCSR 1111, south of
000L4D5 CDo.4:M: o.., aeddrdton in Ruther-
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 -
at 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
dmm?stir• and inr+•5•ria�
I Advertlsing Manager)
me this
Notary Public)
•y 12, 2001

DIVISION OF WATER QUALITY
October 30, 1998
TO: Dave Goodrich
THROUGH: Matt Matthews Y'"fv�
FROM: Kristie Robeson 9
SUBJECT: Draft Permit Corrections:
Dan River Inc. -Harris Facility
NPDES Permit No. NC0083275
Rutherford County
Our office received the draft permit for the subject facility. The effluent limitations
page for this draft contains an incorrect effluent percentage for chronic toxicity. This
facility should be permitted to conduct chronic toxicity testing at 0.75% as opposed to
90%. I spoke with Steve Pellei regarding this error, and he said it would be corrected prior
to permit issuance.
We appreciate your assistance to undertake the necessary steps to correct the
existing draft permit and incorporate the recommendation cited above. Please feel free to
contact me at 2136 if you have any questions.
cc: Steve Pellei-NPDES Permits and Engineering

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NCO083275
U ace ibjormation; z
FacilityName:
Dan River Inc. — arras Facility (formerly New Cherokee)
Permitted ow (MGD):Regional
ice:
ARO
Facility ass:
11
FTTUSUSTopoQuad:
ace ity ermtt Status:
RenewalCode:
2261
County:
Rutherford
:. tream aracterYst�cs
ReceivingStream:
Broad River
Stream Classification:
C 9- (25.5)
inter c s
u asin:
c s
(4.) Drainage Area (mi ):Average
ow c s943
Summer c s(%):
I-G7.5- J
CHANGES TO PERMIT
Changes to the Permit for this permit cycle
rj ammeters ecte'
........
ropose { F= a�nges
,. ,.,._:.. ,...t 4 ...,. ,.
..
axis or, c tinge s
.,.,., ,
Expiration ate
fromOct. , to u y ,
change to 30802 schedule
Limits for Sultide
From 8.2 to on.Ave.)er
effluent guidelines
Limits for Phenols
From 4.1 to on.Ave.)er
ettluent guidelines
Limits forTotal Chromium
From 4.1 to on.Ave.)er
ettluent guidelines
WET
From QAL to QCL
Per memo
Lead
a uce monitoring to Quarterly
Per reasonable potential anti y.
MBAS
Reduce monitoring to Quarterly
Per reasonable potential analy.
inc
Reduce monitoring to Quarterly
Per reasonable potential analy.
Copper
Reduce monitoring to Quarterly
Per reasonable potential analy.
Summary
There are two notable changes since last renewal. The first is due to the sale of the facility (in
Feb. 1997) and the significant increase in production under the new ownership. The second is.
due to the results of the reasonable potential analysis.
The previous WLA was completed by J. Nowell and dated 8/18/93. It gave limits based on 40
CFR 410.45 (NSPS-Simple) using a total production of 82,500 lbs/day for both Monthly Ave.
and Daily Max. Since copper and zinc were known to be present in this type of facility they
were added for monitoring. Data indicated Oil and Grease is present therefore it was limited at
30/60. Additionally Lead and MBAS are suspected to be present and therefore monitoring was
placed in the permit. The facility proposed discharging domestic waste with the process waste.
Since the dilution ratio would be about 0.4% monitoring for fecal was not recommended.
For this renewal, S. Pellei recalculated the limits based on 40 CFR 410.45 (NSPS-Desizing) and
used maximum production of 127,500 lbs/day and average production of 70,1001bs/day. The
justification is (based on information provided by Dan River) the facility desizes100% of its
product, and therefore, the effluent guidelines for desizing apply rather than for simple
manufacturing. If limits were based solely on effluent guidelines the limits would increase due
Version: August 19, 1998

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NCO083275
to the increase in processing. However, the facility's effluent is well below existing permit limits
and has not requested any increase. Therefore, for these reasons and due to anti -backsliding,
there will be no increase for any parameters.
The original permit was issued November 21, 1993. Later, an ATC was issued November 4,
1993 by G. Nizich. A name change was issued February 21, 1997 to change the name from the
New Cherokee Corporation to Dan River Inc.
Broad River Management Strategy reflects a concern with color and suggests the possibility of
color removal if this facility starts dyeing procedures. The 1993 WLA recommended color limits
if any dyeing takes place in the future.
Upon review of the APAM analysis (see reasonable potential sheet) I concluded that there is very
little chance of contravening water quality standards based on effluent concentrations and
dilution due to the receiving stream. A reasonable potential analysis showed no reasonable
potential to violate WQ standards for some parameters, therefore monitoring for them has been
removed form the permit (see table above).
Review of DMR data from February 1996 to February 1998 indicates the facility has been in
compliance during the review period and performing very well. The region reports that the plant
is operated well and well maintained.
For the following parameters listed in the table:
• Conventional parameters are from GKPR data from March 97 to May 98,
• Toxicity is from ESB's 7/15/98 Data Summary from Sept. 1995 to March 1998,
• Metals and MBAS are from DMR data from March 97 to June 98.
PARAMETER
F ow(MGD)
BOD5 (lbs/day)
COD (lbs/day)
TSS (lbs/day)
TN (mg/1)
TP (mg/1)
Toxicity
Sulfide (lbs/day)
Phenols (lbs/day)
Total Chromium (lbs/day)
Oil & Grease
PARAMETER
Corie-.7--,
Copper (Cu)
Chromium (Cr)
Lead (Pb)
MBAS
Zinc
Oil & Grease
RESULTS
0.3 to 0.4 MGD, ave 0.36
23 to 48, ave 29.3
360 to 817, ave. 543
32 to 121, ave 59
8.5 to 15.6, ave 12
3.7 to 4.6, ave 4.2
12 passes, 1 fail
0.06 to 0.8, ave 0.17
0.3 to 0.46, ave 0.06
0.02 to 0.05, ave 0.03
2.5 to 15, ave 5.0
DMR RESULTS
See reasonable potential analysis
See reasonable potential analysis
See reasonable potential analysis
See reasonable potential analysis
See reasonable potential analysis
See reasonable potential analysis
See reasonable potential analysis
ACTION
None
None
None
None
None
None
see above
None
None
None
none
NOTE
Data variable, Leave as is
Reduce monitoring
Required per effluent guidelines
Reduce monitoring
Reduce monitoring
Reduce monitoring
Data variable, Leave as is
Lastly, the expiration date on this permit was changed from Oct. 31, 2003 to July 31, 2003, due
to changes in the 030802 basin schedule.
Version: August 19, 1998

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0083275
Copies of the following are attached to provide further information on the permit development:
• Reasonable Potential Analysis (majors only)
• Existing permit effluent sheets with changes noted (existing facilities only)
• Draft Permit
Prouosed Schedule for Permit Issuance
Draft Permit to Public Notice: 4 — 0[ - 9 b
Permit Scheduled to Issue:
State Contact
If you have any questions on any of the above information or on the attached permit,
please contact Steve Pellei at [phone], extension 516.
NPDES Recommendation
Regional Office Comments
a -Ala C-
Regional Recommendation
Reviewed By:
Regional Supervisor:
NPDES Unit:
u
Version: August 19, 1998

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NCO083275
Copies of the following are attached to provide further information on the permit development:
• Reasonable Potential Analysis (majors only)
• Existing permit effluent sheets with changes noted (existing facilities only)
• Draft Permit
Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: 4 - 9 b
Permit Scheduled to Issue: _ Z C _ a )
If you have any questions on any of the above information or on the attached permit,
please contact Steve Pellei at [phone], extension 516.
NPDES Recommendation by: S '
Regional Office Comments
Regional Recommendation by:
tceviewea is :
Date:
Regional Supervisor:
Date
NPDES Unit:
Version: August 19, 1998

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0083275
During the period beginning on the effective date of the permit and lasting expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001. Such discharges shall be limited and monitored by the pennittee as specified below:
Effluent Characteristics
Lbs/day
Mon. Avg. Daily Max.
Flow
,BOD, 5-Day, 200C
140.4
-Total Suspended Solids
322.e
` (M
221 g. e
Sulfide
'].c, 8.2
Phenols
3, S -44
Total Chromium
].S 4.1-
Oil and Grease
Temperature
Total Nitrogen (NO2 +NO3+ TKN)-
Total Phosphorus
-�oppsr r
wrn,�7a'uNo
Chloride
Acute Toxicity"
Discharge Limitations
Monitoring
Requirements
Units (Specify)
Measurement
Sample
*Sample
Mon. Avg. Daily
Max. Frequency
Type
Location
0.91 MC-0
Continuous
Recording
I or E
272.e-
Weekly
Composite
E
726.9
Weekly ,-
Composite.
E
3440.0-
Weekly
Composite,
E
16.5
Weekly
Grab
E
3.2
Weekly
Grab
E
6.2
Weekly
Composite
E
30.0 mg/I
60.0 mg/I Weekly
Grab I
E
-Nt To am%o 6sci POMltnc cActj-.
Weekly
Grab
E
Semi-annually-
Composite
E
Semi-annually _
Conposite
E
w l�j-AAenthly
Gompos"
—E
t-MorttMy
Eompes"
--E
d l<
p-momMy-
Cempesite
- €
4� #Asftffily
Compostte
--E-
-_ ona
ie
E
Quarterly
Composite
E
* Sample locations: E - Effluent, I - Influent.
@ `mac C IWc.
March, June, September and Decembers . r��
.au.►s�xie. • • �'�
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units at the effluent. Effluent monitoring shall be conducted4lweek--
by grab samples. .fit Vu-ftj� +v evg"t p��i wa kFaAvw t, 0 k V,tr�t
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Dan River Inc EFFLUENT GUIDELINE LIMITATIONS
NCO083275
Fype of Product Produced Effluent Guideline Reference
Noven Fabric Finishing 140 CFR 410, Subpart D
Actual Production Figures (at 1.0 MGD):
Monthly
Daily
( x 1000 Ibs)
70
127.5
sdp
8/3/98
Parameter
EPA Limitations in 40 CFR
(Ibs/1000 Ibs of product)
Guideline Limits
(Ibs/ day)
Comments
NSPS, 40 CFR
Footnote
30 day avg.
Daily Max
30 day avg.
Daily Max
BOD5
2.8
5.5
196 -
701
410.45 desizing
1
COD
38.3
59.5
2,686
7,586
410.45 desizing
1
TSS
6.9
15.6
484
1,989
410.45 desizing
1
Sulfide
0.1
0.2
7.01
25.50
410.45 desizing
1
Phenols
0.05
0.1
3.51
12.75
410.45 desizing
1
Total Chromium
0.05
0.1
3.51
12.75
410.45 desizing
1
pH
6.0-9.0
6.0-9.0
6.0-9.0
6.0-9.0
410.45 desizing
1
Parameter
Exisiting Limits
(Ibs/ day)
Limits per Guidelines
(Ibs/ day)
Change
(tons/ year)
30 day avg.
Daily Max
30 day avg.
Daily Max
30 day avg. Daily Max
BOD5
140
272
196
701
10 78
COD
2,219
3,440
2,685
7,586
85 757
TSS
322
726
1,989
30 230
Sulfide
8.20
16.50
7.01
25.50
-0.22 1.64
Phenols
4.10
8.20
3.51
12.75
-0.11 0.83
Total Chromium
4.10
8.20
3.51
12.75
-0.11 0.83
pH
6.0-9.0
6.0-9.0
6.0-9.0
6.0-9.0
FOOTNOTES:
1. The facility performs desizing of 100% of its finished product per G. Boozer on 8/3/98.
2. These Production figures were obtained from W. Lunney on 6/24/98:
March 97 to March 98 total production = 25,587,719 Ibs/year
70,103 Ibs/day
CONCLUSION:
The only changes to exising lipmits should be for those parameters that have decreased. These
parameters have be enboldened above.
r lTiUuV 11''•a (h v�(il c1vL5 I -Cc,. rv'p ('0 Ilit'1km LIl+.,l-S, -RAY' L��^"'li 41L 66b, Cqb
9"b '141 will c'ir,^A;r 61 ?w PA Vi0.f We-X'^IT WAVIC' TAbLIN IS No 6OM Tlr
WE,. &-Low -CYi$T1NG U Ir-

SDP
Facility Name
Dan River
ter= Chloride
NPDES#
NCO083275
ard= 230000pgn
Qw (MGD)
0.91
7Q10s (cfS)
186
n DL=1/2DUual Data RESULTS
IWC (%)
0.75
1 64000 640DO Sid Dev.
Rec'ving Stream
Broad River
2 25000 25000 Mean
Stream Class
C
3 25000 25000 C.V.
Data: March 97 - June 98
4 25000 25DOO
FINAL RESULTS ugll
Chloride
OKI
Max. Fred Cw
1,222,000
Allowable Cw
33 559,670
Chromium
OKI
Max. Fred Cw
14.82
Allowable Cw
6643.41
Copper - AL
OKI
Max. Fred Cw,
108.10
Allowable Cw
930.08
Lead
OK I
Max. Fred Cw
52.70
Allowable Cw
3321.70
MBAS
OKI
Max. Fred Cw
480.00
Allowable Cw
65434.07
oil & grease
LIMIT
Max. Fred Cw
107.50
Allowable Cw,
60.00
Zinc - AL
OKI
Max. Fred Cw
354.00
Allowable Cw
6643.41
Antimony
Arsenic
Thallium
Bis(2-Ethylhexly)-Phthalate
5
25000
250DO
6
25000
250DO Mu/t Factor=
P 7
26000
25M Max. Value
P 8
235000
2350DO Max. Pred Cw
p 9
25000
25000 Allowable Cw
10
25000
250DO
11
25000
25000 C.V.
12
25000
250DO MF=
13
25000
25000
14
25000
25000
15
25000
25000
16
250M
25000
t,n DUIY MON �TOtii
�ho 2: CI^1oRiAE
CoPPEL
LEop
allow emu
limit conc conc
43000 6.E+06 0.006
0.14 19 0.016
_ 6.3 837 0.002
6.9 917 11
TOXICANT ANALYSIS
52754.7391
40562.
1.30057908
5.
235
1222
3055967
1.30057908
5.2
0
ra Pameter= Chromium Para
Standard= 50 Pg8 Sta
P9n laday
n L=1/2Dctual Dal RESULTS
2 1 9.882 75 Std Dev. 1.87472
5 2 1.845 14 Mean 3.677
5 3 1.845 14 C.V. 0,50985
4 2.108 16
5 4.348 33
2 6 3.689 28 Mu/t Factor= 1.5
000 Pge 7 2.899 22 Max. Value 9.8822 pg8
000 pg8 8 3.558 27 Max. Pred Cw 14.8233 pg/I
Pg/I 9 3.821 29 Allowable Cw 6643.4 pg/I
10 3.821 29
5 11 6.456 49 C.V. 0.50985
12 8.169 62 MF= 1.5
13 5.666 43
14 9.092 69
15 5.798 44
16 7.247 55
17 5.007 38
18 0.395 3
19 3.294 25
20 3.426 26
21 3.821 29
22 3.426 26
23 0.264 2
24 5.007 38
25 2.767 21
26 6.852 52
27 3.689 28
28 2.767 21
29 3.162 24
30 3.031 23
31 3.426 26
32 3.558 27
33 2.24 17
34 2.767 21
35 2.372 18
36 3.294 25
37 3.294 25
38 2.767 21
39 2.24 17
40 3.426 26
41 3.294 25
42 3.294 25
meter= Copper - AL Pammet
ndaM=L-L]pgB Stands
n L=1/2tual DaRESULTS
TOXICANT ANALYSIS
52754.7391
40562.
1.30057908
5.
235
1222
3055967
1.30057908
5.2
0
ra Pameter= Chromium Para
Standard= 50 Pg8 Sta
P9n laday
n L=1/2Dctual Dal RESULTS
2 1 9.882 75 Std Dev. 1.87472
5 2 1.845 14 Mean 3.677
5 3 1.845 14 C.V. 0,50985
4 2.108 16
5 4.348 33
2 6 3.689 28 Mu/t Factor= 1.5
000 Pge 7 2.899 22 Max. Value 9.8822 pg8
000 pg8 8 3.558 27 Max. Pred Cw 14.8233 pg/I
Pg/I 9 3.821 29 Allowable Cw 6643.4 pg/I
10 3.821 29
5 11 6.456 49 C.V. 0.50985
12 8.169 62 MF= 1.5
13 5.666 43
14 9.092 69
15 5.798 44
16 7.247 55
17 5.007 38
18 0.395 3
19 3.294 25
20 3.426 26
21 3.821 29
22 3.426 26
23 0.264 2
24 5.007 38
25 2.767 21
26 6.852 52
27 3.689 28
28 2.767 21
29 3.162 24
30 3.031 23
31 3.426 26
32 3.558 27
33 2.24 17
34 2.767 21
35 2.372 18
36 3.294 25
37 3.294 25
38 2.767 21
39 2.24 17
40 3.426 26
41 3.294 25
42 3.294 25
meter= Copper - AL Pammet
ndaM=L-L]pgB Stands
n L=1/2tual DaRESULTS
1 20
20 Sid Dev.
11.08
2 5
5 Mean
20.63
3 13
13 C.V.
0.537
4 5
5
5 32
32
6 22
22 Mod Factor =
2.3
7 19
19 Max. Value
47 pg8
8 32
32 Max. Pred Cw
108.1 pg/l
9 16
16 Allowable Cw
930.1 P9/1
10 18
18
11 5
5 C.V.
0.537
12 21
21 MF=
2.3
13 23
23
14 47
47
15 26
26
16 26
26
Y\& Vli I TIS l i tJ
f70(L
DrL G 2cASe
Ltr✓D C�RoIMiuN� �n Q.fwler�
ps ;s
8/19/98
8/19/98

TOXICANT ANALYSIS
ter= Lead
ParanMBAS
Parameter= oil & grease
Pa
rd = F261pgA
Standard = ® pgA
Standard = rngA
n L=12ual DaRESULTS
n L=12Rual DatRESULTS
n L=1/213ual Dat RESULTS
1
3
3 Std Dev.
3.577126
1
240
240 Std Dev.
26.2996 1
2
2 Std Dev.
6.38
2
3
3 Mean
4.5625
2
200
200 Mean
208.75 2
43
43 Mean
5.04
3
5
5 C.V.
0.784028
3
200
200 C.V.
0.12699 3
14
14 C.V.
1.27
4
3
3
4
200
200
4
2
2
5
3
3
5
200
200
5
8
8
6
3
3 Mutt Factor =
3.1
6
200
200 Mull Factor =
1.6 6
8
8 Mull Factor =
2.5
7
3
3 Max. Value
17 Ngll
7
200
200 Max. Value
300 po 7
6
6 Max. Value
43 mgA
8
3
3 Max. Prod Cw
52.7 pgA
8
200
200 Max. Pred Cw
480 ligA 8
7
7 Max. Pred Cw
108 mgA
9
3
3 Allowable Cw
3321.7 ugA
9
200
200 Allowable Cw
66434.1 NgA 9
5
5 Allowable Cw
60.0 mgA
10
5
5
10
200
200
10
5
5
11
8
8 C.V.
0.784028
11
200
200 C.V.
0.12599 11
1
1 C.V.
1.27
12
3
3 MF=
3.1
12
200
200 MF=
1.6 12
3
3 MF=
2.5
13
3
3
13
200
200
13
5
5
14
17
17
14
200
200
14
5
5
15
4
4
15
200
200
15
8
8
16
4
4
16
300
300
16
6
6
17
4
4
18
3
3
19
4
4
20
23
23
21
4
4
22
2
2
23
5
5
24
8
8
25
1
1
26
1
1
27
6
6
28
1
1
29
5
5
30
5
5
31
1
1
32
3
3
33
4
4
34
2
2
35
11
11
36
2
2
37
3
3
38
2
2
39
1
1
40
1
1
41
2
2
42
6
6
43
4
4
44
1
1
45
5
5
46
2
2
47
2
2
48
1
1
49
2
2
50
1
1
51
1
1
52
6
6
53
1
1
54
5
5
55
7
7
56
6
6
rameter = Zinc - AL Pa
Standard - F 50j N9A S
n L=12Dtual DatRESULTS
1 170 170 Std Dev. 51.28
2 3 3 Mean 121.9
3 139 139 C.V. 0.421
4 3 3
5 102 102
6 133 133 Mult Factor = 2.0
7 177 177 Max. Value 177 W
8 163 163 Max. Pred Cw 354 pqA
9 114 114 Allowable Cw 6643.4 NgA
10 119 119
11 144 1" C.V. 0.421
12 128 128 MF= 2.0
13 167 167
14 122 122
15 119 119
16 148 148
8/19/98
8/19/98

J
�rho'2
C�R.oY+n�uw.
waVe iti
J� M2s 13 C1� -t;� b CA4 -�o i44 ,
tAASS d,
Q= (bf 4
Co
04M % -PAd LO
�w = o, g t wtC7D 6IV
k�w = �,g�� 1,41ifs
0
c 0 A8,77'. + tcST (0, 0 s- vv� it)
Cx4-
.114
c
C2c -/— 50,4 jr,&41
S;tvc6 (f4LV&,/T C-?( D6-ut"6s ,
-::L? C, 7<, L 3.
go -I( -�o I,(-ll�<l,�

TOXICANTANALYSIS
ParemMr•C.. PranNr• K Pandw r•Leae P. MINIS Pxemrr•Inc-PA.
LmIrE.®yB'I SImgW•�jryl 9xpmtl'OYD1 SIaMs•U.®yyl SIenIIW.®YM
Olos(Ot.)
18fi
aDL=1RDNal Date RESULTS
Im (%)
0.]5
1
aeaw
se. and Na.
52254.239
Bmae Riwr
iRg Srdam
2
-
2sCW Mean
405CZ5
C
efm Geaa
3
2
IsINp C. v.
13005m1
De1e: Men,9]-June
98
4
5
25a03
25000
P:0
256M.
FINAL RESULTS
43a11it
ADIVAN
9
25000
25CN
52
x. Fred Car
#DNNI
y 7
25000
25M MexV;mstrao
"¢A
Cw
6613.41
ya
235WS
eCwrvdS
235W Max PrO
3a
y1S
25099
25aC0 AM6ItmEabdlewCw
.
CNIMee
OKI
25000
25aa0
x. Pree Cw
1222544.34
II
250oa
2.
.N. Cw
3D559570.M
12
25000
25000 Lbeer lMarpol. bl MF
13
250W
250(0
J rod ium
OKI
14
25030
2500D C.V.
1.300579I
x. Fred CW
11324
15
250[O
25000 C.V.at
1.3
bw9ble Ow
6643.41
10
25000
25M C. V. bI
1.4
MFN
50
APPo1-ALOKI
MFb
52
Pee Cw
108.65
MF-
52
3wade Cw
SODA
Lead OK I
c Prod! Cw $3.31
owed. Cw 3321.7C
MEAS OKI
x Fred Cw 486.51
owed. Cw 66434.07
Nickel #DNIUI
x Fred Cw #DNI01
wrebla Cw 11692.40
Silver -AL #OIUXI
x Pree Cw #DNN!
wade Cw 7.92
Selenium #DIVI01
x. Pretl Cw #D
.wade Cw 684.34
L OKI
Cw 3,4711
Cw fi643.41
n L=12Dual DeRESULT0
1
75
15 Sta D. 14
2
M
14 Meen 20
3
14
14 C.V os
4
16
16
5
33
33
6
20
20 Man Fedor- IS
]
22
22 Mac Value 75 yq1
0
22
22 Max Pree Cw 113 yg8
0
29
29 AMwable Cx Wygfl
1a
IS
29
It,,
49
49
12
82,
02 Unen lnlr9oL o1 MF
13
43
'43
14
09
0 aV:. 05
15
44
44 Crr. 1, ` 0.5
16
55
55 a. V. M 'Me
17
30
30 MFM
10
0
3
3 MFb
Ell
19
25
25 Me-
15
30
R
18
21
29
N
22
23
28
2
26
2
21
30
30
25
21
21
2S
52
52
IT
28
20
111
t
91
30
24
23
24
23
31
Is
0
32
2]
V
33
17
1]
Se
21
21
35
10
Ul
M
25
I5
32
25
25
30
21
21
39
f]
1)
40
2S
26
41
25
25
42
25
25
43
W
02
N
2a
20
45
M
22
n 1-11naral DAESULTS
1 20
20 SW Der. 11.06
2 5
5 Mean N.N
3 13
ucV 007
4 5
5
5 32
32
0 N
22 MW Fxtw • 2.3
] 12
19 M- Vahn 47 y,A
6 32
n Max. Pile Cw 100] yyl
8 10
18 Abxabb On 930.1 y9ll
t9 i8
f9
1 s
s
12 21
21 hear lnbry% bIMF
I] 9
23
A O
17 CV, 0531
15 28
20 C V b 0.5
18 29
20 c. V. m 00
MFM 3
MFb 23
=U2 at DAESULT8
1 3
3 $11 Car.
3511
2 3
3 Mean
4Y3
3 5
5 CM
0 ]34
4 3
3
5 3
3
6 3
3 Man FwYa'
31
l 3
3 Max. Varna
17 y,A
6 3
3 Max. Fred Qr
53.31 ylyl
9 3 3 0lbxebM LW 3321.7 y
0 5 s
11 3 S
12 3 ] -a mN o1MF
13 3
11 13 CV. 0 .
16 4 4 C. V. In 66
MFM 32
MFb F 2e
MF. 3.1
a L=IQMal Da1RESULTS
1 240 240 Ste Der. 26..
2 2. 203 Meen 20875
3 200 Yq C.V. 0.1
4 yp
Zq
5 EO
i30
8 21p
200 Fedw• ale
] 21p
Mec Value 3W yp1
00
20D Mex. Free Cw 480.813 yaxi
9 20)
200 NNwebb Cw 66x3a.1 Man
1D INS
200
11 m
200
12 200
M Later lW."o1MF
13 200
200
M M
200 C.V 012559
15 200
200 CV b 0.1
15 300
300 C. V. n1 82
MFM
MFb
MF` 18
n L=1RDual Da RESULTS
L 170
170 St<Dev.
51.28
2 ]
3 Mean
1215
3 139
139 CV.
0421
4 3
3
5 1@
In
8 133
133 MM FMw=
20
] 1II
11i Max. Value
9I do
8 103
163 Max Pree Cw
347,2 yyl
9 114
M4 Moaable Cw
6943410
16 11.
119
11 real
Ia
12 128
126 Under ln1t1an1
of MF
13 167
In
14 I@
1@ C.V.
0421
15 11.
119 CV Io
04
16 148
148 C. V. M
MFM
6 s
2.2
MFb
1.8
MF-
2A
Ma90

SOC PRIORITY PROJECT: No
IF YES, SOC NUMBER
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Steve Pellei
DATE: June 10, 1998
NPDES STAFF REPORT AND RECOMMENDATION
RUTHERFORD COUNTY
PERMIT NUMBER NCO083275
PART I - GENERAL INFORMATION
1. Facility and Address: Dan River Inc. Harris Facility
Mailing: 1843 Jack McKinney Road
Harris, North Carolina 28139
2. Date of Investigation: May 14, 1998
3. Report Prepared By: Roger C. Edwards
4. Persons Contacted and Telephone Number:
5. Directions to Site: From Hwy. 74 exit on to Hwy 221 travel south to
SR 1111 (Jack McKinney Road) turn right. Travel approximately 4
miles to the Harris Facility on the left.
6. Discharge Point(s), List for all discharge points:
Latitude: 350 12' 23" Longitude: 810 53' 15"
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 Fingerville East,
SC -NC
7. Site size and expansion area consistent with application?
X Yes No If No, explain:
8. Topography (relationship to flood plain included): Gentle slope
Page 1

adjacent to large flat bottom land
9. Location of nearest dwelling: >1000 feet
10. Receiving stream or affected surface waters: Broad River
a. Classification:'C;
b. River Basin and Subbasin No.: 030802
C. Describe receiving stream features and pertinent downstream
uses: Wildlife propagation and agriculture
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted MGD (Ultimate
Design Capacity) 0.91 MGD
b. What is the current permitted capacity of the Wastewater
Treatment facility? 0.91 MGD
C. Actual treatment capacity of the current facility (current
design capacity 0.91 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: Equalization basin
with influent bar screen, extended aeration, secondary
clarification, effluent flow measurement, discharge to Broad
River.
f. Please provide a description of proposed wastewater treatment
facilities: N/A
g. Possible toxic impacts to surface waters: Possible toxic
impacts associated with textile finishing waste. However,
treatment of waste stream and selection of production chemicals
will reduce if not eliminate toxic impacts to the receiving
stream.
h. Pretreatment Program (POTWs only). N/A Direct discharge
in development approved
should be required not needed
2. Residuals handling and utilization/disposal scheme:
a. If residuals are being land applied, please specify DWQ Permit
Number WQ0008799
Residuals Contractor Southern Soil Builders
Telephone Number 1-800-411-5527
Page 2

3.
4.
b.
C.
Residuals stabilization: PSRP PFRP OTHER
the waste in industrial only --No Domestic
Landfill:
d. Other disposal/utilization scheme (Specify):
Treatment plant classification (attach completed rating sheet):
SIC Codes (s) : 2261
Primary 55 Secondary 16
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)? N/A
2. Special monitoring or limitations (including toxicity) requests: N/A
3. Important SOC, JOC, or Compliance Schedule dates: (Please indicate)
N/A
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. N/A
Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
5. Other Special Items: N/A
Page 3

PART IV - EVALUATION AND RECOMMENDATIONS
The Dan River Inc. -Harris Facility has an excellent compliance history at
current production levels. The projected increase in production and
equipment modification will increase flow to the WWTP. Lohen the
increases occur, should problems arise, additional wastewater treatment
capacity may need to be added. It is recommended the NPDES Permit be
renewed.
Date
6.
of
Quality Regional Supervisor
Page 4

RATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
Name of Facility: _UA9
Owner or Contact Person:
r' Arl.: C
Mailing Address: • 0. 00.t7 q3
County: cc.`t'It.sa- QL Telephone: Toy- 7` 7-70z t
Present Classification: + New Facility Existing Facility
NPDES Per o. NC00 8 2 Nondisc. Per. No.WQ Health Dept.Per No._
Rated by: Telephone: �,��- 251-6201 Date: G /0 9$�
Reviewed by. Health Dept. Telephone:
Regional Office Telephone:
Central Office Telephone:
ORC: '5 Z. Grade: Telephone: W-1- 2N7-Zo37
Check Classification(s): Subsurface Spray Irrigation Land Application
Wastewater Classification: (Circle One) I III IV Total Points: V7
SUBSURFACE CLASSIFICATION
(check all units that apply)
1. septic tanks
2. pump tanks
3. siphon or pump -dosing systems
4. sand filters
5. grease trapfinterceptor
6_ oiVwater separators
7._,_gravity subsurface treatment and disposal:
8. pressure subsurface treatment and disposal:
SPRAY IRRIGATION CLASSIFICATION
(check all units that apply)
1.
preliminary treatment (definition no. 32 )
2.
lagoons
3.
septic tanks
4.
pump tanks
5.
pumps
6._sand
filters
7`
grease trapfinterceptor
8.
oil/water separators
9,_dislnfection
10.
chemical addition for nutrient/algae control
11.
spray Irrigation of wastewater
In addition to the above classifications, pretreatment of wastewater in excess of these components shall
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, unless 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. Oillwater Separator Systems consisting only of physical separation, pumps and disposal:
2. Septic Tank/Sand Ater Systems consisting only of septic tanks, dosing apparatus, pumps,sand fitters, 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 Remedlation Systems consisting only of oil/water separators, pumps, air -stripping, carbon adsorption, disinfection
and disposal;
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 if 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 closed cycle systems(see definition No. 11). and facilities consisting only of item
(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..................................................................................................................................A
250,001 - 500.000..................................................................................................................................
600.001 - 1,000.000..............................................................................................................................
1.000.001 - 2.000.000...........................................................................................................................10
2.000.001 (and up) rate 1 point additional for each 200.000 gpd capacity • up to a maximum of .................3 0
Design Flow (gpd)
(3) PRELIMINARY UNITSWROCESSES (see definition No.32)
(a)
BarScreens ...........................................................................................................................................I
(b)
or
Mechanical Screens. Static Screens or Comminuting Devices........................................................................�
(c)
Grit Removal........................................................................................................................................... ;,.
or ;
(d)
Mechanical or Aerated Grit Removal.............................................................................................................2
(e)
Flaw Measuring Device................................................................................................................................1
(f)
or
Instrumented Flow Measurement...............................................................................................................
(g)
Preaeratlon...............................................................................................................................................
(h)
Influent Flow Equalization.........................................................................................................................
(i)
Grease or Oil Separators - Gravity.................................................................................................................2
Mechanical.................................................................................................................................................3
DissolvedAir Flotation...............................................................................................................................A
(1)
Prechlodnation.................. .......................................................................................................................5
(4) PRMARYTREATMENT UNITSIPROCESSES
(a)
Septic Tank (see definition No. 43)............................................................................................................2
(b)
Imhoff Tank..............................................................................................................................................5
(c)
Primary Clarglers..........................................................................................................................................5
(d)
Settling Ponds or Settling Tanks for Inorganic Nontoxic Materials (sludge handling facilities for water
purification plants. sand. gravel. stone. and other mining operations except recreational activities such as gem
orgold mining)........................................................................................................................................2
(5) SECONDARY TREATMENT LINT TSIPROCESSES
(a)
Carbonaoeous Stage
(i) Aeration -High Purity Oxygen System..............................................................................
DiffusedAir System......................................................................................................
Mechanical Air System (fixed. floating or rotor) .................................
SeparateSludge Reaeration.............................................................................................3
Trickling Filer
HighRate.............................................................. ,..................................................7
StandardRate...............................................................................................................5
Packed Tower............ ...................................... . .............................................................5
(itl) Biological Aerated Filter or Aerated Biological Filter ................. »...................................... ».10
(iv) Aerated Lagoons..........................................................................................................10
(v) Rotating Biological Contactors......................................................................................10
(VI) Sand Filters -Intermittent biological..................................................................................2
Recirculatingbiological....................................................................................................3
vliStabilization Lagoons ....................................................................................................
(viii) Claritier... ......... s.......................................................................................................
(ix) Single stage system for combined carbonaceous removal of BOD and nitrogenous removal by
nitrification (see definition No. 12)(Points for this Item have to be In addition to items
(5)(a)(1) through (5)(a)(viil).
utilizing the extended aeration process (see definition No.3a)..........................................2
utilizingother than the extended aeration process ........................................................... 8
(x) Nutrient additions to enhance BOD removal......................................................................5
(x1) Biological Culture ('Super Bugs•)addition........................................................................5
(b)
Nitrogenous Stage
(1) Aeration - High Purity Oxygen System............................................................................20
DiffusedAir System.......................................................................................................10
MechanicalAir System (fixed. floating or rotor) .................. ,........... »................... .............. 8
SeparateSludge Reaeratlon............................................................................................3
(11) TrIckling Filter -High Rate...................................................................................................7
StandardRate..........................................................................•--..................................5
PackedTower................................................................................................................5
(ill) Biological Aerated Filter or Aerated Biological Filter .................... »............. ................. »».... 10
(Iv) Rotating Biological Contactors.......................................................................................10
(v) Sand Filter - Intermittent biological..................................................................................2
Recirculatingbiological....................................................................................................3
(vi) Ctarifiar..........................................................................................................................5
(6) TERTIARY ORADVANCEOTREATMENT U ffWROCESSES
(a)
Activated Carbon Beds -
withoutcarbon regeneration...................................................................................................5
withcarbon regeneration.......................................................................................................15
(b)
Powdered or Granular Activated Carbon Feed -
withoutcarbon regeneration.................................................................................................5
withcarbon regeneration.....................................................................................................I s
(c)
Air stripping..............................................................................................................................................5
(d)
Denitrffication Process..............................................................................................................................10
(e)
Electrodlalysls.........................................................................................................................................5
MFoam
Separation.......................................................................................................................................5
(g)
Ion Exchange.................. .........................................................................................................................5
(h)
Land Application of Treated Effluent (see definition No. 22b) (not applicable for sand. gravel. stone
and other similar mining operations) by high rate Infiltration...........»............................................................4
(1)
Microscreens...................................... ........................................................................................................6
(1)
Phosphorous Removal by Biological Processes (See definition No. 26)........................................................20
(k)
Polishing Ponds - without aeration............................................................................................................2
withaeration .... ............... ..»............ ............ .................................................................. 5

(1)
Post Aeration - cascade.................................................................... ..............0 ............................................
diffused or mechanical .............................. .......2
...................................................................
(m)
Reverse Osmosis........................................................................................................................................5
(n)
Sand or Mixed -Media Filters - low rate.................................................................................................2
highrate......................................................................5
(o)
Treatment processes for removal of metal or cyanide...................................................................................15
( p )
treatment processes for remplval of toxic materials other than metal or cyanide..............................................15
(7)
SLUDGETREATMENT
(a)
Sludge Digestion Tank - Heated (anaerobic)...............................................................................................10
Aerobic...........................................................................................................................................J0
Unheated(anaerobic)................................................................................................................................3
(b)
Sludge Stabilization (chemical or thermal).....................................................................................................5
(c)
Sludge Drying Beds - Gravity......................................................................................................................2
VacuumAssisted......................................................................................................................................5
(d)
Sludge Elutrlatlon......................................................................................................................................5
(a)
Sludge Conditioner (chemical or thermal)....................................................................................................5
(f )
Sludge Thickener (gravity).........................................................................................................................5
(g)
Dissolved Air Flotation Unit [not applicable to a unit rated as(3)(1)).............................................................8
(h)
Sludge Gas Utilization (including gas storage).........................................................:...................................2
(1)
Sludge Holding Tank - Aerated...................................................................................................................5
Non• ae rat ed.............:............................................................................................................................. 2
(j)
Sludge Incinerator (not Including activated carbon regeneration).........................................:.....................10
(k)
Vacuum Filter. Centrifuge, or Filter Press or other similar dewatering devices.................................:::...............10 -,
(8)
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 applicationpermit
(c)
•..•.-- -^
orlandfill permit................................................................. . +�d
Dedicated Landfill(burial) by the pemtittee of the wastewater treatment facility...............................................5
(9)
(a)
Chlorination.............................................................................................................................................5
(b)
Dechlortnation..............................:...........................................................................................................5
(c)
Ozone......................................................................................................................................................5
(d)
Radiation.................................................................................................................................................5
(10)
CHEMICAL ADDITION SYSTEM(S) ( see definition No. 9) [not applicable to chemical additions rated as item (3)(j).
(5)(a)(xi).
List
)(a (6) (7 b). (7)(9). (9a). (9)(b) or (9)(c) 5 points each:
..................................................................................................................................
-
...................................................................................................................................5
...............................................................................................................................5
...........................................................................................................................5
.(11)
[1�.�;BU1N80[iS
UNRS�PROCESSES
-
(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
fordomestic wastewater...........................................................................................................................A
-
`
(b) ;
Effluent Flow Equalization not applicable to storage basins which are Inherent In land
q ( aPP 9 application systems).....2
(c)
(d) ;
Stage Discharge (not applicable to storage basins Inherent in land application systems)„„...„........„...........„..
Pumps.....................................................................................................................................................
(0)
Stand -By Power Supply.........................................................................................................................
(fv
Thermal Pollution Control Device............................................................................................................y.3
TOTALPOINTS.......................................................................... 7
..................... ..R.................................................................... 5-25 Points
ClassN.......................................................................................:...............66-Up Points
------- �------------------------------------------------------
FacilhMs 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 classfflcatlon of Class If.
Facilities having treatment processes for the removal of metal or cyanide will be assigned a minimum classification of Class 11.
Faculties having treatment processes for the biological removal of phosphorus will be assigned a minimum classification of Class 111.
MN DEFINITIONS
The following definitions shall apply throughout this Subchapter.
(1) Activated Carbon Beds. A physicallchemicai 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 diffuslon;(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 ton 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 densit.as;
(9) Chemical Addition Systems- The addition of chemicals) to wastewater at an application point for purposes of Improving solids removal, pH adjustment.
alkalinity control. etc.; the capability to experimpnt with different chemicals and different application points to achieve a specific result will be considered one
system; the capability to add chemicals) 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 time, ferric chloride. or a polymer to wet sludge to coalesce the mass prior to
he application to a dewatering device;
(11) Closed Cycle Systems. Use of holding ponds or holding tanks for containment of wastewater containing Inorganic, non-toxlc 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 SOD and Nitrogenous Removal by Nitrification- A single stage system required to achieve perrnh effluent limits on BOD
and ammonia nitrogen within the same biological reactor.
(13) Dechlorinattom The partial or complete reduction of residual chlorine In a liquid by any chemical or physical process;
(14) Denitrffication Process. The conversion of nitrate -nitrogen to nitrogen gas;

(15) Electrodialysis. 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 loam 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 filter 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 oxirlanoxic 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 Aeratlom- 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 nonmechanicai. 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 food controlled into the system;
(31) Preaeratiom 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 load 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,Apended
solids and BOD which Is associated with the solids;
(36) Pumps. All Influent. effluent and In -plant pumps;
(36) Radiation. Disinfection or sterilization process utilizing devices emitting ultraviolet or gamma rays; .r '
(37) Reverse Osmosis. A treatment process in which a heavy contaminated liquid Is pressurized through a membrane fcr W nearly pure Itqutd tree from
suspended solids;
(38) Rotating Biological Contractors. A fixed biological growth process In which wastewater flows through tanks In which aeries of partially submerged circular
surfaces are rotated;
(39) Sand Filters:
(a) Intermittent Biological. Filtration of off luent following septic tanks, lagoons, or some other treatment process In wick further biodecoinposhion Is
expected to produce desired offluents; Hydraulic loading rates on these filters are computed In gpd/ac and have a msutng taw gpnvsf (less -than one);
b) Recirculating biological - the same type of sand filter as defined In Subparagraph (39) (a) of this Rule with the added ability to recycle effluent back
through the sand filter;
(40) Sand or Mixed-Medla Filters. A polishing process by which effluent limits are achieved through a further reduction of su,3ended SOlids;
(a) tow rate -- gravity, hydraulically loaded filter with loading rates In the one to three gpffM range;
(b) high rate — a pressure, hydraulically loaded filter with loading rates In the five gpm/sf range; At any rate, the loading mtewill exceed three gprwsf;
(41) Secondary Clarifiers. A tank which follows the biological unit of treatment plant and which has the purpose of removing ?fudges associated with the
biological treatment units;
(42) Separate Sludge Reaeratlon. A part of the contact stabilization process where the activated sludge Is transferred to a tanl. 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; "I 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 artificlal layers of porous materials upon which digested sewage sludge Is dried by drainage and
evaporation;
(46) Sludge Elutdation. A process of sludge conditioning In which certain constituents are removed by successive washings with fresh water or plant"Muent;
(47) Sludge Gas Utilization. The process of using sewage gas for the purpose of heating buildings. driving engiries, 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 combustbte materials and reduce the sludge to a sterile ash;
(50) Sludge Stabilization (Chemical or Thermal). A process to make treated sludge less odorous and putroscble. and to reduce the pathogenic organism
content; This may be done by pH adjustment. chlorine dosin% 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-blodegradable particulate (floatable solids. suspended solids and BOD
reduction) from municipal and Industrial wastewater treatment systems;
(56) Tertiary Treatment. A stage of treatment following secondary which is primarily for the purpose of effluent polishing; A settling lagoon or sand or coal filter
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;
(67) Thermal Sludge Conditioner. A conditioning process by which heat Is added for a protracted period of time to Improve the dewaterabli€ty of sludge by the
soiub€lizing and hydraulizing of the smaller and more highly hydrated sludge particles;
(58) Toxic Materials. Those wastes or combinations of wastes. Including disease -causing agents which after discharge and upon exposure. hgestlon. 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 malfunctions In reproduction) or physical deformations. In such organisms or their
offspring; Toxic materials Include, by way of illustration and not Iimitallon: lead. cadmium, chromium. mercury. vanadium. arsenic. zinc, ortho-nttro-chforobenzene
(ONCE), polychlorinated biphenyls (PCBs) and dichlorodtphenyl trichloroethane (DDT); and any other materials that have or may hereafter be determined to have
toxic properties;
(69) Trickling Filter. 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 filter Is one which is designed to operate at one to four rngd 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 contlnually by the active biological fixed growth In each successhne layer. This method may produce 'secondary' quality effluent, or may be
adapted to produce a n1triffed effluent;
(61) Vacuum Filter. Centrifuges, or Fitter Presses. Devices which are designed to remove excess water from either digested or undigested sludge prior to disposal
or further treatment.

William J. Lunney
Director of Engineering
Environmental and Safety
August 5, 1998
Mr. Steve Pellei
NCDENC/DWQ/NPDES
P.O. Box 29535
Raleigh, NC 27626-0535
Dan River Inc.
P.O. Box 261 l
Danville, Virginia 24543
804/799 7120
ypIzglo7172
w n 0
r
RE: Harris Permit Renewal #NC0083275
Dan River Inc. - Harris Facility, Rutherford County
Dear Mr. Pellei:
This correspondence will serve to confirm our discussion this
date relative to the queries you raised. The six items are as
follows:
1. What is resin and what is it used for?
Resin is a product manufactured by Sequa Chemicals Inc. and
marketed under the trade name of Permafresh 113B. A copy of
the MSDS is attached.
The resin enhances the "feel" of the fabric to the hand. It
reduces fabric shrinkage and improves the wrinkle resistance
in the fabric.
2. How much of the fabric is resin treated?
Approximately 80% of the fabric is treated.
3. What percent of the fabric is desized?
100% of the fabric is desized.
4. Is the fabric dyed?
The fabric is not dyed.
5. Is there color in the effluent?
No color is observable in the effluent.
QUALITY TEXTILES BY DESIGN

Mr. Steve Pellei
Page 2
August 5, 1998
6. Does any fabric scouring occur other than desizing?
The fabric is bleached and washed in the presence of
hydrogen peroxide and caustic.
Approximately 200 of the fabric is mercerized.
Mercerization is a process in which the shrinkage is
controlled in the presence of caustic. The fabric is then
washed and dryed.
I trust this provides the information you requested. Should
there be any further information required please contact me at
804/799-7120. n
Sincerely,
�r
W . J . / unne y
Dire or of Engineer g,
Env' onmental and Safety
kat
wj198-045
cc: Bill Smith
Mike Patterson

Dan River Inc.
P. 0.Box LL
Danville, Virginia
ia 24543
543
8041799 7000
z
CL
June 24, 1998
c
Mr. Steve Pellei
c?
NCDENC/DWQ/NPDES
= "
P.O. Box 29535
Raleigh, NC 27626-0535
Subject: Renewal of NPDES Permit No. NC0083275
Dan River Inc. - Harris Facility, Rutherford County
Dear Mr. Pellei:
In accordance with our telephone conversation of June 23rd, the
information on production at our Harris Plant is provided.
The highest daily production in the last three years was 27,517
pounds with the highest weekly production being 637,583 poun s'
The attached graph and the quarterly production figures in the
table below show the increase in production since purchase of the
plant in February 1997.
Quarter
Ending
Production °%Increase Over 1996
Pounds Average Production
September 95 4,512,810 -
December 95 2,642,755 -
March 96 3,308,697 -
June 96 4,148,976 -
September 96 4,170,708 - rr
December 96 4, 096, 392 -
March 97 5,43n 38.3
June 97 6;4"664.4
September 97 '5,8950.0
December 97 ( 6,4163.2
March 98 \ 81,� 73. 4
As we discussed during ou' June 23,1998 conversation, the plant
is currently operating wib'd
the same production equipment that
was originally installed permitted in April•1994.
zl 3Z�I to !t/w.VA .
��

Page 2
The plant was designed, however, so that its capacity could be
doubled. Therefore, we respectfully request that the discharge
limits as stated in the current permit remain as is.
If you have further questions, please contact me at 804/799-7120.
Sincerely,,
WiYrronmental
J. Lunney
Dir of Engine
En and
kat
wj198-039
i

HARRIS PLANT POUNDS QUARTERLY PRODUCTION
(000,S)
7,000
6,500
6,000
5,500
{
5,000
1
4,500 -
4,000 j
3,500
3,000
2,500
2,000 ,
9/95 12/95 3/96 6/96 9/96 12/96 3/97 6/97 9/97 12/97 3/98