NC0043320_Fact Sheet_20230731

DEQ/DWR
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES PERMIT NC0043320
Facility Information
Applicant/Facility
Name:
Elevate Textiles/Burlington Richmond Plant
Applicant Address:
P. O. Box 250; CORmvA, NC 28330
Facility Address:
740 Old Cheraw Road; Cordova, NC 28330
Permitted Flow:
Outfall 001: 1.2 MGD
Type of Waste:
Outfall 001: Industrial 96% /domestic 4%
Permitted Discharge:
Outfall 002: Flow estimate 0.01 MGD
Type of Waste:
Outfall 002: Condensate and non -contact cooling water
Facility/Permit Status:
Class III /Active; Renewal
County:
Richmond County
Miscellaneous
Receiving Stream:
Hitchcock Creek
Stream Classification:
C
Subbasin:
03-07-16
Index No.
13-39-(10)b
Drainage Area mil :
134
HUC:
03040201
Summer 7Q10 (cfs):
25
303(d) Listed?:
No
Winter 7Q10 (cfs):
68
Regional Office:
Fayetteville
30Q2 (cfs):
-
State Grid / USGS
Quad:
H19NE
Rockingham, NC
Average Flow (cfs):
174
Permit Writer:
Sergei Chernikov,
Ph.D.
IWC % :
7%
Date:
07/05/2023
BACKGROUND
Elevate Textiles/Burlington Industries operates a textile mill which manufactures textured yarn
and woven fabrics in Cordova, NC in Richmond County (SIC codes 2221 & 2231). The facility is
permitted to discharge treated industrial wastewater through Outfall 001 and condensate and non -
contact cooling water through Outfall 002. The domestic wastewater is chlorinated prior to mixing
with the industrial wastewater influent. Both permitted outfalls combine into a single line that
discharges to Hitchcock Creek, a class C stream in the Yadkin -Pee Dee River Basin.
Process wastewater is generated as part of the yarn texturing and weaving operations. The texturing
process involves drawing/pulling a course synthetic yarn while subjecting it to heat to produce a
softer yarn fabric. Currently, the facility is only operating two weaving process, a mechanical loom
(Rapier) and a Water Jet loom. The air bag weaving operation (ASG) is idle with production
ceasing prior to 2008. The Rapier process is the mechanical weaving of mostly wool to produce
an unfinished fabric. The Water Jet loom uses water jets to produce a continuous filament from
the synthetic yarn.
This type of manufacturing operation is subject to 40 CFR 410 Textile Mills Point, Subpart C Low
Water Use Processing Subcategory. 410.32 General Processing BPT limitations were applied to
develop production based effluent limits for the yarn texturing process and the mechanical loom
process. 410.32 Water Jet Weaving BPT limitations were applied to develop production based
effluent limits for the jet weaving process. To calculate the production based effluent limits an
annual average of each process production over the last 5 years was required.
Fact Sheet
NPDES NC0043320
Page 1 of 5

A field calibrated QUAL2E model was developed for Hitchcock Creek in 1992 with Burlington,
Laurel Hills, and Rockingham the primary permitted dischargers. The model indicated more
stringent effluent limits were needed to address the receiving stream diminished ability to
assimilate the oxygen consuming waste and maintain the instream dissolve oxygen water quality
standard. The model was updated in 2000 when Burlington was the only remaining permitted
discharge. The updated model continued to predict violation of the instream dissolved oxygen
water quality standard. As a result of the continued instream dissolved oxygen compliance
concerns, NH3-N water quality based limits and a dissolved oxygen water quality based limit as
defined by the model for Burlington were applied in each renewed permit. For each renewal, the
40CFR 410 BOD effluent based limit were calculated and compared to the model BOD water
quality based limit, the more stringent BOD effluent limit was applied.
Note in the future, the modeled effluent water quality BOD limits (430 lbs/day or 43 mg/L
monthly, 836 lbs/day or 83.6 mg/L daily); NH3-N limits (50 lbs/day or 5.0 mg/L monthly, 250
lbs/day or 25.0 mg/L daily); DO limit (not less than 5.0 mg/L, daily average) should not be
exceeded regardless of the production levels unless a re-evaluation of Hitchcock Creek
assimilative capacity for oxygen consuming waste demonstrate the increased or change in load
will not impact the stream.
The ITG/Burlington discharge was originally immediately downstream of a hydro -electric dam
and impoundment, which had a significant impact on Hitchcock Creek. However, the dam was
removed and Hitchcock Creek has shown positive signs of improvement. ITG/Burlington
continues to be an active member of the Yadkin -Pee Dee River Basin Association. As long as
membership is maintained in the association, instream monitoring for Outfall 001 is waived.
TREATEMENT PROCESS
Outfall 001: Wastewater is combined from the process systems (88% of WWTP total); chlorinated
sanitary effluent (4% of WWTP total); boiler blowdown and boiler feed water softener system (2%
of WWTP total); and condensate, air washers, and other miscellaneous non-contact/cooling water
sources (6% of WWTP total). After passing through a screen system the combined wastewater is
split between two aeration basins equipped with surface aerators/mixers. The effluent from the
aeration basins is re -combined in a splitter box where the flow is then divided between two
clarifiers. Pumps recycle RAS and divert WAS from the clarifiers to the aerobic digester equipped
with a surface aerator, solid transfer pump, and decant system.
The effluent from the clarifiers is re -combined, passes through a metering flume into a central
manway. An effluent composite sampler takes the required sample. As needed the solids are
pumped to the drying beds which drain the filtrate back to an aeration basin. Solids are removed
from the beds for disposal as needed.
Outfall 002: The cooling tower blowdown flows through a metering flume into a central manway.
The Outfall 001 and Outfall 002 wastewater flows combine in the central manway and then flow
via a single gravity line to the permitted Hitchcock Creek discharge. Sampling requirements for
Outfall 001 and Outfall 002 are collected prior to their merger.
COMPLIANCE HISTORY
During the last 5 years there were eight limit violations: 3 TRC violations, 1 Fecal Coliform
violation, 2 DO violations, and 2 TSS violations. Please see attached.
The last inspection was conducted on 1/11/2022 by the Fayetteville Regional Office. There were
no significant issues or findings noted during the inspection.
Fact Sheet
NPDES NC0043320
Page 2 of 5

Modeled Water Quality Standards
Outfall 001 reported effluent oxygen consuming waste (BOD, NH3-N) levels were consistently
below the modeled maximum limits (except for 2 cases for NH3-N). The DO level in the effluent
was consistently 5.0 mg/L or higher, except for 2 cases when DO was 4.9 mg/L.
Toxicity Outfall 001
The facility conducts quarterly chronic toxicity test using ceriodaphnia at 7% concentration and
has reported passing all tests. Please see attached.
Instream Monitoring
Except for upstream/downstream temperature monitoring for Outfall 002, all other instream
monitoring is provisionally waived as long as the permittee maintains its membership in the
Yadkin -Pee Dee River Basin Association. In recent years the state has maintained an ambient
monitoring station (Q9660000) in Hitchcock Creek immediately upstream from this facility, any
available downstream monitoring stations are in the Pee Dee River after Hitchcock Creek
confluence. The location of the stations is not situated such that an impact assessment could be
readily made. The upstream station has reported summer DO levels less than 5.0 mg/L, the water
quality standard.
Outfall 002 IWC%, summer and winter, is less than 0.01%. The reported Outfall 002 effluent
temperature followed the seasonal instream natural temperature trend. Therefore, based on the
available data a 2.8 °C downstream exceedance of the upstream temperature water quality standard
cannot occur.
PERMITTING STRATEGY
Effluent mass limits for BOD, CBOD, and TSS (Outfall 001) were calculated applying 40 CFR
410 Textile Mills Point, Subpart C Low Water Use Processing Subcategory, 410.32 General
Processing BPT and 410.32 Water Jet Weaving BPT, and applying 40 CFR 133.102 Secondary
Treatment for the Domestic Wastewater. Production numbers were provided in the renewal
application. There was a net decrease in effluent mass -based limits for BOD, TSS, COD, as the
result of the decreased production. See Appendix A for the calculation summary.
The calculated BOD mass -based limits are more stringent than the modeled mass -based water
quality BOD limits, thus, the more stringent mass -based limits will be applied in this permit. To
continue protection of Hitchcock Creek based on the historical lack of stream waste load allocation
capacity, concentration based limits will continue to be imposed for the effluent BOD, NH3-N, and
DO. See Table below for summary of applied limits to Outfall 001in this permit:
Outfall 001 Limits
Effluent
Characteristics
Monthly Average
Daily Maximum
Impact to
Permit
Flow
1.2 MGD
No change
BOD
257 lbs/day
27.1 m /L
502 lbs/day
52.7 m /L
New limits
TSS
167 lbs/day
356 lbs/day
New limits
NH3-N
50 lbs/day
5.0 m /L
250 lbs/day
25.0 m /L
No chane
COD
707 lbs/day
1152 lbs/day
New limits
Fecal Coliform
(geometric mean
200/100
mL
400/100 mL
No change
TRC
28 µg/L
No change
DO
Not less than 5.0 m /L, daily average
No change
pH
Not more than 9.0 S.U. nor less than 6.0 S.U.
No change
Fact Sheet
NPDES NC0043320
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Chronic Toxicity Pass/fail 7% concentration, ceriodaphnia No change
Mercury Statewide TMDL Evaluation
There is a statewide TMDL for mercury approved by EPA in 2012. The TMDL target was to
comply with EPA's mercury fish tissue criteria (0.3 mg/kg) for human health protection. The
TMDL established a wasteload allocation for point sources of 37 kg/year (81 lb/year), and is
applicable to municipals and industrial facilities with known mercury discharges. Given the
small contribution of mercury from point sources (-2% of total load), the TMDL emphasizes
mercury minimization plans (MMPs) for point source control. Municipal facilities > 2 MGD and
discharging quantifiable levels of mercury (>1 ng/1) will receive an MMP requirement.
Industrials are evaluated on a case -by -case basis, depending if mercury is a pollutant of concern.
Effluent limits may also be added if annual average effluent concentrations exceed the WQBEL
value (based on the NC WQS of 12 ng/1) and/or if any individual value exceeds a TBEL value of
47 ng/L.
The application includes 1 sample for mercury. The result was below 200 ng/L. The permit will
include a requirement to use Method 1631 to gather data to evaluate compliance with the
TMDL.
Reasonable Potential Analysis (RPA)
The need for toxicant limits is based upon a demonstration of reasonable potential to exceed
water quality standards, a statistical evaluation that is conducted during every permit renewal
utilizing the most recent effluent data for each outfall. The RPA is conducted in accordance with
40 CFR 122.44 (d) (i). The NC RPA procedure utilizes the following: 1) 95% Confidence
Level/95% Probability; 2) assumption of zero background; 3) use of/2 detection limit for "less
than" values; and 4) streamflows used for dilution consideration based on 15A NCAC 213.0206.
Effective April 6, 2016, NC began implementation of dissolved metals criteria in the RPA
process in accordance with guidance titled NPDES Implementation oflnstream Dissolved Metals
Standards, dated June 10, 2016.
A reasonable potential analysis was conducted on effluent toxicant data collected between
January 2012 and July 2017. Pollutants of concern included toxicants with positive detections
and associated water quality standards/criteria. Based on this analysis, the following permitting
actions are proposed for this permit:
• No Limit: The following parameters will not receive a limit since they did not
demonstrate reasonable potential to exceed applicable water quality standards/criteria
and the maximum predicted concentration was <50% of the allowable concentration:
arsenic, beryllium, cadmium, aluminum, copper, chromium, fluoride, lead, mercury,
molybdenum, nickel, selenium, silver, antimony, barium, and zinc. Pease see attached.
SUMMARY OF PERMIT REQUIREMENTS
Receiving Stream: Hitchcock Creek Class: I C
Outfall 001: Treated industrial/ domestic wastewater from WWTP, Permitted for 0.91 MGD
Treatment: I Extended aeration, clarification, disinfection (chlorination)
Parameters (UOM as noted)
Limits
Bases of Permit Re uirement
BOD, lbs/day
257 monthly avg
502 daily max
40 CFR 410 Subpart C
mg/L
27.1 monthly avg
52.7 daily max
WQ max under permitted flow, QUALM
Model
TSS, lbs/day
167 monthly avg
356 daily max
40 CFR 410 Subpart C
N1713-N, lbs/day
50 monthly avg
250 daily max
WQ, max under permitted flow
Fact Sheet
NPDES NCO043320
Page 4 of 5

m L
5.0 monthly avg
25.0 daily max
WQ, QUALM Model
COD, lbs/day
707 monthly avg
1152 daily max
40 CFR 410 Subpart C
Fecal coliform, #/100 mL
(geometric mean)
200 monthly avg
400 daily max
WQ, 15A NCAC 02B .0211(3)(e)
DO, m /L
5.0 daily min avg
WQ, QUALM Model
H, S.U.
6.0 — 9.0
40 CFR 410 Subpart C
TRC, L
28 daily maximum
WQ, 15A NCAC 02B .0211(3)(1)(iv)
Chronic toxicity, P/F
P/F quarterl ,7% concentration
WQ, DWR toxicity strategy
Temperature
Monitor and report
WQ, 15A NCAC 02B .0508
Conductivity
Monitor and report
WQ, 15A NCAC 02B .0508
Total Nitrogen
Monitor and report
WQ, 15A NCAC 02B .0508
Total Phosphorus
Monitor and report
WQ, 15A NCAC 02B .0508
Other:
1) Added a requirement to use method 1631E for mercury analysis.
2) The new PFAS monitoring and Special Condition was added to the permit to implement Agency's Policy in
accordance with EPA PFAS Guidance.
3) The new 1,4 Dioxane monitoring and Special Condition was added to the permit to implement DWR Strategy.
Outfall 002: Cooling water and condensate, no treatment, no flow limit
Parameters (UOM as noted)
Limits
Bases of Permit Requirement
H, S.U.
6.0 — 9.0
WQ, 15A NCAC 02B .0211(3)( )
TRC, L
28 daily maximum
WQ, 15A NCAC 02B .0211(3)(1)(iv)
Temperature, °C
32 daily max, 2.8 max increase ambient
WQ, 15A NCAC 02B .0211(3)0)
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: July 25, 2023
Permit Scheduled to Issue: September 22, 2023
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please
contact Sergei Chernikov [phone] or email [e-mail].
Fact Sheet
NPDES NCO043320
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