NC0000019_Staff Report_19950721

SOC PRIORITY PROJECT: Yes No-K
If Yes, SOC No.
cc: Permits and Engineering
Technical Support Branch
County Health Dept.
Central Files
WSRO
To: Permits and Engineering Unit
Water Quality Section
Attention: Susan Wilson
Date July 21, 1995
NPDES STAFF REPORT AND RECOMMENDATION
County Ashe
Permit No. NC0000019
PART I - GENERAL INFORMATION
1. Facility and Address: United Chemi-Con Mfg., Inc.
185 McNeil Rd.
Lansing, NC 28643-8301
2. Date of Investigation: July 21, 1995
3. Report Prepared by: George Smith
4. Persons Contacted and Telephone Number:
Mr. Dean Hovermale
[phone]
5. Directions to Site: From Jefferson take Rt. 194/88 North
to Warrensville and go right on Rt. 194 toward Lansing
and go approx. 2 miles then make a right on McNeil Rd.
(SR 1660). The facility is located on the left side
immediately after crossing the North Fork New River.
6. Discharge Point(s), Discharge points are listed in
sequence from upstream to downstream:
Discharge Points 007 001 003 006 005
Latitude: 360 28' 43" 44" 47" 49" 51"
Longitude: 810 30' 20" 21" 23" 24" 25"

Attach a USGS map extract and indicate treatment
facility site and discharge point on map.
U.S.G.S. Quad No. B12NE U.S.G.S. Quad Name Warrensvill
7. Site size and expansion area consistent with
application ?
X Yes No If No, explain:
8. Topography (relationship to flood plain included):
The domestic treatment plant is located on gently
sloping terrain adjacent to the New River, which is in
the flood plain.
9. Location of nearest dwelling:
Aproximately 1000 feet from the Mfg. Plant.
10. Receiving stream or affected surface waters:
North Fork of New River
a. Classification: Class C+
b. River Basin and Subbasin No.: New
05-07-02
C. Describe receiving stream features and pertinent
downstream uses: Pasture land, fishing, wildlife,
and agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted: 0.018 MGD
(Ultimate Design Capacity)
b. What is the current permitted capacity of the
Waste Water Treatment facility? 0.018 MGD
C. Actual treatment capacity of the current facility
(current design capacity)? 0.018 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: Grease trap located adjacent to the
kitchen, bar screen, imhoff tank, dosing tank with
Two bell siphons, dual sand filters, and Two small
sand drying beds.
f. Please provide a description of proposed
wastewater treatment facilities: N/A

2.
3
4
g. Possible toxic impacts to surface waters:
No toxic impacts are suspected from this 100%
domestic waste. However a previous inspection in
January 1994 revealed the highly toxic dimethyl
formamide, and other chemicals in outfall 001.
lid
a
lie
c
Pretreatment Program (POTWs only):
in development approved
should be required not needed X
Residuals handling and utilization/disposal
scheme: Septic tank hauler.
If residuals are being
specify DEM permit no.
Residuals Contractor _
Telephone No.
Residuals stabilization
Other X (imhoff tank)
Landfill: Piedmont
land applied, please
PSRP PFRP
d. Other disposal/utilization scheme (Specify):
Currently all process water is piped to a storage
tank and hauled by Environmental Compliance Corp.,
617 Waughtown St., Winston-Salem, NC 27107.
Contact is Mr. Charles Strickland 1-800-637-6693.
Treatment plant classification (attach completed rating
sheet) : Class I
SIC Code (s): 3675
Primary 02 Secondary 10 14 16 59
Main Treatment Unit Code: 4 6 0 _ 1
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
NPDES Permit Staff Report
Version 10/92
Page 3

2. Special monitoring or limitations (including toxicity)
requests: NONE
3. Important SOC, JOC or Compliance Schedule dates: N/A
(Please indicate)
Date
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Alternative Analysis Evaluation: Has the facility
evaluated all of the non -discharge options available.
Please provide regional perspective for each option
evaluated.
Spray Irrigation: N/A
Connection to Regional Sewer System: No sewer
available.
Subsurface: N/A
Other disposal options: N/A
5. Other Special Items: N/A
PART IV - EVALUATION AND RECOMMENDATIONS
Discharge Pipe 001
This discharge consists of: boiler blowdown, non-conatct cooling
water, discharge water from deionized regeneration system. The
facility is currently hauling away all process wastewater, but
they may still discharge wash water from cleaning operations.
NPDES Permit Staff Report
Version 10/92
Page 4

Discharge Pipe 003
This discharge consists of: non -contact cooling water from
process pumps that pump electrolyte such as dimethyl formamide.
Currently all process water is stored in a tank and hauled away,
but thw facility may use this pipe to discharge wash water and
other process water from manufacturing.
Discharge Pipe 005
This discharge connection was removed and plugged with concrete.
This discharge should be removed from the permit per request of
Mr. Dean Hovermale, Safty/Env. engineer.
Discharge Pipe 006
This is a 18,000 gpd Imhoff tank with sandfilters that discharges
domestic waste from the company. A kitchen, which has a grease
trap, discharges into this system.
Discharge Pipe 007
This system takes in water from the river and sends it through a
sandfilter. The overflow from the sandfilters is discharged from
this pipe. The filtered water is used for non -contact cooling
water and boiler blowdown, which is discharged in pipe 003.
Per request of United Chemi-Con contingent pipe 005 should be
removed from the permit. In addition, this office recommends a
toxicity limit be added to the permit for outfalls 001, 003, 006.
We recommend this NPDES permit request be renewed with these
modifications.
11
Signatu e of report preparer Date
Water Quality Regio
NPDES Permit Staff Report
Version 10/92
Supervisor
/ T�6 S
Date
Page 5

i
State of North Carolina
Department of Environment,
• Health and Natural Resources A
•
Division of Environmental Management ov
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary p E H N F1
A. Preston Howard, Jr., P.E., Director
December 29, 1995
Mr. Ted Fischer, General Manager
United Chemi-Con Manufacturing, Incorporated
185 McNeil Road
Lansing, North Carolina 28643
Subject: NPDES Permit Issuance
NPDES Permit No. NC0000019
United Chemi-Con
Ashe County
Dear Mr. Fischer:
In accordance with your application for renewal of the United Chemi-Con Manufacturing discharge
permit, we are 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 US Environmental Protection Agency dated December 6, 1983. In
response to the letter from United Chemi-Con received December 11, 1995 regarding the draft permit, the
following comments are given.
Based on further review of the effluent data and the comments in United Chemi-Con's letter,
copper, silver, and zinc monitoring has been reduced to quarterly. The data indicate no predicted
exceedances of the action level for these parameters in the past year. The Division recommends that the
quarterly testing for these parameters be conducted during the time of toxicity testing. Aluminum
monitoring shall remain monthly until sufficient data are collected to further evaluate this parameter.
Monitoring for Dimethyl formamide and Butyrolactone shall remain as monthly at this time. After
one year of data have been collected, United Chemi-Con may request that the Division re-evaluate the
frequency of the monitoring requirement for these parameters.
As requested, due to the new requirement for continuous flow monitoring on Outfall 001, the
Division has granted United Chemi-Con's request for delay of implementation of this requirement until
July 1, 1996. The effluent sheet for Outfall 001 reflects this change.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicative hearing upon written request within thirty (30)
days following receipt of this letter. This request must be in the form of a written petition, conforming to
Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative
Hearings, Post Office Drawer 27447, Raleigh, North Carolina 27611 -7447. Unless such demand is
made, this decision shall be final and binding.
Please take notice 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. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Environmental Management
or permits required by the Division of Land Resources, Coastal Area Management Act or any other Federal
or Local governmental permit that may be required.
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

If you have any questions concerning this permit, please contact Susan Wilson at telephone
number [phone], extension 555.
Sincerely,
Original Signed By
R�� &C oW, Jr., P.E.
cc: Central Files
Winston-Salem Regional Office
Mr. Roosevelt Childress, EPA
fern -its and Engineering Unita
Facility Assessment Unit
Aquatic Toxicology and Survey Unit

.P.
Permit No. NC0000019
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Mangement Commission,
and the Federal Water Pollution Control Act, as amended,
United Chemi-Con Manufacturing, Incorporated
is hereby authorized to discharge wastewater from a facility located at
end of NCSR 1659
south of Lansing
Ashe County
to receiving waters designated as North Fork New River in the New River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts I,
II, III, and IV hereof.
The permit shall become effective February 1, 1996..
This permit and the authorization to discharge shall expire at midnight on December 31, 2000.
Signed this day December 29, 1995.
Original Signed By
Ualt!rl A P^A#4r-^k
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Mangement Commission

Permit No. NC0000019
SUPPLEMENT TO PERMIT COVER SHEET
United Chemi-Con Manufacturing, Inc.
is hereby authorized to:
1. Continue to discharge non -contact cooling water, A/C condensate, boiler blowdown,
deionizer backwash, assembled product wash water and process wastewater (001), A/C
condensate (003), domestic wastewater (006), recycled non -contact cooling water and filtered
surface water during maintenance periods only (007) located at United Chemi-Con
Manufacturing, the end of NCSR 1659, south of Lansing, Ashe County (See Part III of this
Permit), and k.
2. Discharge from said treatment works at the location specified on the attached map into North
Fork New River which is classified C waters in the New River Basin.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC000(ln 19
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 - Non -contact cooling water, boiler blowdown, deionization regeneration water, A/C condensate, and process
wash/rinse water. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics Discharge Limitations
Lbs/day Units (Specify
Mon. Avg. Daily Max. Mon. Avg. Daily Max.
Flow 0.2 MOD
Total Suspended Solids
Total Copper
Total Silver
Total Zinc
Total Aluminum
TTO `*
Oil and Grease
BOD5
Temperature
Acute Toxicity ***
Total Residual Chlorine f
Dimethyl Formamide
Butyrolactone
26.0 mg/I . 52.0 mg/I
Monitoring
Requirements
Measurement
Sample
* ampI
Frequency
Zyue
Lop to ion
Continuous 0
Recording
I or E
Monthly
Composite
E
Quarterly
Composite
E
Quarterly
Composite
E
Quarterly
Composite
E
Monthly
Composite
E
Quarterly
Grab
E
Monthly
Grab
E
Monthly
Composite
E
Weekly
Grab
E,U,D
Quarterly
Composite
E
Monthly
Grab
E
Monthly
Grab
E
Monthly
Grab
E
* Sample locations: E - Effluent, I - Influent, U - Upstream at least 100 feet, D - Downstream at least 300 feet.
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED ADDITIVES
TO BIOCIDAL COMPOUNDS. See Part 111, Condition F, Biocide Condition.
** In lieu of monitoring for TTO, the permittee may submit the following certification statement: " Based on my inquiry of the person or persons directly
responsible for managing compliance with the permit limitation for total toxic organics, I certify that, to the best of my knowledge and belief, no dumping
of concentrated toxic organics into the wastewater has occurred since the filing of the last discharge monitoring report".
*�ute Toxicity Testing, 48 hour Daphnid, Quarterly LC50 limit of 75%; January, April, July, and October; See Part III, Condition E.
**** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case
cause the ambient water temperature to exceed 29°C.
0 Continuous monitoring shall be required on July 1, 1996.
t Monitoring requirements apply if chlorine is added to the cooling water (or any other wastewater contributor).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be conducted weekly at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NCO000019
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 003 - A/C Condensate.
Effluent Characteristics Discharge Limitations Monitoring Requirements
Measurement sample*Sample
Monthly. Avg. Weekly Avg, Daily Max. Frequency TyRe Location
Flow MGD Monthly Instantaneous I or E
Temperature Monthly Grab E,U,D
Total Residual Chlorine "' Monthly Grab E
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS. See Part III, Condition F, Biocide Condition.
* Sample locations: E - Effluent, I - Influent, U - Upstream above Outfall 003 at least 100 feet, D - Downstream below Outfall 003 at least 100
feet.
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no
case cause the ambient water temperature to exceed 29°C.
*** Residual chlorine monitoring is required only if chlorine is used as a disinfection method.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored monthly at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NCOOOOOI9.
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 006 - Domestic Wastewater. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic] Discharge Limitations Monitoring Requirements
Units (Specify.) Units (Specify) (Measurement Sample— _, ample
Mon. Avg. Daily Max. Frequency Type Location
Flow 0.018 MGD Weekly Instantaneous I or E
BOD, 5-Day, 200C 30.0 mg/I 45.0 mg/I 2/Month Composite E
Total Suspended Residue 30.0 mg/I 45.0 mg/I 2/Month Composite E
NH3 as N Monthly Composite E
Temperature Weekly Grab E
* Sample locations: E - Effluent, I - Influent.
See Part III, Condition G, Disinfection Condition.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NCOOOM19
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 007 - recycled Non -contact cooling water and filtered surface water.
Effluent Characteristics Discharge Limitations Monitoring Requirements
Measurement Sample 'Sams
Monthly. Avg, Weekly Avg. Daily Max. Frequency Type Lpcation
Flow Monthly Instantaneous I or E
Temperature Monthly Grab E
Total Residual Chlorine "' Monthly Grab E
Settleable Solids Monthly Grab E
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS. See Part 111, Condition F, Biocide Condition.
* Sample locations: E - Effluent, I - influent.
Monitoring shall be performed if discharge occurs.
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in no
case cause the ambient water temperature to exceed 29°C.
*** Residual chlorine monitoring is required only if chlorine is used as a disinfection method.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored monthly at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Part III NC0000019
E. ACUTE TOXICITY PERMIT LIMIT (QRTRLY)
The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined
as definitive in E.P.A. Document 600/4-85/013 entitled "The Acute Toxicity of Effluents to
Freshwater and Marine Organisms. The monitoring shall be performed as a Daphnia
pulex or Ceriodaphnia 48 hour static test, using effluent collected as a 24 hour composite.
The LC50 of this effluent using the previously stated methodology may at no time in any
toxicity test be less than 75%. Effluent samples for self -monitoring purposes must be
obtained during representative effluent discharge below all waste treatment. The first test
will be performed after thirty days from the effective date of this permit during the months
of January, April, July, October.
The parameter code for this test if using Daphnia pulex is TAA3D. The parameter code for
this test if using Ceriodaphnia is TAA3B. 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 appropriate parameter code.
Additionally, DEM Form AT-1 (original) is to be sent to the following address:
Attention:
Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 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 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 any test data from either these monitoring requirements or tests performed by the
North Carolina Division of Environmental Management 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 and appropriate environmental controls, shall
constitute an invalid test and will require immediate retesting(within 30 days of initial
monitoring event). Failure to submit suitable test results will constitute noncompliance
with monitoring requirements.

F. Biocide Condition
The permittee shall not use any biocides except those approved in conjunction with the
permit application. The permittee shall notify the Director in writing not later than ninety
(90) days prior to instituting use of any additional biocide used in cooling systems which
may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide
Worksheet Form 101 and a map locating the discharge point and receiving stream.
G. Disinfection Condition
In the event that violations of the fecal coliform requirements of the North Carolina water
quality standards occur as a result of this discharge, disinfection will immediately be
required and the permit amended to establish a coliform effluent limitation.