WQ0003380_Final Permit_20070404

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April 4, 2007
Charles McLendon, Plant Manager
Georgia-Pacific Wood Products LLC
PO Box 308
Dudley, North Carolina 28333
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
Subject: Permit No. WQ0003380
Name Change from Georgia-Pacific Corporation to
Georgia-Pacific Wood Products LLC
Dudley Plant, Plywood/OSB
Wastewater Recycle System
Wayne County
Dear Mr. McLendon:
In accordance with your request to change the name on the subject permit from Georgia-Pacific
Corporation to Georgia-Pacific Wood Products LLC, received December 8, 2006, we are forwarding herewith
Permit No. WQ0003380, dated April 4, 2007, to Georgia-Pacific Wood Products LLC for the continued operation
of the subject wastewater recycle system.
This permit shall be effective from the date of issuance until November 30, 2009, shall void Permit No.
WQ0003380 issued December 3, 2004, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. Failure to establish an adequate
system for collecting and maintaining the required operational information will result in future compliance
problems.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact David Goodrich at (919) 715-
6162 or by email at [e-mail].
Sincerely,
Ian W, Klimek, RE.
cc: Georgia-Pacific Corporation
Wayne County Health Department
Washington Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
APS Central Files
APS Files
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1PorthCarolina
o Urrturallry
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Telephone: [phone]
Internet: httn1/h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 Fax 1: [phone]
Fax 2: [phone]
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NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended,
and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Georgia-Pacific Wood Products LLC
Wayne County
FOR THE
continued operation of the wastewater recycle facilities located at the Georgia-Pacific Wood Products LLC's
Plywood/OWB Plant in Dudley, North Carolina, which consist of:
a wastewater recycle system used in conjunction with the control of rotary dryer emissions using an
Electrostatic Precipitation Unit (ESP) consisting of a pre -quench unit which consists of a chamber and
duct, holding tank with integral mixer, two 175 GPM recycle pumps, one 133 GPM supply pump; exiting
collection systems; a dual compartment 20,000 gallon concentrate sump with a 8,450 gallon clean water
compartment, a 4,000 gallon concentrated waste compartment, a spray system, a drain system, and
concentrated sensors; a 60 GPM sprayer system for the ESP unit with a collector and return piping
system; a 20,000 gallon concentrated waste storage tank; a 15 GPM spray pump for spraying concentrated
waste on wood waste to be burned; a wash down system with two (2) 375 GPM pumps used individually
to clean the ESP system, and all associated piping, valves, pumps and appurtenances to allow the transfer
of wastewater to the scrubber water discharge recycle system, the veneer dryer wash down recycle
system, the log heating vat water recycle system, the oil/water separator facility, or the Wet Storage Deck
recycle system;
2. a 100,000 GPD log heating vat water recycle system with screen, surge basin with floating aerator,
sand/water separators, extended aeration basin with floating aerators, clarifier with sludge return, and all
associated piping, valves, pumps, controls and appurtenances to allow the transfer of wastewater to the
ESP Unit recycle system, the scrubber water discharge recycle system, the veneer dryer wash down
recycle system, the oil/water separator facility, or the Wet Storage Deck recycle system;
a veneer dryer wash down reclaim system with wash down hose systems, storage tank, and all associated
piping, valves, pumps, controls and appurtenances to allow the transfer of wastewater to the ESP Unit
recycle system, the scrubber water discharge recycle system, the log heating vat water recycle system, the
oil/water separator facility, or the Wet Storage Deck recycle system;

4. a scrubber water discharge recycle system with dual ash settling basins, clear water sump, recycle pump,
and all associated piping, valves, pumps, controls and appurtenances to allow the transfer of wastewater
from the ESP Unit recycle system, the veneer dryer wash down recycle system, log heating vat water
recycle system, the domestic wastewater treatment recycle system, the oil/water separator facility, or the
Wet Storage Deck recycle system;
a 300 GPM oil/water separator with sump and sump pump with ultimate discharge to the ESP Unit
recycle system, the scrubber water discharge recycle system, the veneer dryer wash clown recycle system,
the log heating vat water recycle system., or the Wet Storage Deck recycle system;
6. a 15,000 GPD domestic wastewater treatment system with influent lift station, dual 50 GPM pumps and
high-water alarm, inlet bar screen, aeration basin, final clarifier, aerated sludge holding tank, disinfection
facilities, flow measuring device and 0.11 acre polishing pond with ultimate discharge to the scrubber
water system;
7. a 706,000 GPD wastewater Wet Storage Deck recycle system consisting of a 78,000 cubic foot recycle
pond, two 40 hp pumps, six wet deck sprinklers, one groundwater supply well, one well float control, and
all associated piping, valves, controls and appurtenances to allow the transfer of wastewater to the
scrubber water discharge recycle system, the veneer dryer wash down recycle system, the log heating vat
water recycle system, the oil/water separator facility, or the ESP Unit recycle system;
a 9,000 gallon dirty water sunup with a 2,000 GPM pump, four sidehill screens, a heat exchanger with a
heat transfer rate of 17,800 Btu per hour, a 17,000 gallon clean water sump with a 1,800 GPM pump, and
all associated piping, valves and appurtenances for water distribution,
all to serve the Georgia-Pacific Wood Products LLC Plywood/OSB Facility located in Dudley, North Carolina
with no discharge of wastes to the surface waters, pursuant to the application received December 8, 2006, and in
conformity with the project plan, specifications, and other supporting data subsequently filed and approved by the
Department of Environment and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until November 30, 2009, shall void Permit No.
WQ0003380 issued December 3, 2004, and shall be subject to the following specified conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. The following buffers shall be maintained:
a) 100 feet between treatment/storage units and any wells,
b) 50 feet between treatment/storage units and surface waters, and
c) 50 feet between treatment/storage units and property lines.
d) 10 feet between disposal (wetted) area and upslope ditches, drains, and surface water diversions,
e) 25 feet between disposal (wetted) area and downslope ditches, drains, and surface water
diversions,
f) 100 feet between disposal (wetted) area and wells,
g) 50 feet between disposal (wetted) area and public right of ways or property Iines,
Pa

Some of the buffers specified above may not have been included in previous permits for this waste
treatment and disposal system. These buffers are not intended to prohibit or prevent modifications,
which are required by the Division, to improve performance of the existing treatment facility. These
buffers do, however, apply to modifications of the treatment and disposal facilities that are for the
purpose of increasing the flow that is tributary to the facility. These buffers do apply to any
expansion or modification of the irrigation areas and apply in instances in which the sale of property
would cause any of the buffers now complied with, for the treatment and disposal facilities, to be
violated. The applicant is advised that any modifications to the existing facilities will require a permit
modification.
5. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division of Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate. The approval of the request will be considered on its merits
and may or may not be approved.
6. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Pennittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface or
groundwaters resulting from the operation of this facility.
9. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
10. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
11. Freeboard in the Wet Storage Deck recycle pond shall not be less than two feet at any time.
12. A waste -level gauge, to monitor waste levels in the storage pond, shall be installed within 60 days of
issuance of this permit. This gauge shall have readily visible permanent markings indicating the maximum
liquid level at the top of the temporary liquid storage volume, minimum liquid level at the bottom of the
temporary liquid storage volume, and top of the dam elevations. Caution must be taken not to damage the
integrity of the liner when installing the gauge.
13. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
14. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
15. The effluent from the domestic wastewater treatment system shall be monitored by the Permittee at the
point prior to effluent transfer to the scrubber system every August for the following parameters:
BOD5 TSS
Fecal Coiiform pH
NH3 as N

16. Groundwater Requirements:
a. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary for the disposal system
individually permitted on or after December 30, 1983 is established at either 250 feet from the waste
disposal area, or 50 feet within the property boundary, whichever is closest to the waste disposal area. An
exceedance of Groundwater Quality Standards at or beyond the Compliance Boundary is subject to
rernediation action according to 15A NCAC 2L .0106(d)(2).
b. The REVIEW BOUNDARY is established around the disposal systems midway between the Compliance
Boundary and the perimeter of the waste disposal area. Any exceedance of standards at the Review
Boundary shall require action in accordance with 15A NCAC 2L ,0106(d)(1).
17. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
18. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent malfunctions and
deterioration, operator errors and discharges which may cause or lead to the release of wastes to the
environment, a threat to human health, or a nuisance. The Permittee shall maintain an inspection log or
summary including at least the date and time of inspection, observations made, and any maintenance,
repairs, or corrective actions taken by the Permittee. This log of inspections shall be maintained by the
Permittee for a period of three years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
19. Any duly authorized officer, employee, or representative of the Division may, upon presentation of
credentials, enter and inspect any property, premises or place on or related to the recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
20. The annual administering and compliance fee must be paid by the Permittee within thirty (30) days after
being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate action to
revoke this permit as specified by 15A NCAC 2H .0205 (c)(4).
21. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to an
enforcement action by the Division in accordance with North Carolina General Statute 143-215,6A to 143-
215.6C.
22. The issuance of this permit does not exempt the Permittee from complying with any and all statutes, rules,
regulations, or ordinances which may be imposed by other government agencies (local, state, and federal)
which have jurisdiction, including but not limited to applicable river buffer rules in 15A NCAC 2B.0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCG010000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20_
23. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
24. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone number (252) 946-
6481, as soon as possible, but in no case more than 24 hours or on the next working day following the
occurrence or first knowledge of the occurrence of any of the following:
4

a. Any occurrence at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents
of a basin or tank, the known passage of a slug of hazardous substance through the facility, or any other
unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators,
compressors, etc.;
Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.
Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. Persons reporting such occurrences by
telephone shall also file a written report in letter form within five (5) days following first knowledge of the
occurrence. This report must outline the actions taken or proposed to be taken to ensure that the problem
does not recur.
25. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
26. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its extension.
Upon receipt of the request, the Commission will review the adequacy of the facilities described therein,
and if warranted, will extend the permit for such period of time and under such conditions and limitations as
it may deem appropriate.
Permit issued this the 0 day of April 2007.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
lan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0003380

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SITE LOCATION MAP
GEORGIA-PACIFIC WOOD PRODUCTS LLC
Georgia-Pacl WASTEWATER RECYCLE SYSTEM
DUDLEY PLANT - PLYWOOD/OSB
WAYNE COUNTY
WQ0003380