WQ0003380_Final Permit_19931220

-State of North Carolina
Department of Environment,
Health and Natural Resources 4
Division of Environmental Management a
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary p E H N R
A. Preston Howard, Jr., P.E., Director
December 20, 1993
Charles McLendon, Plant Manager
Georgia-Pacific Corporation
Post Office Box 308
Dudley, N.C. 28333
Subject: Permit No. WQ0003380 Amendment
Georgia-Pacific Corporation
Southern Division, Com -Ply Facility
Wastewater Recycle System
Dudley, North Carolina
Wayne County
Dear Mr. McLendon:
In accordance with your application for permit amendment received October 18, 1993, and
accordance with your permit issued December 15, 1992, we are forwarding herewith Permit No.
WQ0003380 dated December 20, 1993, to Georgia-Pacific Corporation for the construction and operation
of the subject recycle system improvements and the continued operation of the subject recycle system. This
permit amendment is to authorize the addition of a prequench unit, pumping system and piping to allow the
transfer of wastewater from the ESP unit to either the existing storage tank or the log vats.
This permit shall be effective from the date of issuance until November 30, 1997, 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. Issuance of this
permit hereby voids Permit No. WQ0003380 issued December 15, 1992.
If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 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, P.Q. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal 0arx3tlunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

One set of approved pI`ans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Mr. John Seymour at 919/ 733-5083.
Sincerely,
c.9 ` k
A. Prest Howard, Jr., P.E.
cc: Wayne County Health Department
Washington Regional Office
Training and Certification Unit
Facilities Assessment Unit
Georgia-Pacific Corporation, Atlanta Georgia, Mr. Tom Pennella.

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH 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 Corporation
Wayne County
FOR THE
construction and operation of a prequench unit which consists of a chamber and duct, holding tank with
integral mixer, two 175 GPM recycle pumps, one 133 GPM supply pump and all associated controls,
valves, piping, and appurtenances to allow the transfer of waste water from the ESP unit to either the
existing storage tank or the log vats; and the continued operation of a wastewater recycle system used in
conjunction with the control of rotary dryer emissions using an Electrostatic Precipitation Unit (ESP)
consisting of 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 washdown system with two (2) 375 GPM pumps used individually
to clean the ESP system, and all piping valves, pumps and appurtenances; also 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 and clarifier with sludge return; also a veneer dryer
washdown reclaim system with washdown hose systems, storage tank and pumps; also a scrubber water
discharge recycle system with dual ash settling basins, clear water sump and recycle pump; also a 300
GPM oil/water separator with sump and sump pump with ultimate discharge to the scrubber water recycle
system; and also a 15,000 GPD domestic wastewater treatment system with influent Iift station, dual 60
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 recycle system to serve the Comp -Ply Facility located at Dudley, North Carolina with
no discharge of wastes to the surface waters, pursuant to the permit amendment application received
October 18, 1993, and the permit issued December 15, 1992, and in conformity with the project plan,
specifications, and other supporting data subsequently filed and approved by the Department of
Environment, Health and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until November 30, 1997, and shall be
subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plan, 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. 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 Environmental Management 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.
5. Upon completion of construction and prior to operation of the permitted facilities, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
29535, Raleigh, NC 27626-0535.
6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Washington Regional Office, telephone number 919/ 946-6481 shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an in-place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. 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.
10. 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.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
13. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
14. 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 thxeat to human health, or a nuisance. The
Permittee shall keep 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 upon request to
the Division of Environmental Management or other permitting authority.

15. Any duly authorized officer, employee, or representative of the Division of Environmental
Management 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
kept under the terms and conditions of this permit; or may obtain samples of groundwater,
surface water, or leachate.
16. 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 15 NCAC 2H .0205
(c)(4).
17. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
18. The issuance of this permit does not preclude 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.
19. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
20. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone
number 9191946-6481 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:
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 render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
c. 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.
d. Any time that self-monitoring information indicates that the facility is not in
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.

21. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
22. 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.
23. Issuance of this Permit hereby voids Permit No. WQ0003380, issued December 15, 1992.
Permit issued this the 20th day of December, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A.Presto oward, Jr., E., Director
Division o nvironmen Management
By Authority of the Environmental Management Commission
Permit No. WQ0003380
4

Permit No. WQ0003380
December 20, 1993
Engineer's Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project,
Project Name
Location
for the
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of the approved plans and specifications.
Signature
Date
61
Registration No.

�n' I
764 2'30"
1 MILE
W'O'SHlN^G73N
0. F_ M.
990500°'R.N.
�! 35°15'
771 INrmom—GEOLOGICAL SURVEY, RESTON, VIRGINIA— 1976 78n
eol
rl2�R E. L
ROAD CLASSIFICATION s�
Primary highway, Light-duty road, hard or
hard surface--_ improved surface ..... .
Secondary highway, CIS
hard surface..... __ Unimproved road._.._ -==a=¢===
Interstate Route U. S. Route State Route
N. C. ■ 1
QUADRANGLE LOCATOR SOUTHWEST GOLDSBORO, N.C.
N3515—W7800/7.5
1974
AMS 5354 I SE—SERIES V842
t

A
CALE -FOR CLASSIFICATION OF FACILITIES
Name of Plant: C�c� A
9.C.os A�+�
x' Owner or Contact Person: s-r-r�
Mailing Address: Po fox 30O
(i)Aeralion - High Purity Oxygen System ... _ .
County: L,3AYNE
Telephone: _q IG • _73c0 - 4YES
NPDES Permit No.
Nondisc. Per. No.
IssueDate:. o-711-7 jqo
Expiration Date: oLe I -So j qS
Existing Facility ✓
New Facility
Rated By:'Sc" r
Date:
Reviewed (Train. & Cert.)
Reg. Office. f,,%r -r- r'4,/'
Reviewed (Train. & Gert.)
Central Office
ORC
Grade
Plant Class: (circle one)
II til IV Total Paints IQ
ITEM POINTS
(1) Industrial Pretreatment Units and/or
(a) -.Carbonaceous Stage
Industrial Pretreatment Program
(i)Aeralion - High Purity Oxygen System ... _ .
(see definition No- 33)
4
(2) D1 t N FLOW OF PLANT IN GPD
Mechanical Air System (fixed,
(not applicable to non -contaminated cooling waters, sludge
handling facilities for water purification plants, totally
B 1
closed cycle systems (del. No. 11), and facilities
3
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 ..........................
4
250,001 — 500,000 ..........................
5
500,001 --1,000,000 ..........................
8
1,000,001 —2,000,000 ........................
10
2,000,001 (and up) - rate 1 point additional for each
(vi) Sand Filters -
200,000 gpd capacity up to a
intermittent biological .....
maximum .of 30
recirculating biological .....
Design Flow (gpd) :
(vii) Stabilizalion Lagoons ...................
(3) PRELIMINARY UNITS (see definition no, 32)
(viii)Clarilier ..............................
(a) Bar Sueens ................................
1
or
carbonaceous removal of BOD and
(b) Mechanical Screens, Static Screens or
nitrogenous removal by nitrification
Comminuting Devices ........... .............
2
(c) Grit Removal ...............................
1
O through (5) (a) (viii) ... . ........... . .
or Mechanical or Aerated Grit Removal ...........
2
(e) Flow measuring Device .......................
1
or
(xi) Biological Culture (`Super Bugs`) addition
(Q Instrumented Flow Measurement ... . ..........
2
(g) Preaeration................................
2
(h) Influent Flow,Equalization ...................
2
(i) Grease or Oil Separators - Gravity ..........
2
Mechanical..........
3
Dissolved Air Flotation.
8
{)) Prechlorination ..............................
5 -
(4) PRIMARY TREATMENT UNITS
(a) Septic Tank (see definition no. 43) ..............
(b) Imhoff Tank ..................................
1k3 (c) Primary Clarifiers ..:....... . :..........:.
(d) Settling Ponds or Settling Tanks for Inorganic
Non-toxic Materiats {sludge handling facilities
for water purification plants, sand, gravel,
stone, and other mining operations except
recreational activities such as gem or gold
ruining) .....................................
2
(5) SECONDARY TREATMENT UNITS
(a) -.Carbonaceous Stage
(i)Aeralion - High Purity Oxygen System ... _ .
20
Diffused Air System ...........
10
Mechanical Air System (fixed,
floating or rotor) ..............
B 1
Separate Sludge Reaeration ... _ .
3
(ii) Trickling Filler
High bate ...................
7
Standard Rate ...............
5
Packed Tower ...............
5
(iii) Biological Aerated Filler or Aerated
Biotogicat Filter ......................
10
(iv) Aerated Lagoons ....................... .
10
(v) Rotating Biological Conlactors ..........
10
(vi) Sand Filters -
intermittent biological .....
2
recirculating biological .....
3
(vii) Stabilizalion Lagoons ...................
5
(viii)Clarilier ..............................
5
(ix) Single stage system for combined
carbonaceous removal of BOD and
nitrogenous removal by nitrification
(see def. No. 12) (Points for this item
have to be in addition to items (5) (a)
O through (5) (a) (viii) ... . ........... . .
S
(x) Nutrient additions to enhance BOD
removal ...............................
5
(xi) Biological Culture (`Super Bugs`) addition
to enhance organic compound removal .....
5
(b) Nitrogenous Stage
(i) • Aeration - High Purity Oxygen System . _ .. _
20
Diflused Air System ...........
10
Mechanical Air System (fixed,
- -
floating, or rotor) ...... ......
8
Separate Sludge Reaeration ... _ .
3
(ii) Trickling Filler -
.
High Rate ..............
7
Standard Rate ...........
5
Packed Tower...........
5'
(iii) Biological Aerated Filler or Aerated
Biological Filter . _ ... .............
10
(iv) Rotating Biological Contactors .... , _ .
10
(v) Sand ,Filter -
intermittent biological ........
2
recirculating biological .. ......
3
(vi) Clarifier ..... . .... . .....................
5

Si',E • REATMENT
(a)
- - "'-"'' "" V� 1
10
(10) -CHEMICAL ADDITION SYSTEM (S) (See definition No_ 9)
Aerobic ...............
: r�)-ActivaLed
Carbons Beds -
Unheated ...... .......
(not applicable to chemical additions rated as ilem
(b)
Sludge Stabilization (chemical or thermal) .... ...
without carbon regeneration ..................
5
(3) (j). (5) (a) (x i), (6) (a), (6) (b), (7) (b), (7) (e),
2
with carbon regeneration .. . .................
Is
8 a • 9 b , or 9 c 5 rots each: List:
O ( ) O O O { } points
Sludge Efulrialion .............................
(ti)
Powdered or Granular Activated Carbon Feed -
Sludge Conditioner (chemical or thermal) .... ...
5
(f)
Sludge Thickener (gravity) ......................
without carbon regeneration .................
5
Dissolved Air Flotation Unit
with carbon regeneration ....................
is
(h)
Sludge Gas Utilization (including gas storage) ....
(c)
Air Stripping ..............................
5
_
(d)
Denitrification Process (separate process) . ....
10
Sludge Incinerator - (not including activated
(e)
Electrodialysis ........ _ . . . .................5
10
(11) MISCELLANEOUS UNITS
Vacuum Filter. Centrifuge or Filler Press or other
(f)
Foam Separation ...................... . .. . . . .
5
(a) Holding Ponds, Holding Tanks or Settling Ponds
,S) SLUDGE
(g)
Ion Exchange................................
5
for Organic or Toxic Materials including wastes
2
(h)
Land Application of Treated Effluent
from mining operations containing nitrogen and/or
(see definition 22a)
(see definition no. 22b) (not applicable for
_
phosphorous compounds in amounts significantly
-by contracting to a land application operator who
sand, gravel, stone and other similar mining
greater than is common for domestic wastewater ..........
2
operations)
(b) Effluent Flow Equatizalion (not applicable to storage
not hold the permit for the waslewaler treatment
(i) on agricr)llurally managed sites (See def.
faeilily where the sludge is generated .........
basins which are inherent in land application systems).
(c)
Landfilled (burial) .............................
No_ 4) .......... .........................
1 0
(c) Stage Discharge {not applicable to storage basins
(ii) by high rale infiltration on non-agriculturally
5
inherent in land application systems ....................... ...............
Dechlorinalion ........................
5
managed sites (includes rotary distributors
similar fixed nozzle systems)
4
(d) Pumps....... ..:........ .. •�..,_..�.. �.._.._.._..�_.__�..__ ..
`
Radiation ..........................
and ...........
e Sland-B Power Supply
() PPY;rot •• •••••-•••••-•
(iii) by subsurface disposal (includes low pressure
l .......................•••••........3
(f} Thermal Pollution CanGof Device.........................._..._.............
pipe systems and gravity systems except at
plants consisting of septic tank and nitrifica-
tion lines only) • • - • • • .................. . • - - •
4
TOTAL POINTS
(i)
Microscreens ..... .... .......................
5
{j)
Phosphorus Removal by Biological Processes
CLASSIFICATION
(See def. No. 26) ............................
20
(k)
Polishing Ponds - without aeration .......
2
Class I...............' S - 25 Points
with aera;ion ..........
5
Class 11.................. ............. -- 26- 50 Points
(1)
Post Aeration - cascade ..............
0
Class III ...... ........................... ____..._.._ .. 51- 65 Points
diffused or mechanical .. _
5
Class IV................................. ._ _.. »._ 66- Up Points
(m)
Reverse Osmosis ...............................
5
(n)
Sand or Mixed-Media Filters - low rate ...........
2
Facilities having a rating of one through four points, inclusive,
{
high rale ..........
5
do not require a certified operator. Classification of all other
(o)
Treatment processes for removal of metal or
facilities requires a comparable grade operator in responsible
cyanide....................................
15
charge.
(p)
Treatment processes for removal of toxic
materials other than metal or cyanide .........
15
Facilities having an activated sludge process will be assigned
a minimum classification of Class ti.
Si',E • REATMENT
(a)
Sludge Digestion Tank - Heated ...............
10
Aerobic ...............
5
Unheated ...... .......
3
(b)
Sludge Stabilization (chemical or thermal) .... ...
5
(c)
Sludge Drying Beds - Gravity .................
2
Vacuum Assisted .......
5
(d)
Sludge Efulrialion .............................
5
(e)
Sludge Conditioner (chemical or thermal) .... ...
5
(f)
Sludge Thickener (gravity) ......................
5
(g)
Dissolved Air Flotation Unit
(not applicable to a unit rates as (3) () .... ....
8
(h)
Sludge Gas Utilization (including gas storage) ....
2
(i)
Sludge Holding Tank - Aerated .... ...........
5
Non-aeraled ............
2
(j)
Sludge Incinerator - (not including activated
carbon regeneration) .....
10
(k)
Vacuum Filter. Centrifuge or Filler Press or other
similar dewatering devices ....................
10
,S) SLUDGE
DISPOSAL. (including incinerated ash) "
(a)
Lagoons ........................................
2
(b)
Land Application (surface and subsurface)
(see definition 22a)
-where the facMly holds the land app. permit ...
10
-by contracting to a land application operator who
holds the land application permit ................
2
-land application of sludge by a contractor who does
not hold the permit for the waslewaler treatment
faeilily where the sludge is generated .........
10
(c)
Landfilled (burial) .............................
5
3) DISINFECTION
Chlorination .................... . ... .....
5
Dechlorinalion ........................
5
(c)
Ozone ..............................
5
(d)
Radiation ..........................
5
Facilities having treatment processes for the removal of metal
or cyanide will be assigned a minimum classification of Class 11.
Facilities having treatment processes for the biological removal
of phosphorus will be assigned a minimum classification of Class
Ili.
In -plant processes and related control equipment which are an
integral part of, industrial pruduction shall not be considered waste
treatment. Likewise, discharges of wastewater from residences
having a design flow of 1,000 gpd or less, shall not be subject to
rating.
F + + No +]►f►1��+►k�i