WQ0008799_Final Permit_20050826

O� V4A1
'�R Michael F. Easley, Governor
William G. Ross Jr., Secretary
y North Carolina Department of Environment and Natural Resources
—i Alan W. Klimek, P.E., Director
p < Division of Water Quality
August 26, 2005
MR. GREGORY R. BOOZER, EXECUTIVE VICE PRESIDENT OF MANUFACTURING
DAN RIVER, INC.
POST OFFICE BOX 251
DANVILLE, VIRGINIA 24543
Subject: Permit No. WQ0008799
Dan River, Inc.
Harris, NC Finishing Plant
Distribution/Land Application of Residuals from
the Treatment of Other Wastewater
Rutherford County
Dear Mr_ Boozer:
In accordance with your permit modification and renewal application package received on May
27, 2003 as well as the additional information received on August 27, 2003, we are forwarding herewith a
modified and renewed Permit No. WQ0008799, dated August 26, 2005, to Dan River, Inc. for the
operation of a program to distribute residuals from the treatment of other wastewater. The product is a
residual that is generated from the treatment of industrial wastewater at Dan River, Inc.'s finishing plant
located in Harris, North Carolina.
This permit shall be effective from the date of issuance until July 31, 2010; shall void Permit No.
WQ0008799, issued on December 27, 2000 and clarified on May 14, 2001; and shall be subject to the
conditions and limitations as specified therein. Make note of this permit's expiration date and the fact
that a permit renewal application is due to the Division of Water Quality (Division) no later than six
months prior to that date (i.e., see Condition VI. 7.), as the Division does not send reminders to apply for
permit renewal.
This permit is being issued to modify the amount of residuals approved for distribution/land
application from 290 to 318 dry tons per year. This permit approves the continued operation of the
residuals land application program for another five-year cycle. As always, remember to take the time to
review this permit thoroughly, as some of the conditions contained therein may have been added,
changed, or deleted since the last issuance. 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, and/or limitations contained in this permit are unacceptable, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request shall be in the from of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes and filed with the Office of Administrative Hearings at 6714 Mail Service
Center, Raleigh, North Carolina 27699-6714. Unless such demands are made, this permit shall be final
and binding.
lRehCarolina
'Natur,711Y
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Intemet.http:!/h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 Fax [phone]
Fax [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled110% Post Consumer Paper

If you need any additional information concerning this matter, please contact Mr. Duane Leith by-
telephone
ytelephone at [phone], or via e-mail at [e-mail].
Sincerely
for Alan W. Klimek, P.E.
cc: Bob Branch, Branch Residuals and Soils, LLC
Rutherford County Health Department
Asheville Regional Office -Aquifer Protection Section
Technical Assistance and Certification Unit
APS Central Files
LAU Files
LAU Residuals Program Coordinator
2

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
PERMIT FOR THE DISTRIBUTIONILAND APPLICATION OF RESIDUALS FROM THE
TREATMENT OF OTHER WASTEWATER
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
Dan River, Inc.
Rutherford County
FOR THE
continued operation of the distribution and land application of wastewater residuals for Dan River, Inc. and
consisting of the distribution and land application of residuals generated by the Dan River Inc. — Harris
Finishing Plant with no discharge of wastes to surface waters pursuant to the permit modification/renewal
application package received on May 27, 2003 as well as the additional information received on August
27, 2003 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 July 31, 2010; shall void Permit No.
WQ0008799, issued on December 27, 2000 and amended on May 14, 2001; and shall be subject to the
following specified conditions and limitations:
I. PERFORMANCE STANDARDS
The distribution of residuals program shall be effectively maintained and operated as a non -
discharge system to prevent the discharge of any wastes resulting from the operation of this
program.
2. This permit shall become voidable in the event of failure of the residuals program to
adequately protect the assigned water quality standards of the surface waters and
groundwaters.
3. 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 program.

4. In the event that the residuals program is not operated satisfactorily, including the creation of
nuisance conditions, the Permittee shall take any immediate corrective actions as may be
required by the Division of Water Quality (Division).
5. Diversion or bypassing of the untreated residuals or leachate from the residual treatment
facilities is prohibited.
6. All leachate must be reused as a wetting agent for the processing of residuals or routed to the
head of the treatment plant.
11. OPERATION AND MAINTENANCE REQUIREMENTS
1. The residuals treatment facilities shall be properly maintained and operated at all times.
2. No residuals other than the following are hereby approved for distribution in accordance with
this permit:
Permit Volume
Source County Number (dry tons/year)
Dan River, Inca Rutherford NPDES Permit No. NCO083275 318
Only residuals derived from the treatment of industrial wastewater shall be approved for
distribution/land application in accordance with this permit. It is the Division's understanding
that domestic wastewater generated from Dan River Inc.'s Harris, North Carolina Finishing
Plant is treated and disposed of through an on-site conventional sub -surface system. Septage
removed from wastewater treatment/storage units associated with this system shall be removed
off-site and properly disposed. Under no circumstance, shall this septage be introduced to the
plant treating the industrial wastewater. A modification to this permit shall be requested to
and approved by the Division if there is a desire to combine the domestic and industrial
wastewater sources prior to treatment.
3. All residuals shall be adequately stored to prevent leachate runoff until treated. The finished
product may be placed on a concrete pad, placed under shelter or covered until such time as it
is distributed to the buyer. If an alternate storage site is to be used, approval must be obtained
from. the Division.
4. No other residuals other than those specified under Condition II 2 above may be distributed.
The Permittee shall request and obtain a permit amendment from the Division for each
additional residual source prior to acceptance of that residual.
For the residuals to be distributed/land applied, the following shall be satisfied: :
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The Ceiling Concentrations (i.e., on a dry weight basis) and the Pollutant Monthly Average
Concentrations (i.e., on a dry weight basis) shall be maintained:
Ceiling Monthly Average
Concentrations Concentrations
Parameters (mg/k(m/W
Arsenic
75
41
Cadmium
85
39
Copper
4,300
1,500
Lead
840
300
Mercury
57
17
Molybdenum
75
----
Nickel
420
420
Selenium
100
100
Zinc
7,500
2,800
b. Upon classification of the facility by the Water Pollution Control System Operators
Certification Commission (WPCSOCC), the Permittee shall employ a certified residuals
operator to be in responsible charge (ORC) of the residuals program. The operator must hold
a certificate of the type classification assigned to the residuals program by the WPCSOCC.
The Permittee must also employ a certified back-up operator of the appropriate type to comply
with the conditions of 15A NCAC 8G .0202.
7. Adeqaate provisions shall be taken to prevent wind erosion and surface runoff from conveying
pollutants from the residuals treatment area onto the adjacent property or into any surface
waters.
8. A label shall be affixed to the bag or other container in which residuals that are sold or given
away for application to the land, or an information sheet shall be provided to the person who
receives the residuals sold or given away in an other container for application to the land. The
label or information sheet shall contain the following information:
a. The name and address of the person who prepared the residuals that is sold or given
away in a bag or other container for application to the land.
b. A statement that application of the residuals to the land is prohibited except in
accordance with the instructions on the label or information sheet.
c. A statement which identifies that this material shall be prevented from entering any
public or private water supply source (including wells) and any stream, lake, or river.
d. Residuals shall not be applied to any site that is flooded, frozen or snow-covered.
e. Adequate procedures shall be provided to prevent surface runoff from carrying any
disposed or stored residuals into any surface waters.

9. For the residuals to be distributed/land applied, the residuals shall be essentially pathogen -free,
as evidenced by the testing of seven separate and representative samples of the residuals for
the presence of fecal coliform in accordance with Condition III. 3. of this permit.
Distribution/land application of the residuals shall be strictly forbidden if any sample results in
a fecal coliform density of 1,000 most probable number (MPN) or coliform forming units
(CFU) per gram of total dry solids. Note that utilization of the geometric mean shall not be
allowed to meet this condition.
III. MONITORING AND REPORTING REQUIREMENTS
1. Any monitoring (including groundwater, surface water, residuals, soil, or plant tissue analyses)
deemed necessary by the Division to insure protection of the environment will be established
and an acceptable sampling and reporting schedule shall be followed.
Z. Proper records shall be maintained by the Permittee tracking all residual activities. These
records shall include, but are not necessarily limited to the following information:
a. source, volume and analysis of each residuals
b. name of residuals' recipient, volume received, and intended use
3. A residuals analysis shall be conducted annually from the date of permit issuance and any time
that a change in the manufacturing process of the plant producing the residuals occurs. The
results of all residuals analyses shall be maintained on file by the Permittee for a minimum of
five years. if distribution/land application occurs at a frequency less than every annually, a
residuals analysis will be required for each instance of distribution/land application. The
residuals analysis shall include, but shall not necessarily be limited to, the following
parameters:
Aluminum
Ammonia -Nitrogen
Arsenic
Cadmium
Calcium
Copper
Lead
Magnesium
Mercury
Molybdenum
Nickel
Nitrate -Nitrite Nitrogen
Percent Total Solids
PH
Phosphorus
Potassium
Selenium
Sodium
Total Kjeldahl Nitrogen
Zinc
Plant Available Nitrogen
(by calculation)
After the residuals have been monitored for two years at the above frequency, the Permittee
may submit a request to the Division for a permit modification for the reduction of the
frequency of monitoring for pollutant concentrations, but in no case shall the frequency of
monitoring be less than once per year when residuals are distributed/] and applied.
El

4. A Toxicity Characteristics Leaching Procedure (TCLP) analysis shall be conducted by the
Permittee once per permit cycle (every 5 years). Residuals generated by each residuals source -
generating facility listed in permit condition II.2. shall be analyzed to demonstrate that they are
non -hazardous under the Resource Conservation and Recovery Act (RCRA). A corrosivity,
ignitability, and reactivity analysis as well as a Toxicity Characteristics Leaching Procedure
(TCLP) analysis shall be conducted The TCLP analysis shall include the following parameters
(please note the regulatory level in mglL in parentheses):
Arsenic (5.0)
1,4 -Dichlorobenzene (7.5)
Nitrobenzene (2.0)
Barium (100.0)
1,2-Dichloroethane (0.5)
Pentachlorophenol (100.0)
Benzene (0.5)
1,1-Dichloroethylene (0.7)
Pyridine (5.0)
Cadmium (1.0)
2,4-Dinitrotoluene (0.13)
Selenium (1.0)
Ca+x on terach"Orlde (0.5)
Endrin. (0.021
Silver (5,0)
Chlordane (0.03)
Hexachlorobenzene (0.13)
Tetrachloroethylene (0.7)
Chlorobenzene (100.0)
Heptachlor (and its hydroxide) (0.008)
Toxaphene (0.5)
Chloroform (6.0)
Hexachloro-1,3-butadiene (0.5)
Trichloroethylene (0.5)
Chromium (5.0)
Hexachloroethane (3.0)
2,4,5 -Trichlorophenol (400.0)
rn-Cresol (200.0)
Lead (5.0)
2,4,6 -Trichlorophenol (2.0)
o -Cresol (200.0)
Lindane (0.4)
2,4,5 -TP (Silvex) (1.0)
p -Cresol (200.0)
Mercury (0.2)
Vinyl chloride (0.2)
Cresol (200.0)
Methoxychlor (10.0)
2,4-D (10.0)
Methyl ethyl ketone (200.0)
In no case, however, shall the frequency of TCLP monitoring be less than once per permit
cycle when residuals are distributed/land applied.
5. Three copies of all required monitoring and reporting requirements as specified in conditions
III 1, 1112, III 3, III 4 and 111.6, shall be submitted annually on or before March 1 of the
following year to the following address:
Division of Water Quality
Information Processing Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617

6. All residuals included in this permit shall be monitored by the Permittee for compliance with
Condition II. 9. of this permit. The results of all analyses shall be maintained on file by the
Permittee for a minimum of five years. The residuals in the holding tank (i.e., following
digestion) shall be tested prior to each distribution/land application event for the first calendar
year following this permit's issuance. A distribution/land application event shall be defined as
the time period during which residuals are removed from the holding tank such that the
volume has been reduced to a level that is satisfactory to meet the residuals management
needs of the Permittee. Note that this condition requires that distribution/land application
events be initiated from the holding tank alone and not from either of the two digesters. One
set of samples shall be sufficient for each distribution/land application event as long as no
additional residuals are added to the holding tank during the event. .Any time that additional
residuals are added to the holding tank during a distribution/land application event, another set
of samples shall be taken so that compliance with Condition Il. 4. may be verified Before the
event continues. If the samples from each distribution/land application event taken during the
first calendar year complies with the limits set forth in Condition H. 4., then the monitoring
frequency may be reduced to an annual basis. Note, however, if the wastewater treatment
plant is reseeded from a facility that treats domestic wastewater (i.e., Town of Forest City) for
any reason (i.e., upset of the biological process, etc.), the Permittee shall test each batch of
residuals prior to distribution/land application for another calendar year, and the monitoring
frequency may be reduced only as described above.
7. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office, telephone number
[phone], 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 with the distribution program which results in the land application of
significant amounts of wastes which are abnormal in quantity or characteristic.
b. Any failure of the distribution program resulting in a release of material to receiving
waters.
c. Any time that self-monitoring information indicates that the facility has gone out of
compliance with the conditions and limitations of this permit or the parameters on which
the system was designed.
d. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate residual treatment.
e. Any spillage or discharge from a vehicle or piping system during transportation of
residuals.
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.

IV. GROUNDWATER REQUIREMENTS
1. Any groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
V. INSPECTIONS
1. The Permittee or his designee shall inspect the residuals storage, transport, and treatment
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 five years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
2. 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 treatment site or facility 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; and may obtain samples of groundwater, surface water, or leachate.
VI. GENERAL CONDITIONS
1. This permit shall become voidable unless the distribution activities are carried out in
accordance with the conditions of this permit, the supporting materials, and in the manner
approved by this Division.
2. This permit is effective only with respect to the nature and volume of residuals described in
the application and other supporting data.
3. This pen -nit is not automatically transferable. In the event that there is a desire for the facilities
to change ownership or a name change of the Permittee, a formal permit request must be
submitted to the Division accompanied by an application fee, documentation from the parties
involved, and other supporting materials as may be appropriate. The approval of this request
will be considered on its merits and may or may not be approved.
4. 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.
5. 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).
6. 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.
7

7. 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.
This permit may be modified, or revoked and reissued to incorporate any conditions,
limitations and monitoring requirements the Division deems necessary in order to adequately
protect the environment and public health.
Permit issued this the 2Q day of August, 2005.
NORTTd CAR ,fMA F.NVIl3ct)NMENTAL MANAGEMENT COMMISSION
,Lor Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0008799