DEQ-CFW_00060332

IS
IIIPONN-fo
DuPont Fluoroproducts
MES
DEC 16 2014
N.C. Division of Water Resources
Attn: Central Files
1617 Mail Service Center
Raleigh, NC 27699-1617
DuPont Fluoroproducts
22828 NC Highway 87 W
Fayetteville, NC 28306-7332
A
DEC 17 2014 /
RECEIVES
DEC 0 2 2014 vjI'lurCO-
CENTRAL RLES
DW e SECTION
3
November 25, 2014
SUBJECT: Discharge Monitoring Report — October 2014
NPDES Wastewater Discharge Permit No. NC0003573
DuPont Company — Fayetteville Works
Bladen County, North Carolina
Dear Madam or Sir:
Attached is DuPont Company — Fayetteville Works ("DuPont") Discharge Monitoring Report for
the month of October 2014. The report shows exceedances of the Outfall 001 permitted Daily
Maximum and Monthly Average limits of BOD5. While DuPont acknowledges the occurrence
of the two Daily Maximum exceedences, we disagree with the legitimacy of the Monthly
Average exceedence as is explained in this letter.
Outfall 001 Daily Maximum BOD5 Permit Exceedances
The DuPont and Kuraray America manufacturing processes, as well as the site's permitted
wastewater treatment plant ("WWTP"), were all shut down from September 28 through October
13, 2014, for the annual maintenance turnaround.
The Outfall 001 discharges of BOD5 for October 27 and October 29, 2014, were 614.6 lb. and
675.9 lb. respectively, which exceeded the permitted Daily Maximum limit of 484.7 lb/day
BOD5.
The likely cause of these exceedances was due to a longer than normal annual sitewide
maintenance turnaround that resulted in the WWTP microbes becoming unacclimated to the
E. I. du Pont de Nemours and Company FL-4 Rev. 3/2000
DEQ-CFW 00060332

N.C. Division of Water Resources
Central Files
November 25, 2014
Page 2 of 3
Kuraray Butacite® process' plasticizer. This plasticizer is believed to have physically coated the
microbes and inhibited the transfer of biodegradable organics through their cell walls, which in
turn reduced the WWTP system's efficiency to degrade the normal organic wastes.
To prevent recurrence of this permit exceedance, Kuraray Butacite® will be required to startup
in a multi -day staged manner to allow the microbes to reacclimate to the plasticizer after any
outage that exceeds two weeks. Also, certain internal physical testing has been identified that
might help identify when a similar scenario is starting, which will allow DuPont to proactively
respond to the situation before excessive organic compounds, as measured by the BOD5
analytical method, is discharged from the WWTP through Outfall 001.
Outfall 001 Monthly Average BOD5 Permit Exceedance
The DuPont WWTP was shut down from September 28 through October 13, 2014. Since there
was no effluent flow through Outfall 001 or Outfall 002 during this period, sampling of the
outfalls was impossible. In addition, obviously no pollutants were discharged from this site to
the Cape Fear River during this period.
The subject NPDES permit requires that Outfall 001 be monitored for BOD5 three times per
week. The permit defines "calendar week" as "the period from Sunday through the following
Saturday."
Table 1 shows the BOD5 discharges from Outfall 001 during the month of October 2014. The
table is organized and shaded to represent each calendar week in October.
The fourth column in Table 1 is titled "Daily BOD-5 Discharge" and lists the BOD5 discharges
from Outfall 001 either as a direct measurement or as zero (0) for the days when there were no
flow and hence no BOD5 discharges. The table shows the typical Monday, Tuesday, and
Wednesday sampling pattern for the weeks with no flow.
The fifth column is titled "Weekly BOD-5 Average" and lists the average daily BOD5 discharge
from Outfall 001 during each calendar week.
The sixth column is titled "Weekly BOD-5 Discharge" and lists the total pounds of BOD5
discharged from Outfall 001 during each calendar week. It is determined by multiplying the
"Weekly BOD-5 Average" in pounds per day by the number of days in each calendar week. For
example, during the'week of October 26, 2014, the BOD5 average was 584.5 lb/day and there
were six (6) days in that reporting week, for a total discharge of 3507.1 lb. BOD5 for that week.
Summing the weekly BOD5 discharges indicates that 3765.2 lb. of BOD5 were discharged from
Outfall 001 in the month of October. Dividing that quantity by the 31 days of October results in
an actual Monthly Average of 121.5 lb/day BOD5.
DEQ-CFW 00060333

N.C. Division of Water Resources
Central Files
November 25, 2014
Page 3 of 3
While the actual BOD5 average discharge from Outfall 001 in October was 121.5 lb/day, the
NCDENR Division of Water Resources' Compliance Unit is requiring that the Monthly Average
be calculated using only the days with BOD5 analytical results, therefore the reported Monthly
Average of measured BOD5 values for October is 207.1 lb/day, which exceeds the permitted
limit of 182.6 lb/day BOD5-
DuPont respectfully disagrees with this requirement, as it ignores the first thirteen (13) days of
October when there were documented measurements proving there were no Outfall 001 flows,
hence no Outfall 001 BOD5 discharges, during that period.
This requirement also implies that DuPont discharged an average of 207.1 lb/day of BOD5 for
the 31 days of October, or 6420 lb. of BOD5 were discharged in October, which Table 1 proves
to be absolutely incorrect.
If you should have any questions about this report or if you need additional information, feel free
to call me at [phone].
Environmental Manager
Attachment
cc: Belinda S. Henson, NCDENR DWR, FRO
K. Mark Brantley, NCDENR DWR, FRO
Ken W. Cook, DUET, Old Hickory
J. Bart Ruiter, DuET, Wilmington
J. R. Lewis, Fayetteville
File: F-1-3-4
DEQ-CFW 00060334

TABLE 1
DuPont Company - Fayetteville Works
Outfall 001 BOD-5 Discharges - October 2014
Total BOD-5 Discharged during Month (lb) 3765.2
Monthly Average BOD-5 Discharged (lb/day) 121.5
DEQ-CFW 00060335

EFFLUENT
NPDES PERMIT NO. NC0003673 DISCHARGE NO. 001 MONTH October YEAR 2014
FACILITY NAME DuPont - Fayetteville Works CLASS 3 COUNTY Bladen
OPERATOR IN RESPONSIBLE CHARGE (ORC) Jamie R. Lewis GRADE 4 PHONE [phone]
CERTIFIED LABORATORIES (1) TBL Laboratory (Lumberton) (2)
CHECK BOX IF ORC HAS CHANGED PERSON(S) COLLECTING SAMPLES Jamie R. Lewis / Arnold Ray Beard
Mail ORIGINAL and ONE COPY to:
ATTN: CENTRAL FILES l
DIV. OF WATER QUALITY X ` • ��� �- /
DENR (SIGNATU E OF OPERATOR IN RESPONSIBLE CHARGE) DATE
1617 MAIL SERVICE CENTER BY THIS SIGNATURE, I CERTIFY THAT THE REPORT IS
RALEIGH, NC 27699-1617 ACCURATE AND COMPLETE TO THE BEST OF MY KNOWLEDGE
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DEM Form MR-1 (12193) SD - Shutdown
DEQ-CFW 00060336

Facility Status: (Please check one of the following)
All monitoring data and sampling frequencies meet permit requirements
Compliant
All monitoring data and sampling frequencies do NOT meet permit requirements L,J
Noncompliant
If the facility is noncompliant, please comment on corrective actions being taken in respect to equipment, operation,
maintenance, etc., and a time table for improvements to be made.
The Outfall 001 discharges of BOD-5 for 10-27-2014 and 10-29-2014 were 614.6 lb. and 676.9 lb. respectively, which exceeded
the permitted Daily Maximum limit of 484.7 lb/day BOD-5. While the actual average of BOD-5 discharged from Outfall 001 in
October was 121.6 lb/day, because there was no Outfall 001 flow from October 1 to October 13, the reported average of
measured BOD-5 values for October was 207.1 lb/day, which exceeds the permitted Monthly Average limit of 182.6 lb/day
BOD-5. The likely cause of these exceedances was due to a longer than normal annual sitewide maintenance shutdown that
resulted in the WWTP microbes becoming unacclimated to the Butacite process' plasticizer, which in turn reduced the WWTP
system's efficiency to degrade the normal organic wastes. To prevent recurrence of this permit exceedance, Butacite will be
required to startup in a multi -day staged manner to allow the microbes to reacclimate to the plasticizer after any outage that
exceeds two weeks.
"I certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance
with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry
of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information
is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting
false information, including the possibility of fines and imprisonment for knowing violations."
Ellis H. McGaughy - Plant
Permittee (Please print or1
� c
Signature of Permittee*
Date
2014
22828 NC Hwy 87 W, Fayetteville, NC, 28306-7332 [phone] October 31, 2016
Permittee Address Phone Number Permit Exp. Date
00010
Temperature
00076
Turbidity
00080
Color (Pt -Co)
00082
Color (ADMI)
00095 Conductivity
00300 Dissolved Oxygen
00310 BOD5
00340 COD
00400 pH
00530 Total Suspended
Residue
00545 Settleable Matter
00556
00600
00610
00625
00630
PARAMETER CODES
Oil & Grease 00951 Total Fluoride
Total Nitrogen 01002 Total Arsenic
Ammonia Nitrogen
Total Kjeldhal
Nitrogen
Nitrates/Nitrites
00665
Total Phosphorous
00720
Cyanide
00745
Total Sulfide
00927
Total Magnesium
00929
Total Sodium
00940
Total Chloride
01027 Cadmium
01032 Hexavalent Chromium
01034 Chromium
01037 Total Cobalt
01042 Copper
01045 Iron
01051 Lead
01067 Nickel
01077 Silver
01092 Zinc
01105 Aluminum
01147
Total Selenium
31616
Fecal Coliform
32730
Total Phenolics
34235
Benzene
34481
Toluene
38260
MBAS
39516
PCB's
50050
Flow
50060 Total
Residual
Chlorine
71880 Formaldehyde
71900 Mercury
81551 Xylene
Parameter Code assitance may be obtained by calling the Water Quality Compliance Group at [phone], extension 581 or 534
The monthly average for fecal coliform is to be reported as a GEOMETRIC mean. Use only units designated in the reporting
facility's permit for reporting data
* ORC must visit facility and document visitation of facility as required per 15A NCAC 8A .0202 (b) (5) (B).
** If signed by other than the premittee, delegation of signatory authority must be on file with the state per 15A NCAC 2B .0506
(b) (2) (D)
DEQ-CFW 00060337

EFFLUENT
NPDES PERMIT NO. NC0003573 DISCHARGE NO. 002 MONTH October YEAR 2014
FACILITY NAME DuPont - Fayetteville Works CLASS 3 COUNTY Bladen
OPERATOR IN RESPONSIBLE CHARGE (ORC) Jamie R. Lewis GRADE 4 PHONE [phone]
CERTIFIED LABORATORIES (1) TBL Laboratory (Lumberton) (2)
CHECK BOX IF ORC HAS CHANGED PERSON(S) COLLECTING SAMPLES Jamie R. Lewis / Arnold Ray Beard
Mail ORIGINAL and ONE COPY to:
ATTN: CENTRAL FILES f
DIV. OF WATER QUALITY X
DENR (SIGNATU E OF OPERATOR IN RESPONSIBLE CHARGE) DATE
1617 MAIL SERVICE CENTER BY THIS SIGNATURE, I CERTIFY THAT THE REPORT IS
RALEIGH, NC 27699-1617 ACCURATE AND COMPLETE TO THE BEST OF MY KNOWLEDGE
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DEM Form MR-1 (12/93) SD - Shutdown
DEQ-CFW 00060338

Facility Status: (Please check one of the following)
Ali monitoring data and sampling frequencies meet permit requirements �X
Compliant
All monitoring data and sampling frequencies do NOT meet permit requirements
Noncompliant
If the facility is noncompliant, please comment on corrective actions being taken in respect to equipment, operation,
maintenance, etc., and a time table for improvements to be made.
"I certify, under penalty of law, that this document and all attachments were prepared under my direction or
supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate
the information submitted. Based on my inquiry of the person or persons who manage the system, or those
persons directly responsible for gathering the information, the information is, to the best of my knowledge and belief,
true, accurate, and complete. I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonment for knowing violations."
Ellis H. McGaughy - Plant
�mittee (Please print or
A 11 /1. AL
of
11 12W2,o14
22828 NC Hwy 87 W, Fayetteville, NC, 28306-7332 [phone] October 31, 2016
Permittee Address Phone Number Permit Exp. Date
00010 Temperature
00076 Turbidity
00080 Color (Pt -Co)
00082 Color (ADMI)
00095 Conductivity
00300 Dissolved Oxygen
00310 BOD5
00340 COD
00400 pH
00530 Total Suspended
Residue
00545 Settleable Matter
00556
00600
00610
00625
00630
PARAMETER CODES
Oil & Grease 00951 Total Fluoride
Total Nitrogen 01002 Total Arsenic
Ammonia Nitrogen
Total Kjeldhal
Nitrogen
Nitrates/Nitrites
00665
Total Phosphorous
00720
Cyanide
00745
Total Sulfide
00927
Total Magnesium
00929
Total Sodium
00940
Total Chloride
01027 Cadmium
01032 Hexavalent Chromium
01034 Chromium
01037 Total Cobalt
01042 Copper
01045 Iron
01051 Lead
01067 Nickel
01077 Silver
01092 Zinc
01105 Aluminum
01147 Total Selenium
31616 Fecal Coliform
32730 Total Phenolics
34235 Benzene
34481 Toluene
38260 WAS
39516 PCB's
50050 Flow
50060 Total
Residual
Chlorine
71880 Formaldehyde
71900 Mercury
81551 Xylene
Parameter Code assitance may be obtained by calling the Water Quality Compliance Group at [phone], extension 581 or 534
The monthly average for fecal coliform is to be reported as a GEOMETRIC mean. Use only units designated in the reporting
facility's permit for reporting data
* ORC must visit facility and document visitation of facility as required per 15A NCAC 8A .0202 (b) (5) (B).
** If signed by other than the premittee, delegation of signatory authority must be on file with the state per 15A NCAC 2B .0506
(b) (2) (D)
DEQ-CFW 00060339

NPDES NO: NC0003573 DISCHARGE NO: 002 MONTH: October YEAR: 2014
FACILITY: DuPont - Fayetteville Works COUNTY: Bladen
STREAM: Cape Fear River STREAM: Cape Fear River
LOCATION: DuPont River Pump Station LOCATION: Boat Ramp - 4500 ft below Prospect Hall Landing
UPSTREAM DOWNSTREAM
61
•
Rill
DWQ Form MR-3 (Revised 7/2000)
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00610
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DEQ-CFW 00060340

Facility Status: (Please check one of the following)
All monitoring data and sampling frequencies meet permit requirements FX
Compliant
All monitoring data and sampling frequencies do NOT meet permit requirements
Noncompliant
If the facility is noncompliant, please comment on corrective actions being taken in respect to equipment, operation,
maintenance, etc., and a time table for improvements to be made.
"I certify, under penalty of law, that this document and all attachments were prepared under my direction or
supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate
the information submitted. Based on my inquiry of the person or persons who manage the system, or those
persons directly responsible for gathering the information, the information is, to the best of my knowledge and belief,
true, accurate, and complete. I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonment for knowing violations."
Ellis H. McGaughy - Plant Illanager
Pe,Littee (Plea print or pe)
5 ., ,: /1. 11201 of
of Permitteel*
22828 NC Hwy 87 W, Fayetteville, NC, 28306-7332 [phone] October 31, 2016
Permittee Address Phone Number Permit Exp. Date
00010
Temperature
00076
Turbidity
00080
Color (Pt -Co)
00082
Color (ADMI)
00095 Conductivity
00300 Dissolved Oxygen
00310 BOD5
00340 COD
00400 pH
00530 Total Suspended
Residue
00545 Settleable Matter
00556
00600
00610
00625
00630
PARAMETER CODES
Oil & Grease 00951 Total Fluoride
Total Nitrogen 01002 Total Arsenic
Ammonia Nitrogen
Total Kjeldhal
Nitrogen
Nitrates/Nitrites
00665
Total Phosphorous
00720
Cyanide
00745
Total Sulfide
00927
Total Magnesium
00929
Total Sodium
00940
Total Chloride
01027 Cadmium
01032 Hexavalent Chromium
01034 Chromium
01037 Total Cobalt
01042 Copper
01045 Iron
01051 Lead
01067 Nickel
01077 Silver
01092 Zinc
01105 Aluminum
01147 Total Selenium
31616 Fecal Coliform
32730 Total Phenolics
34235 Benzene
34481 Toluene
38260 WAS
39516 PCB's
50050 Flow
50060 Total
Residual
Chlorine
71880 Formaldehyde
71900 Mercury
81551 Xyiene
Parameter Code assitance may be obtained by calling the Water Quality Compliance Group at [phone], extension 581 or 534
The monthly average for fecal coliform is to be reported as a GEOMETRIC mean. Use only units designated in the reporting
facility's permit for reporting data
* ORC must visit facility and document visitation of facility as required per 15A NCAC 8A .0202 (b) (5) (B).
** If signed by other than the premittee, delegation of signatory authority must be on file with the state per 15A NCAC 2B .0506
(b) (2) (D)
DEQ-CFW 00060341