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Home My WebLink AboutDEQ-CFW_00082458DUPont Fluoreproducts Fayetteville Works Plant 22828 NC Highway 87 West Fayetteville, NC 28306-7332 April 29, 2011 Mrs. Dina Sprinkle NCDENIR Division of Water Quality Point Source Branch .1617 Mail Service Center Raleigh, North Carolina 27699-1617 SUBJECT: NPDES Permit Renewal ApIlication .NPDES Permit No. NCO003573 Dear Mrs. Sprinkle: Pursuant to requirements of the referenced NPDES permit, the DuPont Company — Fayetteville Works is submitting the NPDES Forni. I and Form 2C (original and two copies) for permit renewal by the Division of Water Quality. Included in the permit application is a Supplemental Information document which describes the Current Operations and Proposed Changes. This site is being considered for a project to construct and operate a third manufacturing facility that will produce polyvinyl fluoride ("PVF") polymer resins. Two water balances are included in the application: one without the third PVF facility and one with- the third PVF.fiacility. The application is being submitted without the testing results for Bis(chloroniethyl) ether (CAS No. 542-88-1) as these results were not available at the time of this submittal. These absent results are indicated by asterisks (***) on Page V-4 of Form 2C. This data will be submitted as an addendum when the analytical report is received and inputted into a Form 2C. Should you have any questions or need additional inforination, please feel free to call me at (910) 678-1155. UB N."i A Y 0' 'e"iJ 11 i 4'M` :i�OEBRA Z - Enclosures Environmental Manager El du Pont do Nemours and Company DEQ-CFW-00082458 0 0 UNITED STATES DEPARTMENT OF THE INTERIOR GEOLOGICAL SURVEY 7 34' 52' 47' DUART QUADRANGLE STATE OF NORTH CAROLINA NORTH CAROLINA DEPARTMENT OF NATURAL RESOUR 7.5 MINUTE SERIES (TOPOGRAPHIC) AND COMMUNITY DEVELOPMEN-1 SFJ4 SANT PAW 15, QfjADPAMLE RAI Fir.T4 N r ..................................... .................................. ............................................ ............... - ............. Form 2C. Part III B: WATER BALANCE WITHOUT PVF-3 PROCESS (Revised 04129/2011) DuPont Company - Fayetteville Works Flows Unit: Gallons per Day Basis: All Production Manufacturing, using Maximum 30 day average of measured flows NON RAW R COOL to I fr, L— NPDES PERMIT APPLICATION DEQ-CFW-00082463 DuPont Company -- Fayetteville Works NPDES Permit No, NC O003573 Supplemental In -formation Supplemental Information — Permit Renewal Application — April 29, 2011 Current Site Water Management Process wastewater and stormwater from the various manufacturing areas are collected in the respective area sumps and ultin-tately conveyed via a gravity -flow underground process sewer pipe to the site's central wastewater treatment plant (WWTP). Sanitary sewage is conveyed via a separate -underground sewer system to the WWTP. The permitted flowrate of the WWTP is 10 MGD, with an actual average flowrate of approximately one MGD, This process wastewater is commingled in the WWTP Influent Sump where it is pumped to an 850,000-gallon Equalization Basin. The Equalization Basin is mixed with two floating 0 submerged mixers. Three floating surface aerators in the basin cool and aerate the incoming wastewater. A 175,000-gallon Emergency Retention Tank is available for temporary storage of wastewater cl� which may need additional treatment or acclimation in the NV\VTP activated sludge process at a controlled rate that allows for proper biological treatment. Wastewater from the Equalization Basin is normally pumped to a 250,000-gallon Predigester Tank- in -which initial biological activity with tile WWTP activated sludge begins. The Predigester Tank is aerated. The partially treated wastewater from the Predigester Tank is pumped to a 1,700,000-gallon-Aeration Tank, The Aeration Tank- is the site of the majority of the biological activity. The Aeration Tank is aerated primarily by a diffused air system located in the botton-i of the tank, The tank can have supplemental aeration via a floating BiOmixerCK) that injects air through submerged rotors, The biologically treated wastewater is then sent to one of two in -ground clarifiers (119,000 gallons and 168,000 gallons respectively) or an above -ground 679,000-gallon clarifier; with all clarifiers being operated in parallel. The clarified treated effluent is discharged to and through Outfall 001.. The wasted sludge is sent to a Dissolved Air Floatation (DAF) unit, then to a 47,000 gallon Sludge Storage Tank, and finally to a Rotary Filter for thickening. The thickened sludge is dewatered in. a Sludge Press, and can be dried in a steam -heated dryer for additional moisture removal. The dewatered sludge or dewatered/dried sludge is transported off -site to a commercial Subtitle D landfill. Non --contact process cooling water and non -process stormwater are conveyed via surface ditches. In addition, excess riverwater flow and Outfall 001 effluent are discharged directly to a surface ditch. The combined, total flow of water from the site is discharged and monitored at Outfall 002, The DMR reported Outfall 002 maximum 30-day average flow was 20.75 MGD during the period from 2008 to 2010. Flow variability at Outfall 002 was from 3 to 26 MGD, however, this monitored flow was the influent of river water pumped into the site, and did not include the discharge of stormwater or treated sanitary sewage. DEQ-CFW-00082464 DuPont Company — Fayetteville Works NPDES Permit No. NCO003 573 Supplemental Information Supplemental Information — Permit Renewal Application — April 29, 2011 Proposed Changes in Operations PVF-3 Manufacturing Facility: The DuPont Company — Fayetteville Works is being considered as the location for a third DuPorif"I"I Polyvinyl Fluoride ("PVF") manufacturing process ("PVF-Y), The manufacturing facility is .11.1 the process of being designed, and will produce P\TF' polymer resins. PVF resin to be manufactured at the Fayetteville plant is used in DuPonfrl"'Tedlar%) fluoropolyiner film business. Tedlar(t) film is manufactured at other DuPont site location (not the Fayetteville plant). TedlarCR) is used in the photovoltaic industry in photovoltaic cells and the aircraft industry for interior cabin surfaces, as well as many other uses. Assuming this new facility is sited at the DuPont Company --- Fayetteville Works, construction would be completed in August 2013 and the unit would begin production in September 2013. The manufacturing facility will be located near the existing PNT-1 and PVF-2 manufacturing processes. This process will produce polyvinyl fluoride ("PVF") resin (CAS No. 24981-14-4), As with most fluorochemical processes, the main wastewater stream from the PVF-3 manufacturing process would have trace or no biological oxygen demand (BOD5) value. The major pollutant associated with this process wastewater would be solid resin (as Total Suspended Solids). To treat this wastewater, DuPont intends to pump the majority of the PVF-3 process wastewater directly to the third clarifier, which would remove the resin solids as part of the activated sludge removed from. the WWTP system. Ultimately the resin solids would be removed from the system as part of the wasted sludge that is sent off site to a Subpart D landfill, .Approximately 3% of the PN7F-3 process wastewater contains a cleaning solution will be sent to the lie-adworks of the site's WWTP. The PVF-3 Manufacturing Facility would have a process wastewater stream containing a cleaning solution or surfactant. This wastewater stream, representing approximately 3% of the total PVF-3 process wastewater, would be sent to the headworks of the site's WWTP for biological treatment. Finally' non -contact cooling, condensate, and stormwater :from the PVF-3 Manufacturing Facility will be discliarged directly to Out -fall 002 via the site's non -contact water ditch, DEQ-CFW-00082465 DuPont Company Fayetteville Works NPDES Permit No. NC0003573 Supplemental information Supplemental Information — Permit Renewal Application — Apr 129,2011 Current Operating Conditions Butaciteg ManufacturLng: The DuPont Company — Fayetteville Works' Butacite(R manufacturing area produces two final products. DuPont` m ButaciteR Interlayer plastic sheeting is the final Product used in safety glass such as automobile windshields. Polyvinyl butyral (PVB) resin is shipped off site as a transfer to other DuPont locations for -final processing. Wastewater generated from this manufacturing Eacility is treated in the site's biological wastewater treatment plant ("WWTP'). Naflon@ Manufaetu The DuPont Company — Fayetteville Works' Nafion( 110 manufacturing area produces five final products, DuPonfl',11 NafionCR) Membrane is a plastic film used in the chloroalkall industry and in electrochemical -fuel cells. Naflone Resins are ultimately extruded into a finished -film. The FLPR Vinyl Ether and F1FP0 monomers are shipped to other DuPont locations to produce various.fluorochemical products such. as DuPonfl,m TeflonO. Wastewater generated from this manufacturing facility is neutralized and discharged to the ", 'TP. PPA Manufacturing: The DuPont Company — Fayetteville Works' PPA manufacturing area produces several polymer processing aids. The processing aids produced in this unit are used to produce fluoropolyniers and fluorinated telomers, but none of the produced processing aids are used at the Fayetteville Works site. This facility was started up in Novernber 2002. All process wastewater generated from this manufacturing facility is collected and shipped off -site for disposal. No process wastewater from this manufacturing facility is discharged to the site's biological WWTP or to the Cape Fear River. SentryGlas Mauufacturi x a The DuPont Company --- Fayetteville Works' SentryGlao,) manufacturing area produces DuPont:F111 SentryGlas0_0 ionoplast interlayer laminate. SentryGlas09 interlayer is used for laminated safety glass in side, rear., and overhead automobile windows. It is also used in architectural applications desiring safety glass. This facility was started up in June 2005. There is no contact process wastewater generated fi-oni this manufacturing facility, therefore only sanitary waste from this area is treated in. the WWTP. This manufacturing facility does discharge non -contact cooling water to a surface ditch and ultimately to Outfall 002. PVF Manu The DuPont Company — Fayetteville Works' PVF manufacturing area produces polyvinyl fluoride resin is used in the electronics industry as a backing for photovoltaic cells, as well as many other uses. The PVF- I facility was constructed in 2006-2007 and was started up in September 2007. The PVF-2 facility was constructed in 2008-2010 and was started Lip in June 2010, Process wastewater generated from this manufacturing facility is treated in the WWTP. DEQ-CFW-00082466 DuPont Company — Fayetteville Works Supplemental Information — Data Unavailable NPDES Permit No, NC O003573 Supplemental hiffirixiation Permit Renewal Application — April 29,2011 Form 2C Permit Application The Outfall 001 and Outfall 002 analytical results for Bis(chlorometllyl) ether were not available at the dine of this permit renewal application submittal, 'I'liese absent analytical results are indicated with asterisks (***) on Page V-4 of Fom. 2C- This data will be submitted as an addendurn when the analytical report is received. DEQ-CFW-00082467 DuPont Company— Fayetteville Works I\TPDES Permit No. NCO003573 Supplemental Information Supplemental Information — Permit Renewal Application- — A.prfi 29, 2011 Sludge Management Plan The DuPont - Fayetteville Works operates a Class 3 Wastewater Treatment Plant which is comprised of a single -stage activated sludge biological system. Excess sludge is ren-ioved from the system by diverting part of the Recycled Activated Sludge (at approximately 0.6% solids) fiom the clarifiers to a Dissolved Air Floatation ("DAF") unit for initial thickening. The sludge from the DAF (at approximately 3% solids) is transferred to a Mix Tank where polymer agents are added to enliance the dewatering process. The senii-thickened sludge is transferred from the Mix Tank to a Rotary Filter for final, thickening, whereby the sludge is thickened to 6% solids. The thickened sludge is then transferred to a Screw Press where it is dewatered to a concentration of 9-20% solids, Following the Screw Press, the sludge is typically dried in steam heated dryers to a concentration of 40-55% solids. On the average, the weekly quantity of generated dried sludge is approximately 23,000 lb. The (Tried sludge, or on occasion the dewatered sludge, is transported of[ -site to a commercial Subtitle D landfill. This sludge is currently being disposed of at the Waste Industries "Sampson County" Landfill near Roseboro, NC, DEQ-CFW-00082468 DuPont Company - Fayetteville Works NPDES Permit NCO003573 Total Volume of the Water Handling System Between Entry of Biocidal Product and NPDES Discharge Point Flow Diagram from Entry Point of Biocidal Product (PVF-3 Cooling Tower) to the NPDES Discharge Point (NPDES Outfall 002) PVF-3 WASTEWATER NPDES COOLING TREATMENT OUTF-A.L.I., TOWER PLANT 002 1 DEQ-CFW-00082469