NC0006254_Renewal (Application)_20190731

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ROY COOPER t`_3: ,-j
Governor
MICHAEL S.REGAN 4 �,...>> .
Secretary `'x 4xu�F
LINDA CULPEPPER NORTH CAROLINA
Director . Environmental Quality
July 31, 2019
David Hallock
Blue Ridge Tissue Corporation
PO Box 99
Patterson, NC 28661
Subject: Permit Renewal
Application No. NC0006254
Patterson Mill
Caldwell County
Dear Applicant:
The Water Quality Permitting Section acknowledges the July 31, 2019 receipt of your permit renewal application and
supporting documentation. Your application will be assigned to a permit writer within the Section's NPDES WW permitting
branch. Per G.S. 150B-3 your current permit does not expire until permit decision on the application is made.
Continuation of the current permit is contingent on timely and sufficient application for renewal of the current permit. The
permit writer will contact you if additional information is required to complete your permit renewal. Please respond in a
timely manner to requests for additional information necessary to allow a complete review of the application and renewal
of the permit.
Information regarding the status of your renewal application can be found online using the Department of Environmental
Quality's Environmental Application Tracker at:
https://deci.nc.gov/permits-regulations/permit-guidance/environmental-application-tracker .
If you have any additional questions about the permit, please contact the primary reviewer of the application using the
links available within the Application Tracker.
Sincerely,ce
�U1;flL 1b�
Wren The ford
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Administrative Assistant
Water Quality Permitting Section
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North CCar lime Depa rtrnsnt of Environmental Quaiiti} I Divia n of Water Resources
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Blue Ridge Tissue
RECEIVED/NCDEQ/DWR
July 26,2019
JUL 31 019
N.C. Department of Environmental Quality
Division of Water Quality/NPDES Unit Water Quality
1617 Mail Service Center Permitting Section
Raleigh,NC 27699-1617
RE: Permit Renewal Application for NC0006254
Please find enclosed our completed NPDES permit renewal application with attachments as required in support of
our request for the renewal.
Since this permit became effective on February 1, 2015 there have been changes at the facility that should be
noted as follows:
1. The 3 year average daily production for the facility has increased to 26.1 tons/day and the peak 1 year
average has increased to 28.5 tons/day.
2. The 3 year average daily discharge flow has increased from 177,000 GPD to 241,500 GPD_
3. Approval of boiler additives has been attained as a result of the July 26,2016 inspection of the facility by
the N.C. Department of Water Resources Asheville Office.These additives along with dosage rates have
been listed in our application.
4. The brand of defoamer additive that was listed on our previous application has changed and the
replacement is listed on our new application along with dosage rate.
Regarding biocide usage-As required by our current permit,please consider this to be our statement that neither
pentachlorophenol nor trichlorophenol biocides are being used by the facility.
If there is anything further required to complete the application process please do not hesitate to contact me
directly at 828-757-7505 or by email at [e-mail].
Sincerely,
j/66(
David Hallock
VP&General Manager
Blue Ridge Tissue Corporation
Encl.
Permit renewal application.
Attachments A,B,C and D.
Page 1 of 1
Blue Ridge Tissue Corporation—Patterson Mill
1427 Yadkin River Road,Lenoir NC 28645

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number NC0006254
Please print or type.
1. Contact Information:
Owner Name Blue Ridge Tissue Corporation
Facility Name Patterson Mill
Mailing Address 1427 Yadkin River Road
City Lenoir
State / Zip Code NC 28645
Telephone Number 828-757-7505
Fax Number 828-757-7503
e-mail Address [e-mail]
2. Location of facility producing discharge:
Check here if same as above X❑
Street Address or State Road
City
State / Zip Code
County Caldwell
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Blue Ridge Tissue Corporation
Mailing Address 1427 Yadkin River Road
City Lenoir
State / Zip Code NC, 28645
Telephone Number 828-757-7505
Fax Number 828-757-7503
4. Ownership Status:
Federal ❑ State ❑ Private X❑ Public ❑
Page 1 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
(List specific amounts consumed and/or units of production over the last three years)
Product Produced or Raw Material Product Produced or Raw Material
Consumed Consumed
(AVERAGE)* (PEAK)*
per Day 26.1 short tons. (produced) 46.2 short tons. (produced)
per Month 794 short tons. (produced) 981 short tons. (produced)
per Year 9531 short tons. (produced) 10,276 short tons. (produced)
• =Values stated for average and peak are based on previous 36 months,July 1, 2016-June 30, 2019.
11. Frequency of discharge: Continuous X❑ Intermittent ❑
If intermittent:
Days per week discharge occurs: 7 Duration: 24 hours
12. Types of wastewater discharged to surface waters only
Flow
Discharge
(GALLONS PER DAY)
Sanitary - monthly average
Utility water, etc. - monthly average
Process water- monthly average 229,500
Stormwater- monthly average
Other-monthly average
Explain: Incoming river water strainer 12,000
Backflush.
Monthly Average 241,500
total discharge (all types)
Also based on previous 36 months, July 1, 2016-June 30, 2019.
13. Number of separate discharge points: 2 Outfall Identification number(s) #1 and #2
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitudes
Yadkin River. See attachment D.
Page 3 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data [for new or proposed discharges]
Provide data for the parameters listed. Temperature and pH shall be grab samples,for all other parameters 24-hour
composite sampling shall be used.If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
NOTE:Permittees requesting renewal should complete the table ONLY for the parameters
currently monitored. Summarize the past 3 years of effluent data.
Parameter Daily Monthly Units of
Maximum Average Measurement
Biochemical Oxygen Demand (BOD5) 415 169 Lbs./day
Chemical Oxygen Demand (COD)
Total Organic Carbon
Total Suspended Solids 229 101 Lbs./day
Ammonia as N
Temperature (Summer) 29.9 22 Celsius
Temperature (Winter) 23.8 11 Celsius
pH 8.1 7.4
Fecal Coliform (If sanitary waste is
present)
Total Residual Chlorine (if chlorine is
used)
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type Permit Number Type Permit Number
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES NC0006254 Dredge or fill (Section 404 or CWA)
PSD (CAA) Other: Distribution of class A WQ0011532
Non-attainment program (CAA) by-product residuals.
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Fenotech1725-Foam control in outflow. D.R. = 18,587 grams per 24hr period.
Boiler treatment BG-822 Alkalinity control. D.R. = 1326 grams/24hr period.
Boiler treatment BC-621 scale control. D.R. = 1801 grams/24hr period.
Boiler treatment OP-928 Oxygen control. D.R. = 2960 grams/24hr period.
Boiler treatment SR 222 Corrosion control. D.R. = 568 grams/24hr period.
Page 4 of 5 C-MI 10/08

•
NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No X❑
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
/ / - 7- 4-N46L-
Off-V 1 0 !7`i I LL-6(. 1ltc� t7i2�5 re7N+t T fv>�c_/U't
Printed name of Person Signing Title
Signature of A lit Date
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North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 5 of 5 C-MI 10/08

111"
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Blue Ridge Tissue
7-23-19
Attachment A
Description of the Treatment System
Wastewater is pumped from the effluent pit in the floor of the tissue machine area to the distribution
box. From there it flows into the two fiber traps. A large percentage of the fiber/solids is removed from
the waste stream as it travels the length of the fiber traps toward the head boxes at the opposite end. The
effluent from the head boxes travels to the aeration basin where four or five aerators run 24/7 in a
continuation of the treatment process. The effluent from the aeration basis then travels to the
sedimentation basin. Wastewater travels through this basin for the final phase of treatment to the effluent
point where flow is continuously monitored for rate and total flow. This is also where the sampler is
located and from where weekly composite samples of the final effluent are drawn before it discharges
via underground pipe to the river.
Sludge Management Plan
Primary treatment of our wastewater is accomplished through the use of two fiber traps that remove the
majority of the fiber/solids, (see Attachment B for system illustration). During normal operation a cake
of fiber/sludge forms on the surface of the traps. As this cake gets thicker it dewaters and dries out.
Several times per year, (not less than quarterly),we remove the top one to two feet of the cake by
scraping it off the top with a long reach track hoe excavator. It is placed in dump trucks and hauled off
for disposal. In the past this material was land applied in accordance with our Land Application permit
#WQ0011532,which is current and still in effect. However over the last 3-4 years we have had
difficulty in securing land for applying and have defaulted to hauling the material to the Foothills
Regional Landfill, Caldwell County,in accordance with its requirements, (material is approved
annually,minimum percent solids required,TCLP testing at least annually,etc.).
We expect to continue disposal at the landfill for the foreseeable future.
Page 1 of
Blue Ridge Tissue Corporation —Patterson Mill
1427 Yadkin River Road, Lenoir NC 28645

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7/19/2019
Attachment C
Description of the Manufacturing Process
The manufacturing process begins as recycled industrial waste paper(cardboard and/or white paper
board) is brought to the Stock Prep area of the tissue mill. It is loaded into a pulper which is a large vat
where the industrial waste paper and water are mixed. The industrial waste paper is ground up in the
water to a consistency of about 5% stock(industrial waste paper). The stock is stored in large chests
until it is called for by the tissue machine. Before reaching the wet end of the tissue machine the stock
runs through several pumping and refining operations before it is sprayed onto the Wire (a porous fabric
that separates the fiber from the water and forms a sheet) at the Headbox. A portion of the water comes
out of the stock as it is sprayed onto the wire. As the wire carries the slightly dewatered sheet through
the machine it comes in contact and is transferred to the felt(a heavy duty felt like fabric) where it is
further dewatered. The sheet on the felt comes in contact with and is transferred to the Yankee (rotating
pressure vessel that steam passes through) where it is further dried. The sheet leaves the Yankee by
means of a blade and is rolled up on a core by the Reel. Some of the water that is removed from the
stock and sheet is reclaimed to be used in the process; the rest is wastewater that is sent to the Treatment
System.
Page o
g f 1
Blue Ridge Tissue Corporation—Patterson Mill
1427 Yadkin River Road,Lenoir NC 28645

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USGS Quad:C 12SR Buffalo Cove,NC
Lattitude Longitude � `'
Facility: 36° 0'0"N 81° 33' 55"W �"
Outfall 001: 36° 0'2.2"N 81°33'45"W ` <_-.• '' -
Outfall 002: 36°0'3.1"N 81°33'46.4"W Facility Location
Stream Class: C,Tr North
Subbasin: 03-07-01 HUC: 03040101 Patterson Mill NC0006254
Caldwell County
Receiving Stream: Yadkin River