NC0000639_Draft Permit_20220517

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ROY COOPER i ` ,
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Governor �� ,�.��p\
ELIZABETH S.BISER
Secretary *4►a4wvas+
RICHARD E.ROGERS,JR, NORTH CAROLINA
Director Environmental Quality
May 17,2022
Mr.Henry Needham 1
Sapona Yarns,LLC
P.O.Box 128
Cedar Falls,NC 27230-0128
Subject: Draft NPDES Permit NC0000639
Sapona Manufacturing Company WWTP
Grade WW-2 Biological WPCS
Randolph County
Dear Permittee:
The Division has reviewed your request to renew the subject permit. Enclosed with this letter is a copy of the draft
permit for your facility.Please review this draft carefully to ensure your thorough understanding of the
information,conditions,and requirements it contains.
The draft permit includes no significant changes from the existing permit.
Please note that the Deep River is listed as an impaired waterbody on the North Carolina 303(d)Impaired Waters
List. Addressing impaired waters is a high priority with the Division,and instream data will continue to be
evaluated. If there is noncompliance with this permit's effluent limits and stream impairment can be attributed to
your facility,then mitigative measures may be required.
The NPDES standard conditions(Parts II,III,and IV)that are a part of the permit are not included in this draft
document(cover,map,and Part I).The conditions are the same as in your current permit except that agency and
division names have been updated.The latest version is available at https://bit.ly/2BZ4xxx and can be viewed
online or downloaded as a PDF file.
With this notification,the Division will solicit public comment on this draft permit by publishing a notice in
newspapers having circulation in the general Randolph County area,per EPA requirements.Please provide your
comments,if any,to me at the address below no later than 30 days after receiving this draft permit.
Following the 30-day public comment period,the Division will review all pertinent comments and take
appropriate action prior to issuing a final permit. If you have questions concerning the draft,please contact me at
919-707-3616,or via e-mail at [e-mail].
Sincerely,
fillitle- . /)1
Environmental Specialist II
NPDES Compliance and Expedited Permitting
North Carolina Department of Environmental Quality I Division of Water Resources
D ��� 512 North Salisbury Street 11611 Mail Service Center I Raleigh North Carolina 2 7 699-1 61 1
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919.707.9000

Permit NC0000639
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF WATER RESOURCES
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1,other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission,and the
Federal Water Pollution Control Act, as amended,
Sapona Yarns, LLC
is hereby authorized to discharge wastewater from a facility located at
Sapona Manufacturing Company
2478 Cedar Falls Road
Franklinville
Randolph County
to receiving waters designated as the Deep River in subbasin 03-06-09 of the Cape Fear River Basin in accordance
with effluent limitations,monitoring requirements,and other conditions set forth in Parts I,II,III and IV hereof.
This permit shall become effective
This permit and authorization to discharge shall expire at midnight on September 30, 2026.
If the permittee intends to continue to discharge at the facility beyond the term of this permit, a renewal
application must be submitted no later than April 3, 2026(180 days before the expiration of this permit).
Signed this day
Richard E.Rogers,Jr.
Director,Division of Water Resources
By Authority of the Environmental Management Commission
Page 1 of 7

Permit NC0000639
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this permit
issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to
operate and discharge from this facility arises under the permit conditions, requirements, terms, and provisions included
herein.
Sapona Yarns, LLC is hereby authorized to:
1. Continue operation of a 0.01 MGD wastewater treatment facilitywith thefo
llowing
t
components:
❖ Manual bar screen
❖ Aeration basin with diffused aeration from 2 blowers
❖ Clarifier with sludge return
❖ Effluent chlorination
❖ Sodium bisulfate dechlorination
This system discharges via outfall 001 from a facility located at 2478 Cedar Falls Road
in Franklinville, Randolph County.
2. Continue to discharge boiler blowdown, cooling tower blowdown, and air washer
wastewater via outfall 002.
3. Discharge from said treatment works at the locations specified on the attached map into
the Deep River, currently classified C waters in hydrologic unit 03030003 of the Cape
Fear River Basin.
Page 2 of 7

Permit NC0000639
Part I
Grade WW-2 Biological Water Pollution Control System [15A NCAC 08G.0306]
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (001)
[15A NCAC 02B.0400 et seq., 15A NCAC 02B.0500 et seq.]
During the period beginning on the effective date of the permit and lasting until expiration,the Permittee is
authorized to discharge from outfall 001 (Domestic Waste). Such discharges shall be limited and monitored' by
the Permittee as specified below:
PARAMETER DISCHARGE MONITORING REQUIREMENTS
LIMITATIONS
[Parameter Code) Monthly Daily Measurement Sample Type Sample
Average Maximum Frequency Location
Flow 0.01 MGD Weekly Instantaneous Influent or
[50050] Effluent
BOD, 5-day,200C 30.0 mg/L 45.0 mg/L Weekly Grab Effluent
[CO 310]
Total Suspended Solids 30.0 mg/L 45.0 mg/L Weekly Grab Effluent
[C0530]
NH3-N 2/Month Grab Effluent
[C0610]
Fecal Coliform(geometric mean) 200/100 ml 400/100 ml Weekly Grab Effluent
[31616]
Total Residual Chlorine' 28 pg/L 2/Week Grab Effluent
[50060]
Temperature Weekly Grab Effluent
[00010]
Total Nitrogen(NO2+ NO3+TKN) Quarterly Grab Effluent
[C0600]
Total Phosphorus Quarterly Grab Effluent
[C0665]
pH >6.0 and<9.0 standard units 2/Month Grab Effluent
[00400] —
NOTES:
1. The permittee shall submit discharge monitoring data electronically using the Division's eDMR system
[see A. (5)].
2. The Permittee shall report all effluent TRC values reported by a NC-certified laboratory [including
field-certified]. Effluent values below 50 µg/L will be treated as zero for compliance purposes.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
A. (2) PERMIT RE-OPENER: NUTRIENT MONITORING
[NCGS 143-215.1]
Pursuant to N.C. General Statutes Section 143-215.1 and the implementing rules found in the North Carolina
Administrative Code at 15A NCAC 2H.0112 (b)(1)and 2H.0114(a)and Part II sections B-12 and B-13 of this
permit, the Director may reopen this permit to require supplemental nutrient monitoring of the discharge. The
Page 3 of 7

Permit NC0000639
purpose of the additional monitoring will be to support water quality modeling efforts within the Cape Fear River
Basin and shall be consistent with a monitoring plan developed jointly by the Division and affected stakeholders.
In addition,the results of water quality modeling may require that limits for Total Nitrogen and Total Phosphorus
be imposed in this permit upon renewal.
A. (3) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
[15A NCAC 02B.0400 et seq., 15A NCAC 02B.0500 et seq.]
During the period beginning on the effective date of the permit and lasting until expiration,the Permittee is
authorized to discharge from outfall 002 (Boiler Blowdown,Cooling Tower Blowdown,Air Wash
Wastewater). Such discharges shall be limited and monitored'by the Permittee as specified below:
PARAMETER DISCHARGE MONITORING REQUIREMENTS
LIMITATIONS
[Parameter Code} Monthly Daily Measurement Sample Sample
Average Maximum Frequency Type Location
Flow(MGD) Semi-annually Estimate Effluent
[50050]
Temperature2
[00010] Semi-annually Grab Effluent
Total Residual Chlorine' 28 pg/L Semi-annually Grab Effluent
[50060]
pH
> 6.0 and < 9.0 standard units Semi-annually Grab Effluent
[00400] —
NOTES:
1. The permittee shall submit discharge monitoring data electronically using the Division's eDMR system
[see A.(5)]
2. The temperature of the effluent shall be such as not to cause an increase in the temperature of the
receiving waters of more than 2.8°C and in no case cause the ambient water temperature to exceed
32°C.
3. Limit and monitoring requirements apply only if chlorine is added to the cooling water. The Permittee
shall report all effluent TRC values reported by a NC-certified laboratory[including field-certified].
Effluent values below 50 µg/L will be treated as zero for compliance purposes.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
A. (4) BIOCIDE CONDITION
[NCGS 143-215.1]
There shall be no chromium,zinc or copper added to the treatment system except as pre-approved
additives to biocidal compounds.
The permittee shall obtain approval from the Division's Aquatic Toxicology Branch prior to the use of any
biocide(not previously approved by the Division)in the effluent discharged under this permit. Approval for use
of any biocide not previously approved should be requested at least 90 days in advance of any planned usage.
Contact the Aquatic Toxicology Branch for detailed instructions on requesting approval of biocides:
NC DEQ/DWR/Aquatic Toxicology Branch
Page 4 of 7

Permit NC0000639
1621 Mail Service Center
Raleigh,North Carolina 27699-1621
Concentrations of chromium, copper,or zinc added to biocides shall not exceed applicable water quality standards
or action levels in the receiving stream.
A. (5) ELECTRONIC REPORTING OF DISCHARGE MONITORING REPORTS
[NCGS 143-215.1 (b)]
Federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and program
reports. The final NPDES Electronic Reporting Rule was adopted and became effective on December
21, 2015.
NOTE: This special condition supplements or supersedes the following sections within Part II of this
permit(Standard Conditions for NPDES Permits):
• Section B. (11.) Signatory Requirements
• Section D. (2.) Reporting
• Section D. (6.) Records Retention
• Section E. (5.) Monitoring Reports
1. Reporting Requirements [Supersedes Section D. (2.) and Section E. (5.) (a)1
The permittee shall report discharge monitoring data electronically using the NC DWR's Electronic
Discharge Monitoring Report(eDMR)internet application.
Monitoring results obtained during the previous month(s) shall be summarized for each month and
submitted electronically using eDMR. The eDMR system allows permitted facilities to enter
monitoring data and submit DMRs electronically using the internet. The eDMR system may be
accessed at: https://deq.nc.gov/about/divisions/water-resources/edmr.
If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility
being physically located in an area where less than 10 percent of the households have broadband
access,then a temporary waiver from the NPDES electronic reporting requirements may be granted
and discharge monitoring data may be submitted on paper DMR forms(MR 1, 1.1, 2, 3)or
alternative forms approved by the Director. Duplicate signed copies shall be submitted to the
following address:
NC DEQ/Division of Water Resources/Water Quality Permitting Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh,North Carolina 27699-1617
See"How to Request a Waiver from Electronic Reporting"section below.
Regardless of the submission method,the first DMR is due on the last day of the month following
the issuance of the permit or in the case of a new facility, on the last day of the month following the
commencement of discharge.
Starting on December 21,2025,the permittee must electronically report the following compliance
monitoring data and reports, when applicable:
• Sewer Overflow/Bypass Event Reports;
• Pretreatment Program Annual Reports; and
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Permit NC0000639
• Clean Water Act(CWA) Section 316 (b)Annual Reports.
The permittee may seek an electronic reporting waiver from the Division(see"How to Request a
Waiver from Electronic Reporting" section below).
2. Electronic Submissions
In accordance with 40 CFR 122.41(1)(9), the permittee must identify the initial recipient at the time
of each electronic submission. The permittee should use the EPA's website resources to identify the
initial recipient for the electronic submission.
Initial recipient of electronic NPDES information from NPDES-regulated facilities means the entity
(EPA or the state authorized by EPA to implement the NPDES program)that is the designated entity
for receiving electronic NPDES data [see 40 CFR 127.2 (b)].
EPA plans to establish a website that will also link to the appropriate electronic reporting tool for
each type of electronic submission and for each state. Instructions on how to access and use the
appropriate electronic reporting tool will be available as well. Information on EPA's NPDES
Electronic Reporting Rule is found at: https://www.federalregister.gov/documents/2015/10/22/2015-
24954/national-pollutant-discharge-elimination-system-npdes-electronic-reporting-rule
Electronic submissions must start by the dates listed in the"Reporting Requirements" section above.
3. How to Request a Waiver from Electronic Reporting
The permittee may seek a temporary electronic reporting waiver from the Division. To obtain an
electronic reporting waiver, a permittee must first submit an electronic reporting waiver request to
the Division. Requests for temporary electronic reporting waivers must be submitted in writing to
the Division for written approval at least sixty(60) days prior to the date the facility would be
required under this permit to begin submitting monitoring data and reports. The duration of a
temporary waiver shall not exceed 5 years and shall thereupon expire. At such time,monitoring data
and reports shall be submitted electronically to the Division unless the permittee re-applies for and is
granted a new temporary electronic reporting waiver by the Division. Approved electronic reporting
waivers are not transferrable. Only permittees with an approved reporting waiver request may
submit monitoring data and reports on paper to the Division for the period that the approved
reporting waiver request is effective.
Information on eDMR and the application for a temporary electronic reporting waiver are found on
the following web page:
http://deq.nc.gov/about/divisions/water-resources/edmr
4. Signatory Requirements (Supplements Section B. (11.) (b) and Supersedes Section B. (11.) (d)t
All eDMRs submitted to the permit issuing authority shall be signed by a person described in Part II,
Section B. (11.) (a) or by a duly authorized representative of that person as described in Part II,
Section B. (11.) (b). A person, and not a position,must be delegated signatory authority for eDMR
reporting purposes.
For eDMR submissions,the person signing and submitting the DMR must obtain an eDMR user
account and login credentials to access the eDMR system. For more information on North
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Permit NC0000639
Carolina's eDMR system,registering for eDMR and obtaining an eDMR user account,please visit
the following web page:
http://deq.nc.gov/aboutidivisions/water-resources/edmr
Certification. Any person submitting an electronic DMR using the state's eDMR system shall make
the following certification [40 CFR 122.22]. NO OTHER STATEMENTS OF CERTIFICATION
WILL BE ACCEPTED:
"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 submitted 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."
5. Records Retention [Supplements Section D. (6.)l
The permittee shall retain records of all Discharge Monitoring Reports, including eDMR
submissions. These records or copies shall be maintained for a period of at least 3 years from the
date of the report. This period may be extended by request of the Director at any time [40 CFR
122.41].
Page 7 of 7

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USGS Quad:Ramseur,N.C. Facility
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Longitude:79 43033'0( )'001 Sapona Manufacturing Location p
Company
78°43'34" (002) p y
Stream Class:C Subbasin:03-06-09 ����/� Randolph County
Receiving Stream:Deep River Hydrologic Unit: 03030003 ✓V(l�.LIG Map not to scale