WQ0002702_Regional Office Historical File Pre 2018 (33)

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Mr. Randall Andrews
Alchem, Inc.
8135 Red Road
Rockwell, NC 28138
Dear Mr. Andrews:
PID��i2tsL�ir':
Michael F. Easley, Governo
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
NC DEPT. OF ENVIRONMENT WORA
December 28, 2004 AND ' REs ROES
JAN 1 4 2005
MQpRESV1Ll.E WATER SECTIONAL FICE
Otd
pWQ-GROUND
Subject: Permit No. WQ0002702
. Alchem, Incorporated
Industrial Recycle -Bauxite Process
Rowan County
�l
In accordance with your request for renewal received September 23, 2004, we are forwarding herewith
Permit No. WQ0002702, dated December 28, 2004, to Alchem, Inc. for the continued operation of the three (3)
lagoon recycle system.
This permit shall be effective from the date of issuance unt l overnb `= 2 hall void .Permit No.
WQ0002702 issued January, 21, 1999, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. ,Groundwater sampling is now
required in monitor wells MW-1, MW-2, and MW-3 and surface water sampling will be performed on the stream
behind the property every February, June, and October for Total Dissolved Solids, pH, Sulfates, Specific
Conductivity, Aluminum, Total Suspended Solids, and water level. A scaled map of the facility must be prepared
and submitted to the Division. The recycled water will be required to have a pH of not less than 6.0 as it leaves
the wash area and goes into the storage lagoon. A site life estimate and a long range plan for future residuals
disposal are also required -The material removed from Lagoons 1 & 2 during the next lagoon cleanout is required
to have pH readings taken and documented, and the liners of each lagoon are to. be inspected and tested (as
necessary) by a Professional Engineer. Repairs are to be made as needed. The permittee is required to seek
alternate disposal/re-use options for the' fill and submit a proposed schedule for their implementation. The City
Water Supply Line is required to be re -located to the upper perimeter of the residual fill area. Failure to establish
an adequate system for collecting and maintaining the required operational information will result in future
compliance problems. The berm which has been constructed around the residual fill area is to be maintained so as
to keep the fi-H and/or accumulated rainwater from leaving the fill area.
This permit is'being renewed by itself and is'not being combined with Permit No. WQ0016338 at this
time, as the application for the renewal of Permit No. WQ0016338 has not yet been received by the Division.
lZhCarolina
,�Vaiura!!y
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.enr.state. nc.us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

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fL F• D
m Postage
I O Certified Fee
r3 Return Rectept Fee
(Endorsement Required)
PS Form 3811, February 2004 Domestic Return Receipt
_ /L❑ Agent
(� ❑ Addressee
((Printed Name) C. Date of Delivery
LOG/--11Aqr I 14idA I— I
dress different from item 1? ❑ Yes
Ildelivery address below: ❑ No
❑ Ex s Mail
Ct�'Retum Receipt for Merchandise

A Notice of Violation was issued against the facility under Permit No. WQ0002702 on January 7, 2001
t
for violations of State Groundwater Quality Standards as evidenced by the laboratory analyses of groundwater
samples taken during the course of monitoring on -site monitor wells.
A Notice of Violation was also issued against the facility under Permit No. WQ0002702 on May 12, 2003
in response to a release o_ f residuals. into a drainage/wooded area and an intermittent stream. The permittee was
cited for failing to properly operate and maintain the facility as a non -discharge facility, failure to cease reuse
operation once nuisance conditions existed, failure to provide adequate provisions to prevent surface runoff from
conveying 'Pollutants.. into surface waters, and failure to notify the Division of the residuals release into the
receiving stream.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and . filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unless_ such demands are made this permit shall be final and binding.
6162
If you need additional information conceminR this matter, please contact David Goodrich at (919) 715-
/Alan W
cc: Rowan County Health Department
::Mooresville Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
Aquifer Protection Central Files
Permit Files
Klimek, P.E.

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PER.MIT
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
Alchem, Incorporated
Rowan County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serve Alchem, Inc., with no
discharge of wastes to the surface waters, pursuant to the application received September 23, 2004, 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 November 30, 2009, shall void Permit No.
WQ0002702 issued January 21, 1.999, and shall be subject to the following specified conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this. permit, the approved plans and specifications, and other supporting data.
This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
The facilities shall be properly maintained and operated at all times..
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division of Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate. The approval of the request will be considered on its merits
and may or may not be approved.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee. shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
6. The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division._
7. 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 facility.

8. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
9. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
1' 0' Freeboard in all of the lagoons shall not be less than two feet at any time:
11. Waste -level gauges, to monitor waste levels in the settling lagoons, shall be installed within 60 days of
issuance of this permit. These gauges shall have readily visible permanent markings indicating the
maximum liquid level at the top of the temporary liquid storage volume, minimum liquid level at the
bottom of the temporary liquid storage volume, and top of the dam elevations. Caution must be taken not to
damage the integrity of the liner when installing the gauges.
12. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
13. Within ninety (90) days of permit issuance, the recycled system shall be required to keep the recycled water
at a pH of not less than 6.0 Standard Units as it leaves the wash area and goes to the storage lagoon.
\ 14. Within ninety (90) days of permit issuance, the permittee shall submit a site life estimate for the fill area..
15
16
Within ninety (90) days of permit issuance,.the permittee shall submit a long-range plan for future residuals
disposal that shall include a timetable for implementation.
During the upcoming clean out of Lagoons 1 & 2 (scheduled for the spring season of 2005), a pH reading
shall be taken and documented on every load of material removed from the lagoon and placed in the sand
fill area. This information shall be conveyed to the Division within thirty (30) days. of completion of the
clean out procedure.
17. At the conclusion of the clean out of Lagoons 1& 2 (scheduled for the spring season of 2005), the clay
liners of the lagoon shall be inspected and tested (as necessary) by a Professional Engineer. Repairs to the
liners shall be made as needed and prior to the resumption of use.
\ 18. The pennittee shall actively seek alternate disposal/re-use options for the fill produced at the facility. An
alternate means of disposal, along witha proposed schedule for its implementation, shall be identified
within one (1) year of permit issuance and reported by letter to the Division's Central Office at the Aquifer
Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636 and to the Mooresville Regional
Office at the Aquifer Protection Section, 610 East Center Avenue/ Suite 310, Mooresville, NC 28115.
19. The City Water Supply Line shall be re -located to the upper perimeter of the residual fill area within one (1)
year of permit issuance. Any problems with implementing this condition in a timely fashion shall be
reported by letter to the Division's Central Office at the Aquifer Protection Section, 1636 Mail Service
Center, Raleigh, NC 27699-1636 and to the Mooresville Regional Office at the Aquifer Protection Section,
610 East Center Avenue/ Suite 301, Mooresville, NC 28115.
20. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
21. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities. The berm which has been constructed around the residual fill area shall be
maintained so as to keep the fill and/or accumulated rainwater from leaving the fill area.

' 22. The Permittee or his designee shall inspect the wastewater recycle 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 three years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
23. 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 recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
24. 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 15A NCAC 2H .0205 (c)(4).
25. Failure to abide by the conditions and limitations contained in this permit may subject the Pennittee to an
enforcement action by the Division in accordance with North Carolina General Statute 143-215.6A to 143-
215.6C.
26. The issuance of this permit does not exempt 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, including but not limited to applicable river buffer rules in 15A NCAC 2B.0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCGO10000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20.
27. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
28. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704) 663-
1699, 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 at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents
of a basin or tank, the known passage of a slug of hazardous substance through the facility, or any other
unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical 'or electrical failures of pumps, aerators,
compressors, etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.
3

Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. 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.
29. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
30. The recycle lagoons shall not be located within 100 feet of water supply wells.
31. Within sixty (60) days of permit issuance, the permittee shall submit two original copies of a scaled site
map (scale no greater than 1 "=100'); however, special provisions may be granted upon prior approval for
large properties. The map(s) must include the following information:
a. The location and identity of each monitoring well.
b. The location of major components of the waste disposal system.
c. The location of property boundaries within 500 feet of the disposal area(s).
d. The latitude and longitude of the established horizontal control monument.
e. The elevation of the top of the well casing (which shall be known as the "measuring point") relative
to a common datum...
f. The depth of water below the measuring point at the time the measuring point is established.
g. The location of Review and Compliance Boundaries.
h. The date the map is prepared and/or revised.
32. Control monuments shall be installed in such a manner and made of such materials that the monument will
not be destroyed due to activities that may take place . on the property. Maps and any supporting
documentation shall be sent to the Aquifer Protection Section's Central Office at 1636 Mail Service Center,
Raleigh, NC 27699-1636, and to the Mooresville Regional Office at the Aquifer Protection Section, 610
East Center Avenue/ Suite 301, Mooresville, NC 28115.
The permittee is responsible for the geographic accuracy of any map submitted, however produced. .
33. Monitor wells MW-1, MW-2, MW-3, and the stream behind the property shall all be sampled every
February, June and October for the following parameters:
Total Dissolved Solids
Sulfates (SO,)
Aluminum
Water Level
pH
Specific Conductivity
Total Suspended Solids
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The results of the sampling and analysis shall be received on the most -recent version of "Groundwater
Quality Monitoring: Compliance Report Form" (i.e., GW-59 Form) with copies of the laboratory analyses
attached by the Division's Aquifer Protection Section at the following address on or before the last working
day of the month following the sampling month:
4

NCDENR-DWQ
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank reporting forms may be downloaded from the web site for the Division's Aquifer Protection
Section at http://gw.elinr.state.nc.Lis/ or requested from the address listed above.
34. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary for the disposal system individually
permitted on or after December 30, 1983 is established at either 250 feet from the waste disposal area, or 50
feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to remediation action
according to 15A NCAC 2L .0106(d)(2).
35. The REVIEW BOUNDARY is established around the disposal system midway between the Compliance
Boundary and the perimeter of .the waste disposal area. Any exceedance of standards at the. Review
Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
36. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
37. 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.
Permit issued this the 22nd day of December, 2004
NORTH OL1NA ENVIRONMENTAL MANAGEMENT COMMISSION
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002702

Ilm
IMINI'll
J

9

X6
AQUIFER PROTECTION SECTION
APPLICATION REVIEW REQUEST FORM
Date: September 28, 2004
To: ❑
Landon Davidson, ARO-APS
❑
Art Barnhardt, FRO-APS
®
Andrew Pitner, MRO-APS
❑
Jay Zimmerman, RRO-APS
❑ David May, WaRO-APS
❑ Charlie Stehman, WiRO-APS
❑ Sherri Knight, WSRO-APS
From: David Goodrich, AFO Permitting and Compliance Unit
Telephone: [phone] Fax:
E-Mail: david.goodrich(a,ncmail.net
A. ',er mi`t�'liTu, W 00Q2a702
B. Owner: ALCHEM, Inc.
C. Facility/Operation: Industrial Recycle - Bauxite Process
❑ Proposed ® Existing ® Facility
D. Application:
SEP 2 9 2004
® Operation
1. Permit Type: ❑ Animal ❑ Surface Irrigation ❑ Reuse ❑ H-R Infiltration
® Recycle ❑ FE Lagoon ❑ GW Remediation (ND)
❑ UIC - (5QW) closed loop water only geothermal
For Residuals: ❑ Land App. ❑ D&M ❑ Surface Disposal
❑ 503 ❑ 503 Exempt ❑ Animal
2. Project Type: ❑ New ❑ Major Mod. ❑ Minor Mod. ® Renewal ❑ Renewal w/ Mod.
E. Comments/Other Information: ❑ I would like to accompany you on a site visit.
01YIo"� u,t 1' -2 -7 - 0 4
Attached, you will find all information submitted in support of the above -referenced application for your
review, comment, and/or action. Within 30 calendar days, please take the following actions:
® Return a Completed Form APSSRR.
❑ Attach Well Construction Data Sheet.
❑ Attach Attachment B for Certification by the LAPCU.
❑ Issue an Attachment B Certification from the RO*.
* Remember that you will be responsible for coordinating site visits, reviews, as well as additional
information requests with other RO-APS representatives in order to prepare a complete Attachment B for
certification. Refer to the RPP SOP for additional detail.
When you receive this request form, please write your name and dates in the spaces below, make a copy
of this sheet, and return it to the appropriate Central Office -Aquifer Protection Section contact person
listed above.
RO-APS RevieweDate: J C/
FORM: APSARR 09/04 Page 1 of 1

09/28/04
Permit Number WQ0002702 Permit Tracking Slip
Program Category Status Project Type
Non -discharge In review Renewal
Permit Type Version Permit Classification
Wastewater Recycling Individual
Primary Reviewer
t AMID, (oo09_iCH
Permitted FI w
Facilit
Facility Name
Alchem Incorporated Residuals Reuse Program
Location Address
8135 Red Rd
Rockwell NC 28138
Owner
Owner Name
Alchem Incorporated
Dates/Events
Permit Contact Affiliation
Randall Andrews
8135 Red Rd
Rockwell NC 28138
Major/Minor Region
Minor Mooresville
County
Rowan
Facility Contact Affiliation
Owner Type
Non -Government
Owner Affiliation
Randall Andrews
8135 Red Rd
Rockwell NC 28138
Scheduled
Orig Issue App Received Draft Initiated Issuance Public Notice Issue Effective Expiration
01 /21 /89 09/28/04
Regulated Activities Requested/Received Events
Mining & material processing RO staff report received
RO staff report requested
Additional information requested
Additional information received
Groundwater comments requested
Groundwater comments received
Outfall NULL
Waterbody Name Stream Index Number Current Class Subbasin

W A TFyQG
o -c
Randall F. Andrews
ALCHEM, Inc
8135 Red Road
Rockwell , NC 28138
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
October 12, 2004
Subject: Acknowledgement of Application No. WQ0016338
ALCHEM Inc Residuals Reuse Program
Distribution of Residual Solids
Rowan County
Dear Mr. Andrews:
Alan W. Klimek, P.E. Director
Division of Water Quality
The Aquifer Protection Section of the Division of Water Quality acknowledges receipt of your permit
application and supporting materials on September 30, 2004. This application package has been assigned
the number listed above and will be reviewed by David Goodrich
The reviewer will perform a detailed review and contact you with a request for additional information if
necessary. To ensure the maximum efficiency in processing permit applications, the Division requests
your assistance in providing a timely and complete response to any additional information requests.
Please be aware that the Division's Regional Office, copied below, must provide recommendations prior to
final action by the Division. Please also note at this time, processing permit applications can take as long
as 60 - 90 days after receipt of a complete application.
If you have any questions, please contact David Goodrich at 919-715-6162 or via e-mail at
[e-mail]. If the reviewer is unavailable, you may leave a message, and they will
respond promptly.
PLEASE REFER TO THE ABOVE APPLICATION NUMBER WHEN MAKING INQUIRIES ON THIS
PROJECT.
Sincerely,
Kim Colson, P.E.
Supervisor
cc: Mooresville Regional Office, Water Quality Section
Permit Application File-WQ001633$
Nne
orthCarolina
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service )1latura!!y
Internet: h1tp://h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 Fax [phone]
Fax [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

ALCHEM, INC
8135 RED ROAD
ROCKWELL, NC 28138
704-279-7908 fax [phone]
[e-mail]
September 27, 2004
NC DIVISION OF WATER QUALITY
NON -DISCHARGE PERMITTING UNIT
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
RE: Permit #WQ0016338
Dear Sir:
REGEsVED
SEP 2 SNIT
PPRGS
I would like to submit our application for a permit renewal for Permit Number
WQ0016338. We understand there is not a fee for renewal.
Alchem generates several thousand tons of Silica sand per year as a by product of an
Aluminum Sulfate process at Rockwell, NC.
The process is as follows:
Bauxitic Sand + Concentrated Sulfuric Acid in reactor for 6 hours @ 220' F
equals Aluminum Sulfate Solution + Sand.
The Aluminum Sulfate is used as a coagulant at water treatment plants. The sand is
washed several times and the filtrate solution is returned to the process for make up
water. The sand is put in a lined lagoon. Rain water is allowed to collect in the
lagoon and is then pumped back into the process. After several years, the sand is
washed by rainfall so much that no more soluble ions are present. The sand is used to
form a building pad and surrounding support materials on approximately three acres
next to our rail siding.
We have completed a 24" X 24" trench to divert the storm water from Red Road
around the impounded area. We have completed a berm 5' X 8' wide around all the
impoundment area and all low grade areas. There is no contact by storm water with
our plant. There is a complete berm around our plant and all contact storm water is
collected and used in process water.
We are enclosing results of the residual analysis and also the TCLP analysis for your
review.

We would like to request a change in the sampling of residuals to once every five
years. We have been using the same ore material for the last ten years in our
manufacturing process. Our raw material and the manufacturing process have stayed
the same as well. We have been requesting this change since November 2001 but it
seems the letter for this request had been lost in the shuffle in the Raleigh office.
If you have any questions regarding this permit renewal application, please let me
know.
Best regards,
ALCHEM, INC
Randall F. Andrews,
President
pcd
Enclosures

iII
FACILITY EFORMATION (attach. additional pages for additional sources of residuals)
3f , :; . ;sc—s:,Lzds are generated or prepared: • INC
::
2. Facility permit number: WQ0016338 ;'facility per bolder: ALCHEM, INC
3. Specify wbeLher facility in Section III.1 is owned by: federal; x private; state;
4. Specify facility design flow: n/a mgd; facility average daily flow: n/a
Type of residual storage: .in lined lagoons
Volume of residual storage: 20,000 cubic yards
local government;
mod;
;
Length of residuals storage at facility: 3 years days (the Division requires a* CV1
st to units that
are separate from treatment system, i.e, not in clarifiers, aeration basins, etc.);
ME
EStirrtated volume of residuals: 3,000 (dry tons/yr.); SEP
5. If the residual process facility is not the same as the generator, please specify delivery �t11Yty1 f residual to
be processed:
same
6. Facility contact (person familiar with residuals preparation):
7... Facility contact's telepbone number: ( 704
8. Location of treatment facility: NC
9. Malt?n-4 address: 8135 Red Road
Randall F. Andrews, President
279-7908
State;
Rockwell, NC 28138
,
fax [phone]
Rowan I County
10. Specify the source of the residuals: treatment of water (alum sludges); XX treatment of industrial wastewater
(10017c industrial residuals); treatment of industrial wastewater mixed with domestic wastewater (please specify
t'pprop,iate percentages of ro industrial wastewater, % domestic, wastewater);
other (explain): Process bauxite with sulfuric acid — see cover letter
Attach an explanation of either the treatment process, manufacturing process, or bow the .waste is generated. Provide full
and complete details of the entire process. see cover letter.
11. Docs the facility which generates the residuals have an approved pretreatment program? Yes; X No.
This includes facilities which are classified as a "Class I" facility (any publicly owned treatment works required, under 40
CFR 403.8, to have an approved pretreatment program or any facility treating domestic sewage that is classified as "Class
I" b% the appropriate federal or State authority) closed wastewater recycle with no discharge to
sanitary system.
IV. RESIDUALS I\FORIIATIO\° (attach additional pages for additional sources of residuals):
1. Information for Hazardous Waste (RCRA) Determination. The information requested on the 14--nitations specified below
pertain only to those residuals that are generated from a municipal wastewater treatment facility with industrial contribution
or active pretreatment. program and from any other treatment facility with wastewater sources that include industrial sources.
a. Are any of the residuals covered by ibis application listed in 40 CFR 261.31-261.33? Yes; X No.' If Yes,
fist the number(s): n/a
b. Do the residuals exhibit any of the four characteristics defined by 40 CFR 261.21-261.24? Yes; X No.
Attach laboratory, results for the Toxicity Characteristic Leacbing.Procedure Analyses, Reactivity, Ignitability, and
Corrosivity for each residual.
FORM: DORS 06194 Page 2 of 7

it ate: If the following constituent levels'(as determined by the Toxicity Characteristic Leaching
Procedure Analvses) arc
exceeded in the residuals or if the pH of the residual.'is
not within the range listed
below, the residual is b�
definition a Hazardous waste. Chem
Chemical analyses
must be made to MiniDion Lels. -
Minimum Levels.
PPM .
P P M
Arsenic
5..0
Barium '
100.0
Benzene
0.5
Cadmium
1.0 •
Carbon tetrachloride
0.5
Chlordane
0.03
Chlorobenzene
100.0
Chloroform
6.0
Chromium
5.0
o-Cresol
200.0
m-Cresol.
200.0
p-Cresol
200.0
Cresol
200:0
2,4-D '
10.0
IA-Dichlorobenzene
7.5
1,2-Dichloroethane
0.5
1,1-Dichloroethylene
0.7
2,4-Dinitrotoluene
.
0.13
Endrtn
0.02
Heptachlor (and its hydroxide)
0.008
Hexachlorobenzene
0.13
Hexachloro-1,3=butadiene
0.5
Hexachloroethane
3.0
Lead
5.0
Lindane
0.4
Mercury
0.2
Methexychlor '
10.0
Methyl ethyl ketone
200.0
Nitrobenzene
2.0.
Pentachlorophenol
100.0
Pyridine
5.0
Selenium
1.0
Silver
5.0
Tetrachloroethylene
0.7
Toxaphene
0.5
Trichloroethylene
0.5
2,4,5-Trichlorophenol
400.0
2,4,6-Trichlorophenol '
2.0
2,4,5-TP (Silvex)
1.0
Vinyl chloride
0.2
pH (2:1 vol./wQ: >2.0 s.u. - <12.5 s.u. .
NOTE: IF .ANY OF THE RESIDUALS MEET
THE DEFINITIONS OF A HAZARDOUS WASTE,
AS NOTED IIt EITHER ".A"
'OR "B"
ABOVE, A PERMIT .CANNOT BE ISSUED FOR
THAT MATERIAL AND
IT .SHOULD NOT BE INCLUDED' AS PART OF THIS
APPLICATION.
2. For each residual, please attach a complete chemical analysis of the material. This analysis must be comprehensive enough
to completely characterize the residua] and must be based upon a review of the process that generates the material. If the
facility that will generate the residual is not yet in operation, the characterization must be based on similar existing
facilities and projection based on the type of facility. The analysis must include a minimum of the following parameters
and any other 1v-nown and suspected.contaminants that are tributary to the system.
Cadmium Aluminum pH.
Copper Ammonia -Nitrogen . Phosphorus "
Lead Calcium Potassium
Nickel Magnesium Sodium
Zinc Nitrate -Nitrite Nitrogen TKN
Total Solids Plant Available Nitrogen (by calculation)
3. Wastewater residuals cannot be sold or given away if the concentration of any pollutant'in the residuals ekceeds the ceiling
concentrations specified in the table below. Specify the pollutant concentration of these residuals (attach lab analysis):
***The residuals arP nnf-. cniri nr n;�,o„ - ' I
Pollutant
Pollutant Ceiling Concentration (mg/kg)
Dry Weinht Basis
Pollutant Concentration-(mg/kg)
Dry Weieht Basis
Cadmium
85.
Co er
4300
Lead
840
Nickel
420
Zinc
.7500
FORM: DORS 06194 Pate 3 of 7.

4 Provide, all applicable pilot studies and anv, bench Scale tests'perfoi•med on each residual source and the results, includint '
the approximate fertilizer erluivalent. N/A
5. Wastewater'iesiduals can't be sold, or.given,,away,in, bags or other containers for application to the land unless one of the
following options is satisfied. N/p,
N/A •Specify either A'or B.- Please be advised. if the residuals are to be sold or given awayin bulk fonapplication tc
lawn or home garden then Option A is the only option:
A. The pollutant concentration of the residuals 'must be less than Pollutant Monthly Average Concentrations
listed in the table below.
Pollutant
Monthly Average Concentrations
Dry Weight Basis (mg/kg)
Pollutant.Concentration
Dry Weight Basis (mg/kg)
Cadmium
39
Copper"
1500.
Lead
300
Nickel,
420
Zinc'
2800
B': Tbe-product of the concentration of each pollutant,in tb'e,residual and the annual -whole residual application
rate for the residual shall not -cause the Annual Pollutant Loading Rate to be. exceeded.
In order for the Annual Whole Residual Application Rate (AWRAR) to be calculated the Annual Pollutant
Loading Rate (APLR) is divided by. the .pollutant concentration(PC) times 0.001 (a conversion factor) as
follows: .
AWRAR -
PC 0 001
Pollutant.
Pollutant
Concentration
Dry Weight Basis -
(ma/l:g) '
Annual Pollutant,
Loading Rates
(APLR) .
ka/hectare
Annual Whole Residual
Application Rate.
(AWRAR)
kJhectare
Cadmium '
1.9
Copper
.75
Lead.
15
Nickel`-'
21
' Zinc .
140 .
The AWRAR for the residual is the lowest AWRAR calculated. This is the maximum rate at which the
subject residual can be, applied. (to convert kg/bectare to lbs/acre multiply'by 0.8924)., Please specify
kg/hectare or lbs/acre:
AWRAR =' .
V .- PATHOGEN REDUCTION INFORMATION (attach ad)d. pages, f6t additional sources of residuals)
In accordance with 15A NCAC 2H..0200, pathogen reduction can be achieved using either 40.CFR Part 257 or 40 CFR Part
5033. Since the pathogen reduction requirements found in 40 CFR.Part'•257 (note, "Processes to Further Reduce Pathogens" or
PFRP) are incorporated into 40 CFR Part 50"), only Part 503 is-liste'd below. Please check which of the following 'applies to
die subject residual:
FORM: DOTS 06194 Page 4 of 7 . .

1. In order for the residuals to be Class A, in accordance-witb the pathogen requirements in 40 CFR 503.32(a), eitb= Part a or
Pan b �zd one of the options in Part c must be completed (please submit all lab analysis, test results and calculations):
N/Aa. A Fecal coE1form density less than 1000 Most Probable Number per gram of total dry solids, or
N/A b. A Salmonella sp. density less than 3 Most Probable Number per 4 grams of total dry solids. '
N/A c. In addition to Part a or Part b being met, one of the following alternatives must also be completed. Please
specify 1, 2, 3, 4, 5a, 5b, 5c, 5d, 5e, 5f, 5g or 6 below being met
1. tim / m; rrature - an increased residuals temperature should be maintained fur a prescribed period of time, in
accordance with the following guidelines. The results (D) shall be the amount of time, in days, that the residuals
shall remain at the given temperature:
T':_......A Tt'_0 rV;Apl;rPC
Total Solids
Temperature (t)
1 L111 G. OJiV 1,.u,
Minimum Time
-
Fzuadon
Notts
No heating of small
> or = 7%
> or = 50o C
> or = 20 minutes
D=1.31.700.000
panicles by warmed
100.14 t
gases or immiscible
liquid.
> or = 7%
> or = 500 C
> or = 15 seconds
D.=131,700,000
Small particles heated by
100.14 t
warmed gases or
immiscible liouid.
< 75c
> or = 50o C
> or = 15 seconds
D=131.700.000
to
100.14 t
< 30 minutes
< 75c
> or = 500.0
>or = 30 minutes
D = 50,070,000
100.14 t
2. a -aline treatment - the pH of the residuals is raised to greater than 12 for at least 72 hours. During this time, the
temperature of the residuals should be greater than 520 C for at least 12 hours. In addition, after the 72 hour
period, the residuals are to be air dried to at least 50% total solids,
prior testing for Enteric Virus/Viable Helminth Ova - the residuals are analyzed for the presence of enteric viruses
(Plaque -forming units) [pfu] and viable belminth ova. If the residuals are analyzed before the pathogen reduction
process and found to have densities of enteric virus <1 pfu/4 grams of total solids and viable helminth dva <1/4g
total solids, the residuals are Class A with respect to enteric virus and.viable beiminth ova until the next
monitoring episode. If the residuals are analyzed before the pathogen reduction process and found to have densities
of enteric virus > or = 1 pfu/4 g total solids or viable belminth ova > or = 1/4 g total solids, and tested again after
processing and found to meet the enteric virus and viable belminth ova levels listed under "4" below, then the
processed residuals will be Class'A with respect to enteric viruses and viable helminth ova when the operating
parameters for the pathogen reduction process are monitored and shown to he consistent with the values or ranges
of values documented.
4, np, prior tP-,tinc for Enteric Virus Viable Heiminth Ova - if the residuals are not analyzed before pathogen reduction
processing for enteric viruses and viable helminth ova, the density of enteric viruses must be less than 1 pfu/4 g of
total dry solids and the density of viable helminth ova must be less than 1/4 g of total dry solids, or the residuals
must be treated by a "Process to Further Reduce Pathogens" or a "Process to Further Reduce Pathogens" ecuivalcnt
process.
5. The "Processes to Further Reduce Pathogens" (PFRP) are described as follows:
a. Composting - using either the within -vessel or static aerated pile composting methods, the temperature of the
residuals are raised to 550C or higher for three days. Using the windrow composting method, die residuals are
raised to 550 C or higher for fifteen days. During the high temperature period, there will be a minimum of five
turnings of the windrow.
FORM: DORS 06194 Pace 5 of 7

b. Hat Drvinv - residuals are dried b%• direct or indirect contact with hot gases to reduce the moisture content o
the residuals to 1017c, or lower, Either the temperature of the gas in .contact with the residuals exceeds 800 C o
L- e •aye; h;:lh temperature of the ras in.,contact a`ith, the residuals. when the residuals leave the carver. exce-ee,
800 C:
c. Neat Treatment - liquid residuals are heated to a temperature of 1800 C.or hiober for thirty minutes.
d ; h-, onhilic Aerohic Digestion - liquid residuals are agitated with air or oxygen to maintain aerobic condrtiom
at residence times of ten days at temperatures of 550 C to 600 C.
e. Bew Rav Irradiation - residuals are irradiated with beta rays from an accelerator at dosages of at least 1.0
megarad at room temperature (ca. 200 C).
f. Gamma Rav Irradiation - residuals are irradiated with gamma rays from certain isotopes such as 60Co anc
13 7Cc, at dosages of at least 14.0 megarad at room temperature (ca. 200 C).
g. Pa5tewization - the temperature of the residuals is maintained at 700 C or higher for at least thirty minutes.
6. The residuals shall be treated in a process tha( is equivalent to a "Processes to Further Reduce Pathogens" (PFRP),
as determined by the permitting autbority based on evaluations of the recommendations provided by the Pathogen
Equivalency Committee,
VI. GENERAL INFORMATION:
1. Please provide a brief narrative concerningm aterials handling, including the following:
n/a a. How will the materials will be handled and transported from where the residuals were produced to where it will be
trey Led?
n/a b. Wbere will the residuals be stored until processed?
holding po{rd Hov.• will leachate collection belandled?.., .
see attachgd 'What ,vill be the duration of treatment?
cover letter
e. Where will the final product be stored'
f. Now lcng will d,e Final product be stored before being distributed?
g. Nov.• will the final product be distributed (packaging)?
?. Please attach a marketability statement detailing destinations and approximate amounts of the final product to be
di, sz"'Duted. n/a
3. Plea ;e provide either a label which shall be affixed to the bagged processed residual or an information sheet which shall be
provided to the person who receives the processed residual, The label or information sbeet.shall contain, at a minimum, the
following information: n/a
a. The name and address of the person who prepared the residual that is sold or given. away in a bag or other container for
application to the land.
b. A statement that application of the residual to the land is prohibited except in accordance with the instructions on the
label or infornstion sheet."
c. statement that the residuals shall not be applied to any site that is flooded, frozen or snow covered.'
d A sta,_-ntent that adequate procedures shall be provided to prevent surface runoff from carrying any disposed or stored
residuals into any surface waters.
e. information on all applicable buffers including a 10 foot buffer between, application site and.atty public or private water
supply source (including wells).and any stream; la ;e rim,,or: natural drainage way.. ,
f. The Annual Whole Residual Application Rate (AWRAR) for. the residual that does not cause any of the annual
rollutant loading rates to be exceeded (if necessary).
FORM: DORS 06/94 PaLe 6 of 7

,t.
Name and Complew Address of Engineering Firm: _
Cif : Slai2:
Zip:
Telephone Number: ( )
Professional Engineer's Certification:
I, attest that this application for
hasbeen reviewed by me and is accurate and complete to the best of my knowledge. I further attest tliat to the best of.mv knowledge
the proposed design has been .prepared in accordance with the applicable regulations. Although certain portions of this submittal
package may have been developed by other professionals, inclusion of these materials under my signature and seal signifies that I have
reviewed this material and have judged it to be consistent with the proposed design:
North Carolina Professional Engineer's Seal, Signature, and Date:
Applicant's Certification:
I Randall F. Andrews attest that this application for renewal of
permit # WQ0016338
has been reviewed by me and is accurate and complete to the best of my knowledge.. I understand that if all required parts of this
application, are not completed and that if all required supporting informado6and attachments are not included, this application package
will be;returned e as incomplete
Signature 7 , Date "9-21-04
THE COMPLETED APPLICATION PACKAGE. INCLUDING' ALL SUPPORTING INFORMATION AND
MATERIALS, SHOULD BE SENT TO THE' FOLLOWLNG ADDRESS:'
NORTH CAROLIY,--T-1T17tc
-To tit_OF�1?��L'IE\TAL AIANAGEvIE?t'T
NC DIVISION OF WATER QUALITY N
NON -DISCHARGE PERMITTING; UNIT;.. UNIT,
F ,I 617
1617 MAIL, SERVICE CENTER
RALEIGH, NG27699=1617 '': .— .i
RALk iutt, 1Yvni it t.r�r vu�.'. . :,762'6-0535
TELEPHONE NUMBER: [phone]
FORM: DORS i)t,i94 , P::zc 7 of 7

ENVIRONMENTAL
SCIENCE CORP.
Pam Hester
TBL Laboratory
P.O. Box 589
Lumberton, NC 28359
Date Received
August 24, 2004
Description
14412 - Alchem,.Inc.
Sample ID
LAGOON 3
Collected By
Wayne Drye
Collection Date
07/28/04 08:00
Parameter
Dry
Nitrogen
Ammonia Nitrogen
Nitrate -Nitrite
Organic Nitrogen
Kjeldahl Nitrogen, TKN
Total Solids
Potassium
REPORT OF ANALYSIS
12065 Lebanon Rd.
Mt. Juliet, TN 37122
[phone]
1-800-767-5859
Fax [phone]
Tax I.D. 62-0814289
Est. 1970
September 15,2004
ESC Sample # : L169377-01
Site ID .
Project # TBL-14417
Result
Det. Limit
Units
Method
Date
Dil.
100
0.10
mg/kg
SSSA
09/15/04
1
BDL
6.7
mg/kg
350.1
09/13/04
1
1.1
0.10
mg/kg
9056
09/15/04
1
100
10.
mg/kg
Calc.
09/15/04
1
100
10.
mg/kg
351.2
09/14/04
1
74.3
%
2540G
09/14/04
1
570
25.
mg/kg
6010B
08/10/04
1
Cheli Boucher, ESC Representative
Results listed are dry weight basis.
BDL - Below Detection Limit
Det. Limit - Estimated Quantitation Limit(EQL)
Laboratory Certification Numbers:
AIHA - 100789, AL - 40660, CA - I-2327, CT- PH-0197, FL - E87487, GA - 923, IN - C-TN-01
KY - 90010, KYUST - 0016, NC - ENV375,DW21704, ND - R-140, SC - 84004, TN - 2006, VA - 00109, WV - 233
MN - 047-999-395, NY - 11742
Note:
This report shall not be reproduced, except in full, without the written approval from ESC.
The reported analytical results relate only to the sample submitted
Reported: 09/15/04 15:51 Printed: 09/15/04 15:51
Page 1 of 1

ENVIRONMENTAL
SCIENCE CORP.
Pam Hester
TBL Laboratory
P.O. Box 589
Lumberton, NC 28359
Date Received
Description
Sample ID
Collected By
Collection Date
Parameter
pH
Phosphorus,Total
Total Solids
Mercury
Aluminum
Arsenic
Barium
Cadmium
Calcium
Chromium
Copper
Lead
Magnesium
Manganese
Nickel
Selenium
Silver
Sodium
Zinc
August 04, 2004
14417 - Alchem, Inc.
LAGOON 3
Wayne Drye
07/28/04 08:00
REPORT OF ANALYSIS
12065 Lebanon Rd.
Mt. Juliet, TN 37122
[phone]
1-800-767-5859
Fax [phone]
Tax I.D. 62-0814289
Est. 1970
August 19,2004
ESC Sample # : L164185-01
Site ID
Project # TBL-14417
Result
Det. Limit
Units
Method
Date
Dil.
5.5
su
9045C
08/04/04
1
3.0
1.2
mg/kg
9056
08/11/04
1
83.7
%
2540G
08/09/04
1
0.093
0.024
mg/kg
7471
08/06/04
1
17000
6.0
mg/kg
6010B
08/11/04
1
BDL
0.60
mg/kg
6010B
08/12/04
1
75.
0.30
mg/kg
6010B
08/11/04
1
BDL
0.30
mg/kg
6010B
08/12/04
1
9200
30.
mg/kg
6010B
08/18/04
1
12.
0.60
mg/kg
6010B
08/11/04
1
6.9
0.60
mg/kg
6010B
08/11/04
1
23.
0.30
mg/kg
6010B
08/12/04
1
510
6.0
mg/kg
6010B
08/11/04
1
18.
0.60
mg/kg
601013
08/18/04
1
6.6
0.60
mg/kg
6010B
08/18/04
1
BDL
0.60
mg/kg
6010B
08/11/04
1
BDL
0.30
mg/kg
6010B
08/11/04
1
610
30.
mg/kg
601013
08/10/04
1
43.
1.8
mg/kg
6010B
08/11/04
1
Results listed are dry weight basis.
BDL - Below Detection Limit
��J
Det. Limit - Estimated Quantitation Limit(EQL)
Laboratory Certification Nu ers:
AIHA - 100789, AL - 40660, CA - I-2327, CT- PH-0197, FL - E87487, GA - 923, IN - C-TN-01
KY - 90010, KYUST - 0016, NC - ENV375,DW21704, ND - R-140, SC - 84004, TN - 2006, VA - 00109, WV - 233
MN - 047-999-395, NY - 11742
Note:
This report shall not be reproduced, except in full, without the written approval from ESC.
The reported analytical results relate only to the sample submitted
Reported: 08/19/04 12:15 Printed: 08/19/04 14:23
Page 1 of 5

ENVIRONMENTAL
SCIENCE CORP.
Pam Hester
TBL Laboratory
P.O. Box 589
Lumberton, NC 28359
Date Received.
Description
Sample ID
Collected By
Collection Date
Parameter
August 04, 2004
14417 - Alchem, Inc.
LAGOON 3
Wayne Drye
07/28/04 08:00
,TCLP Extraction
Mercury
Arsenic
Barium
Cadmium
Chromium
Lead
Selenium
Silver
TCLP ZHE Extraction
TCLP Volatiles
Benzene
Carbon tetrachloride
Chlorobenzene
Chloroform
1,2-Dichloroethane
1,1-Dichloroethene
2-Butanone (MEK)
Tetrachloroethene
Trichloroethene
Vinyl chloride
Surrogate Recovery
Dibromofluoromethane
Toluene-d8
4-Bromofluorobenzene
TCLP Pesticides
Chlordane
Endrin
Heptachlor
Lindane
Methoxychlor
Toxaphene
Surrogate Recovery
REPORT OF ANALYSIS
August 19,2004
ESC Sample #
12065 Lebanon Rd.
Mt. Juliet, TN 37122
[phone]
1-800-767-5859
Fax [phone]
Tax I.D. 62-0814289
Est. 1970
L164185-02
Site ID
Project TBL-14417
Result Det. Limit Units Limit Method Date Dil
-
1311
08/04/04 1
BDL
0.0010
mg/l
0.20
7470A
08/09/04 1
BDL
0.050
mg/l
5.0
6010B
08/06/04 1
0.052
0.050
mg/l
100
6010B
08/06/04 1
BDL
0.050
mg/l
1.0
601013
08/06/04 1
BDL
0.050
mg/l
5.0
6010B
08/06/04 1
BDL
0.050
mg/l
5.0
6010B
08/06/04 1
BDL
0.050
mg/l
1.0
6010B
08/06/04 1
BDL
0'.050
mg/l
5.0
6010B
08/06/04 1
-
1311
08/06/04 1
BDL
0.050
mg/1
0.50
8260B
08/10/04 1
BDL
0.050
mg/l
0.50
8260B
08/10/04 1
BDL
0.050
mg/l
100
8260B
08/10/04 1
BDL
0.25
mg/l
6.0
8260B
08/10/04 1
BDL
0.050
mg/l
0.50
8260B
08/10/04 1
BDL
0.050
mg/l
0.70
8260B
08/10/04 1
BDL
0.50
mg/l
200
8260B
08/10/04 1
BDL
0.050
mg/l
0.70
8260B
08/10/04 1
BDL
0.050
mg/l
0.50
8260B
08/10/04 1
BDL
0.050
mg/l
0.20
8260B
08/10/04 1
100
% Rec.
8260B
08/10/04 1
95.
% Rec.
8260B
08/10/04 1
120
% Rec.
8260B
08/10/04 1
BDL
0.0050
mg/l
0.030
8081A
08/09/04 1
BDL
0.0050
mg/l
0.020
8081A
08/09/04 1
BDL
0.0050
mg/1
0.00*80
8081A
08/09/04 1
BDL
0.0050
mg/l
0.40
8081A
08/09/04 1
BDL
0.0050
mg/l
10.
8081A
08/09/04 1
BDL
0.010
mg/l
0.50
8081A
08/09/04 1
Laboratory Certification Numbers:
AIHA - 100789, AL - 40660, CA - I-2327, CT- PH-0197, FL - E87487, GA - 923, IN - C-TN-01
KY - 90010, KYUST - 0016, NC - ENV375,DW21704, ND - R-140, SC - 84004, TN - 2006, VA - 00109, WV - 233
Page 2 of 5

ENVIRONMENTAL
SCIENCE CORP.
REPORT OF ANALYSIS
Pam Hester
TBL Laboratory
P.O. Box 589
Lumberton, NC 28359
Date Received August 04, 2004
Description 14417 - Alchem, Inc.
Sample ID LAGOON 3
Collected By Wayne Drye
Collection Date 07/28/04 08:00
12065 Lebanon Rd.
Mt. Juliet, TN 37122
[phone]
1-800-767-5859
Fax [phone]
Tax I.D. 62-0814289
Est. 1970
August 19,2004
ESC Sample # : L164185-02
Site ID
Project TBL-14417
Parameter Result Det. Limit Units Limit Method Date Dil
Decachlorobiphenyl
Tetrachloro-m-xylene
TCLP Herbicides
2,4,5-TP (Silvex)
2,4-D
Surrogate Recovery
2,4-Dichlorophenyl Acetic Acid
TCLP Semi-Volatiles
1,4-Dichlorobenzene
2,4-Dinitrotoluene
Hexachlorobenzene
Hexachloro-1,3-butadiene
Hexachloroethane
Nitrobenzene
Pyridine
m&p-Cresol
o-Cresol
Pentachlorophenol
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
Surrogate Recovery
Nitrobenzene-d5
2-Fluorobiphenyl
p-Terphenyl-d14
Phenol-d5
2-Fluorophenol
2,4,6-Tribromophenol
72. % Rec. 8081A 08/09/04 1
73. % Rec. 8081A 08/09/04 1
BDL
0.0020
mg/l
1.0
8151A
08/09/04 1
BDL
0.0020
mg/l
10.
8151A
08/09/04 1
83.
% Rec.
8151A
08/09/04 1
BDL
0.10
mg/l
7.5
8270C
08/06/04 1
BDL
0.10
mg/l
0.13
8270C
08/06/04 1
BDL
0.10
mg/l
0.13
8270C
08/06/04 1
BDL
0.10
mg/l
0.50
8270C
08/06/04 1
BDL
0.10
mg/l
3.0
8270C
08/06/04 1
BDL
0.10
mg/l
2.0
8270C
08/06/04 1
BDL
0.10
mg/l
5.0
8270C
08/06/04 1
BDL
0.10
mg/l
400
8270C
08/06/04 1
BDL
0.10
mg/l
200
8270C
08/06/04 1
BDL
0.10
mg/1
100
8270C
08/06/04 1
BDL
0.10
mg/l
400
8270C
08/06/04 1
BDL
0.10
mg/1
2.0
8270C
08/06/04 1
52.
% Rec.
8270C
08/06/04 1
71.
% Rec.
8270C
08/06/04 1
89.
% Rec.
8270C
08/06/04 1
58.
% Rec.
8270C
08/06/04 1
61.
% Rec.
8270C
08/06/04 1
74.
% Rec.
,
8270C
08/06/04 1
BDL - Below Detection Limit
Det. Limit - Estimated Quantitation Limit(EQL)
Laboratory Certification Numbers:
AIHA - 100789, AL - 40660, CA - I-2327, CT- PH-0197, FL - E87487, GA - 923, IN - C-TN-01
KY - 90010, KYUST - 0016, NC - ENV375,DW21704, ND - R-140, SC - 84004, TN - 2006, VA - 00109, WV - 233
Note:
The reported analytical results relate only to the sample submitted.
This report shall not be reproduced, except in full, without the written approval from ESC.
Reported: 08/19/04 12:15 Printed: 08/19/04 14:23
Page 3 of 5

Attachment A
List of Analytes with QC Qualifiers
Sample # Analyte Qualifier
L164185-01 Sodium g
L164185-02 Trichloroethene J4
Pentachlorophenol J4
2,4,6-Trichlorophenol J3J6
Methoxychlor J5
Page 4 of 5

Attachment B
Explanation of QC Qualifier Codes
Qualifier Meaning
B (EPA) - The indicated compound was found in the associated method blank as
well as the laboratory sample.
J6 The sample matrix interfered with the ability to make any accurate
determination; spike value is low
J3 The associated batch QC was outside the established quality control range
for precision.
J4 The associated batch QC was outside the established quality control range
for accuracy.
J5 The sample matrix interfered with the ability to make any accurate
determination; spike value is high
Qualifier Report Information
ESC utilizes sample and result qualifiers as set forth by the EPA Contract Laboratory Program and
as required by most certifying bodies including NELAC. In addition to the EPA qualifiers adopted
by ESC, we have implemented ESC qualifiers to provide more information pertaining to our analytical
results. Each qualifier is designated in the qualifier explanation as either EPA or ESC.
Data qualifiers are intended to provide the ESC client with more detailed information concerning
the potential bias of reported data. Because of the wide range of constituents and variety of
matrices incorporated by most EPA methods,it is common for some compounds to fall outside of
established ranges. These exceptions are evaluated and all reported data is valid and useable
unless qualified as 'R' (Rejected).
Definitions
Accuracy - The relationship of the observed value of a known sample to the
true value of a known sample. Represented by percent recovery and
relevant to samples such as: control samples, matrix spike recoveries,
surrogate recoveries, etc.
Precision - The agreement between a set of samples or between duplicate samples.
Relates to how close together the results are and is represented by
Relative Percent Differrence.
Surrogate - Organic compounds that are similar in chemical composition, extraction,
and chromotography to analytes of interest. The surrogates are used to
determine the probable response of the group of analytes that are chem-
ically related to the surrogate compound. Surrogates are added to the
sample and carried through all stages of preparation and analyses.
Control Limits (AQ) (SS)
2-Fluorophenol 31-119 Nitrobenzene-d5 43-118 Dibromfluoromethane 79-126 83-119
Phenol-d5 12-134 2-Fluorobiphenyl 45-128 Toluene-d8 81-114 82-116
2,4,6-Tribromophenol 51-141 Terphenyl-d14 43-137 4-Bromofluorobenzene 65-129 72-126
TIC - Tentatively Identified Compound: Compounds detected in samples that are
not target compounds, internal standards, system monitoring compounds,
or surrogates.
Page 5 of 5

ANNUAL RESIDUAL SAMPLING SUMMARY FORM
Attach this form to the corresponding laboratory analysis
Please note that your permit may contain additional parameters to be analyed than those required to be summarized on this form.
Permit Number WQ0016338
Facility Name ALCHEM, INC. LABORATORY 1 TBL LABORATORY
NPDES # 2)
or WD # (residual only Facilities) 3 )
WWTP Name
Zesidual Analysis Data
Date Sampled (grab) or 08/09/02 01 /15/03
Date Composited
Percent Solids
Parameters (ma/ka dry weiaht)
Aluminum
10,700
7,900
Arsenic
3.05
<.04
Barium
21.9
36.9
Cadmium
2.2
<0.2
Calcium
95.0
583
Chromium
81.10
6.64
Copper
18.8
2.13
Lead
126.0
14.3
Magnesium
25.4
126.0
Manganese
0.7
3.3
Mercury
0.033
0.067
Nickel
7.36
0.554
Selenium
<0.4
<0.4
Silver
0.77
<0.2
Sodium
99.0
101.0
Total Phosphorus
12.8
43.0
Zinc
20.2
1.75
X �CFi� (/ 1-, UAA9tr,, 20' 02/05/03
(SIGNATURE OF PREPARER) DATE
" I certify, under penalty of law, that this document was prepared under my direction or supervision in accordance with a system
designed to assure that qualified personnel property gathered an evaluated the information submitted. I am aware that there are
significant penalties for submitting false information, including the possiblity of fines and imprisonment for knowing violations."
DEM FORM SSF (10/94)

elf
element®ne
FINAL REPORT OF ANALYSES
)b
Element One Inc.
5022-C Wrightsville Ave.
Wilmington, NC 28403
Phone: [phone]
Fax: [phone]
[e-mail]
Pam Hester August 9, 2002
TBL Laboratory Client Project Name ALCHEM, Inc
P.O. Box 589 Client Project Number TBL-12141'
Lumberton, NC 28359 PO Number
E1 Project Number e0625
Sample #
Sample ID
Lagoon #3
Sample Matrix
Sample Type
Date Received <
7/26/02,'
Date Sampled 7/24/02
Time. Sampled:.
0800
Time Received .
1640
Delivered by Picked Up
Sampler
Wayne Drye
Received by
BGH
Page 1 of 1
E1 Sample #
0625-1
Parameter
Result Unit
Dilution
DL
Method
Date
Aluminum
10700 mg/Kg
1000
0.8.
EPA 200.8 .
8/5102 ::
Arsenic
3.05 mg/Kg
1
0.4
EPA 200.8
8/5/02 ..
Barium
21.9 mg/Kg
1
0.4
EPA 200.8
8/5/02:
Cadmium
2.20 mg/Kg
1
0.2
EPA 200.8
Calcium
95.0 mg/Kg
1
1.6
EPA 200.8
8/5/02
Chromium
81.1 mg/Kg
1
0.4
EPA 200.8. ,
8/5/02
Copper
18.8 mg/Kg
1
0.2
EPA 200.8' .
8/5/02:
Lead
126 mg/Kg
1
0.2
EPA 200.8
8/5/02
Magnesium
25.4 mg/Kg
1
0.8
EPA 200.8
8/5/02
Manganese
0.70 mg/Kg
1
0.4
EPA 200.8'',
8/5/02
Mercury
0.033 mg/Kg
1
0.01
EPA 200.8
8/1102 :.
Nickel
7.36 mg/Kg
1
0.4
EPA 200.8
8%5/02
Phosphorus
12.8 mg/Kg
1
0.8
EPA 200.8
8/5/02
Selenium
< 0.4 mg/Kg
1
0.4
EPA 200.8
8/5/02
Silver
0.77 mg/Kg
1
0.2
EPA 200.'8
8/5/02,1 .
Sodium
99.0 mg/Kg
1
0.8
EPA 200.8
8/5102 `.'
Zinc
20.2 mg/Kg
1
0.4
EPA 200:8
pH
3.4 SU
1
EPA 9045C , -..
XenSith, Laboratory Director
NC Certifications: DW 37788 and DWQ DENR 604

el,
elementOne
FINAL REPORT OF ANALYSES
Element One Inc.
5022-C Wrightsville Ave.
Wilmington, NC:28403
Phone: [phone]
Fax: [phone]
[e-mail]
Pam Hester
January 15, 2003
TBL Laboratory
Client Project Name
ALCHEM, Inc.
P.O. Box 589
Client Project, Number
TBL-12614
Lumberton, NC 28359
PO Number
E1 Project
Number e1274
Sample #
Sample ID
Lagoon #3
Sample Matrix
Sample Type
Date Received:,:'.:1/9/03:
Date Sampled 1/7/03
Time Sampled ,-,,0800
Time Received.
,1345 ,".`_•.._...
Delivered by Picked Up
Sampler
Wayne Drye
Received by
CMO
Page 1 of 1
E1 Sample
#
1274-1
Parameter
Result
Unit
Dilution
DL
Method
Date
Aluminum
7900
mg/Kg'
500
0.4
EPA 200.8
`1Z1.3/03
Arsenic
< 0.4.
mg/Kg
1
0.4
EPA 200.8
1/13%03
Barium
36.9
'mg/Kg
1 ...0.4
EPA 200.8
1%13%03
Cadmium
< 0.2
mg/Kg
1
0.2
EPA.200.81
1/.13/03
Calcium
583
mg/Kg
20
1.6
EPA 200.8
1113/03 ;.
Chromium
6.64
mg/Kg
1
0.4
EPA 200.8.
1�/13/03
Copper
2.13
mg/Kg
1
0.2
EPA 200.8,
1/13%03
Lead
14.3
mg/Kg.
1
0.2
EPA 200.8
1/13/03 '•
Magnesium
126
mg/Kg
1
0.8
EPA 200.8
'1/13/03 -
Manganese
3.30
mg/Kg
1
0.4
EPA 200.8
1/13/03
Mercury
0.067
mg/Kg
1
0.01
EPA 245.1,
1/13/03
Nickel
0.554
mg/Kg
1
0.4
EPA 200.8'
1/13/03
Phosphorus
43.0
mg/Kg
1
0.8
EPA 200.8.
1/13/03 - ...
Selenium
< 0.4
mg/Kg
1
0.4
EPA.200.8,
1/13/031..: `
Silver
< 0.2
mg/Kg
1
0.2
EPA 200.8
: 1/13/03 --=•. .
Sodium
101
mg/Kg
1
0.8
EPA 200.8
A/.13/03, _^ :...
Zinc
1.75
mg/Kg
1
0.4
EPA 200.8'
1%13%03
pH
3.73
SU
1
EPA 9045C
1/13/03
en Smith, Laboratory Director
NC Certifications: DW 37788 and DWQ DENR 604

ANNUAL RESIDUAL SAMPLING SUMMARY FORM
Attach this form to the corresponding Annual Report
Please note that your permit may contain additional parameters to be analyzed than those required to be summarized on this form.
Permit Number: WQ0016338 Laboratory: 1) TBL LABORATORY
Facility Name: ALCHEM, INC 2)
NPDES # or 3)
WQ#:
4)
WWTP Name: 5)
Residual Analvsis Data
or
• ,••• Date
MEME
"I certify, under penalty of law, that this document was prepared under my direction or supervision in accordance with a system
designed to assure that qualified personnel properly gathered and evaluated the information submitted. I am aware that there are
significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing- violations.'
LZ)V
Signative of Prepare"O Date
DENR FORM RSSF-B (5/2003)

ANNUAL RESIDUAL SAMPLING SUMMARY FORM
Attach this form to the corresponding Annual Report
Please note that your permit may contain additional parameters to be analyzed than those required to be summarized on this form.
Permit Number: WQ0016338 Laboratory: 1) TBL LABORATORY r
Facility Name: ALC HEM, INC 2)
NPDES # or 3)
WQ#:
4)
WWTP Name: 5)
Residual Analvsis Data
Sample or
1
®-®
• 1
-mPercent
Solids
TotalPhosphorus
"I certify, under penalty of law, that this document was prepared under my direction or supervision in accordance with a system
designed to assure that qualified personnel properly gathered and evaluated the information submitted. I am aware that there are
significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations."
Signa re of Prep er Date
DENR FORM RSSF (5/2003)

el,
elementOne
Element One Inc. .
5022-C Wrightsville Ave.
Wilmington, NC 28403
Phone: [phone].
Fax: [phone]
[e-mail]
FINAL REPORT OF ANALYSES
Pam Hester
August 13, 2003
TBL Laboratory
Client Project Name ALCHEM,
INC
P.O. Box 589
Client Project Number
TBL-1 3205
Lumberton, NC 28359
PO Number
El. Project Number e2075
Sample #
Sample ID
Lagoon.#3
Sample Matrix
Sample Type.
Date Received
7/31/03,:
Date Sampled 7/29/03
Time
Sampled
0800
Time Received
160
Delivered by Picked Up
Sampler'
Wayne Dryer
Received by
PDS-,
Page 1 of 1
El Sample#
2075-1
Parameter
Result
Unit
Dilution
DL
Method
Date
Sodium
153
mg/L.
5
0.01
EPA 200.811:
8/1/03
Magnesium
105.
mg/L
5
0.01
EPA . 2008'
-8/1'/03,�
Aluminum
16800
mg/L,.
5000
0.005
EPA 200.8'
10'_
Phosphorus
76.1
mg/L
5
0.01
EPA 200.8,
1.8/1
8./,1/03':.
Calcium
827
mg/L
5
0.02
EPA 200.8.
18/1 /03
Chromium
12.6
mg/L
5
0.005
EPA 200.8
,
8/1/03
Manganese
4.14
mg/L
5
0,005
EPA 200.8
8/.l-/03-
Nickel
1.23
mg/L
1
0.005
EPA 200.8
.8/1/03*
Copper
2.93
mg/L
5
0.003
EPA 200.8
61110.
Zinc
1.65
mg/L
1
0.005
EPA 200.8
8/1/03
Arsenic
< 0.5,
mg/L
1
0.005
EPA 200.8�
8/1103
Selenium
< 0.5
mg/L
1
0.005,
-EPA 200.8.s
8/1/03
Silver
0.210
mg/L
1
0.002
EPA 200.8
8/1/03
Cadmium
< 0.2
mg/L
1
0.002
EPA 200.8;
8/l/03';-
Barium
66.3
mg/L
5
0.005
EPA 200.8;
8/1/03
Lead
25.9
mg/L
5
0.003
EPA 200.8
8/1/03
Mercury
0.0865
mg/L
i
0.0002
EPA-245.1":
8/6/03
pH
3.60 :
SU
1
EPA 9045C
8/6/03:.
enSmith, Laboratory Director
NC Certifications:, DW 37788 and DWQ DENR 604

o=..
elementOne
Pam Hester
TBL Laboratory
P.O. Box 589
Lumberton, NC 28359
Sample #
Sample Matrix
Date Sampled 12/11/03
Delivered by Picked Up
Page 1 of 1
FINAL REPORT OF ANALYSES
Sample ID
Sample Type
Time Sampled
Sampler
E1 Sample #
Element One Inc.
50,22-C Wrightsville Ave.
Wilmington, NC 28403
Phone: [phone]
Fax: [phone]
el [e-mail]
December 29, 2003
Client Project Name Alchem, Inc.
Client Project Number TBL-13616
PO Number
E1 Project Number e2615
Lagoon #3
0800
Wayne Drye
2615-1
Date Received
12/16/03
Time Received
1515
Received by
PDS
Parameter
Result
Unit
Dilution
DL
Method
Date
Sodium
218
mg/Kg
1
0.02
EPA 200.8
12/17/03
Magnesium
139
mg/Kg
1
0.02
EPA 200.8
12/17/03
Aluminum
21402
mg/Kg
1000
0.005
EPA 200.8
12/17/03
Phosphorus
85.4
mg/Kg
1
0.02
EPA 200.8
12/17/03
Calcium
885
mg/Kg
5
0.05
EPA 200.8
12/17/03
Chromium
14.3
mg/Kg
1
0.005
EPA 200.8
12/17/03
Manganese
4.15
mg/Kg
1
0.005
EPA 200.8
12/17/03
Nickel
1.32
mg/Kg
1
0.005
EPA 200.8
12/17/03
Copper
3.13
mg/Kg
1
0.003
EPA 200.8
12/17/03
Zinc
1.57
mg/Kg
1
0.005
EPA 200.8
12/17/03
Arsenic
0.889
mg/Kg
1
0.005
EPA 200.8
12/17/03
Selenium
0.889
mg/Kg
1
0.005
EPA 200.8
12/17/03
Silver
0.356
mg/Kg
1
0.002
EPA 200.8
12/17/03
Cadmium
0.356
mg/Kg
1
0.002
EPA 200.8
12/17/03
Barium
82.4
mg/Kg
2
0.005
EPA 200.8
12/17/03
Lead
29.7
mg/Kg
2
0.003
EPA 200.8
12/17/03
Mercury
0.0849
mg/Kg
1
0.0002
EPA 245.1
12/23/03
pH
3.57
SU
1
EPA 9045C
12/17/03
en Smith, Laboratory Director
NC Certifications: DW 37788 and DWQ DENR 604

s or-03--00-E ---- 810.97*
s 03•-2r-3o-w
49.00'
qon•
to
Lq//
�\
/33.739 00� % w0 0-0
t
44y � I
r c_
\ I Well e 1%
— — 90 M . 2 i 206.
�' o
\�IV'4 RAC RCAF s -
�' a NORTHWESTERN o -
O CA io
x _ r_
CL
O - 7�
Nh O
�0 viM \ N. CD
N-Ci
Oil , ej t�
N(O O� �?�.�- Z-
M
_ Co h Op �p O'O �.v I Z Y ~� s
f.
_
T° r
s Or-02'-20-E� 1294.02'
1 Well 3 / / •on
Lagoon
- Wal�RU
Top of_ well elevation . 80925'
Ground elavaf(an ■ 808.14-
Latitude . 35•-33•-32!'
Longitude . 80'-25'-24d'
S1atk wafer level below top of cos nQ ■ 32.
( Wafer leant from Woyne Drye of ALCEK (nr )
Wales 2
Top of Wolf Olevctlon . 805J8'
Ground wfevofian . 802 89'
Lafffude .;-1 5--33•-ar6
L.onpltud* •._80--25'-26.G-
Static water level belo�r.. top: of casing • 22
(wafer lard from wU cortstiuctlon records )
-:
Top of well s,levattori`. 793.72-
Ground elevation . 79L20' .'
Lottfude . 35--33'-Z7.5-
Lonpltude . 80--25'-2L5-
static wafer tewl below top of caaloq . IT
t Water level from wep constrvction record, I
/7l fYQ-
�-z_ zaol

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Ak
0
James B. Hunt, Jr., Governor - @ '9
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director NORTH CAROLINA DEPARTMENT OF
j. 4:,ry U. W
`L y; ENVIRONMENT AND NATURAL RESOURCES
January 21, 1999
Mr. Randall F. Andrews
Alchem, Incorporated
8135 Red Road
Rockwell, NC 28138
Subject: Permit No. WQ0002702
Alchem, Incorporated
Industrial Recycle -Bauxite Process
Rowan County
Dear Mr. Andrews:
In accordance with your application received October 23, 1998, we are forwarding herewith Permit No.
WQ0002702; dated January 21, 1999, to Alchem, Inc. for the continued operation of the three (3) lagoon recycle
- system. As a separate issue, we are forwarding Permit No. WQ001. 3N for the distribution of the recycle system
residuals. 6 3.7Y
This permit shall be effective from the date of issuance until December 31, 2004, shall void Permit No.
WQ0002702 issued June 27, 1994, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the revised monitoring requirements in this permit.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and filed with the Office of Administrative Hearings, P.O. Drawer 27447, Raleigh, NC 27611-7447. Unless such
demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please c tact Joe Pearce at [phone]
extension 544.
Si ce
A., reston Howard, Jr., P.E. -
cc: Rowan County Health Department
Mooresville Regional Office, Groundwater Section
Groundwater Section, Central Office
�Maoresv-i�Ile�Regiona fOf =f c �a erg � u"ali�yd�ectio•..
Technical Assistance and Certification Unit
Non -Discharge Compliance/Bnforcement Unit
PO Box 29535, Raleigh, North Carolina 27626-0535
An Equal Opportudity Affirmative Action Employer
Telephone [phone] Fax [phone]
50% recycled/10% post -consumer paper
r

M
NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Inc.
Rowan County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serveAlchem, Inc., with no
discharge of wastes to the surface waters, pursuant to the application received October 23, 1998, 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 December 31, 2004, shall void Permit No.
WQ0002702 issued June 27, 1994, and shall be subject to the following specified conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
This permit is effective only with respect to the nature and volume of wastes described in the application and
other supporting data.
The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there is
a name change of the Permittee, a formal permit request must be submitted to the Division of Water Quality
(Division) accompanied by an application fee, documentation from the parties involved, and other supporting
materials as may be appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
6. The Mooresville Regional Office, telephone number [phone], shall be notified at least forty-eight (48)
hours in advance of operation of the installed facilities so that an in -place inspection can be made. Such
notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m. until 5:00
p.m. on Monday through Friday, excluding State Holidays.

7. ' The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
8. 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 facility.
9. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the discharge
of any wastewater resulting from the operation of this facility.
10. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
11. Freeboard in the all of the lagoons shall not be less than two feet at any time.
12. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
13. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper operation
of the subject facilities.
14. The Permittee or his designee shall inspect the wastewater recycle 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 three years from the date of the inspection and shall be made available to the Division or other
permitting authority, upon request.
15. 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 recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any records
that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
16. 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 15A NCAC 2H .0205 (c)(4).
17. 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.
18. 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.
19. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.

20. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704)663-
1699, 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 at the wastewater treatment facility which results in the treatment of significant amounts
of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents of a basin
or tank, the known passage of a slug of hazardous substance through the facility, or any other unusual
circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators, compressors,
etc.;
c. Any failure. of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.
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 orproposed to
be taken to ensure that the problem does not recur.
21. Upon classification of the facility by the Water Pollution Control Systems Operators Certification
Commission (WPCSOCC), the Permittee shall employ a certified wastewater treatment plant operator to be
in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate of
the type and grade at least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the WPCSOCC. The Permittee must also employ a certified back-up operator of the appropriate
type and grade to comply with the conditions of 15A NCAC 8A .0202. The ORC of the facility must visit
each Class I facility at least weekly and each Class II, III, and IV facility at least daily, excluding weekends
and holidays, and must properly manage and document daily operation and maintenance of the facility and
must comply with all other conditions of 15A NCAC 8A .0202.
22. The recycle lagoons shall not be located within 100 feet of water supply wells.
23. Monitor wells MW-1 and MW-2, depicted on Attachment A, shall be sampled February and July for the
following parameters.
Water Level pH
Aluminum
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth to
water in each well shall be measured from the surveyed point on the top of the casing.
The results of the sampling and analysis must be received on Form GW-59 (Groundwater Quality
Monitoring: Compliance Report. Form) by the Groundwater Section, Permits and Compliance Unit, P.O. Box
29578 Raleigh, N.C. 27626-0578 on or before the last working day of the month following the sampling
month.
24. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.

25.' The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary is for the disposal system
constructed after December 31, 1983 is established at either (1) 250 feet from the waste disposal area, or (2)
50 feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to immediate remediation
action in addition to the penalty provisions applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the disposal systems
midway between the Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of
standards at the Review Boundary shall require remediation action on the part of the permittee.
26. 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.
Permit issued this the/Twenty-first day of January, 1999
NORTH CAROLINA ENVRONIv>;RNTAL MANAGEMENT COMMISSION
�. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002702
4

`o�OF W ATFRQG
Randall Andrews
Alchem, Inc
8135 Red Road
Rockwell, NC 28138
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
September 28, 2004
Subject: Acknowledgement of Application No. WQ0002702
__ Alchem,-Inc -_
Recycle System
Rowan _County
Dear Mr. Andrews:
Alan W. Klimek, P.E., Director
Coleen H. Sullins, Deputy Director
Division of Water Quality
E^
S EP 2 9 2004'
NIC DEFT. OF' �.`�ac,,FK, ,0, s.-N T
AND HA1'i.lRha.
Ni'VO #ESVIL!'E RMi0.'�^ L OFFICE
The Non -Discharge Permitting Unit of the Division of Water Quality (Division) acknowledges receipt of
your permit application and supporting materials on September 23, 2004. This application package has
been assigned the number listed above and will be reviewed by David Goodrich.
The reviewer will perform a detailed review and contact you with a request for additional information if
necessary. To ensure the maximum efficiency in processing permit applications, the Division requests
your assistance in providing a timely and complete response to any additional information requests.
Please be aware that the Division's Regional Office, copied below, must provide recommendations prior to
final action by the Division. Please also note at this time, processing permit applications can take as long
as 60 - 90 days after receipt of a complete application.
If you have any questions, please contact David Goodrich at 919-715-6162 or via e-mail at
[e-mail]. If the reviewer is unavailable, you may leave a message, and they will
respond promptly.
PLEASE REFER TO THE ABOVE APPLICATION NUMBER WHEN MAKING INQUIRIES ON THIS
PROJECT.
Sincerely,
Wim H.
•
Supervisor
cc: looresvill Regionai Office; Wa �er + ualit7 Secti_ _
Wayne Drye
Plant Manager, ALCHEM, Inc.
8135 Red Road
Rockwell, NC 28138
Permit Application File WQ0002702
Non -Discharge Permitting Unit
1636 Mail Service Center, Raleigh, NC 27699-1636
Internet http://h2o.enr.state.nc.us/ndpu MEN
Telephone [phone] Fax [phone]
DENR Customer Service Center
An Eaual ODoortunity Action EmDlover
Telephone [phone]
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SOC PRIORITY PROJECT: Yes Now_
To: Permits and Engineering Unit
Water Quality Section
Attention: Joe Pearce
Date: November 12, 1998
NON -DISCHARGE STAFF REPORT AND RECOMMENDATION
COUNTY: Rowan
Permit No.: WQ0002702
MRO No.: 98-088
PART I - GENERAL INFORMATION
1. Facility and Address: Alchem, Inc. - Recycle Facility
8135 Red Road
Rockwell, North Carolina 28138
2. Date of Investigation(,11-10-98
3. Report Prepared By: G. T. Chen
4. Persons Contacted and Telephone Number: Mr. Wayne Drye, Plant
Manager, [phone]
5. Directions to Site: From the junction of NC Highway 152 and
Link Street (SR 2332) in the Town of Rockwell, travel north on
SR 2332 about 0.25 mile to the junction with Red Road (SR
2323, a partly paved and partly graveled road parallel to the
railroad tracks). Turn left onto Red Road and travel
northwest approximately 0.85 mile. Alchem, Inc. is located on
the right (east) side of the road (and the railroad tracks).
6. Size (land available for expansion and upgrading): Adequate
land area available for expansion/upgrading, if necessary.
7. Topography (relationship to 100 year flood plains included):
Flat, the recycle system is not in a flood plain.
Attach a U.S.G.S. map extract and indicate facility site.
USGS Quad
No.:
E
17 SW
USGS Quad Name:
Rockwell, NC
Latitude:
350
33'
52"
Longitude: 800
25' 26"

8. Any buffer conflicts with location of nearest dwelling and
water supply well: Yes Now_ If Yes, explain:
9. Watershed Stream Basin Information:
a. Watershed Classification: C
b. River Basin and Subbasin No.: Yadkin -Pee Dee & 03-07-04
C. Distance to surface water from disposal system: A wet
weather ditch by the railroad tracks is approximately 200
feet west of an existing settling basin.
PART II - DESCRIPTION OF WASTES AND TREATMENT WORKS
1. a. Volume: 0.004 MGD (Design Capacity)
Residuals: 300 tons per year
b. Types and quantities of industrial wastewater: Estimated
4,000 GPD of wastewater is generated from the processing
of Bauxite.
C. Pretreatment Program (POTWs only): N/A.
2. Treatment Facilities
a. What is the current permitted capacity of the facility?
N/A.
b. What is the actual treatment capacity of the current
facility (design volume)? N/A.
C. Please provide a description of existing or substantially
constructed wastewater treatment facilities: The
existing recycle facility consists of three (3) settling
basins for sand slurry. The supernatant from the basins
is reused in the process of production of aluminum
sulfate. The basins, which are lined with clay, are in
series.
d. Please provide a description of proposed wastewater
treatment facilities: N/A.
3. Residuals handling and utilization/disposal scheme:
Non -Discharge Permit Staff Report
Version 10192
Page 2

PART IV - EVALUATION AND RECOMMENDATIONS
Alchem, Inc. requests that its Non -discharge Permit (No.
WQ0002702) be renewed and modified to allow sand by-products to be
mixed with clay.
-Pending final review and approval by the SERG and the
Groundwater Section, it is recommended that the subject permit be
renewed and modified to allow the sand by-product to be mixed with
clay.
Signature of Report Preparer
Water Quality
// / 2
Date
1 Supervisor
Non -Discharge Permit Staff Report
Version 10192
Page 4

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.State of North Carolina
Department of Environment
'and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Randall Andrews, President
'1.0
October 26, 1998
EMIMMfilz
NOV 5 1998
Alchem, Inc.
8135 Red Road
Rockwell, NC 28138
Subject: Application No. WQ0002702
3n Alchem, Inc.
Recycle Facility
Rowan County
Dear Mr. Andrews:
The Division's Permits and Engineering -Unit acknowledges receipt of your permit application and
supporting materials on October 23, 1998. This application has been assigned the number listed above.
Your project has been assigned to Mr., Joe- Pearce for a detailed engineering review. Should there, be.any-
questions concerning your project, the reviewerwill contact.you4ith a request for additional information°s;=
,r k '
Be aware that the Division's RegionalOffice, copied below, must provide recommendations from
Regional Supervisor or a Procedure Four Evaluation for this project, prior to final action by the division
If you have any questions, please contactMr. Joe Pearce at 919/733-5083 ext. 544. If the engineer is a t:':.. a
unavailable, you may leave a message on their voice mail and theywill respond promptly.
PLEASE REFER TO THE ABOVE APPLICATION NUMBER WHEN MAIIIG INQUIlZES ON
THIS PROJECT.
Sincerely,
4 A-A-n bLAJJ JL�Mj
Kim H. Colson, P.E.
Supervisor, Non -Discharge Permitting Unit
cc: Ville Regional Offiee,_Water Quality
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

ALCHEM, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
Tel. [phone] Ext. 23
Fax [phone]
October 20, 1998
North Carolina Department
Of Environment, Health, and
Natural Resources
Division of Water Quality
Post Office Box 29535
Raleigh, NC 27626-0535
Dear Sir or Madam:
RECEIVED
WATER QUALM`! SECTION
rOrl2 31993
Non -Discharge Permitting
I'D
9
Our permit expires May 31, 1999. We are applying for a permit modification and a peiinit
renewal at the same time.
On the modification, we would like to have authorization to mix the sand by product, which is
a result of Bauxite mixing with Sulfuric Acid at a high temperature with clay. As you will see
from the analytical results, the process leaves basically no leachable metals. You will see that
this material is almost sterile.
If there is something we can assist you with to expedite this procedure, please let us know.
My office phone number and fax number is listed above.
Best regards,
ALCHEM, INC.
04tj
Vy
Randall Andrews,
President
el
7-1
r1 1

IJ 1."L%. Vl • IW. - v-. -...A"
Department of Environment, Health and Natural Resources
B
Division of Environmental Management
Non -Di scharge Permit-Appiication Form
(THIS FORM MAYBE PHOTOCOPIED FOR USE AS AN ORIGINAL)
R,LC�
DISTRIBUTION OF OTHER RESIDUAL"
This application is intended for facilities which are EXEMPT frorrar 2,Y R ParOf
199j,
I. GENERAL INFORMATION: NOn-Dlph
1. Applicant's name (please specify the name of the municipality, corporation, individual, etcc..) Pe��fbn8
m
Alchem, Inc.
2. Print owners or signing official's name and title (the person who is legally responsible for the facility and its compliance):
Randall Andrews — President
3. Mailing address: 8135 Red Road
Citv: Rockwell
State: North Carolina
Telephone Number: ( 704 ) 279-7908
4. Application Date:
5. Fee Submitted: S
October 20, 1998
400.00
Zip: 28138
[The permit processing fee should be as specified in 15A NCAC 2H .0205(c)(5).1
6. Specify how these residuals will be distributed: sold or given away in bags or other containers; lawn (bulk);
home garden (bulk); other, used for a building pad of 3 acres on our site
7. if the alternative for residual disposal consists of "surface disposal" as defined under 40 CFR Part 503, please complete the
application titled "SURFACE DISPOSAL OF RESIDUAL_ SOLIDS. Please identify if there is any storage of residuals in
a surface impoundment or disposal thru landfilling. Explain:
no land filling. no surface impoundment
X
8. Is the residual process facility also the generator? Yes; No
9. Latitude: 35" 30 Minutes Longitude: 80' 20 minutes of residual process facility
10. Specify whether the process facility is owned by: federal; . X private; state; local government;
11. County where facility is located: Rowan
II. PERSIIT INFORMATION:
1. Application No. (will be comp'.eted by D1=IM):
2. Specify whether project is: new; X renewal'; X modification
For renewals, complete all sections included in the application. Engineering Signature and Seal not required for
renewals or if there is not any construction involved with the subject project.
3. If this application is being submitted as a result of a renewal or modification to an existing permit list the existing permit
� number \l1lW-OCO and its issue date June 27, 1994
FORM: DORS 06/94
Nee I of 7

��� 1
{
1. � '.

III. FACILITY ,INFORMATION (attach additional pages for additional sources of residuals):
Alchem, Inc.
..y.......... .... j .. _.­ ,:.sidua.s are gc.,erated or prepared:
2. Facility permit number: W0000272 —;facility permit holder: Alchem. Inc.
3. Specify whether facility in Section III.1 is owned by: federal; X private; state; local government;
4. Specify facility design flow: mgd; facility average daily flow: mgd;
Type of residual storage: in lined lagoons
Volume of residual storage: 20,000 cubic yards ;
Length of residuals storage at facility: 3 years. days (the Division requires a minimum 30 days storage in units that
are separate from treatment system, i.e. not in clarifiers, aeration basins, etc.);
Estimated volume of residuals: 3,000 (dry tons/yr.);
5. If the residual process facility is not the same as the generator, please specify delivery frequency and quantity of residual to
be processed:
6. Facility contact (person familiar with residuals preparation): Wayne Drye
7. Facility contact's telephone number: ( 704 ) 279-7908
8. Location of treatment facility: North Carolina State; Rowan County
9. MaiLng address: 8135 Red Road
Rockwell, NC 28138
10. Specify the source of the residuals: treatment of water (alum sludges); X treatment of industrial wastewater
(10017c industrial residuals); treatment of industrial wastewater mixed with domestic wastewater (please specify
appropriate percentages of 100 % industrial wastewater, % domestic wastewater);
other (explain): Sand from reaction of Bauxite with sulfuric acid
Attach an explanation of either the treatment process, manufacturing process, or how the waste is generated. Provide full
and complete details of the entire process.
11. Does the facility which generates the residuals have an approved pretreatment program? Yes; X No.
This includes facilities which are classified as a "Class I" facility (any publicly owned treatment works required, under 40
CFR 403.8, to have an approved pretreatment program or any facility treating domestic sewage that is classified as "Class
I" by the appropriate federal or State authority) r
IV. RESIDUALS INFORMATION (attach additional pages for additional sources. of residuals):
1. Information for Hazardous Waste (RCRA) Determination. The information requested on the limitations specified below
pertain only to those residuals that are generated from a municipal wastewater treatment facility with industrial contribution
or active pretreatment program and from any other treatment facility with wastewater sources that include industrial sources.
a. Are any of the residuals covered by this application listed in 40 CFR 261.31-261.33? Yes; X No. If Yes,
list the number(.$):
b. Do the residuals exhibit any of the four characteristics defined by 40 CFR 261.21-261.24? Yes; X No.
Attach laboratory results for the Toxicity Characteristic Leaching Procedure Analyses, Reactivity, Ignitability, and
Corrosivity for each residual.
FORM: DORS 06/94 Pate 2 of 7

Note: If the following constituent levels (as determined by the Toxicity Characteristic Leaching Procedure Analvses) arc
rxceedes in the residuals or
if the pH of the residual is not within the range listed
below, the residual is b-,
definition a Hazardous waste.
Chemical analyses must be made to Minimum Detection
Levels.
PPS
PPM
Arsenic
5.0
Barium
100.0
Benzene
0.5
Cadmium
1.0
Carbon tetrachloride
0.5
Chlordane
0.03
Chlorobenzene
100.0
Chloroform
6.0
Chromium
5.0
o-Cresol
200.0
m-Cresol
200.0
p-Cresol
200.0
Cresol
200.0
2,4-D
10.0
1,4-Dichlorobenzene
7.5
1,2-Dichloroethane
0.5
1,1-Dichloroethylene
0.7
2,4-Dinitrotoluene
0.13
Endrin
0.02
Heptachlor (and its hydroxide)
0.008
Hexachlorobenzene
0.13
Hexachloro-1,3-butadiene
0.5
Hexachloroetbane
3.0
bead
5.0
Lindane
0.4
Mercury
0.2
Niethoxychlor
10.0
Methyl ethyl ketone
200.0
Nitrobenzene
2.0
Pentachlorophenol
100.0
Pyridine
5.0
Selenium
1.0
Silver
5.0
Tetrachloroethvlene
0.7
Toxaphene
0.5
Trichloroethylene
0.5
2,4,5-Trichlorophenol
400.0
2,4,6-Trichlorophenol
2.0
2,4,5-TP (Silvex)
1.0
Vinyl chloride
0.2
pH (2:1 vol./wL): >2.0 s.u.
- <12.5 s.u.
NOTE: IF ANY OF THE RESIDUALS MEET THE DEFI1rITIONS OF A HAZARDOUS WASTE.
AS NOTED IN EITHER "A" OR "B" ABOVE, A PERMIT CANNOT BE ISSUED FOR
THAT MATERIAL AND IT SHOULD NOT BE INCLUDED AS PART OF THIS
APPLICATION.
*2. For each residual, please attach a complete chemical analysis of the material. This analysis must be comprehensive enough
�
to completely characterize the residual and must be based upon a review of the process that generates the material. If the
facility that will generate the residual is not vet in operation, the characterization must be based on similar existine
facilities and projection based on the type of facility. The analysis must include a minimum of the following parameters
and any other known and suspected contaminants that are tributary to the system.
�R,
Cadmium
Aluminum
Copper
Ammonia -Nitrogen
Lead
Calcium
Nickel
Magnesium
Zinc
Nitrate -Nitrite Nitrogen
% Total Solids
pH
Phosphorus
Potassium
Sodium
TKN
Plant Available Nitrogen (by calculation)
Wastewater residuals can not be sold or given away if the concentration of any pollutant in the residuals exceeds the ceiling
concentrations specified in the table below. Specify the pollutant concentration of these residuals (attach lab analysis):
Pollutant
Pollutant Ceiling Concentration (mg/kg)'
Dry Weight Basis
Pollutant Concentration (mg/kg)
Dry Weight Basis
Cadmium
85
0.278
Copper
4300
2.23
Lead
840
1.71
Nickel
420
0.73
Zinc
7500
4.73
FORT: DORS 06194 Pale 3 of 7

4 Provide, all applicable pilot studies and any bench scale tests performed on each residual source and the results, includir._
the approximate fertilizer equivalent.
5. Wastewater residuals can't be sold ur given away in bags'or other containers for application to the land unless one of tL:
following options is satisfied.
Specify either A or B. Please be advised. if the residuals are -to be sold or given away in bulk for application tc
lawn or home garden then Option A is the only option.
�-A . The pollutant concentration of the residuals must be less than Pollutant Monthly Average Concentration
listed in the table below.
Pollutant
Monthly Average Concentrations
Dry Weight Basis (mg/kg)
Pollutant Concentration j
D Weight Basis (mJkg)
Cadmium
39
0.278 I
Copper
1500
2.23 j
Lead
300
1.71 j
Nickel
420
0.73
Zinc 1
2800 1
4.73
B . The product of the concentration of each pollutant in the residual and the annual whole residual application
rate for the residual shall not cause the Annual Pollutant Loading Rate to be exceeded.
In order for the Annual Whole Residual Application Rate (AWRAR) to be calculated the Annual Pollutant
Loading Rate (APLR) is divided by the pollutant concentration (PC) times 0.001 (a conversion factor) as
follows:
AWRAR = APLR
PC * 0.001
Pollutant
Pollutant
Concentration
Dry Weight Basis
(m g/kg)
Annual Pollutant
Loading Rates
(APLR)
ka/hectare
Annual Whole Residual
Application Rate
(AWRAR)
kg/hectare
Cadmium
0.278
1.9
0.0068
Copper
2.23
75
0.0336
Lead
1.71
15
0.0087
Nickel
0.73
21 1
0.0287
Zinc 1
4.73
140 1
0.0295
The AWRAR for the residual is the lowest AWRAR calculated. This is the maximum rate at which the
subject residual can be applied (to convert kg/hectare to lbs/acre multiply by 0.8924). Please specify
k0bectare or lbs/acre:
AWRAR = 0.0068
V . PATHOGEN REDUCTION INFORMATION (attach add. pages for additional sources of residuals)
In accordance with 15A NCAC 2H .0200, pathogen reduction can be achieved using either 40 CFR Part 257 or 40 CFR Part
503. Since the pathogen reduction requirements found in 40 CFR Part 257 (note; "Processes to Further Reduce Pathogens" or
PFRP) are incorporated into 40 CFR Part' 503, only Part 503 is listed below. Please check which of the following applies to
the subject residual:
FORM: DORS 06194 Page 4 of 7

1. In order for the residuals to be Class A, in accordance with the pathogen requirements in 40 CFR 503.32(a), aitt= Part a 0-
Part b al d one of the options in Part c must be completed (please submit all lab analysis, test results and calculations):
a. A Fecal coliform density less than 1000 Most Probable Number per gram of total dry solids, or
b. A Salmonella sp. density less than 3 Most Probable Number per 4 grams of total dry solids.
c. In addition to Pan a or Part b being met, one of the following alternatives must also be completed. Please
specify 1, 2, 3, 4, 5a, 5b, 5c, 5d, 5e, 5f, 5g or 6 below being met:
1. time/temp ratu-r- an increased residuals temperature should be m: iutained Lur a prescribed period of time, in
accordance with the following guidelines. The results (D) shall be the amount of time, in days, that the residuals
shall remain at the given temperature:
Time and Temperature Guidelines
Total Solids
Temperature (t)
Minimum Time
Eauation
Notes
No heating of small
> or = 7%
> or = 500 C
> or = 20 minutes
D=131,700,000
particles by warmed
100.14 t
gases or immiscible
liquid.
> or = 7%
> or = 500 C
> or = 15 seconds
D = 131,700,000
Small particles heated by
100.14 t
warmed gases or
immiscible liquid.
< 7%
> or = 500 C
> or = 15 seconds
D = 111,700,000
to
100.14 t
< 30 minutes
< 717c.
> or = 500 C
>or = 30 minutes
D = 50,070,000
100.14 t
2. alkaline treatment - the pH of the residuals is raised to greater than 12 for at least 72 hours. During this time, the
temperature of the residuals should be greater than 520 C for at least 12 hours. In addition, after the 72 hour
period, the residuals are to be air dried to at least 50% total solids.
3. prior testing for Enteric Virus/Viable Helminth Ova - the residuals are analyzed for the presence of enteric viruses
(Plaque -forming units) (pfu] and viable helminth ova. If the residuals are analyzed before the pathogen reduction
process and found to have densities of enteric virus <1 pfu/4 grams of total solids and viable helminth Eva <1/4g
total solids, the residuals are Class A with respect to enteric virus and viable helminth ova until the next
monitoring episode. If the residuals are analyzed before the pathogen reduction process and found to have densities
of enteric virus > or = 1 pfu/4 g total solids or viable helminth ova > or = 1/4 g total solids, and tested again after
processing and found to meet the enteric virus and viable helminth ova levels listed under "4" below, then the
processed residuals will be Class A with respect to enteric viruses and viable helminth ova when the operating
parameters for the pathogen reduction process are monitored and shown to be consistent with the values or ranges
of values documented.
4. no prior testing for Enteric-Virus/Viable Hemminth Ova - if the residuals are not analyzed before pathogen reduction
processing for enteric viruses and viable helminth ova, the density of enteric viruses must be less than I pfu/4 g of
total dry solids and the density of viable helminth ova must be less than 1/4 g of total dry solids, or the residuals
must be treated by a "Process to Further Reduce Pathogens" or a "Process to Further Reduce Pathogens" equivalent
process.
5. The "Processes to Further Reduce Pathogens" (PFRP) are described as follows:
a. Composting - using either the within -vessel or static aerated pile composting methods, the temperature of the
residuals are raised to 550 C or higher for three days. Using the windrow composting method, die residuals are
raised to 550 C or higher for fifteen days. During the high temperature period, there will be a minimum of five
turnings of the windrow.
FORM: DORS 06194 Pasze 5 of 7

D. LLM u� - residuals are dried by direct or indirect contact with hot gases to reduce the moisture content e
the residuals to 10% or lower. Either the temperature of the gas in contact with the residuals exceeds 800 C o
L` e e; l:::lh tem_erature of the eas in contact with the residuals. when the residuals leave the dryer. exce�!:'
800 C.
c. Heat Treatment - liquid residuals are heated to a temperature of 1800 C or higher for thirty minutes.
d T'hctTrtorhilic Aerohic Digestion - liquid residuals are agitated with air or oxygen to maintain aerobic condttiom
at residence times of ten days at temperatures of 550 C to 600 C.
e. Beta Rav Irradiation - residuals are irradiated with beta rays from an accelerator at dosages of at least LC
megarad at room temperature (ca. 200 Q.
f. Gamma Rav Irradiation - residuals are irradiated with gamma rays from certain isotopes such as 50Co anc
13 7CC, at dosages of at least 1.0 megarad at room temperature (ca. 200 Q.
g. Pasteurization - the temperature of the residuals is maintained at 700 C or higher for at least thirty minutes.
6. The residuals shall be treated in a process that is equivalent to a "Processes to Further Reduce Pathogens" (PFRP).
as determined by the permitting authority based on evaluations of the recommendations provided by the Pathogen
Equivalency Committee.
VI. GENERAL INFOR1•IATION:
1. Please provide a brief narrative concerning materials handling, including the following:
a. How will the materials will be handled and transported from where the residuals were produced to where it will be
treated?
b. Where will the residuals be stored until processed?
c. How will leachate collection be handled?
d. What will be the duration of treatment?
e. Where will the final product be stored?
f. How long will dte final product be stored before being distributed?
g. How will the final product be distributed (packaging)?
2. Plea-e attach a marketability statement detailing destinations and approximate amounts of the final product to be
disc-ibuted.
3. Please provide either a label which shall be affixed to the bagged processed residual or an information sheet which shall be
provided to the person who receives the processed residual. The label or information sheet shall contain, at a minimum, the
following information:
a. The name and address of the person who prepared the residual that is sold or given away in a bag or other container for
application to the land.
b. A statement that application of the residual to the land is prohibited except in accordance with the instructions on the
label or information sheet.
c. A statement that the residuals shall not be applied to any site that is flooded, frozen or snow-covered.
d A statement that adequate procedures shall be provided to prevent surface runoff from carrying any disposed or stored
residuals into any surface waters.
e. information on all applicable buffers including a 10 foot buffer between application site and any public or private water
supply source (including wells) and any stream, lake, river, or natural drainage way.
f. The Annual Whole Residual Application Rate (AWRAR) for the residual that does not cause any of the annual
pollutant loading rates to be exceeded (if necessary).
FORM: DORS 06194 Pa-,c 6 of 7

Name and Complete Address of Engineerins Firm:
City:
Telephone dumber:
Professional Engineer's Certification:
I,
State: Zip:
attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I further attest that to the best of my knowledge
the proposed design has been prepared in accordance with the applicable regulations. Although certain portions of this submittal
package may have been developed by other professionals, inclusion of these materials under my signature and sea] signifies that I have
reviewed this material and have judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Seal, Signature, and Date:
Applicant's Certification:
I,
attest that this applica:ion for
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand that if all required parts of this
application are not completed and that if all required supponin_• infornauon•and attachments are not included. this application package
will be returned to me aS incomplete.
S isnature
Date
THE COMPLETED APPLICATION PACKAGE. INCLUDING ALL SUPPORTING INFORMATION AND
MATERIALS, SHOULD BE SENT TO' THE FOLLOWLNG ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL INIANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING liNIT
POST OFFICE BOY 29535
RALEIGH, NORTH CAROLINA 27626-0-535
TELEPHONE NUMBER: [phone]
FORM: DORS 06i94 Pt:�_c 7 of 7

XFOR®
aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYE
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 9- 0 2- 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 9 -14 - 9 8 [phone] 98W63 1 .l Fax [phone]
PAGE 1 OF 1
P.O. #
SAMPLE DESCRIPTION: SAND - TCLP METALS
1. RESULTS FOR THIS SAMPLE - SAND
2. DETECTION LIMIT 1
3. NC LANDFILL MAXIMUM
4. EPA MAXIUMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS
1
2
3
4
5
RESULTS:
ON TCLP LEACHATE
Cadmium,
as Cd, PPM
BDL
0.005
0.1
1.0
93.5
Lead, as
Pb, PPM
BDL
0.010
0.5
5.0
88.2
Copper,
as Cu, PPM
BDL
0.005
*
*
102
Nickel,
as Ni, PPM
.013
0.005
119
Zinc, as
Zn, PPM
.209
0.005
*
*
109
s�M,p
X
X
X
X
Extraction
Fluid Used
#1
X
X
X
X
NOTE: BDL=BELOW DETECTION LIMIT
* UNKNOWN
K MITH, SENIOR ANALYST

z�
(DXFO'RD'
aboratories
J
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYS
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8 W 5 9 4 8 Fax [phone]
SAMPLE DESCRIPTION: #3 SAND
1. #3 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS: WT/WT
Cadmium, as Cd, PPM
Copper, as Cu, PPM
Lead, as Pb, PPM
Nickel, as Ni, PPM
Zinc, as Zn, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1
2
<.200
<.278
1.60
2.23
1.23
1.71
.525
.730
3.40
4.73
71.88
X
N SMITH, SENIOR ANALYST

c
(DxFORD
abor®tories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYS
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8 W 5 9 5 0 Fax [phone]
SAMPLE DESCRIPTION: #3 SAND
1. #3 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS: WT/WT
Aluminum, as Al, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1
2
8610 11200
71.88 %
K N SMITH, SENIOR ANALYST

.
'. 0 XFORD
aboratories
nc.
Analytical and Consulting Chemists
1
DATE RECEIVED Q 9 -1 1- 9 8 316 South Fifth Street
DATE REPORTED 09-22-98 Wilmington, N.C. 28401
9 8 W 6 4 5 7 [phone]
Fax [phone]
PAGE 1 OF 1
ALCHEM INC P.O. #
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: RANDALL ANDREWS
SAMPLE DESCRIPTION: TCLP METALS - SAND
1. RESULTS FOR THIS SAMPLE
2. OXFORD LABORATORIES ROUTINE DETECTION LIMIT
3. NORTH CAROLINA .LANDFILL MAXIMUM
4. EPA MAXIMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS
1
RESULTS: ON TCLP LEACHATE
Arsenic,
as As,
PPM
BDL
Barium, as
Ba, PPM
.256
Cadmium,
as Cd,
PPM
BDL
Chromium,
as Cr,
PPM
BDL
Lead, as
Pb, PPM
BDL
Mercury,
as Hg,
PPM
BDL
Selenium,
as Se,
PPM
BDL
Silver, as
Ag, PPM
BDL
Extraction
Fluid
Used
#1
NOTE: BDL = BELOW DETECTION LIMIT
2 3 4 5
0.005
0.5
5.0
101
0.020
10.0
100.0
92.2
0.005
0.1
1.0
86.7
0.010
0.5
5.0
93.5
0.010
0.5
5.0
80.6
0.0005
0.02
0.2
97.3
0.005
0.10
1.0
89.8
0.010
0.50
5.0
82.1
KEN SMITH, SENIOR ANALYST

- ALCHEM, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
Tel. [phone] Ext. 23
Fax [phone]
October 20, 1998
North Carolina Department
Of Environment, Health, and
Natural Resources
Division of Water Quality
Post Office Box 29535
Raleigh, NC 27626-0535
Dear Sir or Madam:
Our permit expires May 31, 1999. We are applying for a permit modification and a permit
renewal at the same time.
On the modification, we would like to have authorization to mix the sand by product, which is
a result of Bauxite mixing with Sulfuric Acid at a high temperature with clay. As you will see
from the analytical results, the process leaves basically no leachable metals. You will see that
this material is almost sterile.
If there is something we can assist you with to expedite this procedure, please let us know.
My office phone number and fax number is listed above.
Best regards,
ALCHEM, INC.
Randall Andrews,
President
el

ULa LG V1 11V1 L11 Val Vl111L1
Department of Environment, Health and Natural Resources
Division of Environmental Management
Non -Discharge Permit. Application Form
(THIS FORM MA}' BE PHOTOCOPIED FOR USE AS AN ORIGINAL) RECEIVED
WATER QUALITY SECTION
DISTRIBUTION OF OTHER RESIDUAL SOLIDS y�g3
This application is intended for facilities which are EXEMPT from 40 CFR POW
I. GENERAL INFORMATION: Non -Discharge permitting
1. Applicant's name (please specify the name of the municipality, corporation, individual, etc.):
Alchem, Inc.
2. Print owners or signing official's name and title (the person who is legally responsible for the facility and its compliance):
Randall Andrews — President
3. Mailing address:
8135 Red Road
Citv: Rockwell
Telephone Number: (
4. Application Date:
5. Fee Submitted: S
State: North Carolina
704 ) 279-7908
October 20, 1998
400.00
Zip: 28138
[The permit processing fee should be as specified in 15A NCAC 2H .0205(c)(5).]
6. Specify how these residuals will be distributed: sold or given away in bags or other containers; lawn (bulk);
home garden (bulk): other, used for a building pad of 3 acres on our site
7. if the alternative for residual disposal consists of "surface disposal" as defined under 40 CFR Pan 503, please complete the
application titled "SU7RFACE DISPOSAL OF RESIDUAL_ SOLIDS. Please identify if there is any storage of residuals in
a surface impoundment or disposal thru landfilling. Explain:
no land filling. no surface impoundment
8. Is the residual process facility also the generator? X Yes; No
9. Latitude: 35' 30 Minutes Longitude: 800 20 minutes of residual process facility
10. Specify whether the process facility is owned by: federal; . X private; state; local government;
11. County where facility is located: Rowan
II. PERMIT INFORMATION:
1. Application No. (will be completed by Devi):
2. Specify whether project is: new; X rerewal'; X modification
For renewals, complete all sections included in the application. Engineering Signature and Seat not required for
renewals or if there is not any construction involved with the subject project.
3. If this application is being submitted as a result of a renewal or modification to an existingWOO permit- list the existing permit
= number M/Q_U_O 0a and its issue date June 27, 1994
FORM: HORS 06/94 Pate I of 7

III. FACILITY LNFORNIATION (attach additional pages for additional sources of residuals):
.;.siduals are generated or prepared:
Alchem, Inc.
2. Facility permit number: won00272 ; facility permit holder: Alchem. Inc.
s
3. Specify whether facility in Section III.1 is owned by: federal; X private; state; local government;
4. Specify facility design flow: mgd; facility average daily flow: mod;
Type of residual storage: . in lined lagoons
Volume of residual storage: 20,000 cubic yards ,
Length of residuals storage at facility: 3 years. days ([be Division requires a minimum 30 days storage in units that
are separate from treatment system, i.e. not in clarifiers, aeration basins, etc.);
Estimated volume of residuals: 3,000 (dry tons/yr.);
5. If the residual process facility is not the same as the generator, please specify delivery frequency and quantity of residual to
be processed:
6. Facility contact (person familiar with residuals preparation): Wayne Drye
7. Facility contact's telephone number: ( 704 ) 279-7908
8. Location of treatment facility: North Carolina State; Rowan County
9. Mailing address: 8135 Red Road
Rockwell, NC 28138
10. Specify the source of the residuals: treatment of water (alum sludges); X treatment of industrial wastewater
(1001Z industrial residuals); treatment of industrial wastewater mixed with domestic wastewater (please specify
appropriate percentages of 100 % industrial wastewarer, % domestic wastewater);
other (explain): Sand from reaction of Bauxite with sulfuric acid
Attach an explanation of either the treatment process, manufacturing process, or how the waste is generated. Provide full
and complete details of the entire process.
11. Does the facility which generates the residuals have an approved pretreatment program? Yes; X No.
This includes facilities which are classified as a "Class I" facility (any publicly owned treatment works required, under 40
CFR 403.8, to have an approved pretreatment program or any facility treating domestic sewage that is classified as "CIass
I" bN the appropriate federal or State authority)
IV. RESIDUALS INFORMATION (attach additional pages for additional sources. of residuals):
1. Information for Hazardous Waste (RCRA) Determination. The information requested on the limitations specified below
pertain only to those residuals that are generated from a municipal wastewater treatment facility with industrial contribution
or active pretreatment program and from any other treatment facility with wastewater sources that include industrial sources.
a. Are any of the residuals covered by this application listed in 40 CFR 261.31-261.33? Yes; X No. If Yes,
list the number(s):
b. Do the residuals exhibit any of the four characteristics defined by 40 CFR 261.21-261.74? Yes: X No.
Attach laboratory results for the Toxicity Characteristic Leaching Procedure Analyses, Reactivity, Ignitability, and
Corrosivity for each residual.
FORM: DORS 06194 Page 2 of 7

N2te: If the following constituent levels (as determined by the Toxicity Characteristic Leaching Procedure Analyses) arc
exceeded in the residuals or if the pH of the residual is not within the range listed below, the residual is b%
definition a Hazardous waste. Chemical analyses must be made to Minimum Detection Levels.
PPS �
PP1�1
Arsenic
5.0
Barium
100.0
Benzene
0.5
Cadmium
1.0
Carbon tetrachloride
0.5
Chlordane
0.03
Chlorobenzene
100.0
Chloroform
6.0
Chromium
5.0
o-Cresol
200.0
m-Cresol
200.0
p-Cresol
200.0
Cresol
200.0
2,4-D
10.0
1,4-Dichlorobenzene
7.5
1,2-Dichloroethane
0.5
1,1-Dichloroethylene
0.7
2,4-Dinitrotoluene
0.13
Endrin
0.021
Heptachlor (and its hydroxide)
0.008
Hexachlorobenzene
0.13
Hexachloro-1,3-butadiene
0.5
Hexachloroethane
3.0
Lead
5.0
Lindane
0.4
Mercury
0.2
Methoxychlor
10.0
Methyl ethyl ketone
200.0
Nitrobenzene
2.0
Pentachlorophenol
100.0
Pyridine
5.0
Selenium
1.0
Silver
5.0
Tetrachloroethvlene
0.7
Toxaphene
0.5
Trichloroethylene
0.5
2,4,5-Trichlorophenol
400.0
2,4,6-Trichlorophenol
2.0
2,4,5-TP (Silvex)
1.0
Vinyl chloride
0.2
pH (2:1 vol./wL): >2.0 S.U. - <12.5 s.0
tiOTE: IF ANY OF THE RESIDUALS MEET THE DEFINITIONS OF A HAZARDOUS WASTE,
AS NOTED IN EITHER "A" OR "B" ABOVE, A PERMIT CANNOT BE ISSUED FOR
THAT MATERIAL AND IT SHOULD NOT BE INCLUDED AS PART OF THIS
APPLICATION.
*2. For each residual, please attach a complete chemical analysis of the material. This analysis must be comprehensive enough
to completely characterize the residual and must be based upon a review of the process that generates the material. If the
facility that will generate the residual is not yet in operation, the characterization must be based on similar existing
facilities and projection based on the type of facility. The analysis must include a minimum of the following parameters
and any other }.-�tovrn and suspected contaminants that are tributary to the system.
Cadmium
Aluminum
Copper
Ammonia -Nitrogen
Lead
Calcium
Nickel
Magnesium
Zinc
Nitrate -Nitrite Nitrogen
Total Solids
pH
Phosphorus
Potassium
Sodium
TKN
Plant Available Nitrogen (by calculation)
Wastewater residuals can not be sold or given away if the concentration of any pollutant in the residuals exceeds the ceiling
concentrations specified in the table below. Specify the pollutant concentration of these residuals (attach lab analysis):
Pollutant
Pollutant Ceiling Concentration (mg/kg)'
Dry Weight Basis
Pollutant Concentration (mg/kg)
Dry Weight Basis
Cadmium
85
0.278
Copper
4300
2.23
Lead
840
1.71
Nickel
420
0.73
Zinc
7500
4.73
FORM: DORS 06194 Paae 3 of 7

4 Provide, all applicable pilot studies and any bench scale tests performed on each residual source and the results, includin
the approximate fertilizer equivalent.
5. VV'astewater residuals can't be sold or given away in bags'or other containers for application to the land unless one of the
following options is satisfied.
Specify either A or B. Please be advised, if the residuals are -to be sold or given away in bull: for application tc
lawn or home garden then Option A is the only option.
�-A . The pollutant concentration of the residuals must be less than Pollutant Monthly Average Concentrations
listed in the table below.
Pollutant
Monthly Average Concentrations
Dry Weight Basis (mg/kg)
Pollutant Concentration
D Weight Basis (mgAg)
Cadmium
39
0.278
—Copper
1500
2.23
Lead
300
1.71
Nickel
420
0.73
Zinc
2800
4.73
B . The product of the concentration of each pollutant in the residual and the annual whole residual applicatior.
/ rate for the residual shall not cause the Annual Pollutant Loading Rate to be exceeded.
In order for the Annual Whole Residual Application Rate (AWRAR) to be calculated the Annual Pollutant
Loading Rate (APLR) is divided by the pollutant concentration (PC) times 0.001 (a conversion factor) as
follows:
AWRAR = APLR
PC * 0.001
Pollutant
Pollutant
Concentration
Dry Weight Basis '
(m g/kg)
Annual Pollutant
Loading Rates
(APLR)
kg/hectare
Annual Whole Residual
Application Rate
(AWRAR)
kg/hectare
Cadmium
0.278
1.9
0.0068
Copper
2.23
75
0.0336
Lead
1.71
15
0.0087
Nickel
0.73
21
0.0287
Zinc
4.73
140
0.0295
The AWRAR for the residual is the lowest AWRAR calculated. This is the maximum rate at which the
subject residual can be applied (to convert kg/hectare to lbs/acre multiply by 0.8924). Please specify
ke/bectare or lbs/acre:
AWRAR = 0.0068
V . PATHOGEN REDUCTION INFORMATION (attach add. pages for additional sources of residuals)
In accordance with 15A NCAC 2H .0200, pathogen reduction can be achieved using either 40 CFR Part 257 or 40 CFR Part
503. Since the pathogen reduction requirements found in 40 CFR Part 257 (note; "Processes to Further Reduce Pathosens" or
PFRP) are incorporated into 40 CFR Pan 503, only Pan 503 is listed below. Please check which of the following applies to
die subject residual:
FORM: DORS 06194 Page 4 of 7

1. In order for the residuals to be Class A. in accordance with the pathogen requirements in 40 CFR 503.32(a), dlt= Part a o:
• , Pan b mod one of the options in Part c must be completed (please submit all lab analysis, test results and calculations):
a. A Fecal coli form density less than 1000 Most Probable Number per gram of total dry solids, or
b. A Salmonella sp. density less than 3 Most Probable Number per 4 grams of total dry solids.
c. In addition to Pan a or Part b being met, one of the following alternatives must also be completed. Please
specify 1, 2, 3, 4, 5a, 5b, 5c, 5d, 5e, 5f, 5g or 6 below being met:
1. time/temTeratLre - an increased residuals temperature should be maintained fir a presci rbed period of time, in
accordance with the following guidelines. The results (D) shall be the amount of time, in days, that the residuals
shall remain at the given temperature:
Time and Temperature Guidelines
Total Solids
Temperature (t)
Minimum Time
Eauation
Notes
No heating of small
> or = 7%
> or = 500 C
> or = 20 minutes
D = 131,700,000
particles by warmed
100.14 t
gases or immiscible
liquid.
> or = 7%
> or = 500 C
> or = 15 seconds
D = 131,700,000
Small particles heated by
100.14 t
warmed gases or
immiscible liouid.
< 79�
> or = 500 C
> or = 15 seconds
D = 131,700,000
to
100.14 t
< 30 minutes
< 7%.
> or = 50o C
>or = 30 minutes
D = 50,070,000
100.14 t
2. aLkaline treatment - the pH of the residuals is raised to greater than 12 for at least 72 hours. During this time, the
temperature of the residuals should be greater than 520 C for at least 12 hours. In addition, after the 72 hour
period, the residuals are to be air dried to at least 50% total solids.
prior testing for Enteric Virus/Viable Helminth Ova - the residuals are analyzed for the presence of enteric viruses
(Plaque -forming units) [pfu] and viable helminth ova. If the residuals are analyzed before the pathogen reduction
process and found to have densities of enteric virus <1 pfu/4 grams of total solids and viable helminth olra <1/4g
total solids, the residuals are Class A with respect to enteric virus and viable helminth ova until the next
monitoring episode. If the residuals are analyzed before the pathogen reduction process and found to have densities
of enteric virus > or = 1 pfu/4 g total solids or viable helminth ova > or = 1/4 g total solids, and tested again after
processing and found to meet the enteric virus and viable helminth ova levels listed under "4" below, then the
processed residuals will be Class A with respect to enteric viruses and viable helminth ova when the operating
parameters for the pathogen reduction process are monitored and shown to he consistent with the values or ranges
of values documented. '
4. no actor testins for Enteric-Virus/Via le Helminth Ova - if the residuals are not analyzed before pathogen reduction
processing for enteric vinises and viable helminth ova, the density of enteric viruses must be less than 1 pfu/4 g of
total dry solids and the density of viable helminth ova must be less than 1/4 g of total dry solids, or the residuals
must be treated by a "Process to Further Reduce Pathogens" or a "Process to Further Reduce Pathogens" ecuivalent
process. `
5. The "Processes to Further Reduce Pathogens" (PFRP) are described as follows:
a. Composting - using either the within -vessel or static aerated pile composting methods, the temperature of the
residuals are raised to 550 C or higher for three days. Using the windrow composting method, the residuals are
raised to 550 C or higher for fifteen days. During the high temperature period, there will be a minimum of five
turnings of the windrow.
FORM: DORS 06194 Page 5 of 7

o. meat 12Za L, - residuals are dried by direct or indirect contact witli hot gases to reduce the moisture content e
the residuals to 109-o or lower. Either the temperature of the gas in contact with the residuals exceeds 800 C o
tl` a :e; 1:::':h tem_erature of the gas in contact with the residuals. when the residuals leave the drwer. exce:e:'
801) C. '
c. Heat Treatment - liquid residuals are heated to a temperature of 1800 C or higher for thirty minutes.
d T'hcrm rhilic Aerohic Digestion - liquid residuals are agitated with air or oxygen to maintain aerobic condition.,
at residence times of ten days at temperatures of 550 C to 600 C.
e. Beta Rav Irradiation - residuals are irradiated with beta rays from an accelerator at dosages of at least LC
megarad at room temperature (ca. 200 Q.
f. Gamma Ray Irradiatinn - residuals are irradiated with gamma rays from certain isotopes such as 50Co ant
13 7C,:, at dosages of at least 1.0 megarad at room temperature (ca. 200 Q.
g. Pasteurization - the temperature of the residuals is maintained at 700 C or higher for at least thirty minutes.
6. The residuals shall be treated in a process that is equivalent to a "Processes to Funkier Reduce Pathogens" (PFRP).
as determined by the permitting authority based on evaluations of the recommendations provided by the Pathogen:
Equivalency Committee.
VI. GENERAL INFO R1-IATION:
1. Please provide a brief narrative concerning materials handling, including the following:
a. How will the materials will be handled and transported from where the residuals were produced to where it will be
treated?
b. Where will the residuals be stored until processed?
c. How will leachate collection be handled?
d. What will be the duration of treatment?
e. Where will the final product be stored?
f. How long will the final product be stored before being distributed?
e. How will the final product be distributed (packaging)?
2. Plea-,e attach a m,-rkeability statement detailing destinations and approximate amounts of the final product to be
disMbuted.
3. Please provide either a label which shall be affixed to the bagged processed residual or an information sheet which shall be
provided to the person who receives the processed residual. The label or information sheet shall contain, at a minimum, the
following information:
a. The name and address of the person who prepared the residual that is sold or given away in a bag or other container for
application to the land.
b. A statement that application of the residual to the land is prohibited except in accordance with the instructions on the
label or information sheet.
c. A statement that the residuals shall not be applied to any site that is flooded, frozen or snow-covered.
d A statement that adequate procedures shall be provided to prevent surface runoff from carrying any disposed or stored
residuals into any surface waters.
e. information on all applicable buffers including a 10 foot buffer between application site and any public or private water
supply source (including wells) and any stream, lake, river, or natural drainage way.
f. The Annual Whole Residual Application Rate (AWRAR) for the residual that does not cause any of the annual
pollutant loading rates to be exceeded (if necessary).
FORM: DORS 06194 Page 6 of 7

Name and,Complete Address of Engineering Firm:
� Ciq•:
Telephone :`lumber:
Professional Engineer's Certification:
I,
Stave: Zip:
_. attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I furTher attest that to the bcst of my knowledge
the proposed design has been prepared in accordance with the applicable regulations. Although certain portions of this submittal
package may have been developed by other professionals, inclusion of these materials under my signature and sea) signifies that I have
reviewed this material and have judged it to be consistent with Lhe proposed design. V
North Carolina Professional Engineer's Seal, Signature, and Date:
Applicant's Certification:
I,
attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand that if all required parts of this
application are not completed and that if all required supponin information and attachments are not included, this application package
will be returned to me as incomplete. r
Signature
Date
THE CONIPLETL•'D APPLICATION PACKAGE. I\'CLUDING ALL SUPPORTING INFOR.IATIO,N AND
MATERIALS, SHOULD BE SENT TO' THE FOLLOWLNG ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL IMANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NI: FIBER: [phone]
FORM: DORS 00i94 Pa c 7 of 7

,- XFORD
ti aboratories
nc.
Analytical and Consulting Chemists
DATE RECEIVED 0 9 -1 1- 9 8 1316 South Fifth Street
Wilmington, N.C. 28401
DATE REPORTED 0 9— 2 2— 9 8
9 8W6 4 5 7 [phone]
Fax [phone]
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: RANDALL ANDREWS
PAGE 1 OF 1
P. O. # R EQ F'\' S D ION
VyA�ER
iyonpiscllaege Pe�ittin9
SAMPLE DESCRIPTION: TCLP METALS - SAND
1. RESULTS FOR THIS SAMPLE
2. OXFORD LABORATORIES ROUTINE DETECTION LIMIT
3. NORTH CAROLINA .LANDFILL MAXIMUM
4. EPA MAXIMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS: ON TCLP LEACHATE
Arsenic, as As, PPM
Barium, as Ba, PPM
Cadmium, as Cd, PPM
Chromium, as Cr, PPM
Lead, as Pb, PPM
Mercury, as Hg, PPM
Selenium, as Se, PPM
Silver, as Ag, PPM
pH @ 5 % Sample
Extraction Fluid Used
NOTE: BDL = BELOW DETECTION LIMIT
RESULTS
1
BDL
.256
BDL
BDL
BDL
BDL
BDL
BDL
3.5
#1
2 3
0.005
0.5
0.020
10.0
0.005
0.1
0.010
0.5
0.010
0.5
0.0005
0.02
0.005
0.10
0.010
0.50
4 5
5.0
101
100.0
92.2
1.0
86.7
5.0
93.5
5.0
80.6
0.2
97.3
1.0
89.8
5.0
82.1
KEN SMITH, SENIOR ANALYST

C)IXOFORD
abwat®ries
ne.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYE
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 9- 0 2- 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 9 -14 - 9 8 [phone]
9 8 W 6 3 1 .1 Fax [phone]
PAGE 1 OF 1
SAMPLE DESCRIPTION: SAND - TC_LP METALS
1. RESULTS FOR THIS SAMPLE - SAND
2. DETECTION LIMIT
3. NC LANDFILL MAXIMUM
4. EPA MAXIUMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS: ON TCLP LEACHATE
Cadmium, as Cd, PPM
Lead, as Pb, PPM
Copper, as Cu, PPM
Nickel, as Ni, PPM
Zinc, as Zn, PPM
pH @ 5 % Sample
Extraction Fluid Used
NOTE: BDL=BELOW DETECTION LIMIT
* UNKNOWN
RESULTS
1
2 3 4 5
BDL
0.005
0.1
1.0
93.5
BDL
0.010
0.5
5.0
88.2
BDL
0.005
*
*
102
.013
0,005
*
119
.209
0.005
*
*
109
3.5
X
X
X
X
#1
X
X
X
X
K MITH, SENIOR ANALYST

G)XFORD
aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYS
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8 W 5 9 4 8 Fax [phone]
SAMPLE DESCRIPTION: #3 SAND
1. #3 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS: WT/WT
Cadmium, as Cd, PPM
Copper, as Cu, PPM
Lead, as Pb, PPM
Nickel, as Ni, PPM
Zinc, as Zn, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1
2
<.200 <.278
1.60
2.23
1.23
1.71
.525
.730
3. 40
4. 73
71.88
X
N SMITH, SENIOR ANALYST

i
.,OXFORD
- aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYS
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8W5 9 5 0 Fax [phone]
SAMPLE DESCRIPTION: #3 SAND
1. #3 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS: WT/WT
Aluminum, as Al, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1
2
8610 11200
71.88 %
K N SMITH, SENIOR ANALYST

NCDENR MRO Fax:[phone] Mar 23 2005 13:57 P.04 %
NORTH CARO.LINA
ENVIRONibIEiti'TALMANAGEMENT COIti>(MISSION
DEPARTIMENT OF ENN RONiJENT AND NATURAL RESOURCES
RA.LEIGH
RECYCLE SYSTEM PERNUT
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
Al.chem, Incorporated
Rowan. County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serve Alchern, Inc., with no
discharge of wastes to the surface waters, • pursuant to the application received September 23, 2004, 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 November 30, 2009, shall void Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the following specified conditions and limitations:
1. ' This permit shall become voidable unless the facilities are constructed in accordance with the conditions,of
this. permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. The facilities shall be properly maintained and operated at all times,
4. Tkos permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division of 'Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate. The approval of the request will be considered on its merits
and may or may not be approved.
5. In, the event that the facilities fail to perfcTm satisfactorily, including the creation of nuisance conditions, the
Permittee. shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatmcnt or disposal facilities.
6. The residuals generated from these treatment facilities must be disposed in, accordance with General Statute
143-215.1 and iu a manner approved by the Division..
7. 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 facility.

NCDENR MRO Fax:[phone] Mar 23 2005 13:56 P.03
0—
i, A Notice of Violation was issued against the facility under Permit No. WQ0002702 on January 7, 2001
for violations of State Groundwater Quality Standards as evidenced by the laboratory analyses of groundwater
samples taken during the course of m0r itoring or -,site monitor wells.
A Notice of Violation was also issued against the facility under permit No. WQ0002702 on May 12, 2003
in response to a release of residuals into a drainage/wooded area and an intermittent stream. The permittee was
cited for failing to properly operate and maintain the facility as a non -discharge ;facility, failure to cease reuse
operation once nuisance conditions existed, failure to provide adequate provisions to prevent surface runoff from
conveying.'pollutants _into surface waters, and failure to notify the Division of the residuals release into the
receiving stream.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this pemit_ This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and.filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unless. such demands are made this permit.sball be final and binding.
If your need additional information concerning this matter, please contact David Goodrich at (919) 715-
6162_
Sincere
Alan W. Klimek, E.
cc: Rowan County Health Department
: iwlvo> a ville'R#gional Office,'Aquiif� Protection.Section
Technical Assistance and Certification. Unit
Aquifer Protection Central Files'
Permit Files

NCDENR MRO
Fax:[phone] Mar 23 2005 13:56 P.02
A r�RQc
r
Mr. Randall Andrews
,A.lchem, Inc.
8135 Red Road
Rockwell, NC 28138
Dear Mr_ Andrews:
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Nortb Carolina Department of Environment and Natural Resources
December 28, 2004
Alan W. Klimek, P.E., Director
Division of Water Quality
NC c)EPT OF ENV1RWMWT
AND NARECE►V�i3 RCES
JAN 14 2005
MoORERNWGTsOFFICE
I
OU0SR TIO
Subject:. Permit No. WQ0002702
Alclzern, IncorTozatEd
�"Industrial Recycle -Bauxite Process
Rowan County
In accordance with your request for renewal received September 23, 2004, we are fonkarding herewith
Permit No. WQ0002702, dated December 28, 2004, to ,A.lchem, znc..for the continued operation of the three (3)
lagoon recycle system.
This permit shall be effective from the date of issuance until November 30, 2009, shall, void Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the conditions and limitations as. specified therein.
Please pay particular attentioia to the rrlomitoring requirements in this permit. Groundwater sampling is now
required in monitor wells MW-1, MW-2, and 1v1W-3 and surface water sampling will be performed on the stream
behind the property every February, June, and October for Total Dissolved Solids, pid, Sulfates, Specific
Conductivity, Aluminum, Total Suspended Solids, and water leye1, A scaled map of the facility must be prepared
and submitted to the Divisior>. The recycled water will be required to have a pH of not less than 6.0 as it leaves
the wash area- and goes into the storage lagoon. A site life estimate and a long range plan fot funxe residuals
disposal are also required. The material removed faom Lagoons 1 & 2 during the next lagoon cleanout is required
to have pH readings taken and documented, and the liners of each lagoon are to be inspected and tested (as
necessary) by a Professional Engineer. Repairs are to, be made as. needed. The permittee is required to seek
alternate disposal/re-use options for the'fill and submit a proposed schedule for their inTlementation. The City
Water Supply Line is required to be re -located to the upper perimeter of the residual fill area. Failure to establish
arr adequate system for collecting and maintaining the required operational information will result in future
compliance problems. The berm which has been constructed around the residual fill area is to be maintained so as
to keep the fill and/or accumulated rainwater from leaving the fill area.
This permit is being renewed by itself and is not being combined with Permit No. WQ0016338 at this
time, as the application for the renewal of Permit No. WQ001633 8 has riot yet been received by the Division,
1IoCm na"
�tura�r�
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.ear-state.ne.us 2729 Capital Boulevard Raleigh, NC 27604 PAX [phone] 1-877-623-6748
An Equal Opportunity/Aflirmative Action Employer— 50% Recycled110% Past Wsumar Paper

NCDENR MRO Fax:[phone] Mar 23 2005 13:56
�L
r
CDENK
Nar lr Carol na Dnpai merit o' Env ronrnent and Natural Resources
1'-AiChael F. Easley, Governor
From:
FAX COVER SHEET
Division:y V�
Section:
pate: �> / 2
To:
Number of panes (includW6, cover) I C7
Subject:
610 East Center Avenue, Suite 301, Mooresville, North Carolina 28115
Phone: [phone] FAX: [phone] Internet: wnwr.enr,state.nc.us
P. 01
VAI'liarn G. Ross Jr., Secretary
No�rt hCaxohna
An Equal OppOrlunity ! Oirms live Action Employer - 50 % Recycled', IQ 'i= Post Ccnsunler,Paper

Mr. Randall Andrews
Alchem, Inc.
8135 Red Road
Rockwell, NC 28138
Dear Mr. Andrews:
Y, g u LP Michael F. Easley, Governo
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
December 28, 2004 NO DEPT. OF ENVIRONMENT
AND NARECE RESOURCES
ED RCES
JAN 1 4 2005
MOORE ROR SECTION
ICE
0WQ-GOUNDWAT
Subject: Permit No. WQ0002702
.. Alchem, Incorporated
Industrial Recycle -Bauxite Process
Rowan County
a� t
In accordance with your request for renewal received September 23, 2004, we are forwarding herewith
Permit No. WQ0002702, dated December 28, 2004, to Alchem, Inc. for the continued operation of the three (3)
lagoon recycle system.
This permit shall be effective from the date of issuance und%N_ =e er 30.9shall void .Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the conditions and limitations as. specified therein.
Please pay particular attention to the monitoring requirements in this permit. Groundwater sampling is now
required in monitor wells MW-1, MW-2, and MW-3 and surface water sampling will be performed on the stream
behind the property every February, June, and October for Total Dissolved Solids, pH, Sulfates, Specific
Conductivity, Aluminum, Total Suspended Solids, and water level. A scaled map of the facility must be prepared
and submitted to the Division. The recycled water will be required to have a pH of not less than 6.0 as it leaves
the wash area' and goes into the storage lagoon. A site life estimate and a long range plan for future residuals
disposal are also required. The material removed from Lagoons 1 & 2 during the next lagoon cleanout is required
to have pH readings taken and documented, and the liners of each lagoon are to be inspected and tested (as
necessary) by a Professional Engineer. Repairs are to be made as needed. The permittee is required to seek
alternate disposal/re-use options for the fill and submit a proposed schedule for their implementation. The City
Water Supply Line is required to be re -located to the upper perimeter of the residual fill area. Failure to establish
an adequate system for collecting and maintaining the required operational information will result in future
compliance problems. The berm which has been constructed around the residual fill area is to be maintained so as
to keep the fill and/or accumulated rainwater from leaving the fill area.
This permit is being renewed by itself and is not being combined with Permit No. WQ0016338 at this
time, as the application for the renewal of Permit No. WQ0016338 has not yet been received by the Division.
NorthC,,1in,
.,Naturally
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.ennstate.nc.us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal Opportuni ty/A ffirma live Action Employer — 50% Recycled110% Post Consumer Paper

'A Notice of Violation was issued against the facility under Permit No. WQ0002702 on January 7, 2001
for violations of State Groundwater Quality Standards as evidenced by the laboratory analyses of groundwater
samples taken during the course of monitoring on -site monitor wells.
A Notice of Violation was also issued against the facility under Permit No. WQ0002702 on IJay 12, 2003
in response to a release of residuals into a drainage/wooded area and an intermittent stream. The permittee was
cited for failing to properly operate and maintain the facility as a non -discharge facility, failure to cease reuse
operation once nuisance conditions existed, failure to provide adequate provisions to prevent surface runoff from
conveying pollutants into surface waters, and failure to notify the Division of the residuals release into the
receiving stream.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and.filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unlesssuch demands are made this permit shall be final and binding.
6162
If you need additional information concerning this matter, please contact David Goodrich at (919) 715-
Sincere
//-Alan W. Klimek, P.E.
cc: Rowan County Health Department
IVlooresv'Ile Regional Office,'Aquifer Protection Section
T echnical Assistance and Certification Unit
Aquifer Protection Central Files
Permit Files

�r
NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchern, Incorporated
Rowan County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serve Alchem, Inc., with no
discharge of wastes to the surface waters, pursuant to the application received September 23, 2004, 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 November 30, 2009, shall void Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division of Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate.. The approval of the request will be considered on its merits
and may or may not be approved.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
6. The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
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 facility.

The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
10. Freeboard in all of the lagoons shall not be less than two feet at any time.
11. Waste -level gauges, to monitor waste levels in the settling lagoons, shall be installed within 60 days of
issuance of this permit. These gauges shall have readily visible permanent markings indicating the
maximum liquid level at the top of the temporary liquid storage volume, minimum liquid level at the
bottom of the temporary liquid storage volume, and top of the dam elevations. Caution must be taken not to
damage the integrity of the liner when installing the gauges.
12. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
13. Within ninety (90) days of permit issuance, the recycled system shall be required to keep the recycled water
at a pH of not less than 6.0 Standard Units as it leaves the wash area and goes to the storage lagoon.
14. Within ninety (90) days of permit issuance, the permittee shall submit a site life estimate for the fill area.
15. Within ninety (90) days of permit issuance, the permittee shall submit a long-range plan for future residuals
disposal that shall include a timetable for implementation.
16. During the upcoming clean out of Lagoons 1 & 2 (scheduled for the spring season of 2005), a pH reading
shall be taken and documented on every load of material removed from the lagoon and placed in the sand
fill area. This information shall be conveyed to the Division within thirty (30) days of completion of the
clean out procedure.
17. At the conclusion of the clean out of Lagoons 1 & 2 (scheduled for the spring season of 2005), the clay
liners of the lagoon shall be inspected and tested (as necessary) by a Professional Engineer. Repairs to the
liners shall be made as needed and prior to the resumption of use.
18. The permittee shall actively seek alternate disposal/re-use options for the fill produced at the facility. An
alternate means of disposal, along with a proposed schedule for its implementation, shall be identified
within one (1) year of permit issuance and reported by letter to the Division's Central Office at the Aquifer
Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636 and to the Mooresville Regional
Office at the Aquifer Protection Section, 610 East Center Avenue/ Suite 310, Mooresville, NC 28115.
/��19. The City Water Supply Line shall be re -located to the upper perimeter of the residual fill area within one (1)
year of permit issuance. Any problems with implementing this condition in a timely fashion shall be
Q reported by letter to the Division's Central Office at the Aquifer Protection Section, 1636 Mail Service
Center, Raleigh, NC 27699-1636 and to the Mooresville Regional Office at the Aquifer Protection Section,
610 East Center Avenue/ Suite 301, Mooresville, NC 28115.
20. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
21. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities. The berm which has been constructed around the residual fill area shall be
maintained so as to keep the fill and/or accumulated rainwater from leaving the fill area.

22. The Permittee or his designee shall inspect the wastewater recycle 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 three years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
23. 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 recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
24. 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 15A NCAC 214.0205 (c)(4).
25. 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.
26. The issuance of this permit does not exempt 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, including but not limited to applicable river buffer rules in 15A NCAC 213.0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCGO10000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20.
27. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
28. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704) 663-
1699, 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 at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents
of a basin or tank, the known passage of a slug of hazardous substance through the facility, or any other
unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators,
compressors, etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.

Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. 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.
29. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
30. The recycle lagoons shall not be located within 100 feet of water supply wells.
31. Within sixty (60) days of permit issuance, the permittee shall submit two original copies of a scaled site
map (scale no greater than 1"=100'); however, special provisions may be granted upon prior approval for
large properties. The map(s) must include the following information:
a. The location and identity of each monitoring well.
b. The location of major components of the waste disposal system.
.c. The location of property boundaries within 500 feet of the disposal area(s).
d. The latitude and longitude of the established horizontal control monument.
e. The elevation of the top of the well casing (which shall be known as the "measuring point") relative
to a common datum.
f. The depth of water below the measuring point at the time the measuring point is established.
g. The location of Review and Compliance Boundaries.
h. The date the map is prepared and/or revised.
32. Control monuments shall be installed in such a manner and made of such materials that the monument will
not be destroyed due to activities that may take place on the property. Maps and any supporting
documentation shall be sent to the Aquifer Protection Section's Central Office at 1636 Mail Service Center,
Raleigh, NC 27699-1636, and to the Mooresville Regional Office at the Aquifer Protection Section, 610
East Center Avenue/ Suite 301, Mooresville, NC 28115.
The permittee is responsible for the geographic accuracy of any map submitted, however produced.
33. Monitor wells MW-1, MW-2, MW-3, and the stream behind the property shall all be sampled every
February, June and October for the following parameters:
Total Dissolved Solids
Sulfates (SO4)
Aluminum
Water Level
pH
Specific Conductivity
Total Suspended Solids
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The results of the sampling and analysis shall be received on the most -recent version of "Groundwater
Quality Monitoring: Compliance Report Form" (i.e., GW-59 Form) with copies of the laboratory analyses
attached by the Division's Aquifer Protection Section at the following address on or before the last working
day of the month following the sampling month:
4

NCDENR-DWQ
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank reporting forms may be downloaded from the web site for the Division's Aquifer Protection
Section at http: !g_%v,.ehnr.state. ne.us/ or requested from the address listed above.
34. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary for the disposal system individually
permitted on or after December 30, 1983 is established at either 250 feet from the waste disposal area, or 50
feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to remediation action
according to 15A NCAC 2L .0106(d)(2).
35. The REVIEW BOUNDARY is established around the disposal system midway between the Compliance
Boundary and the perimeter of the waste disposal area. Any exceedance of standards at the Review
Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
36. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
37. 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.
Permit issued this the 28th day of December, 2004
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002702

`-�----- STREAM --ti--------�.__/.
EXISTING
BERM
BERM
STORM
DITCH
01 I C. IYIPII
EXISTING CONDITIONS
ALCHEM, INC
8135 RED ROAD
ROCKWELL, NORTH CAROLINA
PROJECT NO. Z�F�ILCNAME
5EO702101P
E
DAT FIGURE 1 G� E LTA
05/18/07

I
0R
F WATF COPY Michael F. Easley, Governor
William G. Ross Jr., Secretary
C r North Carolina Department of Environment and Natural Resources
O Alan W. Klimek; P.E., Director
Division of Water Quality
December 28, 2004
Mr. Randall Andrews
Alchem, Inc.
8135 Red Road
Rockwell, NC 28138
Subject: Permit No. WQ0002702
Alchem, Incorporated
Industrial Recycle -Bauxite Process
Rowan County
Dear Mr. Andrews:
In accordance with your request for renewal received September 23, 2004, we are forwarding herewith
Permit No. WQ0002702, dated December 28, 2004, to Alchem, Inc. for the continued operation of the three (3)
lagoon recycle system.
This permit shall be effective from the date of issuance until November 30, 2009, shall void Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the conditions inn&1imifations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. Groundwater sampling is now
required in monitor wells MW-1, MW-2, and MW-3 and surface water sampling will be performed on the stream
behind the property every February, June, and October for Total Dissolved Solids, pH, Sulfates, Specific
Conductivity, Aluminum, Total Suspended Solids, and water level. A scaled map of the facility must be prepared
and submitted to the Division. The recycled water will be required to have a pH of not less than 6.0 as it leaves
the wash area and goes into the storage lagoon. A site life estimate and a long range plan for future residuals
disposal are also required. The material removed from Lagoons 1 & 2 during the next lagoon cleanout is required
to have pH readings taken and documented, and the liners of each lagoon are to be inspected and tested (as
necessary) by a Professional Engineer. Repairs are to be made as needed. The permittee is required to seek
alternate disposal/re-use options for the fill and submit a proposed schedule for their implementation. The City
Water Supply Line is required to be re -located to the upper perimeter of the residual fill area. Failure to establish
an adequate system for collecting and maintaining the required operational information will result in future
compliance problems. The berm which has been constructed around the residual fill area is to be maintained so as
to keep the fill and/or accumulated rainwater from leaving the fill area. '
This permit is being renewed by itself and is not being combined with Permit No. WQ0016338 at this
time, as the application for the renewal of Permit No. WQ0016338 has not yet been received by the Division.
On
e
NCarolina
Naw'"!rff
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

A Notice of Violation was issued against the facility under Permit No. WQ0002702 on January 7, 2001
for violations of State Groundwater Quality Standards as evidenced by the laboratory analyses of groundwater
samples taken during the course of monitoring on -site monitor wells.
A Notice of Violation was also issued against the facility under Permit No. WQ0002702 on May 12, 2003
in response to a release of residuals into a drainage/wooded area and an intermittent stream. The permittee was
cited for failing to properly operate and maintain the facility as a non -discharge facility, failure to cease reuse
operation once nuisance conditions existed, failure to provide adequate provisions to prevent surface runoff from
conveying pollutants into surface waters, and failure to notify the Division of the residuals release into the
receiving stream.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unless such demands are made this permit shall be final and binding.
6162.
If you need additional information concerning this matter, please contact David Goodrich at (919) 715-
Sincerely,
Alan W. Klimek, P.E.
cc: Rowan County Health Department
Mooresville Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
Aquifer Protection Central Files
Permit Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Incorporated
Rowan County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serve Alchem, Inc., with no
discharge of wastes to the surface waters, pursuant to the application received September 23, 2004, 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 November 30, 2009, shall void Permit No.
WQ0002702 issued January 21, 1999, and shall be subject to the following specified conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division of Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate.. The approval of the request will be considered on its merits
and may or may not be approved.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
6. The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
7. 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 facility.

8. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
9. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
0 Freeboard in all of the lagoons shall not be less than two feet at any time.
%" Waste -level gauges, to monitor waste levels in the settling lagoons, shall be installed within 60 days of
issuance of this permit. These gauges shall have readily visible permanent markings indicating the
maximum liquid level at the top of the temporary liquid storage volume, minimum liquid level at the
bottom of the temporary liquid storage volume, and top of the dam elevations. Caution must be taken not to
damage the integrity of the liner when installing the gauges.
a
A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
J13? Within ninety (90) days of permit issuance, the recycled system shall be required to keep the recycled water
at a pH-ofnot less_than 6.0 Standard Units.as it leaves the wash area and goes to the storage lagoon.
Within ninety (90) days of permit issuance, the permittee shall submit a site life estimate for the fill area.
r1
q-5. Within ninety (90) days of permit issuance, the permittee shall submit a long-range plan for future residuals
disposal that shall include a timetable for implementation.
16. During the upcoming clean out of Lagoons 1 & 2 (scheduled for the spring season of 2005), a pH reading
shall be taken and documented on every load of material removed from the lagoon and placed in the sand
fill area. This information shall be conveyed to the Division within thirty (30) days of completion of the
clean out procedure.
17. At the conclusion of the clean out of Lagoons 1& 2 (scheduled for the spring season of 2005), the clay
liners of the lagoon shall be inspected and tested (as necessary) by a Professional Engineer. Repairs to the
liners shall be made as needed and prior to the resumption of use.
The permittee shall actively -_seek -alternate=disposa_Ure=use_optiohK;for the fill produced at the facility. An
alternate means of disposal, along with a proposed schedule for its implementation, shall be identified
within one (1) year of permit issuance and reported by letter to the Division's Central Office at the Aquifer
Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636 and to the Mooresville Regional
Office at the Aquifer Protection Section, 610 East Center Avenue/ Suite 310, Mooresville, NC 28115.
19. The City Water Supply Line shall be re -located to the upper perimeter of the residual fill area within one (1)
/1 year of permit issuance. Any problems with implementing this condition in a timely fashion shall be
`'oaf reported by letter to the Division's Central Office at the Aquifer Protection Section, 1636 Mail Service
Center, Raleigh, NC 27699-1636 and to the Mooresville Regional Office at the Aquifer,Protection Section,
610 East Center Avenue/ Suite 301, Mooresville, NC 28115.
20. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
In
4P Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities. The berm which has been constructed around the residual fill area shall be
maintained so as to keep the fill and/or accumulated rainwater from leaving the fill area.
2

22. The Permittee or his designee shall inspect the wastewater recycle 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 in-s_.pect'o� n 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 three years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
23. 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 recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
24. 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 15A NCAC 2H .0205 (c)(4).
25. 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.
26. The issuance of this permit does not exempt 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, including but not limited to applicable river buffer rules in 15A NCAC 2B.0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCGO10000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20.
27. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
28. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704) 663-
1699, 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 at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents
of a basin or tank, the known passage of a slug of hazardous substance through the facility, or any other
unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators,
compressors, etc.;
Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.

Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. 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.
29. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
30. The recycle lagoons shall not be located within 100 feet of water supply wells.
31. Within sixty (60) days of permit issuance, the permittee shall submit two original copies of a scaled site
map (scale no greater than 1 "=100'); however, special provisions may be granted upon prior approval for
large properties. The map(s) must include the following information:
a. The location and identity of each monitoring well.
b. The location of major components of the waste disposal system.
c. The location of property boundaries within 500 feet of the disposal area(s).
d. The latitude and longitude of the established horizontal control monument.
e. The elevation of the top of the well casing (which shall be known as the "measuring point") relative
to a common datum.
f. The depth of water below the measuring point at the time the measuring point is established.
g. The location of Review and Compliance Boundaries.
h. The date the map is prepared and/or revised.
32. Control monuments shall be installed in such a manner and made of such materials that the monument will
not be destroyed due to activities that may take place on the property. Maps and any supporting
documentation shall be sent to the Aquifer Protection Section's Central Office at 1636 Mail Service Center,
Raleigh, NC 27699-1636, and to the Mooresville Regional Office at the Aquifer Protection Section, 610
East Center Avenue/ Suite 301, Mooresville, NC 28115.
The permittee is responsible for the geographic accuracy of any map submitted, however produced
.r` . %
ti
Monitor wells MW-I, MW-2, MW-3, and the stream behind the property shall all be sampled every
February, June and October for the following parameters:
Total Dissolved Solids
Sulfates (SO4)
Aluminum
Water Level
pH
Specific Conductivity
Total Suspended Solids
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The results of the sampling and analysis shall be received on the most -recent version of "Groundwater
Quality Monitoring: Compliance Report Form" (i.e., GW-59 Form) with copies of the laboratory analyses
attached by the Division's Aquifer Protection Section at the following address on or before the last working
day of the month following the sampling month:
4

� i t
NCDENR-DWQ
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank reporting forms may be downloaded from the web site for the Division's Aquifer Protection
Section at bttp://aw.ehnr.state.nc.us/ or requested from the address listed above.
34. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary for the disposal system individually
permitted on or after December 30, 1983 is established at either 250 feet from the waste disposal area, or 50
feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to remediation action
according to 15A NCAC 2L .0106(d)(2).
35. The REVIEW BOUNDARY is established around the disposal system midway between the Compliance
Boundary and the perimeter of the waste disposal area. Any exceedance of standards at the Review
Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
36. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
37. 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.
Permit issued this the 28th day of December, 2004
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002702

W A TFRQ
� r
Mr. Randall Andrews
Alchem, Inc.
8135 Red Road
Rockwell, NC 28138
Dear Mr. Andrews:
Michael F. Easley, Govern r-
William G. Ross Jr,, -Secretary
North Carolina Department of Environment and . atural Resources
_--Alan W. Klimek, P.E., Director
Division of Water Quality
Decemb -t8 2004
Subject: Permit No. WQ0002702
Alchem, Incorporated
Industrial Recycle -Bauxite Process
Rowan County
In accordance with your request for renewal received Sepitumber23 -2064-, we are forwarding herewith
Permit No. WQ0002702, datedto Alchem, Inc. for the continued operation of the three (3)
lagoon, recycle system.
This permi sshall be effective from the date of issuance until void Permit No.
WQ0002702 issued Ja�rtuwy-21--9W, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. -CTt R4water-sampl-irag-is>now
-= required-in-=monitor-wellsaMW4= MW=2 --and-MW-6 aird-surface Water sampling wi•1.1-•be-per-formed-or�the_stream
Con activity; Aluminum; —Total -Suspended -Solids; and- water -level. A-searcd-rmap-ef4he-€aciltt3y-must-be-prep-ared-%,
and-sttlarnitted-t-o-the--Bi,,,;�ision. The-reeyeled-water- will -be -required -to -have -a -pH of not less than-6-0-as--it .leaves
the u%ash area a'""'dn goeinta-the-st-&rage.l�geon. A site life estimate and a long range plan for future residuals
disposal are also required. The material removed from Lagoons 1 & 2 during the next lagoon cleanout is required
to have pH readings taken and documented, and the liners of each lagoon are to be inspected and tested (as
necessary) by a Professional Engineer. Repairs are to be made as needed. The permittee is required to seek
alternate disposal/re-use options for the fill and submit a proposed schedule for their implementation. T-he-city
Water Supply Line is required to be re -located to the upper perimeter of the residual fill area. Failure to establish
an adequate system for collecting and maintaining the required operational information will result in future
compliance problems. The-bean-whieh-has-been-constr-ucted-around the-residual-fil.1-area-is-to-be-nmintained-so as
-to-beep-thyfrll`and7-o-r-�rcc~iiri sated -rainwater from leaving flie fi44-area.
h ;n�rmt xs,etn rem nitself`an, isot'beng corribiriedYwith Permit No: WQ0.0-16338 at this
time, as the application for the renewal of Permit No3WQ0'0Y633°8-has hfotyet been received -by the Division.
NorthCarolina
Natimally
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer- 50% Recycledl10% Post Consumer Paper

A Notice of Violal t�ion wasissued-against the facility under Permit No WO0002702 on Januarys, 2001
for violations of State Groundwater Quality Standard as--P,-viclen ed ..y_.the,laboratory analyses of groundwater
samples taken during t the course<o.&mon3toring on -site monitor wells.
AWNoTce oPNq-olatio wa s also issued against t ieiaci.1ity.under PermJt�[o. WQ000.0,2770_2_ on May 12, 2003
in response to a release of residuals' to drainag%ooded area and an intermittent stream. The perrnitteezvas
cited for failing-t o properly operate and maintain the�acilitr-as..a, non -discharge facility, failure to cease reuse
operation once nuisance conditions existed, failure to provide adequate provisions to prevent surface runoff from
conveying pollutants into surface waters, and failure to notify the Division oM&tresidualsyrelease into the
receiving stream.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714.
Unless such demands are made this permit shall be final and binding.
6162.
If you need additional information concerning this matter, please contact David Goodrich at (919) 715-
Sincerely,
cc: Rowan County Health Department
Mooresville Regional Office, Aquifer Protection Section
Technical Assistance and Certification Unit
Aquifer Protection Central Files
Permit Files
2

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Incorporated
Rowan County
FOR THE
continued operation of a wastewater recycle system consisting of 3 settling lagoons to serve Alchem, Inc., with no
discharge of wastes to the surface waters, pursuant to the application received Septemi7mi--23;- 2 O a 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 Navernber 3-0; 20.09, shall void Permit No.
WQ0002702 issued and shall be subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the"Permittee, a formal permit request must be submitted to the Division of Water
Quality (Division) accompanied by an application fee, documentation from the parties involved, and other
supporting materials as may be appropriate.. The approval of the request will be considered on its merits
and may or may not be approved.
5. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
6. The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
7. 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 facility.

8.
The facilities shall be effectively maintained and operated as a non -discharge system to prevent the
discharge of any wastewater resulting from the operation of this facility.
9.
Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
10.
Freeboard in all of the lagoons shall not be less than two feet at any time. ` -_`.� -I ED I—
_ e-level gauges, to monitor waste levels in the settling lagoons, shall be installed within 60 days of
i
issuance of this perms �- Those-gaauges shall have readilye perinmTen mar mgs in icatmg the
maximum liquid level at t e t-sp f-the t ie npor-ary. dquid storage volume, minimum liquid level at the
y
bottom _ f tlio-temporary liquid storage volume, and top of the damelemations. Caution must be taken not to
`$ � ._�I
-Bamage the integrity of the liner when installing the gauges. ------
12.
A protective vegetative cover shall be established and maintained on all earthen basin embankments
r
(outside toe of embankment to maximum pumping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
F
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
13.
6e recycled system shall be required to keep the recycled water
'
at a pH of not less than 6.0 Standard Units as it leaves the wash area and goes to the storage lagoon.
4Q
Within ninety (days of permit issuance, the permittee shall submit &site life estimate for the fill area.
1�5,.
Within ninety (90) days of permit issuance, the permittee shall submit a long-range plan for future residuals
that shall include a timetable for implementation. _
i°.
,disposal
fof�the_sp`r 20.05), reading
1'6.
Durmg e ppom - g clean -out of ageon J,�2._(schedule_d in sea_ a�yof pH
shall be taken and documented on every load of material removed from the lagoon and -placed in the sand
fill area ,,This information shall be conveyed to the Division within thirty (30) days of completion of the
clean out -procedure: --
��@Y
��
��� `�� 11 Q ) lit �- � l 4� � - y •^;..mod
:'--
cKr�/i! 7�s'�' � P - '�:.- �y
aim 4�- �+°<i � `—• � �, �
li�
l
\ The permittee shall actively seek -alternate.. disposal/re-use _optionsIbr thes`fill produced at the facility. An
alternate means of disposal, along with a proposed schedule for its implementation, shall be identified
within one (1) year of permit issuance and reported by letter to the Division's Central Office at the Aquifer
Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636 and to the Mooresville Regional
Office at the Aquifer Protection Section, 610 East Center Avenue/ Suite 310, Mooresville, NC 28115.
19. The City Water Supply Line shall be re -located to the upper perimeter of the residual fill area within one (1)
a year of permit issuance. Any problems with implementing this condition in a timely fashion sha-ll-be
reported by letter to the Division's Central Office at the Aquifer Protection Section, 1636 Mail Service
Center, Raleigh, NC 27699-1636 and to the Mooresville Regional Office at the Aquifer Protection Section,
610 East Center Avenue/ Suite 301, Mooresville, NC 28115.
20. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
2,1:� Ad equate inspection, maintenance, and cleaning shall be p� ovided by the Per`mittee to insure proper
--operation of`the subject facilities: -,The berm which has been constructed around, the residual fi 1 area sha 11 be
maintained so as to keep'the fill and/or accumulated rainwater from leaving -the fill area. \

22. The Permittee or his designee shall inspect the wastewater recycle 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 three years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request.
23. 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 recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
24. 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 15A NCAC 211.0205 (c)(4).
25. 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.
26. The issuance of this permit does not exempt 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, including but not limited to applicable river buffer rules in 15A NCAC 2B.0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCGO10000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20.
27. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
28. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704) 663-
1699, 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 at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents
of a basin or tank, the known passage of a slug of hazardous substance through the facility, or any other
unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators,
compressors, etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit
limitations.

Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. 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.
29. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
30. The recycle lagoons shall not be located within 100 feet of water supply wells.
31. Within sixty (60) days of permit issuance, the permittee shall submit two original copies of a scaled site
map (scale no greater than 1 "=100'); however, special provisions may be granted upon prior approval for
large properties. The map(s) must include the following information:
a. The location and identity of each monitoring well.
b. The location of major components of the waste disposal system.
c. The location of property boundaries within 500 feet of the disposal area(s).
d. The latitude and longitude of the established horizontal control monument.
e. The elevation of the top of the well casing (which shall be known as the "measuring point") relative
to a common datum.
f. The depth of water below the measuring point at the time the measuring point is established.
g. The location of Review and Compliance Boundaries.
h. The date the map is prepared and/or revised.
32. Control monuments shall be installed in such a manner and made of such materials that the monument will
not be destroyed due to activities that may take place on the property. Maps and any supporting
documentation shall be sent to the Aquifer Protection Section's Central Office at 1636 Mail Service Center,
Raleigh, NC 27699-1636, and to the Mooresville Regional Office at the Aquifer Protection Section, 610
East Center Avenue/ Suite 301, Mooresville, NC 28115.
The permittee is responsible for the geographic accuracy of any map submitted, however produced
33. Monitor wells MW-1, MW-2, MW-3, and— w_stream_belhind— e F* shall all be sampled every
February, June and October for the following parameters:
Total Dissolved Solids
Sulfates (SOO
Aluminum
Water Level
pH
Specific Conductivity
Total Suspended Solids
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The results of the sampling and analysis shall be received on the most -recent version of "Groundwater
Quality Monitoring: Compliance Report Form" (i.e., GW-59 Form) with copies of the laboratory analyses
attached by the Division's Aquifer Protection Section at the following address on or before the last working
day of the month following the sampling month:
4

NCDENR-DWQ
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank reporting forms may be downloaded from the web site for the Division's Aquifer Protection
Section at httpa/gw.ehnr.state_iic_us/ or requested from the address listed above.
34. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary for the disposal system individually
permitted on or after December 30, 1983 is established at either 250 feet from the waste disposal area, or 50
feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to remediation action
according to 15A NCAC 2L .0106(d)(2).
35. The REVIEW BOUNDARY is established around the disposal system midway between the Compliance
Boundary and the perimeter of the waste disposal area. Any exceedance of standards at the Review
Boundary shall require action in accordance with 15A NCAC 2L .0106(d)(1).
36. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
37. 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.
Permit issued this the 28-th-day-rofD'ec6mb'er, 2004•y
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
flan if:Rlinrek;P-E-, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0002702

D ISION OF WAS QUAKY
GROUNDWATER SECTION
A200. /9—, / 315k
MEMORANDUM
TO: fro. ✓s �oe�✓La�
/".0V 2Rs u- ►`l (e Regional Office
FROM: /pis ,� A►� wed ~
SUBJECT: Application for - _Permif ,Renewal, _ .. _. _ _ .. - PermitAmendment:
New Permit Repair/Alteration of Exist Disposal System [DEHI .
COMMENTS:
Facility Name: LC H 6 w1., �NG
County: R_0"/0, n.) l )
TypeofProject:_
APPLICABLE PERMIT NO.s: - 1K oaa 2 ��2 I GW I 1 1 _0
DEH ANIMAL WASTE (DWQ)
EPA (CONST. GRANTS) A to C
The Groundwater Section has received ONLY ONE (11 copy of the referenced permit application. A copy of the
application should have been sent to your Regional Water Quality Supervisor, so please use that copy for
your review - IF A COPY HAS NOT BEEN RECEIVED IN THE REGIONAL OFFICE, PLEASE LET ME KNOW.
The Groundwater Section has received ONLY ONE (11 copy of the referenced permit application. A copy of the
application should have been sent to , DEH's Regional Soil Specialist, so please use
that copy for your review - IF A COPY HAS NOT BEEN RECEIVED IN THE REGIONAL OFFICE, PLEASE
LET ME KNOW.
The Groundwater Section received two (2) copies of the referenced permit application. One copy of the application
documents we received is attached.
Please review the application materials for completeness. If you feel additional information is necessary, please let
me know no later than TD e. c - 3, 15 iX . A copy of any formal request for additional information will be
forwarded to you.
If you do not need -any -additional information to complete your review, please provide your final comments by
*0Q. c . 101 1175 t . If you request and/or receive additional information, your final comments are
due no later than 14 days after you receive the additional information.
\9-98TRAN.SHL (rev. 9/29/98)

t
ALCHEM, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
Tel. [phone] Ext. 23
Fax [phone]
October 20, 1998
North Carolina Department
Of Environment, Health, and
Natural Resources
Division of Water Quality
Post Office Box 29535
Raleigh, NC 27626-0535
Dear Sir or Madam:
RECEIVED
WATER QUALITY SECTION
Non -Discharge Permitting
Our permit expires May 31, 1999. We are applying for a permit modification and a permit
renewal at the same time.
On the modification, we would like to have authorization to mix the sand by product, which is
a result of Bauxite mixing with Sulfuric Acid at a high temperature with clay. As you will see
from the analytical results, the process leaves basically no leachable metals. You will see that
this material is almost sterile.
If there is something we can assist you with to expedite this procedure, please let us know.
My office phone number and fax number is listed above.
Best regards,
ALCHEM, INC.
ski
Randall Andrews,
President
el

Department of Envi,.ronment, Health and Natural Resources
Division of Environmental Management
Non -Discharge Permir.Apphcation Form
(THIS FORM MA}' BE PHOTOCOPIED FOR USE AS AN ORIGIN, C El V E D
WATER QUAI-ITY SECTION
DISTRIBUTION OF OTHER RESIDUAL SOLIDS aoa
This application is intended for facilities which are EXEMPTt�
from 40 01WR �3
I. GENERAL INFORMATION: Non -Discharge Permitting
1. Applicant's name (please specify the name of the municipality, corporation, individual, etc.):
Alchem, Inc.
2. Print owners or signing official's name and title (the person who is legally responsible for the facility and its compliance): ,
Randall Andrews — President
3. Mailing address: 8135 Red Road
City: Rockwell
Telephone Number: (
4. Application Date:
State: North Carolina
704 ) 279-7908
October 20, 1998
Zip: 28138
5. Fee Submitted: S 400.00 [The permit processing fee should be as specified in 15A NCAC 2H .0205(c)(5).]
6. Specify how these residuals will be distributed: sold or given away in bags or other containers; lawn (bulk);
home garden (bulk): other, used for a building pad of 3 acres on our site
7. if the alternative for residual disposal consists of "surface disposal" as defined under 40 CFR Part 503, please complete the
application titled "SURFACE DISPOSAL OF RESIDUAL SOLIDS. Please identifv if there is any storage of residuals in
a surface impoundment or disposal thru landfilline. Explain:
no land filling. no surface impoundment
X
8. Is the residual process facility also the generator? Yes; No
9. Latitude: 35 ° 30 Minutes Longitude: 80' 20 minutes of residual process facility
10. Specify whether the process facility is owned by: federal; . X private; state; local government;
11. County where facility is located:
II. PERMIT INFORMATION:
Rowan
1. Application No. (will be competed by DEM): fig % oco 276r2-
2. Specify whether project is: new; X renewal"; X modification
For renewals, complete all sections included in the application. Engineering Signature and Seal not required for
renewals or if there is not any construction involved with die subject project.
3. If this application is being submitted as a result of a renewal or modification to an existing permit_ list the existing permit
numbers , ra�aa and its issue date June 27, 1994
FORA: DORS 06/94 Paoe 1 of 7

III, ' FACILITY 'INFORMATION (attach 'addition, al pages for additional sources of residuals):
_.L___ , Alchem, Inc.
W.•� �• ...��..;AL. ....�.� .�sidua.s are generated or prepared:
1
2. Facility permit number: W0000272 ; facility permit bolder: Alchem, Inc.
3. Specify whether facility in Section III.1 is owned by: federal; X private; state; local government;
4. Specify facility design flow: mgd; facility average daily flow: mod;
Type of residual storage: . in lined lagoons
Volume of residual storage: 20,000 cubic yards
Length of residuals storage at facility: 3 years- days (the Division requires a minimum 30 days storage in units that
are separate from treatment system, i.e. not in clarifiers, aeration basins, etc.);
Estimated volume of residuals: 3,000 (dry tons/yr.);
5. If the residual process facility is not the same as the generator, please specify delivery frequency and quantity of residual to
be processed:
6. Facility contact (person familiar with residuals preparation): Wayne Drye
7. Facility contact's telephone number: ( 704 ) 279-7908
8. Location of treatment facility: North Carolina State; Rowan County
9. NlaiLng address: 8135 Red Road
Rockwell, NC 28138
10. Specify the source of the residuals: treatment of water (alum sludges); X treatment of industrial wastewater
(10017� industrial residuals); treatment of industrial wastewater mixed with domestic wastewater (please specify
appropriate percentages of 100 % industrial wastewater, % domestic wastewater);
other (explain): Sand from reaction of Bauxite with sulfuric acid
Attach an explanation of either the treatment process, manufacturing process, or how the waste is generated. Provide full
and complete details of the entire process.
11. Does the facility which generates the residuals have an approved pretreatment program? Yes; X No.
This includes facilities which are classified as a "Class I" facility (any publicly owned treatment works required, under 40
CFR 403-14 to have an approved pretreatment program or any facility treating domestic sewage that is classified as "Class
I" by the appropriate federal or State authority)
IV. RESIDUALS INFORMATION (attach additional pages for additional sources. of residuals):
1. Information for Hazardous Waste (RCRA) Determination. The information requested on the limitations specified below
pertain only to those residuals that are generated from a municipal wastewater treatment facility with industrial contribution
or active pretreatment program and from any other treatment facility with wastewater sources that include industrial sources.
a. Are any of the residuals covered by this application listed in 40 CFR 261.3i-261.33? Yes; X No. If Yes,
list the number(s):
b. Do the residuals exhibit any of the four characteristics defined by 40 CFR 261.21-261.74? Yes: X No.
Attach laboratory results for the Toxicity Characteristic Leaching Procedure Analyses, Reactivity, Ignitability, and
Corrosivity for each residual.
FORM: DORS 06/94 Page 2 of 7

Note: If the following constituent levels (as determined by
the Toxicity Characteristic Leaching Procedure Analyses) arc
exceeded in the residuals or
if the pH of the residual is not within the range listed
below, the residual is b%
definition a Hazardous waste.
Chemical analyses must be made to Minimum Detection
Levels.
PLY
PPS
Arsenic
5.0
Barium
100.0
Benzene
0.5
Cadmium
1.0
Carbon tetrachloride
0.5
Chlordane
0.03
Chlorobenzene
100.0
Chloroform
6.0
Chromium
5.0
o-Cresol
200.0
m-Cresol
200.0
p-Cresol
200.0
Cresol
200.0
2,4-D
10.0
1,4-Dichlorobenzene
7.5
1,2-Dichloroethane
0.5
1,I-Dichloroethylene
0.7
2,4-Dinitrotoluene
0.13
Endrin
0.02
Heptachlor (and its hydroxide)
0.008
Hecachlorobenzene
0.13
Hexachloro-1,3-butadiene
0.5
Hexachloroethane
3.0
Lead
5.0
Lindane
0.4
Mercury
0.2
Met_hoxychlor
10.0
Methyl ethyl ketone
200.0
Nitrobenzene
2.0
Pentachlorophenol
100.0
Pyridine
5.0
Selenium
1.0
Silver
5.0
Tetrachloroethvlene
0.7
Toxaphene
0.5
Trichloroethylene
0.5
2,4,5-Trichlorophenol
400.0
2,4,6-Trichlorophenol
2.0
2,4,5-TP (Silvex)
1.0
Vinyl chloride
0.2
pH (2:1 vol./wL): >2.0 s.u.
- <12.5 s.u.
*2
NOTE: IF ANY OF THE RESIDUALS MEET THE DEFINITIONS OF A HAZARDOUS WASTE,
AS NOTED IN EITHER "A" OR "B" ABOVE, A PERMIT CANNOT BE ISSUED FOR
THAT MATERIAL AND IT SHOULD NOT BE INCLUDED AS PART OF THIS
APPLICATION.
For each residual, please attach a complete chemical analvsis of the material. This analysis must be comprehensive enough
to completely characterize the residual and must be based upon a review of the process that generates the material. If the
facility that will generate the residual is not vet in operation, the characterization must be based on similar existing
facilities and projection based on the type of facility. The analysis must include a minimum of the following parameters
and any other L-gown and suspected contaminants that are tributary to the system.
Cadmium
Aluminum
Copper
Ammonia -Nitrogen
Lead
Calcium
Nickel
Magnesium
Zinc
Nitrate -Nitrite Nitrogen
Total Solids
pH
Phosphorus
Potassium
Sodium
TKN
Plant Available Nitrogen (by calculation)
Wastewater residuals can not be.sold or given away if the concentration of any pollutant in the residuals exceeds the ceiling
concentrations specified in the table below. Specify the pollutant concentration of these residuals (attach lab analysis):
Pollutant
Pollutant Ceiling Concentration (mg/kg)'
Dry Weight Basis
Pollutant Concentration (mg/kg)
Dry Weight Basis
Cadmium
85
0.278
Copper
4300
2.23
Lead
840
1.71
Nickel
420
0.73
Zinc
7500
4.73
FORS'[: DORS 06194 Paze 3 of 7

+ r-roviae., au appucaoie picot stuaies and any bench scale tests performed on each residual source and the results, includin!
the approximate fertilizer equivalent. ;
5. Wastewater residuals can't be sold or given away in bags*or other containers for application to the land unless one of tL:
following options is satisfied.
Specify either A or B. Please be advised, if the residuals are -to be sold or given away in bulk for application tc
lawn or home garden then Option A is the only option.
e,..,-A . The pollutant concentration of the residuals must be less than Pollutant Monthly Average Concentration
listed in the table below.
Pollutant
Monthly Average Concentrations
Dry Weight Basis (mg/kg)
Pollutant Concentration
D Weight Basis (malig)
Cadmium
39
0.278
Copper
1500
2.23
Lead
300
1.71 i
Nickel
420
0.73
Zinc
2800
4.73
B . The product of the concentration of each pollutant in the residual and the annual whole residual application
rate for the residual shall not cause the Annual Pollutant Loading Rate to be exceeded.
In order for the Annual Whole Residual Application Rate (AWRAR) to be calculated the Annual Pollutant
Loading Rate (APLR) is divided by the pollutant concentration (PC) times 0.001 (a conversion factor) as
follows:
AWRAR = APLR
PC * 0.001
Pollutant
Pollutant
Concentration
Dry Weight Basis
(m g/kg)
Annual Pollutant
Loading Rates
(APLR)
kg/hectare
Annual Whole Residual
Application Rate
(AWRAR)
kg/hectare
Cadmium
0.278
1.9
0.0068
Copper
2.23
75
0.0336
Lead
1.71
15
0.0087
Nickel
0.73
21
0.0287
Zinc
4.73
140
0.0295
The AWRAR for the residual is the lowest AWRAR calculated. This is the maximum rate at which the
subject residual can be applied (to convert kg/hectare to lbs/acre multiply by 0.8924). Please specify
ke/bectare or lbs/acre: y
AWRAR = 0.0068
V . PATHOGEN REDUCTION INFORMATION (attach add. pages for additional sources of residuals)
In accordance with 15A NCAC 2H .0200, pathogen reduction can be achieved using either 40 CFR Part 257 or 40 CFR Part
503. Since the pathogen reduction requirements found in 40 CFR Part 257 (note; "Processes to Further Reduce Pathogens" or
PFRP) are incorporated into 40 CFR Part 503, only Part 503 is listed below. Please check which of the following applies to
Uie subject residual:
FORM: DORS 06194 Page 4 of 7

1. In order for the residuals to be Class A,,in accordance with the pathogen requirements in 40 CFR 503.32(a), either Part a e.
Part b ai . one of the options in Part c must be completed (please submit all lab analysis, test results and calculations):
a. A Fecal coliform density less than 1000 Most Probable Number per gram of total dry solids, or
b. A Salmonella sp. density less than 3 Most Probable Number per 4 grams of total dry solids.
c. In addition to Part a or Part b being met, one of the following alternatives must also be completed. Please
specify 1, 2, 3, 4, 5a, 5b, 5c, 5d, 5e, 5f, 5g or 6 below being met
time/tem, eratnre - an increased residuals temperature should be maintained Pir a prescribed period of time, ir.
accordance with the following guidelines. The results (D) shall be the amount of time, in days, that the residuals
shall remain at the given temperature:
Time and Temperature Guidelines
Total Solids
Tem ramie (t)
Minimum Time
Eauadon
Notes
No heating of small
> or = 7%
> or = 500 C
> or = 20 minutes
D = 131,700,000
panicles by warmed
100.14 t
gases or immiscible
liquid.
> or = 7%
> or = 500 C
> or = 15 seconds
D = 131,700,000
Small particles heated by
100.14 t
warmed gases or
immiscible liquid.
< 7%
> or = 500 C
> or = 15 seconds
D = 131.700.000
to
100.14 t
< 30 minutes
< 7`io
> or = 500 C
>or = 30 minutes
D = 50.070.000
100.14 t
2. aLt;aline treatment - the pH of the residuals is raised to greater than 12 for at least 72 hours. During this time, the
temperature of the residuals should be greater than 520 C for at least 12 hours. In addition, after the 72 hour
period, the residuals are to be air dried to at least 50% total solids.
prior testing for Enteric Virus/Viable Helminth Ova - the residuals are analyzed for the presence of enteric viruses
(Plaque -forming units) (pful and viable helminth ova. If the residuals are analyzed before the pathogen reduction
process and found to have densities of enteric virus <1 pfu/4 grams of total solids and viable helminth o-va <1/4g
total solids, the residuals are Class A with respect to enteric virus and viable helminth ova until the next
monitoring episode. If the residuals are analyzed before the pathogen reduction process and found to have densities
of enteric virus > or = 1 pfu/4 g total solids or viable helminth ova > or = 1/4 g total solids, and tested again after
processing and found to meet the enteric virus and viable helminth ova levels listed under "4" below, then the
processed residuals will be Class A with respect to enteric viruses and viable helminth ova when the operating
parameters for the pathogen reduction process are monitored and shown to he consistent with the values or ranges
of values documented. '
4. no prior testing for Enteric -Virus/Via le Hemminth Ova - if the residuals are not analyzed before pathogen reduction
processing for enteric viruses and viable helminth ova, the density of enteric viruses must be less than 1 pfu/4 g of
total dry solids and the density of viable helminth ova must be less than 1/4 g of total dry solids, or the residuals
must be treated by a "Process to Further Reduce Pathogens" or a "Process to Further Reduce Pathogens" eeuivalenc
process. -
5. The "Processes to Further Reduce Pathogens" (PFRP) are described as follows:
a. Composting - using either the within -vessel or static aerated pile composting methods, the temperature of the
residuals are raised to 550 C or higber for three days. Using the windrow composting method, the residuals are
raised to 550 C or higher for fifteen days. During the high temperature period, there will be a minimum of five
turnings of the windrow.
FORM: DORS 06194 Page 5 of 7

Li.. 1117dL L.JI V I L I - iCJ1LLUdlS dja LIIICU O\' O1rCCI Or 111UIIC'CL CUilL3Ct WILU 11UL Ed-b" LU ICUULU ulC mUIbLure CUMCM O
the residuals to 10% or lower. Eithar the temperature of the gas in contact with the residuals exceeds 800 C o
tl` a xc- l:::lh temperature of the gas in contact with the residuals. when the residuals leave the dryer. exce:el'
800 C.
C. Heat Treatment - liquid residuals are heated to a temperature of 1800 C or higher for thirty minutes.
d. Thermophilic Aerobic Digestion - liquid residuals are agitated with air or oxygen to maintain aerobic condaiom
at residence times of ten days at temperatures of 550 C to 600 C.
e. Beta Rav Irradiation - residuals are irradiated with beta rays from an accelerator at dosages of at least LC
megarad at room temperature (ca. 200 Q.
f. Gamma Rav Irradiation - residuals are irradiated with gamma rays from certain isotopes such as 6000 ant
137Cc, at dosages of at least 1.0 meearad at room temperature (ca. 200 Q.
g. Pasteurization - the temperature of the residuals is maintained at 700 C or higher for at least thirty minutes.
6. The residuals shall be treated in a process that is equivalent to a "Processes to Further Reduce Pathogens" (PFRP),
as determined by the permitting authority based on evaluations of the recommendations provided by the Pathogen:
Equivalency Committee.
VI. GENERAL 1NFOR2MATION:
1. Please provide a brief narrative concerning materials handling, including the following:
a. How will the materials will be handled and transported from where the residuals were produced to where it will be
treated?
b. Where will the residuals be stored until processed?
c. How will leachate collection be handled?
d. What will be the duration of treatment?
e. Where will the final product be stored?
f. How lcne will the final product be stored before being distributed?
g. How will the final product be distributed (packaging)?
2. Please attach a marketability statement detailing destinations and approximate amounts of the final product to be
dismbuted.
3. Please provide either a label which shall be affixed to the bagged processed residual or an information sheet which shall be
provided to the person who receives the processed residual. The label or information sheet shall contain, at a minimum, the
following information:
a. The name and address of the person who prepared the residual that is sold or given away in a bag or other container for
application to the land.
b. A statement that application of the residual to the land is prohibited except in accordance with the instructions on the
label or information sheet.
c. A statement that the residuals shall not be applied to any site that is flooded, frozen or snow-covered.
d A stamment that adequate procedures shall be provided to prevent surface runoff from carrying any disposed or stored
residuals into any surface waters.
e. information on all applicable buffers including a 10 foot buffer between application site and any public or private water
supply source (including- wells) and any stream, lake, river, or natural drainage way.
f. The Annual Whole Residual Application Rate (AWRAR) for the residual that does not cause any of the annual
pollutant loading rates to be exceeded (if necessary).
FORM: DORS 06194 Pa-(,c 6 of 7

Name and Complete Address of Engineering Firm:
City
Telephone Number:
Professional Engineer's Certification:
I,
State: Zip:
attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I furTher attest that to the best of my knowledge
the proposed design has been prepared in accordance with the applicable regulations. Although certain portions of this submitial
package may have been developed by other professionals, inclusion of these materials under my signature and seal signifies that I have
reviewed this material and have judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Seal, Signature, and Date:
Applicant's Certification:
1,
attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand that if all required parts of this
application are not completed and that if all required supportin_ informaLion. and attachments are not included, this application package
will be returned to me as incomplete.
Signature
Date
THE COMPLETED APPLICATION PACKAGE. INCLUDING ALL SUPPORTING INFORMATION AND
\MATERIALS, SHOULD BE SENT TO' THE FOLLOWLNG ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL INIANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOY 29535
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NUMBER: [phone]
FORM: DORS 06194 Pazc 7 of 7

C)XFORD
abwatories
nc.
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 9 -1 1- 9 8
DATE REPORTED 09-22-98 Wilmington, N.C. 28401
9 8 W 6 4 5 7 [phone]
Fax [phone]
RECEIVED
PAGE 1 OF 1 WATER QUALITY SECTION
rGCI 2 31993
AL.CHEM INC P.O. # Non -Discharge Pennihing
8135 RED ROAD r9
ROCKWELL, NC 28138
ATTENTION: RANDALL ANDREWS
SAMPLE DESCRIPTION: TCLP METALS - SAND
1. RESULTS FOR THIS SAMPLE
2. OXFORD LABORATORIES ROUTINE DETECTION LIMIT
3. NORTH CAROLINA LANDFILL MAXIMUM
4. EPA MAXIMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS: ON TCLP LEACHATE
Arsenic, as As, PPM
Barium, as Da, PPM
Cadmium, as Cd, PPM
Chromium, as Cr, PPM
Lead, as Pb, PPM
Mercury, as Hg, PPM
Selenium, as Se, PPM
Silver, as Ag, PPM
pH @ 5 % Sample
Extraction Fluid Used
NOTE: BDL = BELOW DETECTION LIMIT
RESULTS
1
BDL
.256
BDL
BDL
BDL
BDL
BDL
BDL
3.5
#1
2 3
0.005
0.5
0.020
10.0
0.005
0.1
0.010
0.5
0.010
0.5
0.0005
0.02
0.005
0.10
0.010
0.50
4 5
5.0
101
100.0
92.2
1.0
86.7
5.0
93.5
5.0
80.6
0.2
97.3
1.0
89.8
5.0
82.1
KEN SMITH, SENIOR ANALYST

�n
-- XFOR®
aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYE
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 9- 0 2- 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 9 -14 - 9 8 [phone]
98W631.1 Fax [phone]
PAGE 1 OF 1
SAMPLE DESCRIPTION: SAND - TCLP METALS
1. RESULTS FOR THIS SAMPLE - SAND
2. DETECTION LIMIT
3. NC LANDFILL MAXIMUM
4. EPA MAXIUMUM CONTAMINANT LEVEL
5. MATRIX SPIKE % RECOVERY
RESULTS: ON TCLP LEACHATE
Cadmium, as Cd, PPM
Lead, as Pb, PPM
Copper, as Cu, PPM
Nickel, as Ni, PPM
Zinc, as Zn, PPM
pH @ 5 % Sample
Extraction Fluid Used
NOTE: BDL=BELOW DETECTION LIMIT
* UNKNOWN
RESULTS
1
2 3 4 5
BDL
0.005
0.1
1.0
93.5
BDL
0.010
0.1
5.0
88.2
BDL
0.005
*
*
102
.013
0.005
*
*
119
.209
0.005
*
*
109
3.5
X
X
X
X
#1
X
X
X
X
K MITH, SENIOR ANALYST

(DXFORD
aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYE
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8 W 5 9 4 8 Fax [phone]
SAMPLE DESCRIPTION: #3 SAND
1. 93 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS: WT/WT
Cadmium, As Cd, PPM
Copper, as Cu, PPM
Lead, as Pb, PPM
Nickel, as Ni, PPM
Zinc, as Zn, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1 2
<.200
<.278
1.60
2.23
1.23
1.71
.525
.730
3.40
4.73
71.88
X
4N SMITH, SENIOR ANALYST

L
(DxFORD
aboratories
nc.
ALCHEM INC
8135 RED ROAD
ROCKWELL, NC 28138
ATTENTION: WAYNE DRYE
Analytical and Consulting Chemists
1316 South Fifth Street
DATE RECEIVED 0 8 -12 - 9 8 Wilmington, N.C. 28401
DATE REPORTED 0 8 - 31- 9 8 [phone]
9 8W5 9 5 0 Fax [phone]
SAMPLE DESCRIPTION; #3 SAND
1. #3 SAND AS RECEIVED
2. #3 SAND DRY BASIS
RESULTS; WT/WT
Aluminum, as Al, PPM
Total Solids, wt %
PAGE 1 OF 1
RESULTS
1 2
8610 11200
71.88 %
+X-N-"S,MITH, SENIOR ANALYST

Facsimile Over Page
NC DENR
DWQ-Groundvimter Section
P.O. BOX 29578 Raleigh NC 27626-0578
2728 Capital Blvd. Raleigh, NC 27604
Phone: [phone]
Fax: [phone] or [phone]
TO:
From
Company:. - Phone:
Phone: Date: -IA081 Tsw
Fax: Pages including lihis cover page:
comment.-K.
I

GROUNDWATER SECTION GW
DIVISION OF ENVIRONMENTAL INIANAGEMENT
RECCRO OF WASTE DISPOSAL PERMIT APPLICATION REVIeW
REVIEW ICY DATE /2halv.8 FiEL D INVrTIGATION? (YIN) � �5
FACIt Ir( NAME —..-- } COUNTY-�-
LOCATION 11.3< ZZ EW 49!6 111 `-al
TYPE OF DISPOSAL SYSTEM (LAGOON, ETC.) A.!!j ESIGN CAP. (GPD)
DESCRIPTION OF FACILITY �•s�%�` '�f' � �.�-+, ►+ v,�+ .,-, ,6 �c �'x� ��
SIZE OF IMPOUNDMENT (FT SQ.) WOR SIZE OF APPLICATION AREA
WAS�I}RCE: MUN. SLUDGE- MUN. W. WATER: —PRIMARY PRIMARY
----- IND. SLUDGE — 1ND, WELL WATER
SECONDARY TERTIARY
DISTANCE FROM WASTE SOURCE TO NEAREST. STREAM —Fr., WELL f 6' FT -
FOR WELL: TYPE OF USE --_-_-. TH PUMP RATE (EST_)
WHAT DESIGN CO.4NDIT 0.��� EDUCEII CREASE CHANCE OF GW CON;•AMINATIoN- 4 ii`l,
WHAT NATURAtSITE CONDITIONS WILL REDIJCECC;EAS HANCE OF GW C4NTAMINATION: �°► ''
R y4<w,*ft s _
DEPTH T0: SEDROCK _ FT., SEASONAL HIGH W.T.,___ FT., ANNUAL W.T. FLUX �� - FT.
SURFICIAL AC7UIFI°R BEdROCKJARTESIAN AQUIFER
GEN. LITHOLOGY -- -- - - - -
HYD. COND. FTJDAY ESTIMATED
MEASURED FrJG.AY LJ MEASURED- -
g E5TIMAT�17 © ESTIMATED
rri=`
THICKNESS FT. - c
NO, OF MONrFE:R WELLS. EEQ QSED: UP------_... DOWN— ; EXISTING. UP_.. DOWN­La—::,
cr+ r
FROM WORKSHEET, SITE NUMERICAL DESCRIPTION -
T I 2 3 4 5 6 6A 6B
SITE GRADE (HYDRDGEOI,)
SITUATICN rmms-
PROPOS20 SAMPLING SCHEDULE & PARAMETEFi(S): �� � '�4+== � �- �•�-- . /.��
di"
HAVE THERE BEEN ANY EXCEEDANCES OF THE GROUNDWATER STANDARDS? YES ®—a! NO _ ..
HAS ANY ENFORCEMENT ACTION BEEN TAKEN? YES NO _ z� DATE OF A TION: -
8RIEF SUMMARY OF ENE=ORCE;MGNT:ACTION TAKEN! _. SjO� `r bS = $. -p j,4 2 G
REMARKSI RECOMMENDATIONS (Continue on reverse, R necessary):
GW-48 Revised 04;94
HYD. REGIONAL SUPERVISOR

W,
DIVISION OF WATER QUALITY
GROUNDWATER SECTION
December 30, 1998
MEMORANDUM
To: Kim Colson
Water Quality Section
Through: Bob Cheek A 43, G
From: Brian Wootton re!W`
Subject: Alchem, Inc.
Wastewater Recycle System
Rowan County
Permit No. WQ0002702/GW98150
Joe Pearce: SERG Review Engineer
The Groundwater Section has reviewed the subject permit renewal/modification request for
the continued operation of the recycle system and modification to "mix the sand by product, which
is a result of Bauxite mixing with Sulfuric Acid at a high temperature with clay".
Groundwater sampling results obtained from the two (2) existing downgradient monitor wells
indicate there have been no exceedances 2L Groundwater Standards since groundwater sampling
commenced. The parameters TSS, SO4, and TDS may be omitted from the groundwater sampling
program. The upgradient monitor well, MVJ-1 (a potable well), is also sampled separate from this
permit. Groundwater Samples obtained from this well have had exceddances of 2L Groundwater
Standards for Sulphate (SO4) and TDS. The high concentrations of these parameters are most likely
coming from a source upgradient of monitor well MW-1 and not the downgradient lined lagoons
associated with this permit. Since this well (MW-1) is also being sampled separate from this permit,
the requirement for the continuation of sampling of this well is not necessary as a condition in this
permit. Also the installation of another new upgradient monitor well is not necessary, since
background concentrations have been established. However, the owner of the Alchem, Inc. will have
to address the problem of the 2L exceedances in the water supply well (MW-1) separate of this
permit.
Based upon the Groundwater Section's review of the subject permit application and
supporting documentation, the Groundwater Section makes the following recommendations:

J1.JN i' 9
I. Existing monitor wells, MW-1 and MW-2, depicted on Attachment A, shall be sampled
February and July for the following parameters:1t��S:C(i .r.... ,....,
Water Level pH
Aluminum
2. The measurement of water levels must be made prior to sampling for the remaining
parameters. The depth to water in each well shall be measured from the surveyed point on the
top of the casing.
3. The results of the sampling and analysis must be received on Form GW-59 (Groundwater
Quality Monitoring: Compliance Report Form) by the Groundwater Section, Permits and
Compliance Unit, P.O. Box 29578 Raleigh, N.C. 27626-0578 on or before the last working
day of the month following the sampling month.
4. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in
15A NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary for
the disposal system individually permitted after December 31, 1983 is established at either
(1) 250 feet from the waste disposal area, or (2) within 50 feet of the property boundary,
whichever is closest to the waste disposal area. An exceedance of Groundwater Quality
Standards at or beyond the Compliance Boundary is subject to immediate remediation action
in addition to the penalty provisions applicable under General Statute 143- 215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the
disposal system midway between the Compliance Boundary and the perimeter of the waste
disposal area. Any exceedance of standards at the Review Boundary shall require remediation
action on the part of the permittee.
5. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall
be provided.
*Denotes different language than the shell document.
cc: ;Barbar-atiCl ristian,�---
Permit Files
2

-C
C
C4
`�
N,
i C. •
CD(
Ca
0 (
L C +D
QC
C.a.
State of North
of Environment,
vironment,
ral
Health of E NaonmenResources
tal Management
Division
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Randall F. Andws
Alchem, Incorporated
Route 2, Box sN � Carolina
Red Springs,
JUL 5 1994
Tune 27, 19�IVISION OF ENVIR01rd[H1AL fdANA6EMENi BNOORESVILf RE pyi OFFICE
28377t3a02702:
t
Subjec:-erriit ® Inco Coate
Alchem,
Industrial Recycle -Bauxite Pr
Wastewater Recycle System
Rowan County
Dear Mr. Andrews: herewith
accordance with your application received March ated for the continued operation of the
In acco additional lagoons, au,
2702 dated June 27,1994, to Alchem, Incorporated
No. W0000 ration of five (5)
two (2) lagoon recycle system and the construction and operation
of the subject wastewater recycle sy ti • it is understood that only one o
in the previous Permit,rmitted, is currently under cons
tru
new lagoons, previously perm
1999, and shall be s
d therein. Please pay particular attention to the me
This permit shall be effective from e a date of issuance until May 3 � n and mainta
the conditions and limitations as re to establish
problems. issuance of this perm
ate
ste
requirem
ents in this permit. Failure to estab f ture compliance p m for collecting
required operational information, result 8, 1993.
voids Permit No. WQ0002702 issued April
requirements, or limitations contained in this permit are unacceptable, You
any P .q • upon written request within thirty (30) days following
11 ' hearing P stition, conforming to Chapter 150E
right to request an adjudicatory
P,O. Draw
this permit. This request must be in the form of a wntten ptliis permit
shall be final and binding
of
Carolina
General Statutes, and filed with the Oafrfiecm de Administrative Hearings,
Raleigh, NC 27611-7447• Unless such demandslease contact Mr. John S
If you need additional information concerning this matter, p
[phone]. Sincerely,
0 -) n
A. Presty Howard, Jr., P.E.
�: Rowan County Health Department Section
Tonal Office, Water Quality
Mooresville Reg , u Section
Groundwater Section, Central Office
Training and Certification Unit
Facilities Assessment Unit Telephone [phone] FAX 919
p.0. Box 29535, Raleigh, North Carolina 27626-053550% recycled/ 10% post -consumer paper
An Equal opportunity Affirmative Action Employer

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSI "C 1)Ep7„ .
1�rAZ91VkEN7, • Op,
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL REP4:
RALEIGH
D1V1SI�1dpj,, �1;7it1�� ,
RECYCLE SYSTEM PERMIT fod�rfsl
MAN,�gf,!9
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
Alchem, Incorporated
Rowan County
FOR THE
continued operation of two (2) lagoons each approximately 50' W x 200' L x 10' D and the construction
and operation of five additional lagoons, four (4) 180' W x 155' L x 20' D and one (1) 210 W x 155' L x
20' D to serve Alchem, Incorporated with no discharge of wastes to the surface waters, pursuant to the
application received March 23, 1994, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment, Health and Natural
Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until May 31, 1999, and shall be subject to
the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans and specifications, and other supporting
data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications, and other supporting materials. Mail the Certification to the Water Quality
Permits and Engineering Unit, P.O. Box 29535, Raleigh, NC 27626-0535.

6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those
actions that may be required by this Division, such as the construction of additional or
replacement treatment or disposal facilities.
7. The Mooresville Regional Office, telephone number 704/ 663-1699 shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an in -place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The residuals generated from these treatment facilities must be disposed in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. 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 facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in all of the lagoons shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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
three years from the date of the inspection and shall be made available to the Division of
Environmental Management or other permitting authority, upon request.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the recycle system at any reasonable time for the purpose
of determining compliance with this permit, may inspect or copy any records that must be
maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
17. 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 15A NCAC 2H .0205
(c)(4).
18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6(a) to 143-215.6(c).

19. 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.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office, telephone
number 704/ 663-1699 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 at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such as
the dumping of the contents of a basin or tank, the known passage of a slug of
hazardous substance through the facility, or any other unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility
incapable of adequate wastewater treatment, such as mechanical or electrical failures of
pumps, aerators, compressors, etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly to receiving waters without treatment of all or any portion of the influent to
such station or facility; or
d. Any time that self -monitoring information indicates that the facility is not in compliance
with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.
22. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class H, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
23. The recycle lagoons shall not be located within 100 feet of water supply wells.
24. A one time chemical analysis of the lagoon wastewater should be completed for SO4,
aluminum, pH, TDS, and specific conductivity. The results of the sampling and analysis
shall be sent to the Groundwater Section, Permits and Compliance Unit, P.O. Box. 29535
Raleigh, N.C. 27626-0535.
3

25. The monitoring wells MW-1, MW-2, and MW-3 (see attached map) shall be sampled every
February and July for the following parameters:
SO4 pH
Specific Conductivity
Aluminum Total Suspended Solids
Water Levels
The measurement of water levels must be made prior to sampling for the remaining
parameters. The depth to water in each well shall be measured from the surveyed point on
the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to
provide the relative elevation of the measuring point for each monitoring well.
The results of the sampling and analysis shall be sent to the Groundwater Section, Permits
and Comvliance Unit, P.O. Box 29535 Raleigh; N.C. 2 6 0535 on Form GW-59
26. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall
be provided.
27. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in
15A NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary is
for the disposal system constructed after December 31, 1983 is established at either (1) 250
feet from the waste disposal area, or (2) 50 feet within the property boundary, whichever is
closest to the waste disposal area. An exceedance of Groundwater Quality Standards at or
beyond the Compliance Boundary is subject to immediate remediation action in addition to
the penalty provisions applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the
disposal systems midway between the Compliance Boundary and the perimeter of the
waste disposal area. Any exceedance of standards at the Review Boundary shall require
remediation action on the part of the permittee.
28. The permittee shall submit two (2)original copies of a scaled topographic map (scale no
greater than 111: JOY) signed and sealed by a professional engineer or a state licensed land
surveyor that indicates all of the following information:
a. the location and identity of each monitoring well,
b. the location of all components of the waste disposal system,
c. the location of all property boundaries,
d. the relative elevation of the top of the well casing (which shall be known as the
"measuring point"), and
e. the depth of water below the measuring point at the time the measuring point is
established,
f. the latitude and longitude of the established horizontal control monument,
g. the inclusion of topographic markings on the map in five (5) foot increments.
The maps shall be sent to the Groundwater Section, N.C. Division of Environmental
Management P.O. Box 29535 Raleigh, N.C. 27626-0535.
4

29. This survey shall be conducted using approved practices outlined in North Carolina
General Statutes Chapter 89C and the North Carolina Administrative Code Title 21,
Chapter 56. The surveyor shall establish a horizontal control monument on the property of
the waste disposal system and determine the latitude and longitude of this horizontal control
monument to a horizontal positional accuracy of +/- 10 feet. All other features listed in a.
through f. above shall be surveyed relative to this horizontal control monument. The
positional accuracy of features listed in a. through f. above shall have a ratio of percision
not to exceed an error of closure of 1 foot per 10,000 feet of perimeter of the survey. Any
features located by the radial method will be located from a minimum of two points.
Horizontal control monuments shall be installed in such a manner and made of such
materials that the monument will not be destroyed due to activities that may take place on
the property. The map shall also be surveyed using the North American Datum of 1983
coordinate system and shall indicate the datum on the map. All bearings or azimuths shall
be based on either the true or NAD 83 grid meridian. If a Global Positioning System (GPS)
is used to determine the latitude and longitude of the horizontal control monument, a GPS
receiver that has the capability to perform differential GPS shall be used and all data
collected by the GPS receiver will be differentially corrected.
The maps and any supporting documentation shall be sent to the Groundwater Section,
N.C. Division of Environmental Management, P.O. Box 29535 Raleigh, N.C. 27626-
0535.
30. 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.
31. Issuance of this permit hereby voids Permit No. WQ0002702 issued April 8, 1993.
Permit issued this the 27th day of June, 1994
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A. Preston froward, Jr., P.E., Pirector I
Division of Environmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0002702
W

Permit No. WQ0002702
June 27, 1994
ENGINEER'S CERTIFICATION
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, for the
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of this permit, the approved plans and specifications, and other supporting materials.
Signature
Date
Gl
Registration No.

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AS To
Alchem, Inc.
Rowan County
WQ0002702/GW94066
May, 1994
1

A I
�j
MEMORANDUM
TO:
THROUGH:
FROM:
DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
May 23, 1994
Carolyn McCaskill
Bob Cheek
Cindy Boyles
SUBJECT: Alchem, Inc.
Rowan County
WQ0002702/GW94066
(John Seymour: DEM SERG Review Engineer)
N.C. DEPT. OF
ENVIRONMENT, HEALTH,
kNATURAL RESOURCES
40K, b 1S.4
The Groundwater Section has reviewed the subject permit
renewal application for the continued operation of a seven (7)
lagoons to serve Alchem, Inc. with no discharge of wastes to the
surface waters. On April 26, 1994, a Mooresville Regional Office
field representative inspected the site. An area south of the
production building, that previously was used as a storage lagoon,
has raw aluminum ore deposited throughout the area. Although there
is a small containment barrier surrounding the former lagoon, the
run-off into a drainage way still poses a problem to the residents
directly below grade. The Groundwater Section recommends
reissuance of the permit with the following conditions:
1. A chemical analysis of the lagoon wastewater should be
completed for SO4, aluminum, pH, TDS, and specific
conductivity.
2. Monitor wells MW-1, MW-2, and MW-3 (see attached map)
shall be sampled every February and July for the
following parameters: .
Aluminum TDS
pH TSS
SO4 Water Level
Specific Conductivity
3. The measurement of water levels must be made prior to
sampling for the remaining parameters. The depth to
water in each well shall be measured from the surveyed
point on the top of the casing.
The measuring points (top of well casing) of all
monitoring wells shall be surveyed to provide the

Memorandum
May 23, 1994
Page 2
relative elevation of the measuring point for each
monitoring well.
4. The results of the sampling and analysis shall be sent to
the Groundwater Section, Permits and Compliance Unit,
P.O. Box 29535, Raleigh, NC 27626-0535 on Form GW-59
[Compliance Monitoring Report Form] every March and
August.
5. Any additional groundwater quality monitoring, as deemed
necessary by the Division, shall be provided.
6. The COMPLIANCE BOUNDARY for the disposal system is
specified by regulations in 15A NCAC 2L, Groundwater
Classifications and Standards. The Compliance Boundary
for the disposal system constructed after December 31,
1983 is established at either (1 ) 250 feet from the waste
disposal area, or (2) 50 feet within the property
boundary, whichever is closest to the waste disposal
area. An exceedance of Groundwater Quality Standards at
or beyond the Compliance Boundary is subject to immediate
remediation action in addition to the penalty provisions
applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is
established around the disposal systems midway between
the Compliance Boundary and the perimeter of the waste
disposal area. Any exceedance of standards at the Review
Boundary shall require remediation action on the part of
the permittee.
7. The permittee shall submit two (2) original copies of a
scaled map (scale no greater than 1":100') signed and
sealed by a state licensed land surveyor that indicates
all of the following information:
a. the location and identity of each monitoring well,
b. the location of all components of the waste
disposal system,
C.
the location of all property
boundaries,
d.
the latitude and longitude of the established
horizontal control monument,
e.
the relative elevation of
the top of the well
casing (which shall be known as the "measuring
point"),
f.
the depth of water below the
measuring point at the
time the measuring point is
established, and
g.
the inclusion of topographic
markings on the map in
five (5) foot increments.

Memorandum
May 23, 1994
Page 3
This survey shall be conducted using approved practices
outlined in -North Carolina General Statutes Chapter ,89C
and the North Carolina dshalltestabli rative h Code
horizontal
Chapter 56. The surveyor
property of the waste disposal
control monument on the
system and determine t ument to atitua horizontallongitudeand
positional
11 other
horizontal control mon
accuracy of +/-10 feet.be surveyed featureslisted
tolthis
through e. above shallcy of
horizontal contrie positional n'ao through e h above shall have aaratio
features listed
of precision not to exceed an error of closuArnyofeatu�es
per iu,uuG feet ci perimeter of the survey.
radial method will be located from a
located by the
points. Horizontal control monuments
minimum of twoanner
shall be installed in ument will not be destroyed dueuto
materials that the mon lace on the property. The map
activities that may take p
rth American Datum Of
shall also be surveyed using
si gthe N
shall
1983 coordinate system indicate the datum on
the map. All bearings or azimuths shall be based on
either the true or NAD 83 grid meridian. If a Global
Positioning System (GPS) is used to determine the
latitude and longitude of the horizontal control)
GPS receiver that has the capability
to
monument, a
data
perform differential Grl will abed differentially
collected by the GPS ecei er
corrected.
The maps and any supporting documentation shall be sent
to the Groundwater Section,
NC Division onmental
Raleigh, NCof27626r0535.
Management, P.O. Box ,
If there are any questions, please let me know.
Attachment
cc: B�rbar Ch`r�st=ia
Central Files
Permit Files
CAB
GW94066.REN

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Alchem, Inc.
Rowan County
WQ0002702/GW94066
May, 1994

n te
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r .- i z I9 n 3- ti9 r
TO: _1NGIu,�aczz C./iriS ���
DATE:
FRGM: Jack Floyd. —
�1y v z Pt a
r4PR I
DIVISIDPI ;F E147,70vIf11
;;DISV;I�f ReDieI�1 y'}rl;;E`..:cw)'
SUBJECT: Application for V' PMgE',L/A uU= of Permit No. � 0 2402-
Facility Name:
County: I d-O rt._
Type of Project: �� , /,A e A?e0,0,n
Central Office Contact:
Applicable Permit Numbers: WQ 006)a?-�D.,, GW 9w1d6
DEH AC
EPA
The Groundwater Section has received a copy of the above referenced
permit application. A copy of the application package is attached
The Groundwater Section has received a copy of the above referenced
permit application, which has been sent to the regional office water
quality supervisor. If a copy has not been sent to the regional
office please let me know.
The Groundwater Section has received the subject Division of
Environmental Health project for review. A copy of the application
has been forwarded to , Regional Soil
Specialist. Please coordinate your review with the regional soil
specialist.
Please review the application materials for completeness and submit
any request fo additional information to the central office contact on
or before _ Mrs % /� A copy of the formal request for
additional ormation will be forwarded to you.
If you do not require any additional info do to camplete your review,
Please provide your final comments by ,
If you have any questions, please let me know as soon as possible.

SOC PRIORITY PROJECT: Yes
If Yes, SOC No._
To: Permits and Engineering Unit
Water Quality Section
Attention: John Seymour
Date: April 8, 1994
NON -DISCHARGE STAFF REPORT AND RECOMMENDATION
COUNTY: Rowan
Permit No. WQ0002702
PART I - GENERAL INFORMATION
No X
1. Facility and Address: Alchem, Inc. - Red Road Facility
Route 2, Box 521-C
Red Springs, North Carolina 28377
2. Date of Investigation: 04-08-94
3. -Report Prepared By: G. T. Chen
4. Persons Contacted and Telephone Number: Mr. Wayne Drye, Plant
Manager; [phone]
5. Directions to Site: From the junction of NC Highway 152 and
Link Street (SR 2332) in the Town of Rockwell, travel north on
SR 2332 about 0.25 mile to the junction with Red Road (SR
2323, a gravel road paralleled by the railroad tracks). Turn
left onto Red Road and travel northwest approximately 0.85
mile. Alchem, Inc. is located on the right (east) side of the
road (and the railroad tracks).
6. Size (land available for expansion and upgrading): Adequate
land area available for expansion/upgrading, if necessary.
7. Topography (relationship to 160 year flood plain included):
Flat slopes; the recycle system is not in a flood plain.
Attach a U.S.G.S. map extract and indicate facility site.
USGS Quad No.: E 17 SW USGS Name: Rockwell, NC
Latitude: 35' 33' 52"
Longitude: 80" 25' 26"
8. Any buffer conflicts with location of nearest dwelling and
water supply well: Yes No X If Yes, explain:
9. Watershed Stream Basin Information:

a. Watershed Classification: C
b.. River Basin and Subbasin No.: Yadkin -Pee Dee & 03-07-04
C. Distance to surface water from disposal system: A wet
weather ditch by the railroad tracks is approximately 200
feet west of an existing lagoon.
PART II - DESCRIPTION OF WASTES AND TREATMENT WORKS
1. a. Volume: 0.004 MGD (Design Capacity)
Residuals: 300 tons per year
b. Types and quantities of industrial wastewater: Estimated
4,000 GPD of wastewater is generated from the processing
of Bauxite.
C. Pretreatment Program (POTWs only): N/A.
in development: approved:
should be required: not needed:
2. Treatment Facilities
a. What is the current permitted capacity of the facility?
N/A.
b. What is the actual treatment capacity of the current
facility (design volume)? N/A.
C. Please provide a description of existing or substantially
constructed wastewater treatment facilities: The recycle
facility consists of two (2) lagoons. One lagoon is
completely full of residuals and is no longer in use.
Please note, Alchem, Inc. was permitted to construct and
operate five (5) additional lagoons. Currently, only one
new lagoon is under construction.
d. Please provide a description of proposed wastewater
treatment facilities: N/A.
3. Residuals handling and utilization/disposal scheme: Sand and
slurry residuals are currently stored in the lagoons. Solids
will be removed from the lagoons and commercialized.
a. If Residuals are being land applied, please specify DEM
Permit No..
Residual Contractor:
Telephone Number:
Non -Discharge Pez7d t Staff Report
Version 10192
Page 2

b.
c.
Residuals stabilization: PSRP:
PFRP:
Other:
Landfill:
d. Other disposal/utilization scheme (specify):
4. Treatment plant classification (attach completed rating
sheet): No rating given.
5. SIC Code(s): 2819
Wastewater,-Code(s) of actual wastewater, not particular
facilities, i.e., non -contact cooling water discharge from a
metal plating company would be 14, not 56.
Primary: 84 Secondary:
Main Treatment Unit Code: 50000
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds (municipals only)? N/A.
2. Special..monitoring requests: N/A.
3. Important SOC, JOC or Compliance Schedule dates: (Please
indicate): N/A.
Date
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Air Quality and/or Groundwater concerns or hazardous materials
utilized at this facility that may impact water quality, air
quality, or groundwater: The Groundwater Section may want to
comment regarding the existing lagoons. No immediate air
quality concerns. Sulfuric acid (66.0 %) is used and stored
at this facility for the processing of Bauxite.
5. Other Special Items: N/A.
PART IV - EVALUATION AND RECOMMENDATIONS
Non Discharge Permit Staff Report
Versi on 10192
Page 3

It is recommended that the subject Permit be renewed as
requested.
�- TIC �--
Signature"of Report Preparer ,
Water Quality
Date
ional Supervisor
Non -Discharge Permit Staff Report
Versi on 10192
Page 4

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State of North Carolina
(wq l
Department of Environment, z.v s.,.
Health and Natural Resources
s �=
Division of Environmental Mana t
9 emenN.C. DEpT. OF ,, `�
ViRONMEI•IT, HEALT
James B. Hunt, Jr., Governor & NATURAL RESOUR
Jonathan B. Howes, Secretary, APR � 1994 p E H N
A. Preston Howard, Jr., P.E., Director
DI9ISI MOOAES�ILE R� 0�A1 0114E�
March 28, 1994
MR RANDALL F. ANDREWS
ALCHEM, INC.
RT. 2 BOX 521-C
RED SPRINGS, NORTH CAROLINA 28377
Dear MR ANDREWS:
Subject: Application No. WQ0002702
Red Road # 8134 Renewal
Recycle Facility
Rowan County
The Division's Permits and Engineering Unit acknowledges receipt of your permit application and
supporting materials on March 23, 1994. This application has been assigned the number shown
above. Please refer to this number when making inquiries on this project.
Your project has been assigned to John Seymour for a detailed engineering review. Should there be any
questions concerning your project, the reviewer will contact you with an additional information letter.
Be aware that the Division's regional office, copied below, must provide recommendations from the
Regional Supervisor or a Procedure Four Evaluation for this project, prior to final action by the
Division.
Ifyou have any questions, please contact John Seymour at [phone].
G' Car " Mkaskill
Supervisor, State Engineering Review Group
cc: Mooresville Regional Office
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

VVIP Na
tVA 9NM-p of
Staiebf No'ki"C'arolina 'Pup ,�t ZA
Department of Environment,, Health, and Natural Resources ZAI-
s- ­�t -' '- ii " -` ijk' RESOURCES
Divi io-n 6 Env� ' ironmen L. Management A P,9 S
- Non -Discharge Permit Application 19
(THIS FORM MAYBE PHOTOCOPIED FOR USE ASANOPIGLiftft 94
prr
RECYCLE FACILITIES
I. GENERAL INFORMATION:
1. Applicant (corporation, individual, or other): Alchem, Inc.
J-7
2. Print Owners or Signing Official's Name and Title (the person who is legally"
responsible for the facility. and its compliance): Mr. Randall Andrews, Preside -at
-.0
3. Mailing Address: Rt. 2, Box 521-C
City: Red Springs State: NC Zip: 28377
Telephone No.: 910 843-2121
4. Project Name (subdivision, facility, or establishment name - should be consistent with
project name on plans/specs., letters of flow acceptance, Operational Agreements, etc.):
Alchem, Inc.
5. Application Date: 3/21/94 6. Fee Submitted: $ 200.00
7. County where project is located: Rowan
8. Latitude: 350-331-30" --; Longitude 80o-25'-00" of recycle facility location
11. PERMIT INFORMATION:
1. Permit No. (will be completed by DEM):
2. Specify whether project is: -- new; X renewal*; - modification.
*If renewal, complete only sections 1, 11, 111, & applicant signature
(on pg.6). Submit, only pgs. 1, 2, 6 (original and 3 copies of each). Engineer
signature not required for renewal.
3. If this application is being submitted as a result of a renewal or modification to an
existing permit, list the existing permit numbe?Q 0 0 0 2 7 0 2 `and issue date 4-8-93
4. Specify whether the applicant is - public or xprivate.
FORM: RFAC 4/91
Page 1 of 7

RECYCLE FACIL.ITIES� '
PAGE 2 (4/91) '
UIL INFORMATION ON WASTEWATER:
1. Nature of Wastewater. %'Domestic; % Commercial;
100;% Industrial; % Other waste (specify):
`2. Please provide a%one or two Word description specifying the origin of the wastewater,
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
industrial recycle
3. Volume of recycle water generated by this project: 4,000 gallons per day
4. Explanation of how recycle water volume was determined: estimate from measuring
mix tanks
5. Brief project description: This is a sand washing recycle operation. The sand is
Sulfuric Acid insoluble and is washed until there is no more Aluminum Sulfate
adhering.
IV. DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of tanks, pumping facilities, high water alarms, filters,
ponds, lagoons, etc.:
2. Name of closest downslope surface waters:
3. Classification of closest downslope surface waters: (as established
by the Environmental Management Commission & specified on page 4 of this
application).
4. If a power failure at the facility could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent such impact, as
required in 15A NCAC 2H .0200:
5. The facilities must conform to the following buffers (and all other applicable buffers):
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100 feet between a surface sand filter and any residence under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) 50 feet between the recycle facilities and property lines;
2of7

RECYCLE FACILTITES
PAGE 3 (4/91)
6. If any of the buffers specified in no. 5 above are not being met, please explain how the
proposed buffers will provide equal or better protection of the Waters of the State with
no increased potential for nuisance conditions:
7. Are any components of the recycle facility located within the 100-year flood plain?
yes; no. If yes, briefly describe the protective measures being taken to protect
against flooding.
THIS APPLICATION PACKAGE WILL NOT BE ACCEPTED BY THE
DIVISION OF ENVIRONMENTAL MANAGEMENT UNLESS ALL OF
THE APPLICABLE ITEMS ARE INCLUDED WITH THE SUBMITTAL
Required Items
a. One original and three copies of the completed and appropriately executed application form.
b. The appropriate permit processing fee, in accordance with 15A NCAC 2H .0205(c)(5).
C. Five sets of detailed plans and specifications signed and sealed by a North Carolina
Professional Engineer. The plans must include a general location map, a site map which
indicates where any borings or hand auger samples were taken, along with buffers,
structures, and property lines. Each sheet of the plans and the first page of the specifications
must be signed and sealed.
d. For industrial wastewater, a complete chemical analysis of the typical wastewater
must be provided. The analysis may include, but shall not be limited to, Total Organic
Carbon, BOD, COD, Chlorides, Phosphorus, Nitrates, Phenol, Total Trihalomethanes,
TCLP analysis, Total Halogenated Compounds, Total Coliforms, and Total Dissolved
S olids.
e. If lagoons are a part of the facilities and the recycle water is industrial, provide a
hydrogeologic description of the subsurface to a depth of 20 feet or bedrock, whichever is
less. The number of borings shall be sufficient to define the following for the area
underlying each major soil type at the site: significant changes in lithology, the vertical
permeability of the unsaturated zone, the hydraulic conductivity of the saturated zone, and
the depth of the mean seasonal high water table.
f. Five copies of all reports, evaluations, agreements, supporting calculations, etc., must be
submitted as a part of the specifications which are signed and sealed by a North Carolina
Professional Engineer. Although certain portions of this required submittal must be
developed by other professionals, inclusion of these materials under the signature and seal
of a North Carolina Professional Engineer signifies that he has reviewed this material and
has judged it to be consistent with his proposed design.
g. Five copies of the existing permit if a renewal or a modification.
3 of 7

RECYCLE FACILI
PAGE 4 (4/91)
TO: REGIONAL WATER QUALITY SUPERVISOR
Please provide me with the classification of the .surface waters identified in number 5
below and on the attached map segment:
Name of surface waters:
Classification (as established by the Environmental Management Commission):
Proposed Classification, if applicable:
Signature of regional office personnel:
INSTRUCTIONS TO ENGINEER
Date:
In order to determine whether provisions for dual or standby power may be required for the
subject facility, the classification of the closest downslope surface waters (the surface waters that
any overflow from the facility would flow toward) must be determined. You are required to
submit this form, with items 1 through 10 completed, to the appropriate Division of Environmental
Management Regional Water Quality Supervisor (see attached listing). At a minimum, you must
include an 8.5" by 11" copy of the portion of a 7.5 minute USGS Topographic Map which shows
the subject surface waters. You must identify the location of the facility and the closest downslope
surface waters (waters for which you are requesting the classification) on the submitted map copy.
The application may not be submitted until this form is completed and included with the submittal.
Applicant (corporation, individual, or other):
2. Name and Complete Address of Engineering Firm:
City:
Telephone No.
3. Project Name:
4. Storage Facility Volume:
State:
5. Name of closest downslope surface waters:
6. County(s) where project and surface waters are located:
7. Map name and date:
8. North Carolina Professional Engineer's Registration No.
9. Print Name of Engineer
10. Seal and Signature (specify date):
4of7
Zip:
gallons

IDIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL OFFICES (4/91)
Asheville Regional WQ Super.
Washington Regional WQ Super.
Raleigh Regional WQ Super.
59 Woodfin Place
P O Box 1507
3800 Barrett Dr., Suite 101
Asheville, NC 28802
Washington, NC 27889
Raleigh, NC 27609
704/251-6208
919/946-6481
919i733-2314
Avery Macon
Beaufort Jones
Chatham Nash
Buncombe - Madison
Bertie Lenoir
Durham Northampton
Burke McDowell
Camden Martin
Edgecombe Orange
Caldwell Mitchell
Chowan Pamlico
Franklin Person
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay - Rutherford
Currituck Penquimans
Halifax Wake
Graham Swain
Dam Pitt
Johnston Warren
Haywood Transylvania
Gates Tyrell
Lee Wilson
Henderson Yancy
Greene Washington
Jackson
Hertford Wayne
Hyde
Fayetteville Regional WQ Super.
Mooresville Regional WQ Super.
Wilmington Region. WQ Super.
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845
919/486-1541
704/663-1699
919/395-3900
Anson Moore
Alexander Mecklenburg
Brunswick New Hanover
Bladen Robeson
Cabamis Rowan
Carteret Onslow
Cumberland Richmond
Catawba Stanly
Columbus Pender
Harnett Sampson
Gaston Union
Duplin
Hoke Scotland
Iredell Cleveland
Montgomery
Lincoln
Winston-Salem Regional WQ Super.
8025 North Point Boulevard, Suite 100
Winston-Salem, NC 27106
919/761-2351
Alamance Rockingham
Alleghany Randolph
Ashe
Stokes
Caswell
Surry
Davidson
Watauga
Davie
Wilkes
Forsyth
Yadkin
Guilford
5 of 7

Name and Complete Address of Engineering Firm:
RECYCLE FACn rT'lES'- "
PAGE 6 (4/91)
City: State:
Telephone No.
Professional Engineer's Certification:
I,
, attest that this application for
Zip:
has been reviewed by me and is accurate
and complete to the best of my knowledge. I further attest that to the best of my knowledge the
proposed design has been prepared in accordance with the applicable regulations. Although certain
portions of this submittal package may have been developed by other professionals, inclusion of
these materials under my signature and seal signifies that I have reviewed this material and have
judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Registration No.
Print Name of Engineer
Seal and Signature (specify date):
Applicant's Certification:
I,
, attest that this application for
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand
that if all required parts of this application are not completed and that if all required supporting
information and attachments are not included, this application package will be returned as
incomplete.
Signature n, A /I V Date
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL SUPPORTING
INFORMATION AND MATERIALS, SHOULD BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE PDX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NUMBER: 919/733-5083
6of7

LCE, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
March 21, 1994
Ms. Carolyn McCaskill,
Supervisor
State Engineering Review Group
State of North Carolina
Permits and Engineering Unit
Division of Environmental
Management
P. 0. Box 29535
Raleigh, NC 27626-0535
Dear Ms. McCaskill:
I would like to, submit our application for a permit renewal
for Permit Number WQ0002702. We are enclosing our check
for $200.00 for the renewal fee. If you have any questions
regarding this permit renewal application, please let me
know.
Best regards,
ALCHEM, INC.
Randall F. Andrews,
President
sj
Enclosures

F R
01 07 1900 00:52
IC D"FiAll.
3 12 R 8 A sbury, S Loa Raj :j;q :q 2 21 k j
Phone: (919) 733,3221
ram: Q, 1 NJ I ISOM
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el

01.07.1990 00:53 P. 2
State of North Carolina
Department of Environment, Health, and Natural Resources
Division of Environmental Management
Non -Discharge Permit .Application
(THIS FORM MAY BE PHOTOCOPIED FOR USE AS AN ORIG DVAL)
RECYCLE FACILITIES
I. GENERAL INFORMATION:
1. .A�plicant (corporation, individual, or other): Al chem, Inc.
2. Print Owners or Signing Official's Name and Title (the person who is legally .
responsible for the facility. and its compliance): Mr, Randall Andrews, President
3. Mailing Address: Rt. 2, sox .521-C
City:-.- t:inas State: NC Zip:__ 28377
�910 ) 843-2121
4. 1':c ,division, facility, or establishment name . should be consistent with
proj ,'ans/specs., letters of flow acceptance, Operationa., Agreerrc;ms, t..;.
AZchen:, Inc.
5. Aliplication Date: 3 / 21 J 94 _ 6. Foe Submitted: $ 200 , o0
7. County where project is located: Rowan
8. Latitude: 3533'-30�' ; Longitude 8oe-25'-00'1 of recycle facility location
f, PERMI4, INFORMATION:
I . Permit No. (will be completed by DEM): —
2. Specify whether project is: new; x renewal,,; _ modification.
*If renewal, complete only sections I, II, .III, & applicant signature
(on pg.6). Submit- only pgs., 2, 6 (original and 3 copies of each). Engineer
signature not required for rene ,al,
3. If this application is being submitted as a result of a renewal or modification to an
existing permit, list the existing permit numbeia00002702 and issue date 4-8-93___ _
4. Specify whether the applicant is public or ____� private.
FORM: RFAC 4/91 rage 1 of 7

F R',Q-1
H 4_1 • _ _
vu..., 'aauV-
PAGE 2 (4191)
M. INFO 1; ATION ON WASTEWAT9k:
1. Niture of Wattewater: '% JDt'Ms'tic; .-- % Commercial;
P. 3
r
—0 % industrial; % Othgr waste (specify):
2. Pique provide'a ... a or two `w6id description specifying the origin of the wastewater,
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
Industrial recycle
3. Volume of recycle water genemted'iby this project: 4 , Q0Q gallons per day
4. Explanation of how recycle watervolume was determined: eater m y ng
mix tanks
5. ll�efproject description: This is a sand washing recycle operation. The sand is
Sulfuric Acid insoluble and his washed until there is no more Aluminum Sulfate
e
IV. DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of tanks, pumping facilities, high water alarms, filters,
potids, lagoons, etc.:
2. Name of closest downslope surface waters
3. Classification of closest downslopp surface waters: (as established
tv Ville Enviionmtntal Management Commission & specified on page 4 of this
application).
I
f
4, if a power failure at the facility (could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent suci impact, as
required in 15A NCAC 2H .0200:
5. lb6 facilities trust conform to the following buffers (and all other applicable buffers):
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100 feet between a surface sand filter and any residenoe under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) ' 50 feet between the recycle facilities and property lines;
2of7

F'F011 01.07. 1990 00.54 F. 4
t bL;Y(:LE FACILITMS
Name and �Omplete Address of Engineering Firm: PAGE 6 (4/91)
City: L State;
Telephone �0. p' � ----
Professio�Ial Engineer's Certlflcntjon;
attest that this application for
een reviewed
and comple a to the best of my lrnowledge. ; I further attest that the besot of my knowledgeme and is tthe
ain
Proposed de;ign has been prepared in accordance with the applicable regulations. Although cth
portions of tlns submittal package may have been developed by other professionals, inclusion of
these materials'under my signature and seal'sipifies that I have reviewed this material
jud,ge4 it to be consistent with the proposed 4stgn, and have
I
igorth Carol na .Professional Engineer's Registration No.
Print Name of Engineer
Seal O.nd Signature (specify date):
Applicant's' Certification:
1, ____
attest that this application for
has been reviewed by me and is accurate and complete to the best of my lmowlec;ge. I understand
that if all regbired parts of this application are not completed and that if all required supporting information and attachments are not included, this application package will be returned as
incomplete.
Signature Date
t
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL, SUPPORTING
INFORINATION AND MATERIALS, SHO&LD BE SENT TO TIME FOLLOWING ADDRESS:
NORTH CA.ROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROL INA 27626.0535
TELEPHONE NIJMBER: 919/733-5083
6of7

FROM—01.07.1990 00:55• F. 5
a ,
ALICHEM, INC.
813$ RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
i
March 21, 1994
Ms. Carolyn McCaskill,
Supervisor
It State Engineering Review ;Group
State of North Carolina t,
Permits and Engineering Unit
Division of Environmental
Management =
P. 0. Box 29535
Raleigh, IBC 27626-0535 - r7,c.
n .,
Dear Ms. McCaskill:
1 would like to,submit our application for a permit renewal
for Permit Number WQ0002702. We are enclosing our check
for $200.00 for the renewal fee. if you have any questions
regarding this permit renewal application, please let me
know. . 1
Best regards,
ALCHEM, INC.
IRandall F. Andrews,
President
sj
Enclosures

DIVISION OF ENVIRONMENTAL MANAGEMENT
April 27, 1994
MEMORANDUM TO: Cindy Boyles
DEM - GW Compliance Group
FROM: Rob Krebs 0
MRO - GW Section
THROUGH: Barbara Christian
MRO - GW Supervisor
SUBJECT: Alchem, Inc.
Storage Lagoon
WQ #2702/GW #94066
A site inspection of the facility revealed some areas of
concern by the MRO Groundwater Section that would need to be
addressed prior to permit renewal.
1. An area south of the production building, that previously.
was used as a storage lagoon, has raw aluminum ore deposited
throughout the area. Although there is a small containment
barrier surrounding the former lagoon, the run-off into a
drainage way still poses a problem to the residents directly
below grade (see GW Incident If 2997).
2. The bi-annual compliance monitoring reports have indicated
that the wells have not been purged prior to sampling and
TSS levels were greater than 5 mg/liter. After consulting
with the sampler, it was noted that normal sampling protocol
and QA/QC procedures have been inadvertently absent.
3. A chemical analysis of the lagoon wastewater should be
completed for SO4, aluminum, pH, TDS and specific
conductance.
4. A current topographic site plan showing the locations of all
monitor wells, existing lagoons and former lagoons should be
submitted to the MRO-GW Section (the monitor well locations
that are shown on the issued permit were incorrectly
located).

ALCHEM INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
April 20, 1993
,a
01 1+7A
Mr. Jack Floyd Vs, ptor
State of North Carolina 00010jo
Department of Environment, Heal t 3 tigg3
and Natural Resources N?ik -t
Division of Environmental Management aZA�+,�^6jH
512 N. Salisbury Street 4iF �►�y%mm.'�' EDGE
Raleigh, NC 27604 Ox,itolva i�,lata
Dear Mr. Floyd:
SUBJECT: Permit No. WQ0002702 Amendment
I would like to present you with some information so that the requirement
for monitoring wells might be alleviated. Our process works as follows:
We buy an ore called Bauxite which is dug out of the ground in Georgia and
processed by drying and grinding before being shipped to us. We react the
Bauxite with Sulfuric Acid in a digestor. The Bauxite consists of Aluminum
Hydroxide and sand. The Aluminum Hydroxide reacts with the Sulfuric Acid
to form Aluminum Sulfate. After the reaction is complete, the agitation
is stopped and the highly concentrated hot Aluminum Sulfate is pumped to
a tank. The sand is washed three times to remove adhering Alum and the wash
water is collected and stored until the next reaction --at which time it is
used for water of dilution to dilute the hot concentrated Alum. After wash-
ing and after checking to make sure that the pH is high enough, the sand
slurry is pumped into the lagoon. All of the liquid in the lagoon is even-
tually brought back into the plant for dilution water. None is discharged.
At the point where the sand is put in the lagoon, only a minute amount of
Aluminum Sulfate is still present.
We have two water supply wells. They are approximately 300 feet deep. It
is approximately 90 feet to ground water. The entire area is on a mass of
thick, heavy, red clay. There are no rocks out cropping at all in the area.
We do not intend to build all of these lagoons at once. We may find that
we will never need all five. We only intend to build two at the present
moment. I feel that these would last for several years --possibly as much
as five years. Obviously, what we would like to do is wash the sand enough
so that it could be sold or used as a product. I am planning to start look-
ing into this at a later date. Naturally, we would consult with your waste
management people before doing anything. This would allow us to not have
to construct more than two more lagoons. Would you please advise me if you
need further information.

ALCHEM, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
[phone]
Mr. Jack Floyd
NC Department of Environment,
Health and Natural Resources
Page Two
April 20, 1993
Very truly yours,
ALCHEM, INC.
P4""'.tw UJA-��
Randall F. Andrews,
President
sj
cc Mr. David Eudy, Mooresville Regional Office
d

A. C. DEFT. OF NA'ry*v' -
+ RES00'r:F
of a �, Q0111tiirN► :ti'
:APR 1 4 1993
IIYISION
State of North Carolina MOORESVILLE 'RE&Ivi<nl Offlu"E
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
April 8, 1993
Mr. Randall F. Andrews
Alchem, Incorporated
Route 2, Box 521-C
Red Springs, North Carolina 28377
A. Preston Howard, Jr., P. E.
Director
Subject: Permit No. WQ0002702 Amendment
Alchem, Incorporated
Industrial Recycle - Bauxite Process
Wastewater Recycle System
Rowan County
Dear Mr. Andrews:
In accordance with your application received October 19, 1992, we are forwarding herewith Permit
No. WQ0002702 as amended, dated April 8, 1993, to Alchem, Incorporated for the continued operation
of the two (2) lagoon recycle system and the construction and operation of five (5) additional lagoons.
This permit shall void Permit No. WQ0002702 issued December 10, 1990 and shall be effective
from the date of issuance until December 31, 1994, and shall be subject to the conditions and limitations as
specified therein. Please 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, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
704/251-6208 919/486-1541 704/663-1699 919/571-4700 919/946-6481 919/305-3900 919/896-7007
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

1 l

' One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Ms. Angela Y. Griffin at 919/ 733-5083.
Sincerely,
A. Presto oward, r., P.E.
Director
cc: Rowan County Health Department y
I""xes Reg ala f ce=VVat& Qcaality Section
Mooresville Regional Office, Groundwater Section
Jack Floyd, Groundwater Section, Central Office
Salisbury Engineering & Planning
Facilities Assessment Unit
Training and Certificaton Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Incorporated
Rowan County
FOR THE
continued operation of two (2) lagoons each approximtely 50' W x 200' L x 10' D and the construction
and operation of five additional lagoons; four (4) 180' W x 155' L x 20' D and one (1) 210 W x 155' L x
20' D to serve Alchem, Incorporated with no discharge of wastes to the surface waters, pursuant to the
application received October 19, 1992 and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment, Health and Natural
Resources and considered a part of this permit.
This permit shall void Permit No. WQ0002702 issued December 10, 1990 and shall be effective
from the date of issuance until December 31, 1994, and shall be subject to the following specified
conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction of the five lagoons and prior,to operation of this permitted
facility, a certification must be received from a professional engineer certifying that the
permitted facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
29535, Raleigh, NC 27626-0535.
1-

6. In the event that the facilities failto perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Mooresville Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an in- .
place inspection can be made. Such notification to the regional supervisor shall be made
during the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a mariner approved by the North Carolina Division of
Environmental Management.
9. 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 facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment -facilities is prohibited.
12. Freeboard in the lagoons shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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 keep 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 three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, .enter and inspect any property,
premises or place on or related to the recycle system 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; or may obtain samples of groundwater,
surface water, or leachate.
17. 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).
18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
2

19. 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.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville 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 at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as,the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility .
incapable of adequate wastewater treatment such as mechanical or electrical failures . .
of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-
pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility is not iri
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.
22. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and, IV facility at least daily, excluding weekends and
holidays, and must properly manage and. document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202
23. The recycle lagoons shall not be located within 100 feet of water supply wells.
24. Prior to beginning waste disposal operations, three (3) monitor wells, one (1) upgradient
and two (2) downgradient, shall be installed to monitor groundwater quality. The well(s)
shall be constructed such that the water level in the well is never above or below the
screened (open) portion of the well at any time during the year. The exact location and
construction details for these wells shall be approved by the Mooresville Regional Office.
3

25. The monitoring wells shall be sampled initially after construction (and prior to waste
disposal operations) and thereafter every February and July for the following parameters:
'IDS pH
SO4 Specific Conductivity
Aluminum Total Suspended Solids
Volatile Organic Compounds - In February only (by Method 1 or Method 2 below).
Method 1: Method 6230D (Capillary - Column), "Standard Methods For The
Examination of Water and Wastewater", 17th ed., 1989.
Method 2: Method 502.2 "Methods For The Determination of Organic Compounds in
Drinking Water", U.S. EPA - 600/4-88/039.
The measurement of water level must be made prior to sampling for the remaining
parameters.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to
provide relative elevations of the measuring point for each monitoring well. These
elevations shall be provided to the Regional Hydrogeologist within 60 days after well
construction. The depth of water in each well shall be measured from the surveyed point
on top of the casing.
If any volatile organic compounds are detected by method 6230D, or the equivalent method
502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds
which may be present. The results of all analyses specified in the monitoring requirements,
including 604 and 611 if required, must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW-59 (Compliance Monitoring Report Form) every
March and August.
26. The Compliance Boundary for the disposal system is specified by regulations in 15A
NCAC 2L, Groundwater Classifications and Standards. An exceedance of Groundwater
Quality Standards beyond the Compliance Boundary is subject to the penalty provisions
applicable under General Statute 143-215.6(1)a. The sale of property, by the Permittee,
which is within or contiguous to thedisposal site, may alter the location of the Compliance
Boundary.
For facilities permitted on or after December 30, 1983, the Compliance Boundary is
established at the lesser of 250 feet from the storage lagoon, or 50 feet within the property
boundary.
If the title to any property which may affect the location of the Compliance Boundary is
changed, the Permittee shall notify the'DEM Director within 14 days. The Director shall
then establish a modified Compliance Boundary which will be done as a modification to the
Permit. .
4

The REVIEW BOUNDARY for the disposal system is specified by regulations in 15
NCAC 2L, Groundwater Classifications and Standards. A REVIEW BOUNDARY is
established around disposal systems midway between the Compliance Boundary and the
perimeter of the waste disposal area. When the concentration of any substance equals or
exceeds the maximum allowable concentration of that substance at the REVIEW
BOUNDARY, as determined by monitoring, the permittee shall githrj (i) demonstrate,
through predictive calculations or.modeling, that natural site conditions, facility design and
operational controls will prevent a violation of standards at the Compliance Boundary; or,.
(ii) submit a plan for the alteration of existing site conditions, facility design or operational
controls that will prevent a violation of standards at the Compliance Boundary, and
implement that plan upon its approval by the Director.
27. The lagoon shall have a liner of natural material at least one (1) foot in thickness at all
locations with a hydraulic conductivity of no greater than 1 x 10-6 centimeters per second
when compacted. Following installation and inspection of the lagoon liner, and prior to
waste disposal operations, verification of the liner's compliance with hydraulic conductivity
and thickness specifications must be provided to the Division of Environmental
Management, Groundwater Section, by the project engineer.
28-. All wells that are constructed for purposes of groundwater monitoring shall be constructed
in accordance with 15A NCAC 2C .0108 (Standards of Construction for Wells Other Than
Water Supply) and any other state and local laws and regulations pertaining to well
construction.
29. The Mooresville Regional Office, telephone number [phone] shall be notified at
least two weeks prior to the construction of any monitoring well so that an inspection can
be made of the monitoring well location. Such notification to the regional groundwater
supervisor shall be made during the normal office hours from 8:00 a.m. until 5:00 p.m. on
Monday through Friday, excluding state holidays.
30. Within sixty (60) days of completion of all monitoring wells, the permittee shall submit two
original copies of a scaled topographic map (scale no greater than 1:24000) signed and
sealed by a professional engineer or a registered land surveyor that indicates all of the
following information:
a. the location and identity of each monitoring well,
b. the location of the waste disposal system;
C. the location of gill property boundaries,
d. the laititude and longitude of each monitoring well,
e. the relative elevation of the top of the well casing (which shall be
known as the "measuring point")
f. and the depth of water below the measuring point at the time the measuring
point is established.
All monitoring well locations and elevations shall be surveyed by a registered land
surveyor.
31. Upon completion of all well construction activities, a certification must be received from a
professional engineer certifying that the monitoring wells are located and constructed in
accordance with the Well Construction Standards (15A NCAC 2C) and this permit. This
certification should be submitted with copies of the Well Completion Form (GW-1) for
each well. Mail certification and the associated GW-1 forms to the Permits and Compliance
Unit, Groundwater SEction, P.O Box 29535, Raleigh, N.C., 27626-0535.
E

32. For the initial sampling of the well as specified elsewhere in the permit, the permittee shall
submit a copy of the GW-1 form with the Compliance Monitoring Form (GW-59) for that
well. Compliance Monitoring Forms that do not include copies of the GW-1 form will be
returned to the initiation of enforcement activities pursuant to NC General Statutes 143-
215.6.
33. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall
be provided.
34. 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.
Permit issued this the 8th day of April, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A. Preston Lloward, Jr., P E., Director
Division of avironmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0002702 Amendment
0

Perctiit No. WQ0002702 Amendment
April 8, 1993
Engineer's Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, for the
Location Project .Name
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of the approved plans and specifications.
Signature
Date
h
Registration No.

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SOC Priority Project: Yes No X
If Yes, SOC No.:
To: Permits and Engineering Unit
Water Quality Section
Attention: Angela Griffin
Date: December 16, 1992
NON -DISCHARGE STAFF REPORT AND RECOMMENDATION
County: Rowan
Permit No. WQ0002702
PART I - GENERAL INFORMATION
1. Facility and Address: Alchem, Inc. - Red Road Facility
Route 2 Box 521 - C
Red Springs, North Carolina 28377
2. Date of Investigation: December 15, 1992
3. Report Prepared by: Kim H. Colson, Environmental Engineer I
4. Persons Contacted and Telephone Number: Wayne Drye, Plant
Manager, [phone]
5. Directions to Site: From the intersection of NC Hwy 152 and
Link Street in the Town of Rockwell, turn left onto Link
Street. Proceed to the intersection of Link Street and Red
Road. Turn left onto Red Road and travel approximately 0.8
mile. Alchem, Inc. is located on the right side of Red Road.
6. Size (land available f•or expansion and upgrading): There is
adequate land available for expansion,and upgrading.
7. Topography (relationship to 100 year flood plain included):
Flat slopes; the WWT facilities are not located within the
100 year flood plain.
Attach a U.S.G.S. map extract and indicate facility site.
U.S.G.S. Quad No.: E17SW U.S.G.S. Quad Name: Rockwell, NC
Latitude: 350 33' 52" Longitude: 800 25' 26"
8. Any buffer conflicts with location of nearest dwelling and
water supply well? Yes No X If Yes, explain:
9. Watershed Stream Basin Information: UT to Second Creek
a. Watershed Classification: C
b. River Basin and Subbasin No.: Yadkin - Pee Dee 030704
c: Distance to surface water -from disposal system: A small
wet weather branch is approximately 150 feet from a
proposed lagoon location..

Page Two
PART II — DESCRIPTION OF WASTES AND TREATMENT WORKS
1. a. Volume O D40 MGD (design capacity)
Residuals: 300, tons per month
b. Types and quantities of. industrial wastewater:
Wastewater is generated from the processing of Bauxite.
C. Pretreatment Program (POTWs only): N/A
2. Treatment Facilities
a. Current permitted capacity of the facility: N/A
b. Actual treatment capacity of the current facility (design
volume): N/A
C. Please provide a description of existing or substantially
constructed wastewater treatment facilities: There are
two lagoons currently permitted. One lagoon is
completely full of residuals and is no longer used.
d. Please provide a description of proposed wastewater
treatment facilities: The proposed modification consists
of the addition of five lagoons.
3. Residuals handling and utilization/disposal scheme: Residuals
are currently stored in the lagoons which will be closed out
when full. The company is investigating the use of the
residuals in concrete. The residuals consist mainly of sand
that has been separated from the Bauxite. The company is also
planning to change to a higher grade .bauxite which contains
less sand.
a. If Residuals are being land applied, please specify DEM
permit no: N/A
Residual Contractor:
Telephone No.:
b. Residuals stabilization: PSRP PFRP Other
C. Landfill: N/A
d. Other disposal/utilization scheme (Specify): N/A
4. Treatment plant classification
sheet): No Rating
5. -SIC Code(s): 2819
Wastewater Code(s)
Primary: 84 Secondary:
Main Treatment Unit Code:. 50000
(attach completed rating

Page Three
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
funds (municipals only)? N/A
2. Special -monitoring requests: N/A
3. Important SOC, JOC or Compliance Schedule dates (Please
indicate): N/A
4. Air Quality and/or Groundwater concerns or hazardous materials
utilized at this facility that may impact water quality, air
quality, or groundwater: Groundwater comments should be
obtained. Sulfuric Acid is the only known hazardous material
stored onsite. There are no known Air Quality concerns.
5. Other Special Items: N/A
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee, Alchem, Inc., has applied for permit
modification. The modification consists of the construction of
five lagoons.
The permit should include a condition requiring the permittee
to maintain a freeboard of at least 2 feet in the lagoons. A
condition should also be included requiring an erosion.control plan
from the Division of Land Resources since the proposed modification
will disturbed greater than one acre.
If the facility is required to obtain a stormwater permit, the
applicant should apply for a stormwater permit before approval of
the modification.
It is recommended the permit be modified provided the above
mentioned concerns are addressed.
Signature of Report Preparer
— 2) , k-e�� -
Water Quality R ional Supervisor
2 Date —T� Z.

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Name of Plant�t_"Lr­.,
ZNc — Zc1
Owner or Contact :Person:
Mailing Address:
9C Z��:jq--
County: _ 1Zg).,.rati`
Telephone: tEIR& (n���— 1
NPDES Permit No. NC00 ti� )= Nondisc: Per.
lssueDate: Ta�.�o� two
Expiration Date:__ 19�14
Ekisting Facility ✓
New Facility
- _ - Rated By: 14, CoUso,-t
Date.--/;
Reviewed (Train. & Cert.)'
Reg. Office
Reviewed (Train. & Cert.)
Central Office
ORC WA
Grade ti-\A
Plant Class: (circle one)
I II III IV Total Points Z
ITEM POINTS
(1) Industrial Pretreatment Units and/or
Industrial Pretreatment Program
(see definition No. 33)
4
(2) D SI ,N FLOW OF PLANT IN GPD
(not applicable to non -contaminated cooling waters, sludge
handling facilities for water purification plants, totally
closed cycle systems (def. No. 11). and facilities
consisting only of Item (4) (d) or Items (4) (d) and (11) (d))
- 0 -- 20,000.........................
1
20.001 — So,o00...................... .
2
50,001 — 100,000...........................
3
100,001 — 250.000......................
4
250.001 — S0o,000..........................
5
500,001—1,0001000.........................
8
1,000,001 — 2.000.000 ..........................
......... .... .........
10
2,000.001 (and up) - rate 1 point additional for each
"
200.000 gpd capacity up to a
maximum of 30
Design Flow (gpd) ;
(3) PRELIMINARY UNITS (see definition no. 32)
(a) Bar Screens ................................
1
or
(b) Mechanical Screens, Static Screens or
Comminuting Devices .......... ..............
2
(c) Grit Removal
...............................
or
1
(d) Mechanical or Aerated Grit Removal ...........
2
(e) Flow Measuring Device ............."
1
or " ......
(Q Instrumented Flow Measurement ....
2
(g) Preaeration................................
2
(h) Influent Flow -Equalization ..........
2
n Grease or Oil Separators - Gravity..........
2
Mechanical . .. .. ..
3
Dissolved Air Flotation.
8
U- Prechlorulation ..............................
(4) PRIMARY TREATMENT UNITS
(a) Septic Tank (see definition no. 43) ..............
2
(b) Imhoff Tank..................................
5
(c) Primary Clarifiers ............................
5
(d) Settling Ponds or Settling Tanks for Inorganic
Non -toxic Materials (sludge handling facilities
for water purification plants, sand, gravel,
stone, and other mining operations except
recreational activities such as gem or gold
mining)
......................................
2
(5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(i)Aeration - High Purity Oxygen System .....
Diffused Air System ...........
Mechanical Air System (fixed,
floating or rotor) ..............
Separate Sludge Reaeralion .....
(ii) Trickling Filler
High Rate ...................
Standard Rate ..........
Packed Tower ...............
Oil) Biological Aerated Filler or Aerated
Biological Filter ......................
(iv) Aerated Lagoons ..................... .
(v) Rotating Biological Contactors ..........
(vi) Sand Filters.
intermittent biological .....
recirculating biological .....
K,J Stabilization Lagoons .........
(viiiWarifier .................. ...... ..
(ix) Single stage system for combined
carbonaceous removal of BOD and
nitrogenous removal by nitrification
(see def. No. 12) (Points for this item
have to be in addition to items (5) (a)
n through (5) (a) (vii7
.
(x) Nutrient additions to enhance SOD .
temoval...............................
(xi) Biological Culture ('Super Bugs') addition
to enhance organic compound removal .... .
(b) Nitrogenous Stage
0) Aeration - High Purity Oxygen System .....
Diffused Air System ...........
Mechanical Air System (fixed,
floating, or. -rotor) ...... ......
Separate Sludge Reaeration .....
u) Trickling Filler -
High Rate ............ .
Standard Rate ............
Packed Tower............
(iii) Biological Aerated Filter or Aerated
Biological Filter .........................
(iv) Rotating Biological Contactors ............
(v) Sand Filter -
intermittent biological ........
recirculating biological ........
(vi) Clarifier ................................

(6) TERTIARY OR ADVANCED TREATMENMNIT
(10) OHEMICAL ADDITION SYSTEM (S) (See definition No. 9)
(a) Activated Carbons Beds -
(not applicable to chemical additions rated as item
without carbon regeneration .................. 5
(3) 0). (5) (a) (xi). (6) (a), (6) (b), (7) (b). (7) (e),
with carbon regeneration ..................... 15
(g) (a). (g) (b). or (9) (c) 5 points each: List:
(b) Powdered or Granular Activated Carbon Feed -
, .... 5
without carbon regeneration ................. 5
...... 5
with carbon regeneration ................... S
5
(c) fair Stripping ............................. 5
..... 5
(d) Denitrificalion Process (separate process) ....'. 10
(e) Electrodialysis ............................. 5
(11) MISCELLANEOUS UNITS
(q Foam Separation ............................. 5
(a) Holding Ponds, Holding Tanks or Settling Ponds
(g) son Fxchange................................ 5
for'Organic or Toxic Materials including wastes
(h) Land Application of Treated Effluent
from mining operations containing nitrogen and/or
(see definition no. 22b) (not applicable for
phosphorous compounds In amounts significantly
sand, _gravel, stone and other similar mining
greater than is common for domestic wastewater .......... 4
operations)
(b) Effluent Flow Equalization (not applicable to storage
() on agriculturally managed sites (See del.
basins which are inherent in land application systems). 2
No. 4) ................................... ' 10
(c) Stage Discharge (not applicable to storage basins
(i) by high rate infiltration on non -agriculturally
inherent in land application systems-----.--..--- 5
managed sites (includes rotary distributors
(d) Pumps._ - 3
and similar fixed nozzle systems) ........... 4
(a) Stand -By Power Supply _.._ 3
(iii) by subsurface disposal (includes low pressure
(f) Thermal Pollution Control Device.—----.. 3
pipe systems and gravity systems except at
plants consisting of septic tank and nitrifica-
Z
tion limes only) ............................. 4
TOTAL POINTS
(0 Microscreens ................................... 5
Phosphorus Remofal by Biological Processes
CLASSIFICATION
(See def. No. 26) ............................ 20
(k) Polishing Ponds - without aeration ....... 2
Class 1 5 - 25 Points
with aeration .......... 5
Class 11 26- 50 Points
(1) Post Aeration - cascade .............. .0
Class III .___ 51- 65 Points
diffused or mechanical ... 5
Class IV 66- Up Points
(m) Reverse Osmosis ............................... 5
(n) Sand or Mixed -Media Filters - tow rate ....:...... 2
Facilities having a rating of one through four points, inclusive,
high rate .......... 5
do not require a certified operator. Classification of all other
(o) Treatment processes for removal of metal or
facilities requires a comparable grade operator in responsible
cyanide .................................... 15
charge.
(p) Treatment processes for removal of toxic
materials other than metal or cyanide ......... 15
Facilities having an activated sludge process will be assigned
a minimum classification of Class II.
II SLUDGE TREATMENT
Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank - Heated ............... 10 or cyanide will be assigned a minimum classification of Class If.
Aerobic ..............
5
Unheated .............
a Facilities having treatment processes for the biological removal
(b) Sludge Stabilization (chemical or thermal) .......
5 of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Gravity ................
2 Ill.
Vacuum Assisted .......
5
(d) Sludge Elutriation .............................
5 In -plant processes and related control equipment which are an
(e) Sludge Conditioner (chemical or thermal) ........
5 integral part of industrial production shall not be considered waste
(I) Sludge Thickener (gravity) ......................
5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit
having a design flow of 1,000 gpd or less, shall not be subject to
(not applicable to a unit rates as (3) () .........
6 rating.
(h) Sludge Gas Utilization (including gas storage) ....
2
(i) Sludge Holding Tank - Aerated ................
5 ADDITIONAL COMMENTS:
Non -aerated .... .. .
2
(j Sludge Incinerator - (not including activated
carbon regeneration) .....
10
(k) Vacuum Filter, Centrifuge or Filter Press or other
similar dewatering devices ....................
10
(8) SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons .........................................
2
(b) Land Application (surface and subsurface)
(see definition 22a)
mere the facility holds the land app. permit ...
10 -
-by contracting to a land application operator who
holds the land application permit ... .... ... . 2
-land application of sludge by a contractor who does
not hold the permit for the wastewater treatment
facility where the sludge Is generated .........
10
(c) Landfilled (burial) .............................
5
(9) DISINFECTION
5
(a) Chtorinat'ion .............................
(b) Dechlorinat'ion ........................
5
(c) Ozone ..............................
5
5
(d) Radiation ..........................

U
R C. DEP r. OF N®nMAZ
RESOURCES AND
POMMUNI-ry DEi'EZopxf,1.T
l
ROV 1 2 1992
DIVISION OF EKV(kGPf;,°E;;7pl 11ANAGIMEN State of North Carolina
%'P \ MOORESVILLE RED � otnae t - of Environment, Health and Natural Resources
Division of Environmental Management
\` 512 North Salisbury Street • Raleigh, North Carolina 27604
nV James G. Martin, Governor George T. Everett,Ph.D.
William W. Cobey, Jr., Secretary Director
October 20, 1992
MR RANDALL F. ANDREWS
1 �`1 ALCHEM, INC.
P RT. 2 BOX 521-C
RED SPRINGS; NORTH CAROLINA 28377
Subject: Application No. WQ0002702
8135 Red Road
Recycle Facility
Rowan County
Dear MR ANDREWS:
The Division's Permits and Engineering Unit acknowledges receipt of your permit application and
supporting materials on October 19, 1992. This application has been assigned the number shown
above. Please refer to this number when maldng.inquiries on this project.
Your project has been assigned to Angela Griffin for a detailed engineering review. A technical
acknowledgement will be forthcoming.
Be aware that the Division's regional office, copied below, must provide recommendations from the
Regional Supervisor or a Procedure Four Evaluation for this project, prior to final action by the
Division.
If you have any questions, please contact Angela Griffin at [phone].
Sincerely,
Donal Safrit, P
Supervisor, Permits and Engineering Unit
M,g e R -ton
SalisburyEngineering & Planning
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

. Inc..Analytical
Kxford
an ns
:iAaboratories, l
1316 South Fifth Street
DATE RECEIVED 2-8-89
2-23-89 Wilmington, N.C. 28401
DATE REPORTED
[phone]
8 9W4 6 6 6
PAGE 1 OF 1
�;c,-ate-: ,.: ;,..
•
AGRI CHEMICALS
P.0 • l
,'INDU,STRIAL
ED:'j!SP�INGS.; t'' N. c...28377
,I
:ATTENTI.ONt_,..'RANDALL ANDREWS
SULFURIC ACID INSOLUBLE MATERIAL
7SAMPLE DESCRIPTION:
rSULFURIC'ACID INSOLUBLE
MATERIAL FROM BAUXITE
RESULTS
'.t •1.'y.�i vie Lr!:.
1
Results`on'teachate '
7ax,senic as As PPM
, ,
�.e 1::ium''., •as Ba , PPM .
.400
• i as Cd , PPM
.Cadmium
<.•010
`L,gad ; '� as Pb , PPM
as Cr PPM
<.010
, ,
,chromium
Hg .PPM o
<.0005
e.r.cury, , as ,
Selenium as Se
,
'lver• , as Ag , PPM
•N'':: 1. f.: ?..:
�.itrial
8.0
•PH.
EinxF,
" �'
R , CHEMIST

Oxford Laboratories, Inc. Analytical and Consulting •Chemists
-� DATE RECEIVED 10-31-89 1316 South Fifth Street
DATE REPORTED 11-6-89 Wilmington, N.C. 28401
s9ws65o [phone]
PAGE 1 OF 1
INDUSTRIAL AGRI CHEMICALS '
P.O. #
RT.2 BOX 521-C
RED SPRINGS , N.C. 28377
ATTENTION:. RANDALL ANDREWS
SAMPLE DESCRIPTION: LIQUID FRICTION
1. LIQUID FRACTION _
ESULT
. 1
luwinum , as Al t .001
Sulfate Gravimetric , as SO4 , PPM 103
ROGER C. OXFORD , CHEMIST
NOTE: The pH of the liquid fraction was determined to be 2.5 by Mr. Randall
Andrews in his company -owned laboratory.
_D

State of North Carolina
Department of Environment, Health, and Natural Resources
Division of Environmental Management
Non -Discharge Permit Application
(THIS FORM MAYBE PHOTOCOPIED FOR USE AS AN ORIGINAL)
RECYCLE FACILITIES
I. GENERAL INFORMATION:
1. Applicant (corporation, individual, or other):
2. Print Owners or Signing Official's Name
and Title
(the person
who is legally
responsible for the facility. and its compliance):
01rZ
1=A0QALI.
.G NO [ek-UJI-7
3. Mailing Address: Z. Quo X SZI - C,
City: Q_S �o rJ.r State: N._ Zip:
r �� 7A /Z� O T 7^ �l G✓
Telephone No.: (, � )
4. Project Name (subdivision, facility, or establishment name - should be consistent with
project name on plans/specs., letters of flow acceptance, Operational Agreements, etc.):
5. Application Date: i / e/ a 6. _Fee Submitted: $
7. County where project is located: 1r,,0vQAQ
8. Latitude: A) 5'5'-')0 Longitude f3Dc' 2-5 —CO t o of recycle facility location
I1. PERMIT INFORMATION:
1. Permit No. (will be completed by DEM): h) C?(-)r) A m
2. Specify whether project is: new; renewal*; modification.
*If renewal, complete only sections I, II, III, & applicant signature
(on pg.6). Submit only pgs. 1, 2, 6 (original and 3 copies of each). Engineer
signature not required for renewal.
3. If this application is being submitted as a result of a renewal or modification to an
existing permit, list the existing permit number WQ cw z-10Land issue date t o 0
4. Specify whether the applicant is public or _4 private.
FORM: RFAC 4/91 Page 1 of 7

RECYCLE FACILITIES
PAGE 2 (4/91)
III. INFORMATION ON WASTEWATER:
1. Nature of Wastewater: % Domestic; % Commercial;
1(20 % Industrial; % Other waste (specify):
2. Please provide a one or two word description specifying the origin of the wastewater,
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
.J LWCuSTW_IAL
3. Volume of recycle water generated by this project:
4Q)O
gallons per day
4. Explanation of how. recycle water volume was determined: AS,
1 i4 k Lei N cc` f I Y�-dam G ni i':'4 �rt:v'T VJ A'"Tt ?_
5. Brief project description:
P-Aia -sC i'rrt- PCICCeL51:1
IV. DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of taAks, pumping facilities, high water alarms, filters,
ponds, lagoons, etc.: tU 5 A PPu (A-t ►o"%J t y 15c.r Om;-r-rt-0 fAC,
NooiFtL4T1,ti1 -r•o rE­r,Mi? - NO W&L— O 27c2Z TU;J
Mori I,-''C -TiotJ rN\;c�_vt;L5 21-k- Anpr-rsofJ o ff- f:�%v c.
L_AL-3no,'J!�J To :CL4P P�_-eMrrtij�> F►acaur-ry,
2. Name of closest down slope surface waters: T_ie1 dTA'-1Y Td 5EL-'01412 Cei- -K
3. -Classification of closest downslope surface waters: C� (as established
by the Environmental Management Commission & specified on page 4 of this
application).
4. If a power failure at the facility could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent such impact, as
required in 15A NCAC 2H .0200:
5. The facilities must conform to the following buffers (and all other applicable buffers):
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100 feet between a surface sand filter and any residence under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) 50 feet between the recycle facilities and property lines;
2of7

RECYCLE FACILITIES
PAGE 3 (4/91)
6. If any of the buffers specified in no. 5 above are not being met, please explain how the
proposed buffers will provide -equal or better protection of the Waters of the State with
no increased potential for nuisance conditions: W A
7 . Are any components of the recycle facility located within the 100-year flood plain?
yes; _ , no. If yes, briefly describe the protective measures being taken to protect
against flooding.
THIS APPLICATION PACKAGE WILUNOT BE ACCEPTED BY THE
DIVISION OF ENVIRONMENTAL MANAGEMENT UNLESS ALL OF
THE APPLICABLE ITEMS ARE INCLUDED WITH THE SUBMITTAL
Required Items
a. One original and three copies of the completed and appropriately executed application form
b. The appropriate permit processing fee, in accordance with 15A NCAC 2H .0205(c)(5).
c. Five sets of detailed plans and specifications signed and sealed by a North Carolina
Professional Engineer. The plans must include a general location map, a site map which
indicates where any borings or hand auger samples were taken, along with buffers,
structures, and property lines. Each sheet of the plans and the first page of the specifications
must be signed and sealed.
d. For 'industrial wastewater, a complete chemical analysis of the typical wastewater
must be provided. The analysis may include, but shall not be limited to, Total Organic
Carbon, BOD, COD, Chlorides, Phosphorus, Nitrates, Phenol, Total Trihalomethanes,
TCLP analysis, Total Halogenated Compounds, Total Coliforms, and Total Dissolved
Solids.
e. If lagoons are a part of the facilities and the •recycle water is industrial, provide a
hydrogeologic description of the subsurface to a depth of 20 feet or bedrock, whichever is
less. The number of borings shall be sufficient to define the following for the area
underlying each major soil type at the site: significant changes in lithology, the vertical
permeability of the unsaturated zone, the hydraulic conductivity of the saturated zone, and
the depth of the mean seasonal high water table.
f. Five copies of all reports, evaluations, agreements, supporting calculations, etc., must be
submitted as a part of the specifications which are signed and sealed by a North Carolina
Professional Engineer. Although certain portions of this required submittal must be
developed by other professionals, inclusion of these materials under the signature and seal
of a North Carolina Professional Engineer signifies that he has reviewed this material and
has judged it to be consistent with his proposed design.
g. Five copies of the existing permit if a renewal or a modification.
3of7

RECYCLE FACIL=S
PAGE 4 (4/91)
TO: REGIONAL WATER QUALITY SUPERVISOR
Please provide me with the classification of the surface waters identified in number 5
below and on the attached map segment:
Name of surface waters: -rr2 -raiz-r -ro
Classification (as established by the Environmental Management Ro , ission): G
N. C. DEPT. or N T I L
Proposed Classification, if applicable: e� RESOURCES AND
Signature of regional office personnel: J' ;f—a-:,,, Date: /S
INSTRUCTIONS TO ENGINEER 01101uid of x!AN GNEdi
h,iiG ES iitf RICIGNaI OFFICE
In order to determine whether provisions for dual or standby power may be required for the
subject facility, the classification of the closest downslope surface waters (the surface waters that
any overflow from the facility would flow toward) must be determined. You are required to
submit this form, with items 1 through 10 completed, to the appropriate Division of Environmental
Management Regional Water Quality Supervisor (see attached listing). At a minimum, you must
include an 8.5" by 11" copy of the portion of a 7.5 minute USGS Topographic Map which shows
the subject surface waters. You must identify the location of the facility and the closest downslope
surface waters (waters for which you are requesting the classification) on the submitted map copy.
The application may not be submitted until this form is completed and included with the submittal.
1. Applicant (corporation, individual, or other): A L (:. N E VA , _rj L
2. Name and Complete Address of Engineering Firm: LN6,11Jk_4Lw1 NCB
:- (-04NNIA-k7 1 c5l p -A N , 0A1N i-r,
City: State: N L,_ Zip: Z8 t 44-
Telephone No. 7v l -
3. Project Name: A Lc.a I
4. Storage Facility Volume: 4 5C<) gallons
5. Name of closest downslope surface waters: T-o sE-CoNgo
6. County(s) where project and surface waters are located: Ro-,ATi
7. Map name and date: R u +,_w ti-t -
8. North Carolina Professional Engineer's Registration No. q r-51 Z
9. Print Name of Engineer PAr,-JzYL E. w acjo,qE�
10. Seal and Signature (specify date): C�r;����,,�,
�O . �ESS(p;�•. 9 of
ram SEP,
9572 =
RrL L.
_4__/f V.1
4

DIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL, OFFICES (4/91)
Asheville Regional WQ Super.
Washington Regional WQ Super.
Raleigh Regional WQ Super.
59 Woodfm Place
P O Box 1507
38W Barrett Dr., Suite 101
Asheville, NC 28802
Washington, NC 27889
Raleigh, NC 27609
704/251-6208
919/946-6481
919i133-2314
Avery Macon
Beaufort Jones
Chatham Nash
Buncombe Madison
Berrie Lenoir
Durham Northampton
Burke McDowell
Camden Martin
Edgecombe Orange
Caldwell Mitchell
Chowan Pamlico
Franklin Person
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay Rutherford
Currituck Perquimans
Halifax Wake
Graham Swain
Dare Pitt
Johnston Warren
Haywood Transylvania
Gates Tyrell
L= Wilson
Henderson Yancy
Greene Washington
Jackson
Hertford Wayne ,
Hyde
Fayetteville Regional WQ Super.
Mooresville Regional WQ Super.
Wilmington Region. WQ Super.
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845
919/486-1541
704/663-1699
919R95-3900
Anson Moore
Alexander Mecklenburg
Brunswick New Hanover
Bladen Robeson
Cabarrus Rowan
Carteret Onslow
Cumberland Richmond .
Catawba Stanly
Columbus Pender
Harnett Sampson
Gaston Union
Duplin
Hoke Scotland
lredell Cleveland
Montgomery
Lincoln
Winston-Salem Regional WQ Super.
8025 North Point Boulevard, Suite 100
Winston-Salem, NC 27106
919l161-2351
Alamance
Rockingham
Alleghany
Randolph
Ashe
Stokes
Caswell
Sung
Davidson
Watauga
Davie
Wilkes
Forsyth
Yadkin
Guilford
5of7

RECYCLE FACILITIES.
PAGE 6 (4/91)
Name and Complete Address of Engineering Firm:► L �alz-r►U i r`7 �r1c,�itiLx
pu4N.,tiC � lji&-, -A 0. +AAI J SY
City: :�,AuSF,epzy State: NC; Zip: Z-6(++
Telephone No. 7y4 -
Professional Engineer's Certification:
I, L�,27zyL- I- L'JAvai-i<-z , attest that this application for Ao,10cA-r10J
-rO F6,ZP^17 "Te, ff-ACy-ry has been reviewed by me and is accurate
and complete to the best of my knowledge. I further attest that to the best of my knowledge the
proposed design has been prepared in accordance with the applicable regulations. Although certain
portions of this submittal package may have been developed by other professionals, inclusion of
these materials under my signature and seal signifies that I have reviewed this material and have
judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Registration No. Q 57 Z
Print Name of Engineer �e.2Yt- t •
11j117111/1/'
Seal and Signature (specify date):
gEP, -
g57 241
:,, •.FNGI� . v .4
"'9, R?1-L L. `1�;;
Applicants Certification:��
attest that this applicatia w r -
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand
that if all required parts of this application are not completed and that if all required supporting
information and attachments are not included, this application package will be returned as
incomplete. 9
Signature ���� Date
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL SUPPORTING
INFORMATION AND MATERIALS, SHOULD BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NUMBER: 919/733-5083
6of7

RECYCLE FACILITIES
PAGE 7 (4/91)
PERMIT APPLICATION PROCESSING FEES
(effective October 1,1990)
CATEGORY NEW APPLICATIONS/ RENEWALS WITHOUT
MODIFICATIONS MODIFICATIONS
> 1,000,000 GPD
Industrial $400 $300
Domestic/Cooling Water $400 $300
10,001 - 1,000,000 GPD
Industrial $400 $250
Domestic/Cooling Water $400 $250
1,001 - 10,000 GPD
Industrial' $400 $200
Domestic/Cooling Water $400 $200
< or = 1,000 GPD and
Single Family Dwelling $240 $120
Sludge < or = 300 Acres $400 $250
Sludge > 300 Acres $400 $250
Sewer Extensions
(nondelegated) $400 0
Sewer Extensions
(delegated) $200 0
Closed -Loop Recycle
or Evaporative $400 $200
NOTE: The Fees for Soil Remediation Projects are the same as for Sludges.
Under the Sewer Extension Fee, "delegated to municipalities" applies
only to those governmental jurisdictions that have specific delegation
review authority, as granted by the Division of Environmental
Management.
7of7

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ply .
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street - Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Randall F. Andrews
Alchem, Inc.
Route 2, Box 521-C
8135 Red Road
Rockwell, NC 28377
Dear Mr. Andrews:
R. Paul Wilms
Director
January 10, 1990
Subject: Permit No. WQ0002702
Alchem, Inc.
Industrial Recycle - Bauxite Process
Rowan County
In accordance with your application received November 17, 1989 we are forwarding
herewith PertYiit No. WQ0002702, dated January 10, 1990, to Alchem, Inc. for the construction
and operation of the subject recycle facility.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the conditions and limitations as specified therein.
If any parts, requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request an adjudicatory hearing upon written request within 30 days
following receipt of this permit. This request must be in the form of a written petition, conforming
to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative
Hearings, P.O. Box 11666, Raleigh, NC 27604. Unless such demands are made this permit shall
be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need
additional information concerning this matter, please contact Mr. William Barlow at 919/
733-5083.
Si cerely, .
/ S
Charles R. Wakil
Acting Director
cc: Rowan County Health Department
Mooresville Regional Office
Environmental Hydrogeological Consultants
Groundwater Section ;
Polludon Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Inc.
Rowan County
FOR THE
construction and operation of two (2) lagoons each approximately 50' W x 200' L x 10' D and all
associated pipes, valves and appurtenances to serve Alchem, Inc. with no discharge of wastes to
the surface waters, pursuant to the application received November 17, 1989, and in conformity
with the project plan, specifications, and other supporting data subsequently filed and approved
by the Department of Environment, Health and Natural Resources and considered a part of this
permit.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the following specified conditions and limitations: ,
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting
data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
27687, Raleigh, NC 27611.

6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Mooresville Regional Office, phone po. 704/663-1699, shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an in -place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The'sludge generated from these treatment facilities must be disposed of in accordance with
General .Statute.143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. 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 facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the lagoon shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to, insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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 keep 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 three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the disposal site and 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; or may obtain samples of
groundwater, surface water, or leachate.
17. 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).
18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6.
2

19. 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.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project. 1
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office,
telephone no. 704/663-1699, 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 at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
C. Any failure of a pumping station, sewer line, or treatment facility resulting in a
by-pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility has gone out of
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.
22. The Permittee shall employ a certified wastewater treatment plant operator to be in
responsible charge of the wastewater treatment facilities. The operator must hold a
certificate of the grade at least equivalent to the classification assigned to the wastewater
treatment facilities by the Certification Commission. Within thirty days after the
wastewater treatment facilities are 50% complete, the Permittee must submit a letter to the
Certification Commission which designates the operator in responsible charge.
J/23. The lagoon shall have a liner of natural material at least one (14 foot in thickness at all
locations with a hydraulic conductivity of no greater than 1 x 10 centimeters per second
when compacted. Following installation and inspection of the lagoon liner, and prior to
waste disposal operations, verification of the liner's compliance with hydraulic conductivity
and thickness specifications must be provided to the Division of Environmental
Management, Groundwater Section, by the project engineer.
24. 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.
25. The recycle lagoon shall not be located within 100 feet of water supply well.
3

DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
MEMORANDUM /
TO:iJi:
DATE:
FROM: Jack FloyE/---t—
V. C. DEPT. OF NATURAM
RESOURCES AND
COMMUNITY DEVELOPMEPTl°
P,!n, V 1 2 1992
1IVISIGII RF' BVIR01114EI1TU HNAGEMMT,
MOOCESVi.EE REGIONAL OFF{CE
SUBJECT: Application for Renewal/Amendment of Permit No. (,�f Z40 Z
New Permit
Facility Name Achem , J G .
County ,P0L06 Vk
Type of Project: i a-G onn "'It gs w�
Central Office Contact:
Applicable Permit Numbers: W,Q Ci�L7Z GW
EPA AC
We have received a copy of the above referenced application,
which was sent to your regional office for comment on or about
ln,r , l 9 9 Z-
You should review the application package for completeness
and adequacy of relevant information and submit your request for
ad�dlitional informatiop to me (via telephone or memo) by -
/Vd✓ z3 , 10'Cso that all required information can be
requested from the applicant at one time. A copy of our formal
request to the applicant for additional information will be
provided to you.
If you do not require additional information from the
applicant to complete your evaluation of the project, you should
re iew the. application package and submit your comments to me by
7W
If a copy of the application package has not been made
available to your office, PLEASE LET ME KNOW IMMEDIATELY so that_
a copy can be forwarded to you as soon as possible.
Cat cd�,,e. �.� � /� .�- � -� � - �a79-7qoa'

MEMO
oa � T .:
J f
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_'r� f w 1 r.".r
r ✓Q i �_
' -
.�" r• raft,
/ !-, ter �.(r`+ f-e, ti; ♦
'i.
i +.. � ?; /. , .. - 1,
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�. , � .,- - A./Y ,
fir, , ,
/'• /�� ,.,, �' ir,i
«-. r _. , t! �. -, � - .,.'f'fir. .A. .J -t
:�'I .
fth
uarolina Department of Envilronmen,
Health, and Natural Resou rces
V F QUAM 11tR1

MEMORANDUM
TO: Don Safrit
THROUGH: Bob Cheek
FROM: Jack Floy 7—L--
March 11, 1993
>R SOVIZCE§lVr
001WAIVl "T7 ",EVE ®pury'T
MAR 15 1993
MINE OF EiR81ROMIENTA1 F,IAlIAGEREN
ODDRESVIUE i
�6�D1yA< OfF10E
SUBJECT: Modification to Permit No. WQ0002702
Alchem, Inc.
Proposed Solids Storage Lagoons
Rowan County
WQ0002702/Gg92288
Angela Griffin : Review Engineer
The Groundwater Section has reviewed the subject permit
application to construct 5 additional lagoons for solids disposal. The
solids are generated by the production of alum. The lagoons are
proposed to be built above existing grade on the property and will be
lined with a natural clay material (permeability no greater than
1 x 10 cm/sec). Volume of these lagoons are unknown.
The lagoons will be constructed on site approximately 100 feet
downgradient of a water supply well serving the industry. An unnamed
tributary is located approximately 200 feet downgradient of the
proposed lagoons. The depths to a seasonal high water table and
bedrock are approximately 30 and 40 feet respectively. Because of the
location of the water supply well, the Section believes groundwater
monitoring may be necessary. To ensure the integrity of the lagoon
liner and to protect the downgradient water supply wells, the Section
believes groundwater monitoring is warranted.
- Therefore the Groundwater Section recommends issuance of the
permit to include the following conditions:
1. Prior to beginning waste disposal operations, two (2)
monitor wells, one (1) one upgradient and one (1)
downgradient, shall be installed to monitor groundwater
quality. The well(s) shall be constructed such that the water
level in the well is never above or below the screened (open)
portion of the well at any time during the year. The exact
location and construction details for these wells shall be
approved by the Mooresville Regional Office.

v
2. The monitor wells shall be sampled initially after
construction (and prior to waste disposal operations) and
thereafter every February and July for the following
parameters:
TDS pH
Water Level SO4
Specific Conductivity Aluminum
Total Suspended Solids
Volatile Organic Compounds - (In February Only by method 1 or
2 below)
Method 1: Method 6230D (Capillary - Column), "Standard
Methods For The &amination of Water and
Wastewater", 17th ed., 1989
Method 2: Method 502.2 "Methods For The Determination
Of Organic Compounds In Drinking Water", U.S.'
EPA - 600/4-88/039
The measurement of water level must be made prior to
sampling for the remaining parameters.
The measuring points (top of well casing) of all
monitoring wells _shall be surveyed to provide relative
elevations of the measuring point for each monitoring
well. These elevations shall be provided -to the
Regional Hydrogeologist within 60 days after well
construction. The depth of water _in each well shall be
measured from the surveyed point on the top of the
casing.
If any volatile organic compounds are detected by method
6230D, or the equivalent method 502.2, then EPA methods 604
and 611 must also be run to detect other organic
compounds which may be present. The results of all
analyses specified in the monitoring requirements,
including 604 and 611 if required, must be submitted
simultaneously.
The results of the sampling and analysis shall be sent to
the N.C. Division of Environmental Management on Form GW-59
[Compliance Monitoring Report Form] every March and August.

3. The Compliance Boundary for the disposal system is specified
by regulations in 15A NCAC 2L, Groundwater Classifications
and Standards. An exceedance of Crou:ndwater Quality
Standards beyond the Compliance Boundary is subject to the
penalty provisions applicable under General Statute
143-215.6(1)a.
For facilities permitted on or after December 30, 1983, the
Compliance Boundary is established at the lesser of 250 feet
from the storage lagoon, or 50 feet within the property
boundary.
If the title to any property which may affect the location
of the Compliance Boundary is changed, the Permittee shall
notify the DEM Director within 14 days. The Director shall
then establish a modified Compliance Boundary which will be
done as a modification to the Permit.
The REVIEW BOUNDARY for the disposal system is specified by
regulations in 15A NCAC 2L, Groundwater Classifications and
Standards. A REVIEW BOUNDARY is established around disposal
systems midway between the Compliance Boundary and the
perimeter of the waste disposal area. When the concentration
of any substance equals or exceeds the maxim= allowable
concentration of that substance at the REVIEW BOUNDARY, as
determined by monitoring, the permittee shall either (i)
demonstrate, through predictive calculations or modeling,
that natural site conditions, facility design and operational
controls will prevent a violation of standards at the
Compliance Boundary; or, (ii) submit a plan for the
alteration of existing site conditions, facility design or
operational controls that will prevent a violation of
standards at the Compliance Boundary, and implement that plan
upon its approval by the Director.
4. The lagoon shall have a liner of natural material at least
one foot in thickness, compacted to 95% proctor standard dry
density and installed and compacted in layers no thicker than
six inclIes, with a hydraulic conductivity of no greater than
1 x 10 an/sec. Following installation and inspection of
the lagoon liner, and prior to waste disposal operations,
verification of . the liner's compliance with hydraulic
conductivity and thickness specifications must be
provided to the Division of Environmental Management,
Groundwater Section, by the project engineer.
5. Any additional groundwater quality monitoring, as deemed
necessary by the Division, shall be provided.

6. All wells that are constructed for purposes of
groundwater monitoring shall be constructed in
accordance with_ 15A NCAC 2C .0108 (Standards of
Construction for Wells Other than Water Supply)
and any other state and local laws and regulations
pertaining to well construction.
7. The Mooresville Regional Office, telephone number
704-663-1699 shall be notified at least forty-eight (48)
hours prior to the construction of any monitoring well so
that an inspection can be made of the monitoring well
location. Such notification to the regional groundwater
supervisor shall be made during the normal office hours from
8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding
state holidays.
8. Within sixty (60) days of completion of all monitoring wells,
the permittee shall submit two original copies of a scaled
topographic map (scale no greater than 1:24000) signed and
sealed by a professional engineer or a state licensed land -
surveyor that indicates all of the following information:
a. the, location and identity of each monitoring well,
b. the location of the waste disposal system,
C. the location of all property boundaries,
d. the latitude ,anti longitude of each monitoring well,
e. the relative elevation of the top of the well
casing (which shall be known as the "measuring
point'),
f. and the depth of water below the measuring point
at the time the measuring point is established.
All monitoring well locations and elevations shall be
surveyed by a state licensed land surveyor.
9. Upon completion of all well construction activities, a
certification must be received from a professional engineer
certifying that the monitoring wells are located and
constructed in accordance with the Well Construction
Standards (15A NCAC 2C) and this permit. This certification
should be submitted with copies of the Well Completion Form
(GW--1) for each well. Mail this certification and the
associated GW-1 forms to the Permits and Compliance Unit,
Grotmdwater Section, P.O. Box 29535, Raleigh, NC, 27626-0535.
10. For the initial sampling of the well as specified elsewhere
in the permit, the permittee shall submit a copy of the.GW-1
form with the Compliance Monitoring Form (GW-59) for that
well. Compliance Monitoring Forms that do not include copies
of the GW-1 form will be returned to the permittee without
being processed. Failure to submit these foams as required
by this permit may result in the initiation of enforcement
activities pursuant to NC General Statutes 143-215.6.

If there are any questions, please let me know.
BC/JF:ja/92288.
cc: .a T
Central Files
Permit Files

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f�ftN :.DaLK Yla�� GROUNDWATER SECTION
DIVISION OF ENVIRONMENTAL MANAGEMENT Gw a- g
RECORD OF WASTE DISPOSAL PERMIT APPLICATION REVIEW
REVIEW BY �A v r°� �ud `/ DATE 121;;5Afl!,- FIELD INVESTIGATION? d)�) /
FACILITY NAME Alr k„ ,LNG . COUNTYyb coa u
LOCATION Se f-
TYPE OF DISPOSAL SYSTEM ( LAGOON, ETC.) ;Pecye-le Iaa ao�15 DESIGN CAP. (GPD )
DESCRIPTION OF FACILITY &tAx;+e is rest-Tfd w ♦�. f/� SOd fa proclace cslurhlnu� aIlu'i �i�lua�i_ -f
SIZE OF IMPOUNDMENT (FT. SQ) Ala
WASTE SOURCE: [D MUN. SLUDGE MUN
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W. WATER: E] PRIMARY []SECONDARY
D TERTIARY
E]IND. SLUDGE IND. W. WATER OTHERS
DISTANCE FROM - WASTE SOURCE TO NEAREST: STREAM -'- Zo O FT., WELL /v® FT,
FOR WELL: TYPE OF USE V s�^PAI� %Hr-W'4DEPTH Uh ka-uar.. , PUMP RATE (EST..) Y►lkyvwAl
WHAT DESIGN CONDITIONS WILL REDUCEAER0W CHANCE OF GW CONTAMINATION: ao/As aft -Fo 6e
Co.+Sfrac fPciOw ioA a"P exrsl�nq lurG( Suf-i�LG. PranosPd c(Qy /finer 4 lave, gto average jwrwl oT l i�N�O L��SeG
WHAT NATURAL SITE CONDITIONS WILL REDUCE / INCREASE CHANCE OF GW CONTAMINATION
DEPTH TO: BEDROCK FT. , SEASONAL HIGH W. T. 130 FT. , ANNUAL W. T. FLUX :—::j—FT.
SURFICIAL AQUIFER BEDROCK / ARTESIAN AQUIFER
GEN. LiTHOLOGY Gla Q o/Cori1: :OG
HYD. COND. �� _g FT./DAY El /�� FT./DAY 11 MEASURED
ESTIMATED lz ESTIMATED
THICKNESS /0 Fr.
NO. OF MONITOR WELLS: PROPOSED: UP l DOWN_ ; EXISTING: UP O DOWN
FROM WORKSHEET: SITE NUMERICAL DESCRIPTION —
pp TT 1 2 3 4 5 6 6A 6B
SITE GRADE (HYDROGEOL.) SITUATION GRADE _
PROPOSED SAMPLING SCHEDULE &c PARAMETER(S) : /e/Juc��► a nGi J`uItivr
R�E�1pv�/ARKS/RECOMMENDATIONS: I'"y- efi -V^4 tr,r I�U�T(A)e f [ On °V 5451A D'f'
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GW,413 Revised 8/87 HYD. REGIONAL SUPERVISOR

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State of North Carolina
Department of Environment, Health, and Natural Resources
Division of Environmental Management
Non -Discharge Permit Application
(THIS FORM MAY BE PHOTOCOPIED FOR USE AS AN ORIGINAL)
RECYCLE ]FACILITIES
I. GENERAL INFORMATION:
1. Applicant (corporation, individual, or other): . % j!`�'L" =
2. Print Owners or Signing Official's Name and Title (the person who is legally
responsible for the facility and its compliance): QAtJDA`-L- APC%ukL,Pt,Z
3. Mailing Address: PT 2- box 5 Z 1 - C.
City: C1 State: N C/ Zip:
Telephone No.: (:
4. Project Name (subdivision, facility, or establishment name - should be consistent with
project name on plans/specs., letters of flow acceptance, Operational Agreements, etc.):
�• mac,.
_ co
5. pllrca>tia� /+ bmitt
` 6. Fee Sued: $
7. County where project is located: OwAQ -
8. Latitude: `�� 3�t-Yt; Longitude &0' - Z5 ,-CO to of recycle facility location
II. PERMIT INFORMATION:
1. Permit No. (will be completed by DEM): CSC U� off%
2. Specify whether project is: new; renewal*; modification.
*If renewal, complete only sections I, II, III, & applicant signature
(on pg.6). Submit only pgs. 1, 2, 6 (original and 3 copies of each). Engineer
signature not required for renewal.
3. If this application is being submitted as a result of a renewal or modification to an
existing permit, list the existing permit number WQ cro z7Ozand issue date r c ` iO
4. Specify whether the applicant is public or _�4 private.
FORM: RFAC 4/91 Page 1 of 7

RECYCLE FACILITIE§
PAGE 2 (4/91)
III. INFORMATION ON WASTEWATER:
1. Nature of Wastewater: % Domestic; % Commercial;
( CEO % Industrial; % Other waste (specify):
2. Please provide a one or two word description specifying the origin of the wastewater,
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
3. Volume of recycle water generated by this project. gallons per day
4. Explanation of how. recycle water volume was determined: AL, t�FT��zw+Ncj� rTv
6AYq;" l crJ ll�J p1� E.Z i AcJ aL1 .
5. Brief project description: T N ux satzi A c, f AC-4 - T7 —
IV. DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of tanks, pumping facilities, high water alarms, filters,
ponds, lagoons, etc.: '04 t 1) APr^L.A (xT tom (y '5ti +5)%A+-'Tf_1_') fAC
Mott t=+(_4-r10-J To rc-f 4t'T - NO. W QoCpn_ 27oz , Tu +�
Mon- i r-ILA-t',ot-r LNtic�_Vt�_7 _32N4-, 402=0ons OF- f %V c.
LAL n OO.a! ! O V-t i t' I" % Ttr> F+ac_+L/T`f,
2. Name of closest downslope surface waters: r " J 7Ar'_Y 70 5 ELO+2+.7) Cei-'-K
3. -Classification of closest downslope surface waters: C1 (as established
by the Environmental Management Commission & specified on page 4 of this
application).
4. If a power failure at the facility could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent. such impact, as
required in 15A NCAC 2H .0200:
5. The facilities must conform to the following buffers (and all other applicable buffets):
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100 feet between a surface sand filter and any residence under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) 50 feet between the recycle facilities and property lines;
2of7

RECYCLE FACILITIES
PAGE 3 (4/91)
6. If any of the buffers specified in no. 5 above are not being met, please explain how the
proposed buffers will provide equal or better protection of the Waters of the State with
no increased potential for nuisance conditions: 0 A
7. Are any components of the recycle facility located within the 100-year flood plain?
yes; , _ no. If yes, briefly describe the protective measures being taken to protect
against flooding.
THIS APPLICATION PACKAGE WILUNOT BE ACCEPTED BY THE
DIVISION OF ENVIRONMENTAL MANAGEMENT UNLESS ALL OF
THE APPLICABLE ITEMS ARE INCLUDED WITH THE SUBMITTAL
Required Items
a. One original and three copies of the completed and appropriately executed application form
b. The appropriate permit processing fee, in accordance with 15A NCAC 211.0205(c)(5).
c. Five sets of detailed plans and specifications signed and sealed by a North Carolina
Professional Engineer. The plans must include a general location map, a site map which
indicates where any borings or hand auger samples were taken, along with buffers,
structures, and property lines. Each sheet of the plans and the first page of the specifications
must be signed and sealed. I
d. For industrial wastewater, a complete chemical analysis of the typical wastewater
must be provided. The analysis may include, but shall not be limited to, Total Organic
Carbon, BOD, COD, Chlorides, Phosphorus, Nitrates, Phenol, Total Trihalomethanes,
TCLP analysis, Total Halogenated Compounds, Total Coliforms, and Total Dissolved
Solids.
e. If lagoons are a part of the facilities and the recycle water is industrial, provide a
hydrogeologic description of the subsurface to a depth of 20 feet or bedrock, whichever is
less. The number of borings shall be sufficient to define the following for the area
underlying each major soil type'at the site: significant changes in lithology, the vertical
permeability of the unsaturated zone, the hydraulic conductivity of the saturated zone, and
the depth of the mean seasonal high water table.
f. Five copies of all reports, evaluations, agreements, supporting calculations, etc., must be
submitted as a part of the specifications which are signed and sealed by a North Carolina
Professional Engineer. Although certain portions of this required submittal must be
developed by other professionals, inclusion of these materials under the signature and seal
of a North Carolina Professional Engineer signifies that he has reviewed this material and
has judged it to be consistent with his proposed design.
g. Five copies of the existing permit if a renewal or a modification.
3of7

ti
RECYCLE FACI1-1711ES
PAGE 4 (4/91)
TO: REGIONAL WATER QUALITY SUPERVISOR
Please provide me with the classification of the surface waters identified in number 5
below and on the attached map segment:
Name of surface waters: To c.,f&.eac.
Classification (as established by the Environmental Management Commission):
ission):
N. C. DEPT. or NA'TtPkAi
Proposed Classification, if applicable: uw 1L%.,,,,,,It Ii..SO
: -IJ P.C6S ANll. 1. /1rR1"�d
Signature of regional office personnel: --2v� Date: /S
%J:..07z
INSTRUCTIONS TO ENGINEER >iANAG MENi
k;GGIES i11E RIMNA1 OFFICE
In order to determine whether provisions for dual or standby power may be required for the
subject facility, the classification of the closest downslope surface waters (the surface waters that
any overflow from the facility would flow toward) must be determined. You are required to
submit this form, with items 1 through 10 completed, to the appropriate Division of Environmental
Management Regional Water Quality Supervisor (see attached listing). At a minimum, you must
include an 8.5" by 11" copy of the portion of a 7.5 minute USGS Topographic Map which shows
the subject surface waters. You must identify the location of the facility and the closest downslope
surface waters (waters for which you are requesting the classification) on the submitted map copy.
The application may not be submitted until this form is completed and included with the submittal.
1. Applicant (corporation, individual, or other): A Lc.i4LVN , =ram.
2. Name and Complete Address of Engineering Firm: ��,u�� �Z� �_N� ^� •r Nc7
P�r4n�+v,nAf �flp -�, 0, MAW 5T,
City: 5,�����,r����z�r' State: ti L, Zip: Z,�3 < 44-
Telephone No.
3. Project Name: A LC - A � ►�- , yNC-.
4. Storage Facility Volume: 4 c,CK) gallons
5. Name of closest downslope surface waters: C�e-CONo
6. County(s) where project and surface waters are located: F,o+iA"i
7. Map name and date: R cc KV-J e-L-4-
8. North Carolina Professional Engineer's Registration No. -2 '15' Z
9. Print Name of Engineer .PAP-AzYL i_.
10. Seal and Signature (specify date): � CAr?,�/
moo��,SS/p�J/9%
o�
9572
sE
4of7

DIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL OFFICES (4/91)
Asheville Regional WQ Super.
Washington Regional WQ Super.
Raleigh Regional WQ Super.
59 Woodfin Place
P O Box 1507
3800 Barrett Dr., Suite 101
Asheville, NC 28802
Washington, NC 27889
Raleigh, NC 27609
704/251-6208
919/94676481
919f133-2314
Avery Macon
Beaufort Jones
Chatham Nash
Buncombe Madison
Berne Lenoir
Durham Northampton
Burke McDowell
Camden Martin
Edgecombe Orange
Caldwell Mitchell
Chowan Pamlico
Franklin Person
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay Rutherford
Currituck Perquimans
Halifax Wake
Graham Swain
Dare Pitt
Johnston Warren
Haywood Transylvania
Gates Tyrell
Lee Wilson
Henderson Yancy
Greene Washington
Jackson
Hertford Wayne -
Hyde
Fayetteville Regional WQ Super.
Mooresville Regional WQ Super.
Wilmington Region. WQ Super.
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845
919/486-1541
704/663-1699
919i395-3900
Anson Moore
Alexander Mecklenburg
Brunswick New Hanover
Bladen Robeson
Cabarrus Rowan
Carteret Onslow
Cumberland Richmond .
Catawba Stanly
Columbus Pender
Harnett Sampson
Gaston Union
Duplin
Hoke Scotland
Iredell Cleveland
Montgomery
Lincoln
Winston-Salem Regional WQ Super.
9025 North Point Boulevard, Suite 100
Winston-Salem, NC 27106
919l161-2351
Alamance
Rockingham
Alleghany
Randolph
Ashe
Stokes
Caswell
Surry
Davidson
Watauga -
Davie
Wilkes
Forsyth
Yadkin
Guilford
5of7

RECYCLE FACILITIES
PAGE 6 (4/91)
r
Name and Complete Address of Engineering Firm: 9 t, tia�z�y f r j Eft- A-ki
iiA A 1 N S�
City: 4-,Au13r -pzy State: rvC_ Zip: 2814+
Telephone No. 104- 8
Professional Engineer's Certification:
I, L tz2Yi, L wAyoeJ —,attest that this application for Aoo;FicA-ric-•t
-ro P6-rzM+-r -ro F.a,uL+TY has been reviewed by me and is accurate
and complete to the. best of my knowledge. I further attest that to the best of my knowledge the
proposed design has been prepared in accordance with the applicable regulations. Although certain
portions of this submittal package may have been developed by other professionals, inclusion of
these materials under my signature and seal signifies that I have reviewed this material and have
judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Registration No. el 51 Z
Print Name of Engineer t�6e.rY(_ L.,�.,
� \\N CARO(,,;
Seal and Signature (specify date): ``•O SSI�� �'rr'�
SEAL
957 2. , • r��
�F,..
YL
Applicant's Certification: rr,�S# L' �J���
attest that this aPP licatil6 r
—
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand
that if all required parts of this application are not completed and that if all required supporting
information and attachments are not included, this application package will be returned as
incomplete.
Signature Date _
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL SUPPORTING
INFORMATION AND MATERIALS, SHOULD BE SENT TO THE FOLLOWDTG ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NUMBER: 919/733-5083
6of7

RECYCLE FACILITIES
PAGE 7 (4/91)
y S
PERMIT APPLICATION
PROCESSING FEES
(effective October 1,1990)
CATEGORY
NEW APPLICATIONS/
RENEWALS WITHOUT
MODIFICATIONS
MODIFICATIONS
> 1,000,000 GPD
Industrial
$400
$300
Domestic/Cooling .Water
$400
$300
10,001 - 1,000,000 GPD
Industrial
$400
$250
Domestic/Cooling Water
$400
$250
1,001 - 10,000 GPD
Industrial'
$400
$200
Domestic/Cooling Water
$400
$200
< or = 1,000 GPD and
Single Family Dwelling
$240
$120
Sludge < or = 300 Acres
$400
$250
Sludge > 300 Acres
$400
$250
Sewer Extensions
(nondelegated)
$400
0
Sewer Extensions
(delegated) $200 0
Closed -Loop Recycle
or Evaporative $400 $200
NOTE: The Fees for Soil Remediation Projects are the same as for Sludges..
Under the Sewer Extension Fee, "delegated to municipalities" applies
only to those governmental jurisdictions that have specific delegation
review authority, as granted by the Division of Environmental
Management.
7 of 7

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State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Randall F. Andrews
Alchem, Inc.
Route 2, Box 521-C
8135 Red Road
Rockwell, NC 28377
Dear Mr. Andrews:
R. Paul Wilms
Director
January 10, 1990
Subject: Permit No. WQ0002702
Alchem, Inc.
Industrial Recycle - Bauxite Process -
Rowan County
In accordance with your application received November 17, 1989 we are forwarding
herewith Permit No. WQ0002702, dated January 10, 1990, to Alchem, Inc. for the construction
and operation of the subject recycle facility.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the conditions and limitations as specified therein.
If any parts, requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request an adjudicatory hearing upon written request within 30 days
following receipt of this permit. This request must be in the form of a written petition, conforming
to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative
Hearings, P.O. Box 11666, Raleigh, NC 27604. Unless such demands are made this permit shall
be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need
additional information concerning this matter, please contact Mr. William Barlow at 919/
733-5083.
Si cerely, .
Charles R. Wakil
Acting Director
cc: Rowan County Health Department
Mooresville Regional Office
Environmental Hydrogeological Consultants
Groundwater Section
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

4
NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Inc.
Rowan County
FOR THE
construction and operation of two (2) lagoons each approximately 50' W x 200' L x 10' D and all
associated pipes, valves and appurtenances to serve Alchem, Inc. with no discharge of wastes to
the surface waters, pursuant to the application received November 17, 1989, and in conformity
with the project plan, specifications, and other supporting data subsequently filed and approved
by the Department of Environment, Health and Natural Resources and considered a part of this
permit.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting
data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
27687, Raleigh, NC 27611.

6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Mooresville Regional Office, phone po. 704/663-1699, shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an in -place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The -sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. 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 facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the lagoon shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to, insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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 keep 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 Peinuttee for a period
of three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the disposal site and 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; or may obtain samples of
groundwater, surface water, or leachate.
17. 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).
18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6.
2

19. The issuance of this pernut 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.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office,
telephone no. 704/663-1699, 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 at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
C. Any failure of a pumping station, sewer line, or treatment facility resulting in a
by-pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility has gone out of
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.
22. The Permittee shall employ a certified wastewater treatment plant operator to be in
responsible charge of the wastewater treatment facilities. The operator must hold a
certificate of the grade at least equivalent to the classification assigned to the wastewater
treatment facilities by the Certification Commission. Within thirty days after the
wastewater treatment facilities are 50% complete, the Permittee must submit a letter to the
Certification Commission which designates the operator in responsible charge.
J/23. The lagoon shall have a liner of natural material at least one (11 foot in thickness at all
locations with a hydraulic conductivity of no greater than 1 x 10-6 centimeters per second
when compacted. Following installation and inspection of the lagoon liner, and prior to
waste disposal operations, verification of the liner's compliance with hydraulic conductivity
and thickness specifications must be provided to the Division of Environmental
Management, Groundwater Section, by the project engineer.
24. 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.
25. The recycle lagoon shall not be located within 100 feet of water supply well.
3

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Oxford Laboratories, Inc. Analytical and Consulting Chemists
DATE RECEIVED 10-31-89 1316 South FIfth Street
DATE REPORTED 11-6-89 Wilmington, N.C. 28401
89W8650 [phone]
PAGE 1 OF 1
INDUSTRIAL AGRI CHEMICALS P.O. #
RT.2 BOX 521-C 4
RED SPRINGS , N.C. 28377
ATTENTION:.RANDALL ANDREWS
SAMPLE DESCRIPTION: LIQUID FRACTION
1. LIQUID FRACTION
RESULT§
luminum an Al .001
�alfate Gravimetric as SO4 PPM 103
`-' `J�S `rat--.�
ROGER C. OXFORD CHEHIST
NOTE: The pH of the liquid fraction was determined to be 2.5 by Mr. Ra-ndall
Andrews in his company -owned laboratory.

xf&.d Laboratories, Inc'.
INDU,STRIAL AGRI CHEJICALS
4RT•: 2 :' BOX •.521-C
gE �SPtINGS.: • N'. C.. 28377
A'':
s ;�TTEN.TION.i':'RANDALL ANDREWS
Analytical and (;onsutting• Vnemisbb
DATE RECEIVED 2-8-89 1316 South Fifth Street
DATE REPORTED '2-23-89 Wilmington,
N.C.
28401
09W4666 ) 763-9793
PAGE 1 OF 1
P.O. #
PLE DESCRIPTION: SULFURIC ACID INSOLUBLE MATERIAL
V`YW"�SULFURICACID INSOLUBLE MATERIAL FROM BAUXITE
RESULTS
_� •'!•'err' �i;'?�� 1 .
Results'•on'Leachate
}pr.senic , as As , PPM
Z. :•
'� .400
,a;:-ium'•:, -as Ba , PPM
Cadmium as Cd j, PPM <.010
Lg:ad,'•;'..as Pb , PPM
,Chromium , as Cr , PPM .
e.r.cury. , as Hg , PPM <.0005
,.:. PPM < . 0 0 5 _. .... .._
elenium , as Se.,
tive•r:as Ag p PPM <.005
8.0
t.ia�. 'pH.
CHEMIST

4+
r
ALCHEM, INC.
8135 Red Road
ROCKWELL, NORTH CAROLINA 28138
[phone]
September 8, 1989
Mr. J. William Reid,
Environmental Supervisor,
Permits Group
State of North Carolina
Department of Natural Resources and
Community Development
Division of Environmental Management
512 North Salisbury Street
Raleigh, NC 27611
Dear Mr. Reid:
SUBJECT: Recycle Lagoon, Rowan County, 0001987/GW89300
czl:szln
��
' J0,
Thank you for your letter of September 1 concerning our permit number 0001987/
GW89300. I have included a copy of analytical work done on the liquid fraction
of the sand slurry. All three perimeters are on the two sheets of paper. I have
circled the perimeters in which you are interested. Oxford Laboratories did some
other analytical work for me at the same time and this is included also, however,
it has nothing whatsoever to do with our plant in Rockwell.
We have, at Rockwell, two water supply wells. The well within 60 feet of the
lagoon is for process water only. This water would be used for no other pur-
pose than the manufacture of Aluminum Sulfate. The other well, which is 140 feet
from our lagoon site, is the only well used for drinking water and other office
uses. I have included in the permit application information sgowing that our
hydraulic conductivity of the floor is no greater than 1 x 10 centimeters per
second. These readings are on an uncompounded basis.
The lagoon is lined with naturally occurring clay which seems to
40 feet in thickness. Would there be any other details of liner
which you would need? Please feel free to contact me if you have
Very truly yours,
%A�L�CHE_M�)Y nINC.
(NC ..�1 _ -
� 1C,U1" �1ag 1,V�" 1&Q)V_
Randall F. Andrews
sj
enclosures
cc William E. Bright
Jesse Wells
Bill Barlow
be approximately
construction
any questions.

(Tank
No..
Capacity
(Gallons)
Contents
Tank
Material
1
4 500
Sulfuric
Acia
S
2
4,500
if it
S
3
12,000
Cool down
water
F
4
7,000
Reactor
F
5
10,000
#2
-Reactor
E
6
4,000
Slurry
Mixer
F
7
4,000Sto-rage
Water
Pp
8
4,000
" "
PP
9
10,000
Alum
F
10
10 000
Water
F
11
4,500
" "
PP
12
10 000
Alum
F
13
10,000
"
F
14
4,500
ater
torajZe
PP
15
6,000
Process
Water
PP
16:
10,000
Alum
F
17
10,000
"
F
18
5,000
"
PP
19
5 000
"
PP
20
4 S00
"
PP
21
5,000
"
PP
= Steel
Fiberglass-
' Poly.
N
Property Line
I Lagoon .- I
Lagoon
Nearest. domes-rlc well. is
approximately boo feet- from
the lagoons W -Me ..1irection
bf the arrow
0 = Auger Hole
3 = Supply Well
O = Tank
- 20
Secondary 19 © 2
Containment gE�vIJ
10 3 ALCHEM
Emergency OFFICE O
g Y �9
Sump
25,000 gallons O
O
!J K0CES�
_ 2
D/W - Property Line
Froph.Iene- go""'
at'rern Railroad Red Road
SCALE: DATE:r E H C
TITLEALCHEM, INC.
11, = 100, May 18, 1939 ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS 8135 Red Road
JOB NO
(AprQ�c. ) Rockwell, NC
HYDROLOGY • GEOLOGY • EXPLORATION .• ANALYTICAL .

J
Oxford Laboratories, Inc.
INDUSTRIAL AGRI CHEMICALS
RT.2 BOX 521-C
RED SPRINGS , N.C. 28377
ATTENTION: RANDALL ANDREWS
Analytical and Consulting Chemists:..`:,:;'
DATE RECEIVED 2-8-89 1316 South Fifth Street-,.,--"..
DATE REPORTED 2-10-89 Wilmington, N.C. 28401,.;
89W4666 [phone]..'.0 `.
PAGE 1 OF 2
P.O. #
SAMPLE DESCRIPTION: ZINC-444P-SULFURIC
'ACID BAUXITE
1. SAMPLE ZINC FROM W.HA EITON �,�/ . qjq Z e i 4c)AI
2. 444P
3. SULFURIC ACID INSOLUBLE MATERIAL FROM BAUXITE
RESULTS
Zinc , as Zn , %
Manganese , as Mn , %
Boron , as B , %
Aluminum , as Al , %
Sulfate Gravimetric', as SO4 , PPM
Results on Leachate
Arsenic , as As , PPM
Barium , as Ba , PPM
Cadmium , as Cd , PPM
Lead , as Pb , PPM
Chromium , as Cr , PPM
Me r curry , as Hg , PPM
Selenium , as Se , PPM
1
2 3
28.1
17.0 X
X .
4.81 X
X
1.46 X
X
X .19*
X
X <20
X
X
<.005
X
X
.400
X
X
<.010
X
X
<.010
X
X
<.010
X
X
<.0005
X
X
<.005

Oxford Laboratories, Inc. Analytical and Consulting Chemists
DATE RECEIVED, 2-8-89 1316 South Fifth Street
DATE REPORTED 2-10-89 Wilmington, N.C. 28401
8 9W4 6 6 6 [phone]
PAGE 2 OF 2
INDUSTRIAL AGRI CHEMICALS P.O. #
RT.2 BOX 521—C
RED SPRINGS , N.C. 28371
ATTENTION: RANDALL ANDREWS
SAMPLE DESCRIPTION: �I+ C-,D:B.AUXITE,E-,
1. SAMPLE ZINC FROM W.HA EITON
2. 444P
3 Sl[w7LFiJ�RI�C1�C_D�!`INfSO-LTJBT,'-E�MATE I=AL=FROluY=BUX-2TE
RESULTS
Silver , as Ag , PPM
Initial pH
1 2 3
X X < . 0 0 5
X X 8.0
NOTE: * SAMPLE SUBJECTED TO ACID DIGESTION (AQUA REGIA). DOES NOT
SEEM TO DIGEST VERY WELL.
ROGER C. OXFOR , CHEMIST

I
ALCHEM, INC.
P. O. BOX 171
ROCKWELL, NORTH CAROLINA 28138
[phone]
July 16, 1990
Mrs. Carolyn D. McCaskill
Environmental Supervisor
State of North Carolina
Department of Environment, Health,
and Natural Resources
P. O.Box 27687
512 N. Salisbury Street
Raleigh, North Carolina 27611-7687
Dear Mrs. McCaskill:
Subject: Permit NO. WQ0002702
A C D�PT
nanfU p�Y®s AN
Jll/ v8Q$lvplvr
DIp(Slcid pf —w
�t;C.rifSVll���;�filJil(q �'� G �';Ht
l QF/'1CF
I am enclosing a copy of the results of the permeability testing,
which was performed on our lagoon in Rockwell. I believe every-
thing is in order.
Would you please issue us a certificate so that we may begin using
this facility.
Very truly yours,
INDUSTRIAL AND AGRICULTURAL CHEMICALS INC.
Randall F. Andrews
RFA/sb
Enclosure
cc: Mr. Wayne Drye
Alchem, Inc.
Rockwell, N. C.
cc: Mr. Alan Hardy
Div. of Environmental Management
Mooresville, N. C.

iA . y
J
JOE E. GODWIN. SR. P.E.. R.L.S.
RONNIE E. JORDAN. R.L.B.
JAMES E. GODWIN
Godwin - Jordan & Associates, P.A.
ENGINEERING. SURVEYING & PLANNING
102 WEST BROAD STREET
P. O. BOX 249
DUNN. N. C. 28334
MATERIALS TESTING DIVISION
PHONES: FAY. 483-1489
DUNN 892-8159
REPORT OFe Coefficient of Permeability (Fall Head Method)
MADE FOR: Alcliem Inc.
PROJECT: Lagoon in Rockwell, N.C.
K = . 2 3 AT : log10' Ho
K = Coefficient -of Permeability, CM/sec
A = Cross sectional area of permeameter, CM2
L = Length of Specimen, CM
a = Cross sectional area of standpipe; CM
T = Time of test,sec
Ho=Head at start of test, CM
H = Head at end of test, CM
Q = Discharge, CC
Test # H_ H T O a L A
W
1 32.07 29.36 86,400 1.27 0.47 7.15 8.71 3.94'x 10-7
K required = 1.0 x 10-6
Test Locations:
NOTE: Test Silty clay zed:" -in color material
I.
NOTES:
Testing TechniciansPbe*�Earl
Joh P0n, C.E'.'T.
0

ALCHEM, INC.
8135 Red Road
ROCKWELL, NORTH CAROLINA 28188
l�A` hy�s� [phone]
tytVE5i9N � �Nv,
�,ppO4E$V114E'
August 18, 1989
Mr. Bill Barlow
State of North Carolina
Department of Natural Resources
and Community Development
P. 0. Box 27687
Raleigh, NC 27611-7687
RE: Application No. WQ 0001987 Industrial Recycle WWTF
Dear Mr. Barlow:
On our recent application for Closed System Permit, some
errors were made on page two of the application submitted.
Please accept and insert the new Page 2 which is enclosed
and discard the old Page 2. If you have any questions,
please call me.
Very truly yours,
Randall F. Andrews
sj
enclosures
cc Mr. Jessie Wells, NRCD, Mooresville, NC
Mr. Michael Cleary, NRCD, Raleigh, NC

5.0 CAPACITY OF LAGOONS --------- CAK
Th total approximate capacity of the 2 lagoons, each approximately
50' W x 20 ' L x 10' D.,is 4,938 tons, or sufficient capacity to receive
and store the sand slurry for about 15 months. (Figure 4).
6.0 TREATMENT MQCESS SYSTEM
The raw materia consisting exclusively of bauxite will be reacted
with sulfuric acid and\ater in a reaction vessel. Subsequent to reaction
completion, the materill be pumped to a settling basin from which the
liquid (aluminum -sulfate) wil be pumped to storage tanks) and the settle-
able insoluble.material (mostly andy material, Si02) will be washed until
the PH of the material elevates to iI\ mininum of about 6.0. The PH of the
material will be determined by using a fisher Digital PH meter on a daily
basis.
The washed water will also be returned to storage or process water
tanks and the sand slurry and other minor insolub ti will be released to
dual lagoons. When and as often as necessary, the li` uid in the lagoons
will be returned to the process water tank(s); thereby m lefin the closed
P Y � P g
system (Figure 3).
7.0 HYDROG$OLOGIC DESCRIPTION OF THE SUBSURFACE
7.1 CHANGES IN LITHOLOGY
A total of 6 holes were powered augered at this site using an Ola, e
160 Series combination auger/rotary drill (Figure 2). These holes ranged\,
in depth from about 28'-30' and none encountered the water table. ~
The material underlying this site to bedrock is typical multiple
EHC
LEAKING BURIED TANKS LEAKING STORAGE LAGOONS CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 0 LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS

i
2
5.0 CAPACITY OF LAGOONS
The total approximate capacity of the 2 lagoons, each approximately
50' W x 200' L x 10' D, is 4,938 tons, or sufficient capacity to receive
and store the sand slurry for about 15 months (Figure 4).
6.0 TREATMENT PROCESS SYSTEM
�.�he .�aw�materiah,, o istng- excPusively of';- bauxite wl.]`.�beu reacted
with sulfuric acid -and. water in :a reaction'ves el _After_reacTtion µ;
completion,; the.anaterial -'will -be^pumped._ _t'o' !a ' fiberglass.;s,ett°ling: tank from
which_ the:Aiquid= (;a-lum num sulfate)�w l __lie:.pumped,_to-storage tan'k'(s) arid77'
the settleable insolib'le'material: (mostly=sandy:_materal;-`SiO will!:be'
� ash'ed until uthe PHiabf the;'material •elevates -to,-,a m nimum, of about 6 0
The PH of the material will be'determined by using a Fisher Digital PH
meter on a daily basis.
The wash water will also be returned to storage or process water
tanks and the sand slurry and other minor insolubles will be released to
dual lagoons. When and as often as necessary, the liquid in the lagoons
will be returned to the.process water tank(s); thereby completing the closed
system (Figure 3).
7.0 HYDROGEOLOGIC DESCRIPTION OF THE SUBSURFACE
7.1 CHANGES IN LITHOLOGY
A total of 6 holes were power augered at this site using an Olathe
160 Series combination auger/rotary drill (Figure 2). These holes ranged
y in depth from about 28'-30' and none encountered the water table.
The material underlying this site to bedrock is typical multiple
EHC
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICALSPILLS • LAND APPLICATION OF SLUDGE m LANDFILLS • PERMITS
t;;3

�16
YK
R��'�l asEIAEO
aMMON OF ENVAIWN1AENTAL M/Ja
�6
d„a 4A7Lp
22 1990
State of North Carolina
�ent of Environment, Health and Natural Resources
$EG�
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Randall F. Andrews
Alchem, Inc.
Route 2, Box 521-C
8135 Red Road
Rockwell, NC 28377
Dear Mr. Andrews:
R. Paul Wilms
Director
January 10, 1990
Subject: Permit No. WQ0002T02
Alchem, Inc.
Industrial Recycle - Bauxite Process
Rowan County
In accordance with your application received November 17, 1989, we are forwarding
herewith Permit No. WQ0002702, dated January 10, 1990, to Alchem, Inc. for the construction
and operation of the subject recycle facility.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the conditions and limitations as specified therein.
If any parts, requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request an adjudicatory hearing upon written request within 30 days
following receipt of this permit. This request must be in the form of a written petition, conforming
to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative
Hearings, P.O. Box 11666, Raleigh, NC 27604. Unless such demands are made this permit shall
be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need
additional information concerning this matter, please contact Mr. William Barlow at 919/
733-5083.
Si cerely,
harles R. Wakil')d—e
Acting Director
cc: Rowan County Health Department
VMooresville Regional Office
Environmental Hydrogeological Consultants
Groundwater Section
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
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
Alchem, Inc.
Rowan County
FOR THE
construction and operation of two (2) lagoons each approximately 50' W x 200' L x 10' D and all
associated pipes, valves and appurtenances to serve Alchem, Inc. with no discharge of wastes to
the surface waters, pursuant to the application received November 17, 1989, and in conformity
with the project plan, specifications, and other supporting data subsequently filed and approved
by the Department of Environment, Health and Natural Resources and considered a part of this
permit.
This permit shall be effective from the date of issuance until December 31, 1994, and shall
be subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting
data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
27687, Raleigh, NC 27611.

6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Mooresville Regional Office, phone no. 704/663-1699, shall be notified at least
forty-eight (48) hours in advance of operation of the installed facilities so that an in -place
inspection can be made. Such notification to the regional supervisor shall be made during
the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. 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 facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the lagoon shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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 keep 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 three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the disposal site and 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; or may obtain samples of
groundwater, surface water, or leachate.
17. 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).
18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management -in
,
accordance with North Carolina General Statute 143-215.6.
2

19. 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.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville Regional Office,
telephone no. 704/663-1699, 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 at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
C. Any failure of a pumping station, sewer line, or treatment facility resulting in a
by-pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility has gone out of
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 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.
22. The Permittee shall employ a certified wastewater treatment plant operator to be in
responsible charge of the wastewater treatment facilities. The operator must hold a
certificate of the grade at least equivalent to the classification assigned to the wastewater
treatment facilities by the Certification Commission. Within thirty days after the
wastewater treatment facilities are 50% complete, the Permittee must submit a letter to the
Certification Commission which designates the operator in responsible charge.
23. The lagoon shall have a liner of natural material at least one (14 foot in thickness at all
locations with a hydraulic conductivity of no greater than 1 x 10- centimeters per second
when compacted. Following installation and inspection of the lagoon liner, and prior to
waste disposal operations, verification of the liner's compliance with hydraulic conductivity
and thickness specifications must be provided to the Division of Environmental
Management, Groundwater Section, by the project engineer.
24. 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.
25. The recycle lagoon shall not be located within 100-feet of water. supply well.
3

Permit issued this the loth day of_January, 1990
TH CAROLINA NVIR NMENTAL MANAGEMENT COMMISSION
J
Charles R. Wakild, q
r
for
Division of Environmen gement
By Authority of the Environmental Management Commission
Permit No. WQ0002702
January 10, 1990
Enzineer's. Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, for the
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the
observation of the construction such that the construction was observed to be built within substantial
compliance and intent of the approved plans and specifications.
Signature
Date
Registration No.
1.2

y�d S ATt4
State of North Carolina
Department of Environment, Health, and Natural Resources
Mooresville Regional Office
James G. Martin, Governor Albert F. Hilton, Regional Manager
William W. Cobey, Jr., Secretary
DIVISION OF ENVIRONMENTAL MANAGEMENT
August 2, 1990
Mr. Randall F. Andrews
Alchem, Inc.
Post Office Box 171
Rockwell, North Carolina 28138
RE: Permit No. WQ 0002702
Alchem, Inc.
Industrial Recycle - Bauxite Process
Rowan County, N.C.
Dear Mr. Andrews:
This Office is in receipt of the supporting data you submitted
dated July 16, 1990 as required in Condition No. 23 of the subject
permit. Based upon the data submitted by Mr. Joseph E. Johnson,
Godwin -Jordan Associates, the lagoon liner would meet the hydraulic
conductivity specification as outlined in Condition No. 23.
Sincerely,
Brenda J. Smith, P.G.
Regional Supervisor
Attachment
cc: Jack Floyd
JWW/pl
919 North Main Street, Mooresville, N.C. 28115 • Telephone [phone] • FAX [phone]
An Equal Opportunity Affirmative Action Employer

ALCHEM, INC.
P. O. BOX 171
ROCKWELL, NORTH CAROLINA 28138
[phone]
July 16, 1990
Mrs. Carolyn D. McCaskill
Environmental Supervisor
State of North Carolina
Department of Environment, Health,
and Natural Resources
P. O.Box 27687
512 N. Salisbury Street
Raleigh, North Carolina 27611-7687
Dear Mrs. McCaskill:
Subject: Permit NO. WQ0002702
tTy % ANb
T
JUL
�s[ oF�1eE` T
I am enclosing a copy of the results of the permeability testing,
which was performed on our lagoon in Rockwell. I believe every-
thing is in order.
Would you please issue us a certificate so that we may begin using
this facility.
Very truly yours,
INDUSTRIAL AND AGRICULTURAL CHEMICALS INC.
Randall F. Andrews
RFA/sb
Enclosure
cc: Mr. Wayne Drye
Alchem, Inc.
Rockwell, N. C.
Cc: Mr. Alan Hardy
Div. of Environmental Management
Mooresville, N. C.

REPORT OF:' Coefficient of Permeability (Fall Head Method)
MADE FOR: Alchem Inc.
PROJECT: Lagoon in Rockwell, N.C.
K = 2.3 AT ,log10 H
K = Coefficient -of Permeability, CM/sec
A = Cross sectional area of permeameter, CM
L = Length of Specimen, CM
a = Cross sectional area of standpipe, CM
T = Time of test,,sec
Ho=Head at start of test, CM
H = Head at end of test, CM
Q = Discharge, CC
Test 4 H_ H T 0 . a' L A
K
1 32.07 29.36 86,400 1.27 0.47 7.15 8.71 3.94'x 10-7
K required = 1.0 x 10-6
Test Locations:
NOTE: Test Silty clay red in color material
NOTES:
Testing Technicia
se Earl Joh on, O.E.T.

DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
December 1, 1989
MEMORANDUM
TO: Don Safrit
THROUGH: BoI h4
FROM: Bill Reid
SUBJECT: Alc hem, c.
Recycle Lagoon
Rowan County
WQ0001987/GW89459
(Bill Barlow: DEM SERG Review Engineer)
The Groundwater Section has reviewed the subject permit
application and recommends issuance of the permit with the following
conditions:
1. Any groundwater quality monitoring, as deemed *necessary by
the Division, shall be provided.
2. The recycle lagoon shall not be located within 100 feet of a
water supply well.
3. The lagoon shall have a liner of natural material at least
one foot in thickness at all locations with a hydraulic
conductivity of no greater than 1x10� centimeters per
second when compacted.
JWR/MC/ja
c c : e,s _s_e 'die I
Central Files
Permit Issuance Files

l
DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
October 12, 1989
MEMORANDUM RECEIVED
TO: Don Safrlt 4111311N Of ENVIRONMENTAL MAPIAKHAEN7
THROUGH: Bob Cheek (� � OCT 17 1989
MOORESVILLE
FROM: Bill Reid r AEOIONAl4FQCj 1:
SUBJECT: Alchem, Ind.
Recycle Lagoon
Rowan County, WQ0001987/GW89300
(Bill Barlow: DEM SERG Review Engineer)
In a September 1, 1989 letter to the applicant we requested
that the proposed lagoon site be relocated to provide a 100 feet
separation from an adjacent water supply well and that the
applicant provide details of lagoon liner construction.
The applicant responded by indicating that the well within
60 ft. of the lagoon is for process water only. The proposed
lagoon site was not relocated. Both 15 NCAC 2H. 0200 (Waste not
Discharged to Surface Waters and 15 NCAC 2C (Well Construction
Standards) require a 100 feet horizontal separation between a
well and a contamination source. These requirements are
applicable to all water supply wells (except monitor wells)
including drinking water and process water wells. While at the
present time, the well in question is utilized for process water
only, we can not control future usage. Additionally, if not
properly constructed, the annular space around the well casing
may serve as a pathway for downward migration of contamination.
The applicant did
per requirements of 15
hydraulic conductivity
2.2 x 10-5 cm/sec., 4
Only one of the sgil
less than 1 x 10 cm
The application does n
or the location and (
information provided i
the liner requirements
not provide details of liner construction
NCAC 2H. 0219. The results of three soil
tests were provided. The test values are
93 x 10 cm/sec. and 1.78 x 10 cm/sec.
;ampler exhibited a hydraulic 'conductivity
sec. as specified in 15 NCAC 2H .0219(f).
)t specify the method of sample collection,
epth of the soil samples. Based on the
t does appear that the'inplace soils meet
in 15 NCAC 2H.0219.
The Groundwater Section can not recommend approval of the
subject project as currently proposed.
JWR/MC/ja
cc
Central Fi es
Permit Issuance Files

DIVISION OF ENVIRONMENTAL MANAGEMENT
October 1.1, 1989
MEMORANDUM TO: Bill Reid
THROUGH: Brenda Smith96
FROM: Jesse Well
P-
RE: Alchem, Inc.
GW 489300
Rowan County, N. C.
The Mooresville Regional Groundwater Staff has reviewed the
revised operation plan submitted by Mr. Randall Andrews dated
August 18, 1989. The regional office comments dated August 21,
1989 are still applicable and no additional comments will be
submitted.
If any questions, please advise.
JWW: s j u

10
State of North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street v Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Randall F. Andrews,
Alchem, Inc.
Route 2, Box 521-C
Red Springs, NC 28377
Dear Mr. Andrews:
September 1, 1989 R. Paul Wilms
Director
President
RECEIVE
1XVI$ION U ENV,IPOW MfAL MAAWM66
SEP F 1989
SUBJECT: Alchem, Inc.
MOORESVILLE
Recycle Lagoon. REGIONAL 0FROS
Rowan County
0001987/GW89300 _`-- -
As part of. the Division of Environmental Management's
comprehensive approach in addressing the impact of waste
treatment, storage, or disposal projects on the environment,
your permit application has been forwarded to us for assessment
of the potential impact of the project on groundwater quality.
Our initial review indicates that the data submitted is
not sufficient to make this assessment.
Before your application can be processed therefore, - you
are requested to submit , the following information to the
Groundwater Section. This information should be submitted in
full within 60 days of the date of this letter. ,
1. A chemical analysis of the liquid fraction of the sand
slurry for pH, Aluminum and sulfate. The sample analyzed
may be from a bench -scale test.
2. Figure 2 of the Report prepared by EHC shows the proposed
lagoons located within 60 ft. of a water supply well.
Regulations in 15 NCAC 2H .0200 (Waste Not Discharged to
Surface Waters) require a minimum 100 ft. buffer zone
between the treatment works and any well (except monitor
wells). The lagoon site must be relocated to provide
adequate horizontal separation and the change reflected on
the project plans.
3. Please note that in order to be in accordance with 15 NCAC
2H .0219 (f), any lagoon or pond used for treatment, storage
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

or disposal of waste shall have either a liner of natural
material at. least one foot in thickness and having
hydraulic conductivity of no greater than 1 x 10-
centimeters per second when compacted, or a synthetic liner
of sufficient thickness to exhibit structural_ integrity and
an effective hydraulic conductivity no greater than that of
the natural material liner. The project plans should
include details of liner construction.
Please feel_ free to contact the Groundwater Section, at
[phone], if clarification or information is required.
Sincerely,
J.. 0 0, f
.William Reid
Environmental Supervisor
Permits Group
tej
cc: Zric Klingel
Bill Barlow
Mike Cleary
Central Files
Permit Issuance Files

DIVISION OF ENVIRONMENTAL MANAGEMENT
August 21, 1989
MEMORANDUM TO: Bill Reid
THROUGH: Eric Klinge1
FROM: Jesse Well�'j.a��
RE: Alchem, Inca.
GW #89300
Rowan County, N. C.
The Mooresville Regional Groundwater Staff has reviewed the application
package submitted by Environmental Hydrogeological Consultants, Inc. on behalf
of Alchem, Inc. The applicant proposes to process bauxite in an effort to
increase the production of aluminum sulfate. The waste system is proposed as a
closed system with no release to the surface waters. The following comments
address their proposal:
1. Per a discussion with Mr. Randall Andrews, owner of Alchem, the
treatment process discussed on page 2 is not accurate. Mr. Andrews
indicated that no reaction process will take place outside a
contained area. (i.e. the settling basin will not be utilized in the
reaction process). In addition, the washing of the sand slurry and
pH adjustment will take place within a contained area (i.e. reactor,,
fiberglass tank). Mr. Andrews was requested to send a letter revising
the operation plan.
2. The only recommendation I have concerning this site is that the
permittee submit monthly pH readings of the liquid slurry to be
stored in the lagoon. This should insure adequate washing of the
slurry prior to storage. The slurry is reacted with H2SO4 in the
reaction process.
Should you have any questions, please advise.
cc: Rex Gleason
JWW:pb

L71C\JVIVVVVn,u� •.1LV11`/I'1 GW #1 V-(60 .
i y DIVISION OF ENVIRONMENTAL MANAGEMENT
RECORD OF WASTE DISPOSAL PERMIT APPLICATION KLVILW
REVIEW BY �,! c ss �- w�.e (ls DATE S�II ° FIELD INVESTIGATION ? (Y/N )�1T
FACILITY NAME filcher»
_T
COUNTY_��>,la,.�
LOCATION S l j� }�e� 2oc��
i�ac 4'w�t t �b-4A
: ATTAC/-I C D�
TYPE OF DISPOSAL SYSTEM
( LAGOON, ETC. )C Insed "Ic.le. C� or,) DESIGN CAP. (GFDj )
DESCRIPTION OF FACILITY, Acr
-1-� rllr� re-per
Aa'2:f fVl,-fr`l.
SIZE OF IMPOUNDMENT (FT.
SQ)
� .) 10 'C U
& / OR SIZE OF APPLICATION AREA
WASTE SOURCE : ❑ MUN. SLUDGE MUN. W. WATER: PRIMARY SECONDARY TERTIARY
❑✓ IND. SLUDGE F_]IND. W. WATER OTHERS
DISTANCE FROM WASTE SOURCE TO NEAREST: STREAM ' I P e o FT., WELL FT.
2-"L4_7 PUMP RATE ( EST. )
FOR WELL: TYPE OF USE 4016-Si T c SuPPLV DEPTH
WHAT DESIGN CONDITIONS WILL REDUCE / INCREASE CHANCE OF GW CONTAMINATION: Sc2inj rna Lri _ y
cc% oncr �, � l,c,rcrc', ,n ;.•., r: z .S 7cr,= e lCarc :ems
WHAT NATURAL SITE .CONDITIONS WILL REDUCE / INCREASE CHANCE OF GW CONTAMINATION
of .'ic.:.11SufTciC� y Ccur,tfy-o,V, 7 7 < r 5 17x icy �ab.it ✓` {7G�nu� l/�J,r� �u,` icQi
DEPTH TO: BEDROCK ? I FT. , SEASONAL HIGH W. FT. , ANNUAL W. T. FLUX :5- i Q FT.
SURFICIiaL A�:�iUIF�_I� L BEDRO�I; /ARTESIAN AGU!FER_I
!
GEN. Lli-IOLOGY, iry .'?i-< i ,,,,. plc l
1:1
HYD. CON D. %'wj 1_ yFT. /DAY MEASURED /, � FT./DAY MEASURED.
® ESTIMATED ESTIMATED
THICKNESS Zoo FT.
NO. OF MONITOR WELLS: PROPOSED: UP 0 DOWN U ; EXISTING: UP- DOWN
FROM *WORKSHEET: SITE NUMERICAL DESCRIPTION =��o ?_0 5.0 2 Zr .f3 — 8 .4�
TT 1 2 3 4 5 6 6A 65
SITE GRADE (HYDROGEOL.) SITUATION GRADE _
PROPOSED SAMPLING SCHEDULE & PARAMETER(S) : NOME RE-C rr tf .vDE T,
REMARKS/RECOMMENDATIONS
a
-GW-48 Revised 8/87 ,�b. JcEGPN,AL /PPERNSOR

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i

' OFFICE OF WATER AND AIR RESOURCES
' =WEL REC D GROUND WATER DIVISION
P. 0. BOX 27687 - RALEIGH; N. C. 27611
DRILLING CONTRACTOR KannapoliS W612 Arllin"REG. NO. 33 WELL CONSTRUCTION PERMIT NO.
I . WELL LOCATION: (Sim o ksich of the Joca ipn gp bacof form
Nearest Town: OCWe a Il (iaro.( in&— gj�a County: P,r •.ram
Off Crescent Road. Quadrangle No.
C 14Vd Community or Subdivision and Lot No.
2. OWNER: s
3. ADDRESS_P. Oo Box 171, Rockwell, N. Ce
4. TOPOGRAPHY: drmr, valley, slope, hilltop, flat 28138
5. USE OF WELL: Plant _ DATE: 9-15�-83
6. DOES THIS WELL REPLACE AN EXISTING WELL? NO
7. TOTAL DEPTH: 265' RIG TYPE OR METHOD: lilt° Rat
8. FORMATION SAMPLES COLLECTED: =YES No. of Bags
D. CASING: Inside WoII thick.
or
Depth Diam. weight /ft. Type
From 0 1o12 ft. 1—Galy-
10. GROUT: Depth Material Method
From 0 to 20 ft @Tg mt by hand
I I. SCREEN: Depth Diam. Type and Openina
From to fI.
,12. GRAVEL: 'Depth Size Material
From to ft.
13. WATER ZONES(depih):
DRILLING LOG
rWPTH
?' ION DES�R1pTI0N _
M
T
0
1
Red Dirt a_
15 t
0 t I
Brola, C1&
01
1001
Sand Rock
loot
127t
Soft Rock.
1271
2651
Mixed G
8o z5 z/
-35 33 jq
S 2y o
_
'—
---
-- --
14. STATIC WATER LEVEL: 35 ft. above top of casing.
below
Casing is 1 ft. above land surface. ELEV.
DATE MEASURED: September-'15th, 1.983----
15. YIELD(gpm): 7-5 METHOD OFTESTING: Air
16. PUMPING WATER LEVEL: ft. after hours
at gpm.
17. CHLORINATION: Type Ht I Tablet rr,ounll%Tablets
18. WATER QUALITY: TEMPERATURE(°F)
19. PERMANENT PUMP:(Show a sketch of well head on bock of form)
Date installed Type Make
Capacity (gpm) HP
Intake Depth Airline Depth
?20 �,HAVE YOU INFORMED THE WELL OWNER OF THE
..DEPARTMENTS REQUIREMENTS AND RECOMMENDATIONS? ®s
.21. REMARKS:
-_
b
At
a
I do hereby certify that this well -record is true and exact.
�ATUF='CONTRACTOR OR AGENT DATE

NORI H GARULIN'A UENAK I MEN 1, Ur NA I UKAL ANIJ LUUNUMII; KUHRUES
OFFICE OF WATER AND 'AIR RESOURCES
�V�,IE� L L GE ORG GROUND WATER DIVISION Ro -�l 1 v
P. 0. BOX 27687 - RALEIGH, N. C. 27611
DRILLING CONTRACTOR Kannanolis Well. Drill!Dl7_ Cos REG. NO. 33 WELL CONSTRUCTION PERMIT NO.
I • WELL LOCATION: (St,ox a �tch ..ppii the�Ipocrct'an op back form
Nearest Town: ttOCKwe11�g 1VOr�% �arOf�ina 5138 County Rowan
Off Crescent Road. Quadrangle No. 41 -
=/
2 owNER: Alchem, 6• mmunoity or Subdivision an of No.
3. ADDRESS: P • 0. Box 171, Rockwell, N. C • DRILLING OG
4. TOPOGRAPHY: draw., valley, slope, hilltop, flat 28138
FROM EDE TH TO FORMATION DESCRIPTION
5. USE OF WELL: Ghhm Plant DATE: 9-17-81 0 401 Red Dirt
6. DOES THIS WELL REPLACE AN EXISTING WELL? No 401 1101 Sand Ronk.
7. TOTAL DEPTH: 3451 RIG TYPE OR METHOD: Air Rotary 110 1351 Soft Rock.
8. FORMATION SAMPLES COLLECTED: =YES No, of Bogs 1351 3451 Grey Granite.
9. CASING. Inside Wall thick.
or
From 0 Deepth 1 Djgm• wei i /ft. Type � — 33
' 0
10. GROUT: Depth Material Method
From 0 t,, 20 ft 1-2-cement by hand
11. SCREEN: Depth Diam.
From to. ft.
12. GRAVEL: Depth
From to
13. WATER ZONES(depth):
Type and Opening
Size Material
14. STATIC -WATER LEVEL:'30_ft: above
top of casing.
ow
Casing is �- ft. above land surface: ELEV.
DATE MEASURED: September 17• 1981
15. YIELD(gpm): 3 METHOD OF TESTING: Air
16. PUMPING WATER LEVEL: ft. after hours
at q pm.
17. CHLORINATION: Type HTH Tablets Amount 15 Tablets
18. WATER QUALITY: TEMPERATURE(°F)
19. PERMANENT PUMP:(Show a sketch of well head on back of form)
Date Installed Typ• Make
Capacity (qpm) HP
Intake Depth Airline Depth
20. HAVE YOU INFORMED THE WELL OWNER OF THE
DEPARTMENTS REQUIREMENTS AND RECOMMENDATIONS? Yes
21. REMARKS:
I do hereby certify that this well record is tr a and exact.
IGNATUlE CONTRACTOR OR AGENT DATE
O
r.

DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
MEMORANDUM
TO: Ee c. kU.19a
DATE: 8J49
FROM: Bill Reid
SUBJECT: Application for Renewal/Amendment of Permit No.
New Permit
Facility Name 14IcAe.n r,7c.
County
Type of Project ��,y6D/1 �lcpcy�%g .Sysn
Applicable Permit Numbers : WQ 000198"i' GWgg3da
EPA AC
We have received a copy of the above referenced application,
which was sent to your regional office for comment on or about
�A/y 1989.
You should review the application package for completeness and
adequacy of relevant information and submit your request for
additional information to -.',me (via telephone or memo) by
- us 1989 .so that all required information can be,,;
requested from the applicant at one time. .,A copy of our formal'`,
request to the applicant-'--" for additional information will be
provided to you..
at
If you do not require additional information from the
applicant to complete your evaluation of the project, you should
review the application package and submit your comments to me by
uar,�rf a�- 1989
41r
If a copy of the application package has not been made
available to your office, PLEASE LET ME KNOW IMMEDIATELY so that a
copy can be forwarded to you as soon as possible.
MDC/APPMEMO

"Over 25 Years Experience"
Environmental Hydrogeological Consultants
P. O. Box 2622
LUMBERTON, N.C. 28359
[phone] N. C. DEPT. OF NATURAL
RESOURCES AND
COMIUNITY DE ✓ELOPIELFIN b
February 27, 1989 MAR 0 i 1989
GsVlv12F; f!i 11riVlioef�?°;�hiir�t L��w�:.Biln�ia
LE' AL E9dL
I:
Dr. Eric J. c:lin.gel, PhD, C.P.G.
Regional supervisor
Mooresville Regional Office
Division -of Environmental Management
Mooresville, NC 28115
SUBJECT s Application For Non -Discharge Permit
ALCI111 M, II+?C .
Rockwell, IC;C
Dear Dr. Klingel:
ALCIIR1,1, Inc., Route 3, Box 215-A, Rockwell, NC 28138 (7_04-
279-7908) is contemplating applying for a non-discha rge
permit (no discharge to the surface waters of the State).
Further, the process will utilize a close system as shown
on page 2-389 of the Administrative Code Section, 15 NCAC
2H.02CO(blue book) .
The process will involve the manufacture of aluminum sulfate
(used in water treatment) from the mineral bauxite. The residual
sand and other insolubles(see attached analysis) wi11 be pumped
to two (2) existing lagoons/'ioldi.ng ponds thereby eliminating
the need for any type of land application of wastewater.
Sufficient data is currently available concerning the hydro -
geologic description of the subsurface to a depth of more than
20 feet, depth to mean seasonal high water table, etc-. As you
know this speicific site and the general area are underlain
by multiple colored(mostly red -brown -orange) sapr.olitic mat-
erial. Five (5) auger holes were extended to 20-25 feet and
none encountered the water table.
Therefore, because of the similarity of the saprolitic
material from hole to hole, at this site, it is requested
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS ® CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE . LANDFILLS • PERMITS

fir. Eric Jo Klingel
February 27, 1989
Page 2
that con-iderat'on be given to allowing the use of the value
of l�rlCr-1X10- -or`• the vertical permeability of the un-
saturated zone. This value is believed by many to adequately
represent; typical saprolitic material® This should be suff-
icient because the residual sandy material that will be
pumped to the lagoons/holding ponds is considered to be
innocuous and perhacs beneficial as a fill material.
If this request is granted the application for the permit
can be submitted, hopefully' in about 2-3 weeks. We appreciate
very much your cooperation in this matter as we have in other
projects that we have worked on.
GdEB/ka
Attachment
Sincerely'
r
Willi a i 4E . �t 9 P.G
nydrogeologist
PNr-
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICALSPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS . PERMITS

Analytical and Consulting Chemists
Oxford Laboratories, Inc.
DATE RECEIVED 2-8-89 1316 South Fifth Street
DATE REPORTED 2-23-89 Wilmington, N.C. 28401
8 9W4 6 6 6 [phone]
PAGE 1 OF 1
INDUSTRIAL AGRI CHEMICALS
P.O. #
RT.2.BOX 521-C
RED SPRINGS , N.C. 28377
ATTENTION: RANDALL ANDREWS
SAMPLE DESCRIPTION: SULFURIC
ACID INSOLUBLE MATERIAL
;:-: 1. .SULFURIC ACID INSOLUBLE
MATERIAL FROM BAUXITE
RESULTS
1
Results -on Leachate
.'Arsenic , as As , PPM
<.005
..-Barium , as Ba , PPM
.400 :.
Cadmium , as Cd PPM
<.010
.:-Lead , as Pb , PPM
<.010
Chromium , as Cr , PPM
<.010
'.'Mercury , as Hg , PPM
<.0005
Selenium as Se , PPM
<.005
Silver as Ag PPM
<.005
.Initial pH
8.0
ROGER C. OXF R , CHEMISE"

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Date:c
STAFF REPORT AND RECOMMENDATIONS
County: Rowan
WQ No. 0001987
PART I - GENERAL INFORMATION
1. Facility and Address: Alchem, Inc.
Route 2, Box 521-C
Red Springs, North Carolina 28377
2. Date of Investigation: October 3, 1989
3. Report Prepared By: Allen Hardy, Environmental Engineer I
4. Person Contacted: Wayne Drye, Manager; telephone number
[phone]
5. Directions to Site: From Mooresville travel Highway 152
east to Fisher Road (approximately 3/4 mile before the city
limits of Rockwell). Turn left and travel to the
intersection of Crescent Road. Turn right on Crescent Road
and proceed approximately 1 mile to Red Road. Turn right on
Red Road and the site will be on the left approximately 1/4
mile from the intersection.
6. Discharge Point - Latitude. 35° 334 5311
Longitude: 800 25' 26"
Attach a USGS Map Extract and indicate treatment plant site
and discharge point on map.
USGS Quad No.: E 17 SW
7. Size (land available for expansion and upgrading): There
appeared to be adequate land available for expansion and
upgrading.
8. Topography (relationship to flood plain included): The
topography was relatively flat, 2-8o slopes. The site did
not appear to be in the flood plain.
9. Location of Nearest Dwelling: The nearest dwelling was
approximately 300 feet from the site.
10. Receiving Stream or Affected Surface Waters: N/A

Page Two
PART II - DESCRIPTION OF DISCHARGE AND 'TREATMENT WORKS
1. Type of wastewater: 0% Domestic
100o Industrial
a. Volume of Wastewater: Approximately 300 tons per month
of sand slurry.
b. Types and quantities of industrial wastewater: N/A
C. Prevalent toxic constituents in wastewater: N/A
d. Pretreatment Program (POTWs.only): N/A
2. Production Rates (industrial discharges only) in Pounds:
N/A
3. Description of Industrial Process (for industries only) and
Applicable CFR Part and Subpart: N/A
4. Type of Treatment (specify whether proposed or existing):
The proposed treatment will be in a closed loop recycle
system consisting of dual lagoons. A sand slurry will be
discharged into the lagoons and the supernatant will be
reused in the process.
5. Sludge Handling and Disposal Scheme: The sludge produced
from the filter press is to be taken to the landfill, as
stated by the manager. The sand. slurry. produced. will be
stored in two (2) lagoons.
6. Treatment Plant Classification: Unknown
7. SIC Code(s): Unknown
Wastewater Code(s): Unknown
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grants
Funds (municipals only)? No
2. Special monitoring requests: No
3. Additional effluent limits requests: No
4. Other: No
PART IV - EVALUATION AND RECOMMENDATIONS
The applicant, Alchem, Inc., is proposing to discharge 300
tons per month of sand slurry, produced from the production of
aluminum sulfate, into two lagoons. The production of the
aluminum sulfate will occur in a closed loop recycle system with
no discharge to surface waters.
The treatment process involves the production of both a sand
slurry and a cake from a filter press. The sand slurry was

Page Three
analyzed and considered inert and innocuous and the leachate
parameters were all within acceptable levels as stated in the
engineering proposal. The filter press cake was not mentioned in
the engineer's report as a sludge produced in this process.
There did not appear to be any problems with the site or the
proposal of storing the sand slurry in lagoons, provided that the
sand slurry is not hazardous and does not have the potential of
causing groundwater problems.
It is recommended that the ERG and Groundwater Section
provide comments before permit issuance, and that the applicant
provide information explaining where the cake sludge is to be
disposed and if it is acceptable. Pending approval and
acceptance of the above, it is recommended that the permit be
issued.
Signature of Report Prepar
i
water. Quality RP4j�onal Supe
isor

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State of North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
July 31, 1989
Randall F. Andrews, President
Alchem, Inc.
Route 2, Box 521-C
Red Spriungs, NC 28377
Subject: W00001987
Alchem, Inc.
Industrial Recycle
Rowan County
Dear Mr. Andrews:
R. Paul Wilms
Director
The Permits and Engineering Unit has completed a preliminary engineering review of the
subject application.
The following item(s) must be addressed before we can complete our review. Please note that
these item(s) must be received by September 29, 1989, in order to prevent your project from
being returned as incomplete:
1 . Our regulations require all plans and specification of treatment works to signed and sealed by a
North Carolina Professional Engineer. Please have your plans signed and sealed.
2. Submit two (2) copies of calculations used to determine the size of your settling basin, ,lagoons
and the amount of sulfuric acid that will be required.
3. Where will the sulfuric acid be stored?
If you have any questions on this matter, please call Mr. William Barlow at [phone].
Sincerely,
,01
William Barlow ���;�
oPn,
cc: Mooresville Regional Office Review Engineer AUG G 2 1989
Environmental Hydrogeological Consultants, Inc.
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

1
/21
State of North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor R. Paul Wilms
William W. Cobey, Jr., Secretary Director
July 28, 1989
MEMORANDUM
To: Rex Gleason
WQ Regional Engineer
Mooresville Regional Office
From:
William Barlow
Raleigh, Central Office
Subject: WQ0001987
Alchem, Inc
Industrial Recycle
Regional comments are requested
1V. C. D ^pT ogr NA
nFs®unC TURAZ
Es AND
cola-11VIU ITY DiIrz, .
0
% I r,'�:1nG��ciai
dl�� L Qti'jL6
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

North Carolina Department of Natural Resources and Community Development
DEM USE ONLY
Environmental Management Commission
p¢ rm1t. Nu-Lnber:
NON -DISCHARGE PERMIT APPLICATION
County:
iL(?lnrw t
in accordance with NC General Statutes Chapter 143, Article 21
Applicant (name of board, Individual, or others): Application Date:
ALCHEIM. INC-
Project (name of city, village, town, sanitary district, establishment):
8135 Red ,Road, Rockwell ,NNC
FOR:
Brief Project Description:
Process approximately 00 tons of bauxitoEl ;��r
Non -Discharge Treatment/Disposal Facilities
month from s!}IiCjl e.pPru,.ii;ia.tely 300 ion 5 pe,
❑ Pretreatment Facilities
Month of sand slurry will be produced in ;a
❑ Sewer Collection System (private)
closed or recycle system with no di.schar�le
❑ Extension of Sewer Systems (public)
to the sur tce waters of thr� st°3te .
❑ Sludge Disposal
❑ Spray Irrigation
NATURE OF WASTEWATER:
❑ Domestic Sewage.
❑ Sludge/Industrial Waste
Estimated Completion Date:
`❑ Other Waste Sand Slurry
From (sewers, pretreatment plant): Serving (city, institution, industry):
I
I A I N/A
Into (name of treatment plant): Average Daily Gallons Sewage or Waste Flow:
T%J/A I N/A
At (location of plant): (NPDES No.)
iFj/A NC00 N/A.
Name and Complete t5 i::ti.,
Erivironnlenta.i I,ydroReologics.l Con.sultan Z:3S3
Address of 'Engineering Firm: Zip Code:
P_0. Box ?622 Telephone No. (919) 739-.3V88
Lumberton, TIC
Applicant assures that proposed works will be constructed, supervised, operated and maintained in accordance
with approved plans and specifications or approved changes thereto..
Randall F. f ndi-1-rtJs Mailing Route 2, Box Sal-C
Print Name: Address:
Title: Preen , 1': Red Springs, NC Zip Code: ==8 377
Signature: ''' " `�'i � Telephone No. / 919 / ' ,--212.1
INSTRUCTIONS:
1. Fill-in All Spaces. If not applicable, enter N/A.
2. Secure appropriate signature (mayor/city manager for municipality, chairman for sanitary district board,
owner/proper official of corporation, or legally constituted board or commission in charge of proposed works).
A letter of authorization is required from proper official if design engineer or other agent signs application.
3. Submit to Division of Environmental Management, Permits and Engineering Unit, P.O. Box 27687, Raleigh, NC 27611
the original and first copy of application, 3 sets of finalized plans, specifications and other supporting data as
required by Commission Rules. and permit fee.
FOR ASSISTANCE, CALL THE STATE CENTRAL OFFICE [phone], P9RMITS 8<., ENGINEERING UNIT, OR :
Asheville [phone] Mooresville [phone] Washington [phone] Winston-Salem [phone]
,159 Woodfin Street 919 North Main Street 1424 Carolina Avenue 8025 N. Point Blvd.
Asheville, NC 28801 Mooresville, NC 28115 Washington, NC 27889 Suite 100
Winston-Salem, NC 27106
Fayetteville [phone] Raleigh [phone] Wilmington [phone]
Suite,714 Wachovia Building Box 27687 7225 Wrightsville Avenue
Fayetteville, NC 28301 Raleigh, NC 27611 Wilmington, NC 28403

State of North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor ; R. Paul Wilms
William W. Cobey, Jr., Secretary Date: - 1 < ' ! f i`;~ 19 P Director
J
i
I• 1 iY i 1; J g it _
d
'�; `° _ .i: ,r' i J ...Jz�„ ' Are✓'"��a
Dear ` a' .r' t A.
SUBJECT: Application No. WQ';f
6 tl�itli i�-"�� 3 1 f...! � i.• `� iv � a i�_ �t;'i zr 1
a
The Divisions Permits and Engineering Unit acknowledges receipt of your permit application and supporting
materials on - _ + 7 , 19 :�`"� . This application has been assigned the number shown above. Please
refer to this number when making inquiries on this project.
Your project has been assigned to -� R ti �'"�� `' r 1 for a detailed engineering
review. A technical acknowledgement will be forthcoming. If this acknowledgement is not received within thirty (30)
days, please contact the engineer listed above.
Be aware that the Divisions regional office, copied below, must provide recommendations from the Regional Super-
visor or a Procedure Four Evaluation for this project, prior to final action by the Division.
If you have any questions, please call the review engineer listed above at [phone].
Sincerely
r, t A.i
Arthur Moulberry, P.E.
i- Supervisor, -'Permits and Engineering
�. j•i
CC: n , ; ' x a Regional Supervisor
Pollution Prevention Pays
P.O. Box 27687, Raleigh, Norih7Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

APP.LI.CATION FOR
CLOSED SYSTEM PERMIT
ALCHEM,, INC.
8135 RED ROAD {
ROCKWELL,,NORTH CAROLINA 28f38
y��r��l�� ..
May 18, 1989 C G
NfAy
By: William E. Bright, P.G. p E2[VI iT 8 i�G':'!':-•-s.'. ',(;
Environmental Hydrogeological consultants
P.O. Box 2622
Lumberton, North Carolina 28358SED
a�H•ee�r�o��
IN
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EHC
LEAKING BURIED TANKS LEAKING STORAGE LAGOONS • CONTAMINATED G�&f JDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS

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Page
1.0 Location .............................................. 1
2.0 Introduction ......................................... 1
3.0 Chemical Analysis of Sand Slurry ........................ 1
4.0 Sand Slurry Production .................................. 1
5.0 Capacity of Lagoons ........ 2
6.0 Treatment Process System ................................ 2
7.0 Hydrogeologic Description of the Subsurface ............. 2
7.1 Changes in Lithology ............................... 2
7.2 Vertical Permeability of Lagoon Bottoms ............ 3
7.3 Hydraulic Conductivity of
7.4 Depth to Mean Seasonal High
7.5 Depth to Bedrock ...........
8.0 Groundwater Monitoring ..........
9.0 Area Wells ......................
10.0 Conclusion ......................
FIGURES
1. Location Map
2. Site Map
3. Process System Schematic
4. Lagoon Views
Sand Slurry Analysis
Coefficient of Permeability
C
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS

1
1.0 LOCATION
Alchem, Inc., 8135 Red Road. Rockwell, Rowan County,North Carolina
28138, is located along the Southern Railroad track approximately 1.5
miles northwest of Rockwell (Figure 1).
2.0 INTRODUCTION
Predicated on being properly permitted, Alchem, Inc., will process
bauxite•'fl�umi�numliydroxzdes in an effort to increase product-
ion of aluminum 'sulfate (used in water treatment) to meet growing industrial
demands.
The sand slurry, containing dirt and a small amount of aluminum hydrate,
that is generated during such production will be pumped to existing dual
lagoons from which the liquid portion will be returned to a 6,000 gallons
processing water tank. In addition to not being hazardous, the sand slurry
is considered inert -and innocuous.
The production of the aluminum sulfate will occur in a closed system
with no discharge to the waters of the state.
3.0 CHEMICAL ANALYSIS OF THE SAND SLURRY
An analysis of the sulfuric acid insoluble material (sand slurry) from
bauxite dated February 10, 1989 is attached. The analysis indicates that
the leachate parameters are all within acceptable levels, if present at all.
4.0 SAND SLURRY PRODUCTION
Approximately 700 tons Hof bauxite ger month vi11 be processed, at
this facility. from which approximatel 600 tanskiper moStgh ; s�ai d s,16u rry�
will be produced.
1
EIS C
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWJ \
CHEMICALSPILLS • LAND APPLICATION OF SLUDGE • \
LANDFu i c ..,..,,.,'

5.0 CAPACITY OF LAGOONS
The total approximate capacji_-y of the 2 lagoons, each approximately
50' W x 200' L x 10' D, is 4,938 tons, or sufficient capacity to receive
and store the sand slurry for about 15•months (Figure 4).
6.0 TREATMENT PROCESS SYSTEM
The raw material consisting exclusively�of bauxite will be reacted
with sulfuric acid and water in a reaction vessel. After reaction nln2e�
completion, the material will be / d� �, p pumped to a fiberglass settling tank from ��-.�
which the liquid (aluminum sulfate) will be pumped to storage tank(s) and
the settleable insoluble material (mostly sandy material, SO 2) will be
washed until the PH of the material elevates to a minimum of about 6.0.
The PH of the material will be'determined by using.a Fisher Digital.PH
meter on a daily basis.
The wash water will also be returned to storage or process water
tanks and the sand slurry and other minor insolubles still be released to
dual lagoons. When and.as often as necessary, the liquid in the..lagoons
will be returned to the. -process water tank(s); thereby completing the closed
system (Figure 3)•.
7.0 HYDROGEOLOGIC DESCRIPTION OF THE SUBSURFACE
7.1 CHANGES IN LITHOLOGY
A total of 6 holes were power augered at this site using an Olathe
160 Series combination auger/rotary drill (Figure 2). These holes ranged
~ in depth from about 28'-30' and none encountered' the- water table..
Z ecvyAReirial underlying this site to bedrock is typical multiple
��y1S10N ENVIRONMENTAL MAAASEM
s E H C
lAOORESVILLE :. •
L 1(�k IED TANKS, • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS LAND APPLICATION OF SLUDGE- LANDFILLS •. PERMITS

2
5:6� CAPACITY OF LAGOONS
\alapproximate capacity of the 2 lagoons, each a' p Y g proximately ;
i..:
50' WD, is 4,938 tons, or sufficient capacity toR EP Vand srry for about 15 months(Figure 4). AUG 22 1989
6.0 SYSTEM PERMITS EGINEER;G
The raw material con isting exclusively of bauxite willbe reacted
with sulfuric acid and water 'n a reaction vessel. Subsequent to reaction
completion, the material will be umped to a settling basin from which the
liquid (aluminum•sulfat6) will be pu ed to storage tank(s) and the settle-
able insoluble';material (mostly sandy ma erial, SiO2) will be washed until
the PH of the material elevates to a mininum of about 6.0. The PH of the
material will be determined by using a Fisher Digital PH meter on a daily
basis.
The washed water will also be returned to storage or process water
tanks and the sand slurry and other minor insolubles will be released to
dual lagoons. When and as often as necessary, the liquid in the lagoons
will be returned to the process water tank(s); thereby completing the closed
system (Figure 3).
7.0 HYDROGtOLOGIC DESCRIPTION OF THE SUBSURFACE
7.1 CHANGES IN LITHOLOGY
A total of 6 holes were powered augered at this site using an Olathe
160 Series combination auger/rotary drill (Figure 2). These holes ranged
in depth from about 281-301 and none encountered the water table.
The material underlying this site to bedrock is typical multiple
l
EHC
LEAKING BURIED TANKS •LEAKING STORAGE LAGOONS •
CHEMICAL SPILLS CONTAMINATED GROUNDWATER RECOVERY
LAND APPLICATION OF SLUDGE 0 LANDFILLS • PERMITS

3
colored (red -brown -yellow -orange) saprolite. ,The saprolite is composed
mainly of silty, micaceous clay -like material. With perhaps some minor
variations, mainly color, there.are no significant lithologic differences
to bedrock.
This material, although somewhat easy to auger; especially the mica-
ceous silty streaks, is nevertheless considered very impermeable and not
very suitable for obtaining even domestic water supplies.
7.2 VERTICAL PERMEABILITY OF LAGOON BOTTOMS
Because the material underlying the site is very similar, all over,
the vertical permeability should also be similar. Therefore, based on
laboratory results the permeability of the lagoon bottoms and presumably
the entire site is very low but desirable, in this case, ranging from about
2.2 x 10-5 - 1.7 x 10-7 with an average permeability of about 1.9 x 10-6
Cm/Sec. Based on this value and the fact that the sand slurry is consider-
ed innocuous, the lagoons should be very suitable for their intended
purpose.
7.3 HYDRAULIC CONDUCTIVITY OF THE SATURATED ZONE
If a saturated zone is present underlying this site, it is more than
about 30 feet below land surface as no water was encountered in any of
the 6 somewhat deep auger holes.
7.4 DEPTH TO MEAN SEASONAL HIGH WATER TABLE
The depth to the mean seasonal high water table, at this site, is
more than 30 feet below land surface. There are currently 2 water''supply
wells located at this site. One of the wells (#1) is about 360 feet deep,
EHC
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICALSPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS

4
and the other (#2) is reported to be about 280 feet deep. In well #1,
the water level was reported to be about 60 feet and well #2 about 50 feet
below land surface. '
7.5 DEPTH TO BEDROCK
Based on the 2 on -site water supply wells, the depth to bedrock was
reported to be about 50-60. feet below land surface or approximately 50
feet below the bottom of the lagoons.
8.0 GROUNDWATER•MONITORING
Because there does not appear to be any relatively shallow water
(15'-201) underlying the site the construction of monitor wells would not
only seem perhaps impractical but unnecessary.
In lieu of constructing such wells the existing.supply wells, on site,
which would equate to monitor wells, if any are required, could be monitored
as often as deemed necessary.
9.0 AREA WELLS
The area where this facility is located is somewhat sparsely populated
with only'one (1) dwelling on the westside and it is about 400 feet away.
On.the eastside and at least 350-400 feet away, there are several homes,
one served by an individual well, and the other homes by a "community well"
which is located at least 450-500 feet away from the facility. There are
no wells located nearby, either to the north or south of the facility.
10.0 CONCLUSIONS
1) The production of aluminum sulfate from bauxite, at this site,
will occur in a closed system.
1 EHC
LEAKING BURIED TANKS LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 9 LAND APPLICATION OF SLUDGE 9 LANDFILLS 9 PERMITS

5
2) The aluminum sulfate will be distributed for use in water
treatment-.
3) The sand slurry generated, at this site, from the production
of bauxite is considered both inert and innocuous.
4) The permeability of the lagoon bottoms meet established
criteria.
5) The water table underlying this site is reported to be in the
range of 40-45 feet below land surface.
6) The nearest off -site water supply well is located approximately
400 feet to the east.
7) Any water that will collect in the lagoons will be recycled.
8) American Cyanamid, located in Plymouth, North Carolina, is
currently utilizing this process.
9) This facility is located in a sparsely populated area.
1
EHC
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 0 LAND APPLICATION OF SLUDGE • LANDFILLS 9 PERMITS

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� •��°��•_~_•\- il jl�y _./% � \�' •.�J '-G�J - °y �\,`=�_.J�• ,it...Lj111'(((1(f (.`'� - f � i°
co
750
ejIC
- 1 % p', = L -
if" -(111
-�� / mod` ��11' •�� •BM
R ^ 709 / u, '\ LT�Na r�TTTak •n 773 1
�'la J �e\\\I ��i' • ,I II ° • ° ' �i II, �'_,.
• n it �782 ' '7571 /i -- r /'fi °.I�\��! \'�:�•/• �,• .II /�' /' '�17�
ovruare Cti J\V ` \ :. Lam, ' •1J' ! i • v yI(^ u�
M
ZZ
It r
� / � ro •f� \1---\ !; _ `,\ \✓ � j�•�1' '� i 7 , i• �\ <�y -Jri://il .tl � °_�`jo� �
�� I fat �� `\ � �, \�,. C_�� �-,e �., • _ _ �'� /\l ,I � v,'l,�1 � Ur =
SCALE: DATE: - _ - - � � � - '
TITLE: Fi ur e 1.
1:24000 - Y 9 ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS
JOB. NO. Location MapHYDROLOGY • GEOLOGY • EXPLORATION • ANALYTICAL

N
2500, 4-- PROPERTY LINE
LAC30ON
2
6 CLAY PARTITION _
LAGOON
21 1
13
SECONDARY I9 17 1
CONTAINMENT I 1 II 92
® 1
10
EMERGENCY O 5 SUW. 25000 GALLONS
•1
NEAREST DOMESTIC WELL IS
APPROXIMATLY 400 FEET FROM
THE LAGOONS,IN THE DIRECTION
OF THE ARROW.
— — —� 200'
KEY
= AUGER HOLE
® = SUPPLY WELL
O = TANK
0
O°o
ALCHEM
OFFICE O
00
FIGURE 2 , 4
D/1J PROPERTY LINE 5=Steel, F=Fiberglass,
SPO---- lypropyleneILROAD
SCALE: 1" = 135
(Approx.)
Tank
No.
Cap.
Gals.
Conts.
Tank
Mat.
1
4,500
Sulfuric
Acid
S
2
4,500
�� it
S
3
12,000
oluTn.
F
4
7,000
eactor
F
5
10,000
Reactor
F
6
4,000
Water
Storage
F
7
4,000
it if
P
8
4,000
it it
P
g
10,000
Alum
F
10
103000
Water
Stora e
F
11
4,500
Alum
P
12
10,000
��
F
13
10,000
��
F
14
4,500
��
P
15
6,000
Process
P
16
10,000
Alum
1 F
17
10,000
��
F
18
5,000
P
19
5,000
T�
P
20
4,500
IT
P
21
5,000
It
P
22
10.000
Cool .
Down
F
DATE: G n TITLE:
ALCHEM, INC.
ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS 8135 Red Road
JOB. NO.
HYDROLOGY • GEOLOGY • EXPLORATION • ANALYTICAL Rockwell, NC

0
SCALE: NTS
LAGOON
CLAY PARTITION
3 LAGOON
KEY
SUPPLY WELL --__— 4" PVC
= PUMP - - - - 2" PVC
O = TANK
PUMP NO.
MATERIAL
TYPE
H/P
1
S.S.-316
CENTRIF.
5.0
2
S.S.-316
CENTRIF.
25
3
S.S.-316
CENTRIF.
25
4
POLYPROPYLENE
SELF PRI
5.0
THE SCHEMATIC SHOWS THAT SULFuRrc ACID REACTS
WITH BAUXITE AND WATER IN THE REACTORS FROM
WHICH THE WATER IS PUMPED TO LAGOONS AND THEN
TO APROCESS WATER TANK PRIOR TO RETURING TO
THE REACTOR VESSEL. `
WATER FROM BOTH OF THE ON SITE SUPPLY WELLS
IS PUMPED TO WATER STORAGE TANKS, THEN TO
THE REACTORS.
THE LIQUID ALUMINUM SULFATE IN THE REACTORS
IS PUMPED TO A COOL DOWN TANK AND THEN TO
AL U I STORAGE TANKS.
DATE: E H C
ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS
JOB. NO.
HYDROLOGY - GEOLOGY - EXPLORATION - ANALYTICAL
FIGURE#3
TITLE:
ALCHEM, INC.
8135 Red Road
Rockwell, NC

LAGOON
CLAY PARTITION
A LAGOON
8
200'
A. PLAN VIEW
19
Of MAY WATGR IFVM
IZ0'
FIGURE 4
TITLE:
ALCHEM, INC.
8135 Red Road
7 XTP

Analytical and Consulting Chemists
DATE RECEIVED '2-8-89 1316 South Fifth Street
DATE REPORTED w
2-23-89 Wilmington, N.U. Zoi
89W4666.' [phone]
PAGE 1 OF
INDUSTRIAL AGRI CHEMICAL P.O.
5 2 1!!-.c
�'-,:RT-. 2 BOX
SPRINGS. N.C. 28377
ATTENTION RANDALL ANDREWS
SAMPLE,,.DESCRIPTION: SULFURIC ACID INSOLUBLE.,MATERIAL
51,"VSULFURIC -ACID INSOLUBLE MATERIAL ;FROM BAUXITE
RESULTS
Results' -on LeachAte
z.senic as As PPM <.005
. Ba rlum'--, :as-Ba PPM .400
-Cadmium '.as Cd PPM <.010
as Pb PPM <.010
,Chromi um " as Cr PPM <.010
Ae.rcury, as Hg PPM <.0005
Selendum as Se y, PPM <.005
'17ilver.- as Ag PPM. <.005
An I t 3L a I PH 8.0
OGER'C. OXCtFR CHEMIST
E W.

J..
r
JOE E. GODWIN. OR. P.E. R.L.S.
RONNIE C JORDAN: R.L.B. '
JAMS* E. GODWIN
0Z
Godwin - Jordan & Associates, P.A. .
ENGINEERING. SURVEYING & PLANNING
XV
102 WEi1T !ROAD mTREET
P. O. ®OX 245
DUNN. N. C. 28334
PNONEe: FAY. 48'-1480
DUNN melt-®1mm
MATERIALS TESTING DIVISION
REPORT OF: Coefficient of Permeability (Falling Head Method)
MADE FOR: William.E. Bright
PROJECT: Alchem Corporation Rockwell, N.C.
K = 2.3 aL to Ho
AT g10 H
K = Coefficient of Petmeabil' tyr .CM�Se.c
A = Cross sectional • area of pe.3 >meameteX CM2
L = Length of Speciinen, CM
a = Cross sectional area of stan_dpipe,'.CM?
T = Time of test, sec
io = Head at start of test, CM
H = Head at 'end of -test, CM
Q Discharge, CC
Test # H� H T Q a i
T
1
32.07
25.40
4 080
3.7
.47
7.15
��
8.71
1\
0.00002-2025
i lA
32.07
30.16
4,800
1.0
.47
7.15
8.71
0.000004930
2
32.07
31.91
10,800
0.1
.47
7.15
18.71
0.000000178
K'required = 1 x'1076 0.000001.
Test Locations: Test 1 & 2 Sampled by William E. Bright
Test #1 Liquid Limit = 53.0 Plasticity Index = N/P (MH)
Test #2 Liquid Limit = 56.0 Plasticity Index = 12.7(MH) "
NOTES: Above tests represent spot checks only
Te in Technician

TO;
DATE,
01, 'ojpqoll
53
ID A
Nolth Carolina Depaftentof Environment
rl Healthland Natural mesources,

I
•DIVISION OF ENVIRONMENTAL MANAGEMENT
Nov_Te ber:-29, -1989
MEMORANDUM TO: Bill Barlow,�C
FROM: D. Rex Gleason'-0
PREPARED BY:
W. Allen
Hardy
G)A 4
SUBJECT:
Alchem,
Inc. -
WQ 0002702 (Formerly WQ 0001987)
The Mooresville Regional Office is in receipt of a resubmittal for Alchem,
Inc. Comments were prepared in a staff report (dated October 11, 1989) for the
original submittal (WQ 0001987). The report and recommendations should also apply
for the resubmittal (WQ 0002702).
If you have any comments or questions, please advise.
WAH/bb

1 State of North Carolina NOV 2
Department of Natural Resources and Community Pryelopment; pp
Division of Environmental Management tol� a''•:- .'_� hip l ;;;;9St l°;
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor R. Paul Wilms
William W. Cobey, Jr., Secretary Date: 1 19 Director
l ` ` SUBJECT Application No. WQ
r
Dear
The Divisions Permits and Engineering Unit acknowledges receipt of your permit application and supporting
materials on 1 , 19 . . , ' . This application has been assigned the number shown above. Please
refer to this number when making inquiries on this project.
Your project has been assigned to �f for a detailed engineering
review. A technical acknowledgement will be forthcoming. If this acknowledgement is not received within thirty (30)
days, please contact the engineer listed above.
Be aware that the Divisions regional office, copied below, must provide recommendations from the Regional Super-
visor or a Procedure Four Evaluation for this project, prior to final action by the Division.
If you have any questions, please call the review engineer listed above at [phone].
CC:
Sincerely
Arthur Mouberry, P.E.
Supervisor, Permits and Engineering
Regional Supervisor
Pollution Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

F
North Carolina Department of Natural Repousces, and Community Development
', DEM USE ONLY
Environmental Management Commission
Permit Number:
NON -DISCHARGE PERMIT APPLICATION*
In accordance with NC General Statutes Chapter 143, Article 21 \�
County:
Appli}cant%(name of board, individual, or others): Application Date:
Ir11Er"I, I I1C. Novembeir 1 3 a 1939
Project (name of city, village, town, sanitary district, establishment):
FOR:
Brief Project Description:
❑x Non -Discharge Treatment/Disposal Facilities
Prock;s s approximately 700 this of bauxite
❑ Pretreatment Facilities
por mond--i from M-0ch approximately 300 i"on� ,
❑ Sewer Collection System (private)
per month of sand slurry vjill be prodded
El Extension of Sewer Systems (public)
in a cicse,l or r°�_:ycle s�,�sb,;,,m with no
•-
El Sludge Disposal
u1b, schdrgar3 to the surface waters ter"s of the
State.
❑ Spray Irrigation
NATURE OF WASTEWATER:
❑ Domestic Sewage
❑ Sludge/Industrial Waste
['Estimated Completion Date:
NIA
❑X Other Waste Sand S1i.9rr'y
From (sewers, pretreatment plant): Serving (city, institution, industry):
N/A N/A
Into (name of treatment plant): Average Daily Gallons Sewage or Waste Flow:
At (location of plant): (NPDES No.)
NIA NC00
Name and Complete
Address of %Engirieeni"ng>+ inmc Env r'tiri)61ent,-,11 �-i!jt�6"o(-eol ocli e (I Consul t�i€ tszip6 Code: 28,358
P.O. box 2,6'.)' n i.Uirlberton m NC Telephone No.
Applicant assures that proposed works will be constructed, supervised, operated and maintained in accordance
with approved plans and specifications or approved changes thereto..
Print Name: Randal i F. r1ndreyis Mailing Address: kou je 29 Box 521—C
Title: Red Sprinqz, NC Zip Code: -'`'3 I
)'�~LrXi-+`�°�(i f-if/'1�•L%'= Telephone No.
Signature: 44
INSTRUCTIONS:
1. Fill-in All Spaces. If not applicable, enter N/A.
2. Secure appropriate signature (mayor/city manager for municipality, chairman for sanitary district board,
owner/proper official of corporation, or legally constituted board or commission in charge of proposed works).
A letter of authorization is required from proper official If design engineer or other agent signs application.
3. Submit to Division of Environmental Management, Permits and Engineering Unit, P.O. Box 27687, Raleigh, NC 27611
the original and first copy of application, 3 sets of finalized plans, specifications and other, supporting data as
required by Commission Rules. and permit fee.
FOR ASSISTANCE, CALL THE STATE CENTRAL OFFICE [phone], PERMITS 6t ENGINEERING UNIT, OR
Asheville [phone] Mooresville [phone] Washington [phone] Winston-Salem [phone]
159 Woodfin Street 919 North Main Street 1424 Carolina Avenue 8025 N. Point Blvd.
Asheville, NC 28801 Mooresville, NC 28115 Washington, NC 27889 Suite 100
Winston-Salem, NC 27106
Fayetteville [phone] Raleigh [phone] Wilmington [phone]
Suite 714 Wachovia Building Box 27687 7225 Wrightsville Avenue
Fayetteville, NC 28301 Raleigh, NC 27611 Wilmington, NC 29403

"Over25 Years Experience"
Environmental Hydrogeological.Consultants, Inca
Post Office Box 2622
LUMBERTON, NORTH CAROLINA 28359
[phone]
'November 13, 1989
F Mr. William Barlow
Permits and Engineering Unit
NCEHNR-DEM
P.O. Box 27687
Raleigh, North Carolina 27611-7687
Subject: Resubmittal of Application
WQ0001987
Al Chem, Inc.
Industrial Recycle
Rowan County
Dear Mr. Barlow:
The attached revised application for subject permit, including all DEM
requested changes, represents a resubmittal of the original permit application,
dated May 18, 1989.
We appreciate very much your cooperation in the application and if you
need -additional information or clarification, please advise.
Sincerely,
G Wi11 am E. Bright P.G.
Hydrogeol ogi st
WEB/onb.:=
Attachments '
LEAKING BURIEDTANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS • UST REGULATIONS
SITE ASSESSMENTS • SOIL AND WATER SAMPLES • GROUNDWATER SUPPLIES

APPLICATION FOR
- CLOSED SYSTEM PERMIT
ALCHEM, INC.
8135 RED ROAD
ROCKWELL, NORTH CAROLINA 28138
November 13, 1989
By: William E. Bright, P.G.
Environmental Hydrogeological Consultants,•I.nc.
P.O. Box 2622
-- Lumberton, North Carolina 28358
This application for a closed
system permit reviewed by:
.o'��H CARP NµsIMNN0,#i
°�
•••....AR l �,� •,� A�.�`�� CAR01.1 •.
0,4
5 " :
SEAL
o 15472.
06
SHi
PN^
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE LANDFILLS PERMITS

TABLE OF CONTENTS
4 _ Page
_ 1.0 'Location-.,............,... .............:..:............... 1 .
2..0. Introduction .............. ............................. 1 _
3:0 _.Chemic&q'Analysis of Sand Slurry ..................... 1
4._0 Sand Slurry,Production ...........:................... 1.
- 5.0 Capacity of Lagoons ......
6.0- Treatment Process System ............................. 2
7.0 Hydrogeologic Description of the Subsurface 2
7.1 Changes in Lithology ............................ 2
7.2' Vertical -Permeability of Lagoon Bottoms ......... 3
- 7.3 Hydraulic Conductivity of the Saturated Zone .... 3
7.4- Depth to Mean Seasonal High Water Table .........
3
:.7.5-..-Depth of Bedrock .................................
4
_ - 8.0.. Groundwater Monitoring ...............................
4
_ 9.0- Area'Wells .............. ...........,_.............
4
10. o -Conclusion-. ..
FIGURES
- 1. Location Map-.-
2. Site Map
3:. Process System Schematic
-_ 4.--_- Lagoon -.Views
ATTACHMENTS: -
Sand Slurry Analysis
Coefficient of Permeability
LEAKING BURIED TANKS •LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS 9 PERMITS

- -1.0 -LOCATION
Alchem, Inc., 8135'Red Road, Rockwell, Rowan County, North Carolina
' 28138; is located along the Southern Railroad track approximately 1.5
miles.northwest-of Rockwell (Figure 1).
2:0--INTRODUCTION
Predicated on being properly permitted, Alchem, Inc., will process .
-bauxite (mixture'of aluminum hydroxides) in an effort to increase product-
- ion of aluminum sulfate (used in water treatment) to meet growing industrial
demands.
The sand slurry, containing dirt and a small amount of -aluminum hydrate,
that -is generated during such production will be'pumped to existing dual
lagoons from which the liquid portion will be returned to a 6,000 gallons
processing water tank. In addition to not being hazardous, the sand slurry
' is considered inert and innocuous.
The production of -the aluminum sulfate will occur in a closed system
with no discharge to the waters of'the state.
3.0 CHEMICAL ANALYSIS;OF THE SAND SLURRY
An analysis of the sulfuric acid insoluble material (sand slurry)
from bauxite dated February 23, 1989, and of the liquid fraction dated
November 62~ 1989,"are attached: The analyses indicates that 'the leaclate
parameters are all -within acceptable levels, if present at all.
4.0 SAND SLURRY PRODUCTION -
Approximately 700 tons of bauxite per month will be processed, at
this facility, .from which approximately 300 tons per month of sand slurry
will be -produced,.. _
FHA
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • -PERMITS

jI
2
5.0 CAPACITY OF LAGOONS
The total approximate capacity of the 2 lagoons, each approximately
50' W x 200' L x 10' D, is 4;938 tons, or sufficient capacity to receive
and store the ewand slurry for about 15 months (Figure 4).
6.0 TREATMENT PROCESS SYSTEM
The raw material consisting exclusively of bauxite will be reacted
with sulfuric acid and water in a reaction vessel. After reaction
completion, the material will be pumped to a fiberglass settling tank from
which the liquid (aluminum sulfate) will be pumped to storage tank(s) and
the settleable insoluble material (mostly sandy material, Si0 2) gill be ;
was�-:
,ed�a�ant:tl-the-P -"ofYthe matefttaVel'evate . to ai=i inirium of about
The of the material will be•determined by using a Fisher Digital PH
meter on a daily basis.
The wash water will also be returned to storage or process water
tanks and the sand slurry and other minor insolubles will be released to
dual lagoons. When and as often as necessary, the liquid in the lagoons
will be returned to the process water tank(s); thereby completing the closed
system (Figure 3).
7.0 HYDROGEOLOGIC DESCRIPTION OF THE SUBSURFACE
7.1 CHANGES IN LITHOLOGY
A total of 6 holes were power augered at this'site using an Olathe
160 Series combination auger/rotary drill (Figure 2). These holes ranged
in depth from about 28'-30' and none encountered the water table.
The material underlying this site to bedrock is typical multiple
EIS C
LEAKING BURIED TANKS • LEAKING STORAGE•LAGOONS CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS PERMITS

3
colored (red -brown -yellow -orange) saproli'te. .The saprolite is composed
mainly of silty, micaceous clay -Like material. With perhaps some minor
variations, mainly color, there.are no .significant lithologic differences
l to bedrock.
This mate
rial,•although somewhat easy to auger; especially the mica-
ceous silty streaks, is nevertheless considered very impermeable and ,not
very suitable for obtaining even domestic water supplies.
7.2 VERTICAL PERMEABILITY OF LAGOON BOTTOMS
Because the,material underlying the site is�very similar, all over,
the, vertical permeability should also be similar. Therefore. based nn
laboratory results the permeability of the lagoon bottoms and presumably
the entire site is very low but desirable, in this case, ranging from about
1r0 1'y10"7 with -an average permeability of about 1-.8 x 107.7
Cm/Sec. Based on this value and the fact that the sand slurry is consider-
ed innocuous, the lagoons should be very suitable for their intended
purpose.
7.3HYDRAULIC CONDUCTIVITY OF THE"SATURATED ZONE
If a saturated zone is present underlying this site, it is more than
about 30 feet below land surface as no water was encountered in any of
the 6 somewhat deep auger holes.
7.4 DEPTH TO MEAN SEASONAL HIGH WATER TABLE
The depth to the mean seasonal high water table, at this site, is
more than 30 feet below land surface. 'There are currently 2 water supply
wells located at this site. One of the wells (#1), is'about 360 feet deep,
EHC
LEAKING BURIED TANKS LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 9 LAND APPLICATION OF SLUDGE 9 LANDFILLS • PERMITS

4
and the other (#2) is reported to be about 280 feet deep. In well #1,
7.
the.water level was reported to be•about 60 feet and well #2 about 50 feet
below land surface.
7.5 DEPTH TO BZ)ROCK '
Based on the 2'on-site water supply wells, the depth -to bedrock was
reported to be about 50-60 feet below',land surface or approximately 50
feet below the bottom of the lagoons..
8.0 GROUNDWATER -MONITORING
Because there does not appear'to be any relatively shallow water
(15�-20a) underlying the site the construction of monitor wells would not,
only seem perhaps impractical but unnecessary.
In lieu of constructing such wells the existing.supply wells, on site,
which would equate to monitor wells, if any are required, could be monitored
as often as deemed necessary.
9.0 AREA WELLS
T
The area where this facility is located is somewhat sparsely populated
with only one (1) dwelling on the westside and it is about 400 feet away.
On.the eastside and at least 350-400 feet away, there are several homes,
one served by.an individual well, and the other homes by a "community well"
which is located at least 450-500 feet away from the facility. There are
no wells located nearby, either to the north or south of the facility.
10.0 CONCLUSIONS
1) The production of aluminum sulfate. from bauxite, at this site,
will occur in a closed system...-
., E H C
LEAKING BURIED TANKS LEAKING STORAGE LAGOONS CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 0 LAND APPLICATION OF SLUDGE LANDFILLS • PERMITS

5
2) The aluminum sulfate•will be distributed for. use in water
treatment:
3) The sand slurry generated, at this site, from the production
of bauxite is considered both inert and innocuous.
4) The permeability of the lagoon bottoms meet established
criteria.
5) The water table underlying this. site is reported to be in the
range of 40-45 feet below land surface.
6) The nearest off -site water supply well is located approximately
400 feet to the east.
7) Any water that will collect in the lagoons will be recycled.
8)'American Cyanamid, located in Plymouth, North Carolina, is
currently utilizing this process.
9) This facility is located in a sparsely populated area.
10) A pump with a ten horsepower motor will pump sand slurry from
the settling tank to the settling pond.
11) A pump with a twenty horsepower
pond liquid to the process water
i •
FH
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS 0 LAND APPLICATION OF SLUDGE 9 LANDFILLS • � PERMkTS

,
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• °• 7% , Ale ., .1•\ \t� / -� • - -_ J r' oy9. r. r ;• •t•jl�, \,.v �::: �Y Fe3 /� �.. �• / .. ,!e
° 7 ( If •,
• °•'I'� s -�.���% ! ��'�;j,: /�� "• ocr�naieCtii,''J \ � : \` ' � �' 1 ' � °
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17
( .t`If:�\ ;. \, \ , ��—, a ,l' liI'' ° "i 'v'l��rrl "1 • _r T f
SCALE DATE F TITLE
�, �`ay 18, lg8g Fi�ura ,. I.
1:24000 ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS
JOB. NO. Location Map
HYDROLOGY • GEOLOGY • EXPLORATION • ANALYTICAL

J
It 3 " x
[--NEAREST DOMESTIC WELL- I S
APPROXIMATLY 400•FEEEM FROM
THE LAGOONS. IN TI-E, DIRECTION
OF TF-E ARROW.
PROPERTY LINE.,..
2500:.' --- ---
LAGOON
6 CLAY PART?.IGN
LAGOON
Is
SECONDARY 1® l7 I
CONi TAINIMwr' I ! I f 2
Ea9ERQZ�ICY O.
5 SUW. 25000 GALLONS 9
22
o�.
ALCHEM
OFrICE
00
-� 200'.
KEY'`,
AUGER - HOLE 4
SUPFLY' bOELL.
0 = TANK
FIGURE 2a
RO .-
. •a .• -
IIU11it11tltpl��110 IJ1���.�/I��OIIIHI 1lt1f1 /OERflrait IU11ltllIItpll{NFI UA f,Lt�gltlUtllflt�alltAflfllHlu uR�tu.Uwu 'tA Ntt�'L 6fl..N[11��171//1 i • ..
._■ 11,.
SCALE: 11s = 135 DATE:
(Approx.)
JOB. NO.
Tank
No:
C
C�: Gont s .
Tank -
Matt
��.
1
{SuIfuric
' Acid
S .
2
tt tt
S _
3
"lu
12,. 3n;: F
;r
r: , F
A', 000 c.: F
4,000 '+ P
4,000 tt (�
4
6
7
8' •
9
1:fi,000
Alum.
F i
10
To, 000
Storare
F
11
-«,S00
,alum
) _P
-i
13
14,, 000
++
F '
14
4,500 :
tt
15
(r,000
Process
Water
P_
16
yi<, 000 I
Alum
F
17
1I0,000
++
F
18
•5,000
p
19
5, 000
++
p
20
.500
++
p
21
4,000
rt
P
22
10 000
Cool
Down �
_F _�
" 0 ' �" TITLE: ALCHEM, INC.
ENVIRONMENTAL HYDROGEOLOGICAL CONSULTANTS 8135 Red Road
Rockwell, NC
HYDROLOGY • GEOLOGY • EXPLORATION ANALYTICAL

KEY'
a SUPPLY WELL
PUMP
0 TAW
PIMP NO.
MATERIAL
TYPE
H/P
I
S.S.-316
CENTRIF
5.0
2
S. S. -316
CENTRIF
. 25
3
S:S.-316
CENTRIF
. 25
4"
POLYPROPYLENE
SElf PRI
5.0
VALVE e 7 �.� THE SCH94ATIC SHOWS' THAT SULFURIC ACID REACTS
I rr 4, WITH BAUXITE AND WATER IN THE REACTORS FROM
' WHICM.THE WATER IS PUMPED TO. LAGOONS AND THEN,
- - - - - - - - - T0_APRQCESS WATER TANK PRIOR TO RETURINS TO`
5 THE REACTOR VESSEL.
WATER FROM BOTH OF THE ON SITE SUPPLY WELLS
IS PLnLR�PE'D TO WATER STORAGE TANKS, THEN TO
THE REACTORS.
i
I 2 THE LIQUID ALUMINUM SULFATE IN THE REACTORS`
IS PUMPED TO A COOL DOWN TANK AND THEN TO
ALUM STORAGE TANKS.
SCALE: NTS
DATE: E H C TITLE: - - - —
ENVIRONMENTAL HYDROGROLOGICAL CONSULTANTS ALCHEM, INC.
JOB. NO. 8135 Red Road,
HYDROLOGY GEOLOGY EXPLORATION ANALYTICAL Rockwell, NC

e-
i
LAGOON
C
CLAY PARTITION 1401.1
LAGOON
i
Z00"
Al PLA►N,' V I E :
FIGURE' .4
E' MAX. WATER LEVEL
SECT I ON A -k � EART}T : �iF_L; I WN, 0m0
SCALE: Zit = 671 DATE: r.F_1 C TITLE:
(Approx.) ENVIRONMENTAL HYDROGEOLOGICAL CONSULTANTS AL•CHEM, INC.
JOB. NO. 8135 Red Road
HYDROLOGY • GEOLOGY • EXPLORATION • ANALYTICAL Rnrk-wP 1 1 _ NC

Oxford Laboratories) Inc. Analytical and Consulting 'Chemists
DATE RECEIVED 10-31-89 1316 South Fifth Street
DATE. REPORTED 11-6-89 Wilmington, N.C. 98401
89WS650 [phone]
PAGE I OF 1
INDUSTRIAL AGRI CHEMICALS P.O. #
RT.2 BOX 521-C a
-.RED SPRINGS o N.C. 28377
ATTENTION: RANDALL ANDREWS
-SAMPLE DESCRIPTION: LIQUID FRACTION
1 LIQUID FRACTION
RESULTS
minum as Al .001
Afate Gravimet.ric., as SO4 PPM 103
(je
ROGER C. OXFORD CHEMIST
NOTE; The pH of -the liquid fraction was determined to be 2.5 by Mr. Randall
Andrews in his company -owned laboratory.

SSIWSHo ' 2i 3Xo • 0 US902i
9000> Wad ' bK se ' •: ae't ,
S00' > waa . `. _a.S. sle
' ..�.uznuaTa
s000•> 4, waa ' bx. se it � a1,1
> Waa ' �o s�. urniiuoiy
0
T-0 •f
OTO•> w a a " qa s`e':prl.
Wda .` p0 se ` �. tunTmpSo,
0To•>�.:
o06• Wdd g i g: g le ..e .UIn T..J
soo.> wad
sir sE �uas'xU
a��go�aZ uo,8gTn9M&
., �
ssznsau
SSlxnVg wox3 ZVIUSsVw azanzosmi:al�
x iGlri� .
"GIOV oixnagns :wolsalxosSa. Szaw�s.
CL£82..o.N;•j`'''SJNI'25`;�' ttr�,
O' ci sgvoIw3Hb . I2tJ�1. 'ZKIZiSS'nCit�l "
>;. .
T 3 o T soma
E6L6-99L (610 999�M68"
dSS2ioASH Siva
Tom'O'H `uolvutullm 68-£Z-Z
r.,
loollS uj3q glnoS 91CI 68-8-Z GSAIS03E Siva
nsuo gat ism '•DUj (squojeaogvrj
elcntiaUr).Bui9T 1 Pug l :::, x

J
Godwin =. Jordan & Associates, P.A.
ENGINEERING. SURVEYING & PLANNING \
IOE W[ST BROAD STREET
_ P. O. BOX 249
JOE [. OODWIN. SR. P.E. R.L.E. DU,NN. N. C. !OSl4 PHONES: FAY. 483-1489
RONNI[ E. JORDAN. R.L.S. U DUNN 892-6169
JAMES K. OODWIN
MATERIALS TESTING 'DIVISION
R1:PORT OF: Coefficient of Permeability (Fall Head Method)
MADE FOR: Bill Bright
PROJECT) Stockwell, NC
K •_ -2. 3 AT 1og10H November 9, 1P89
•K =-Coefficient of Permeability, CM/sec
-A s Cross sectional area of permeameter, CM -"
L = Length of Specimen, CM
a Cross sectional area of standpipe, CM
T = Time of•test,sec
:'Ho= Head at start of test, CM
H = Head at end of test, CM
(7 a Discharge, CC
'rest # 11.-- H m
1
32.07
26.35
691,200
2.69
.47
7.15
8.71
0.000000109
2
32.07
28.25
187,200
1.80
AT.
7.15
8.11
0.000000261
K required =
Test-' Locations: _
Test 1 and 2 Sample furnished by Bill Bright
i
i
NOTES: Ahove tests represent spot checks only
Testing Technician: Joseph E. Johnson

`Subject:.. WQ0001987
Alchem, Inc.
Industrial Recycle
Rowan County
Dear Sir;
Reference i§ made to your letter subject as above, dated July 31, 1989,
and addres"sed"to Mr. Randall F. Andrews.
The"following"prismoidal formula was used to determine the approximate
storage capacity of the lagoon(s):
V- (A + 4 B+ C) x D
6
�;' •- :.." - ...where ... • ' ,
V Volume of lagoon in cubic feet
A = Area of the lagoon at the ground surface
,. in square feet_...
B = Area of the excavation at the middepth point
(1/2-D) in square feet
C = Area of the excavation at the bottom of the
lagoon in square feet
D = Average depth of the sand slurry
6 = Constant
V = ,(50) (200)+4(42) (192)+(34) (184) t 8
6
V = 10000 + 32256 + 6256 + 8
6
`•: V = .(64682.67) (90 lbs/cu ft)
2000
V - 2910.72 tons (1/2 total capacity)
V 5821.44 tons
LEAKING BURIED TANKS • LEAKING STORAGE LAGOONS • CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS • PERMITS

Mr. William Barlow.
August 22, 1989
Pap
.-NOTE: Based on producing approximately'300 tons
of sand slurry per month, the lagoons)
can receive and store approximately
5,8.21,tQns.
'Your' -questions concerning the storage and use of sulfuric acid, at
this facility, were according to those Mr. Andrews answered when he met with
you in your office on or about July 25, 1989.
If'you need additional information or clarification, please advise.
Sincerely,
William E. Bright, P.G.,
Hydrogeologist
Project -Manager
WLB/Pnb
This letfer and the application for closed system permit, dated May 18, 1989,
reviewed by: o"1801111f
4 date
b
P I L152
�1
R 2 _b of
R
(See at
1!5 47 2
sees
CK
LEAKING BURIED TANKS *'LEAKING STORAGE LAGOONS e CONTAMINATED GROUNDWATER RECOVERY
CHEMICAL SPILLS • LAND APPLICATION OF SLUDGE • LANDFILLS PERMITS