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Home My WebLink AboutWQ0006060_Compliance Evaluation Inspection_20220614ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Mr. Mitchell Fralick, EHS Manager Gerdau Charlotte Steel Mill 6601 Lakeview Road Charlotte, North Carolina 28269 Dear Mr. Fralick: NORTH CAROLINA Environmental Quality June 14, 2022 and Email Subject: Non -Discharge Permit Inspection Gerdau Ameristeel US — Charlotte Steel Mill CLRS Closed -Loop Recycle System Permit # WQ0006060 Mecklenburg County Staff of the Mooresville Regional Office (MRO) conducted a compliance inspection on May 18th, 2022. The MRO would like to thank you for your time during the inspection. The system and records appeared maintained at the time of inspection. The following items were discussed while on -site for overall program requirements: Screening equipment for processing of Mill Scale residuals was down since Jan. 2022, waiting for motor repair. Mill scale from the recycle ponds is removed weekly to dewater, then collected and processed for resale by onsite TMS International, Mill Services company. MRO staff mentioned need to process, reuse materials (mill scale, lime, etc.) to reduce stockpiles and potential of runoff. Per additional research, the storage is approximately 250 feet south-southeast of an unnamed tributary to Long Creek. Your NCS000304 NPDES Stormwater Permit shows the outfall #3 is the closest outfall to the storage area. It is recommended you follow-up with your Solid Waste and Stormwater permitting inspectors (state and local) for guidance. Recent staff changes may require form update for Signature Delegation. A copy will be emailed with this letter and the most current forms are located on our DWR Non -Discharge Branch website here: https://deq. nc.gov/about/divisions/water-resources/water-resources-permits/wastewater-branch/non-discharge- permitting-unit/application#miscellaneous-documents. Form submittal and questions may be directed to Nathaniel.Thornburg@ncdenr.gov, Supervisor for our Non -Discharge Permitting Staff. The inspection report should be self-explanatory; however, please contact Maria Schutte by phone (704-235- 2184) or email (maria.schutte(a�ncdenr.gov) with questions. Sincerely, 1- DocuSigned by: fi444e4V H P444.4 F161FB69A2D84A3... Andrew H. Pitner, P.G., Assistant Regional Supervisor Mooresville Regional Office Water Quality Regional Operations Section Division of Water Resources, NCDEQ Attachment(s): WQ0006060 Inspection Report Signature Delegation Authority Letter (form NDSDAL) CC: Marcos Mattiello, Vice President, and General Manager (email) D_E QNORTH CAROLINA Depshnanl of Environment Monti"' North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1601 East Center Avenue, Suite 301 I Mooresville, NC 28115 704.663.1699 Compliance Inspection Report Permit: WO0006060 Effective: 06/01/20 SOC: Effective: County: Mecklenburg Region: Mooresville Expiration: 12/31/25 Expiration: Contact Person: Bob Churchill Title: Owner : Gerdau Ameristeel US Inc Facility: Gerdau Ameristeel US - Charlotte Steel Mill CLI 6601 Lakeview Rd Charlotte NC 28269 Phone: 704-596-0361 Ext.3128 Directions to Facility: From Charlotte, take State Highway 115 North past the Brockenbrough Airport approximately 2 miles. Turn left onto Lakeview Road. Facility is first property on your right. / From MRO, take I-77S to the WT Harris Blvd exit, turn left onto Lakeside Rd. System Classifications: Primary ORC: Certification: Phone: Secondary ORC(s): On -Site Representative(s): Related Permits: NCS000304 Gerdau Ameristeel US Inc - Ameristeel Corporation Inspection Date: 05/18/2022 Entry Time 10:08AM Primary Inspector: Maria Schutte Secondary Inspector(s): Exit Time: 12:08PM Phone: 704-663-1699 Reason for Inspection: Routine Inspection Type: Compliance Evaluation Permit Inspection Type: Closed -Loop Recycle Facility Status: Compliant ❑ Not Compliant Question Areas: ▪ Treatment Flow Measurement -Effluent ▪ Treatment Flow Measurement -Water Use Records ▪ Treatment Lagoons (See attachment summary) • Treatment Flow Measurement -Influent ▪ Treatment ▪ Treatment Flow Measurement ▪ Miscellaneous Questions ▪ Record Keeping ▪ Storage Page 1 of 4 Permit: WQ0006060 Owner - Facility: Gerdau Ameristeel US Inc Inspection Date: 05/18/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Inspection Summary: Staff of the Mooresville Regional Office (MRO) conducted a compliance inspection on May 18th, 2022. The MRO would like to thank you for your time during the inspection. The system and records appeared maintained at the time of inspection. The following items were discussed while on -site for overall program requirements: Screening equipment for processing of Mill Scale residuals was down since Jan. 2022, waiting for motor repair. Mill scale from the recycle ponds is removed weekly to dewater, then collected and processed for resale by onsite TMS International, Mill Services company. MRO staff mentioned need to process, reuse materials (mill scale, lime, etc.) to reduce stockpiles and potential of runoff. Per additional research, the storage is approximately 250 feet south-southeast of an unnamed tributary to Long Creek. Your NCS000304 NPDES Stormwater Permit shows the outfall #3 is the closest outfall to the storage area. It is recommended you follow-up with your Solid Waste and Stormwater permitting inspectors (state and local) for guidance. Recent staff changes may require form update for Signature Delegation. A copy will be emailed with this letter and the most current forms are located on our DWR Non -Discharge Branch website here: https://deq.nc.gov/about/divisions/water-resources/water-resources-permits/wastewater-branch/non-discharge-permitting-unil /application#miscellaneous-documents. Form submittal and questions may be directed to Nathaniel.Thornburg@ncdenr.gov, Supervisor for our Non -Discharge Permitting Staff. The inspection report should be self-explanatory; however, please contact Maria Schutte by phone (704-235-2184) or email (maria.schutte@ncdenr.gov) with questions. Page 2 of 4 Permit: WQ0006060 Owner - Facility: Gerdau Ameristeel US Inc Inspection Date: 05/18/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Type Yes No NA NE Reuse (Quality) ❑ Infiltration System ❑ Lagoon Spray, LR ❑ Single Family Spray, LR ❑ Activated Sludge Spray, HR ❑ Activated Sludge Spray, LR ❑ Activated Sludge Drip, LR ❑ Single Family Drip ❑ Recycle/Reuse Treatment Yes No NA NE Are Treatment facilities consistent with those outlined in the current permit? • ❑ ❑ 0 Do all treatment units appear to be operational? (if no, note below.) • ❑ ❑ ❑ Comment: This is a closed loop recycle system utilizing groundwater, stormwater and pH adjusted leachate, from old DWM approved fill -site, as cooling water in the mill process. The recycle unit skimmers are positioned and used as needed. Oil / water separators are located at both recycle ponds. Spent oil is removed and processed for reuse by Crystal Clean. Mill scale residuals are managed by onsite company, TMS International (Mill Services Company), processed and resold for its Iron Ore content. MRO staff noted I -Beam and rebar mixed in w/mill scale residuals and enquired about reuse process. See comments in Summary Section and Cover Letter on residuals storage and processing. Treatment Flow Measurement -Influent Is flowmeter calibrated annually? Is flowmeter operating properly? Does flowmeter monitor continuously? Does flowmeter record flow? Does flowmeter appear to monitor accurately? Yes No NA NE ❑ • ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑•❑ ❑ • ❑ ❑ ❑ Comment: As noted in previous reports, there is a flowmeter at the landfill/leachate building but flows of stormwater and recycled water are not tracked for this closed -loop cooling process. Groundwater from onsite well is also utilized as needed. Treatment Flow Measurement -Water Use Records Is water use metered? Are the daily average values properly calculated? Comment: See comments under influent section. Treatment Flow Measurement -Effluent Is flowmeter calibrated annually? Is flowmeter operating properly? Yes No NA NE ❑ ❑ • ❑ ❑ ❑ • ❑ Yes No NA NE ❑ ❑ • ❑ Page 3 of 4 Permit: WQ0006060 Owner - Facility: Gerdau Ameristeel US Inc Inspection Date: 05/18/2022 Inspection Type : Compliance Evaluation Reason for Visit: Routine Does flowmeter monitor continuously? ❑ ❑ • ❑ Does flowmeter record flow? ❑ ❑ • ❑ Does flowmeter appear to monitor accurately? ❑ ❑ • ❑ Comment: See comments under influent. This closed loop recycle system does not produce an effluent. Record Keeping Is a copy of current permit available? Are monitoring reports present: NDMR? NDAR? Are flow rates less than of permitted flow? Are flow rates less than of permitted flow? Are application rates adhered to? Is GW monitoring being conducted, if required (GW-59s submitted)? Are all samples analyzed for all required parameters? Are there any 2L GW quality violations? Is GW-59A certification form completed for facility? Is effluent sampled for same parameters as GW? Do effluent concentrations exceed GW standards? Are annual soil reports available? # Are PAN records required? # Did last soil report indicate a need for lime? If so, has it been applied? Are operational logs present? Are lab sheets available for review? Do lab sheets support data reported on NDMR? Do lab sheets support data reported on GW-59s? Are Operational and Maintenance records present? Were Operational and Maintenance records complete? Has permittee been free of public complaints in last 12 months? Is a copy of the SOC readily available? No treatment units bypassed since last inspection? Yes No NA NE • ❑ ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑•❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑•❑ ❑•❑ ❑ Comment: There is no land application or irrigation with this permit. Most questions are not applicable. Weekly inspections of the recycle ponds and groundwater leachate systems are documented on in house form that includes freeboard levels at both recycle ponds. Entries should be initialed w/date and time of inspections. Hauling records for waste oil and spent mill scale material appeared well maintained. MRO staff had questions about volume reuse material stored onsite for processing. See comments in Summary Section and Cover Letter. Page 4 of 4