WQ0006060_Final Permit_20010831

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
I
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Gregory J. Thorpe, Ph.D., Acting Director
Anthony S. Read, Vice President/Division Manager
AmeriSteel Corporation — Charlotte Steel Mill Division
P.O. Box 481980
6601 Lakeview Road
Charlotte, NC 28269
Dear Mr_ Read:
i
A Now
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
August 31, 2001
Subject: Permit No, WQ0006060
AmriSteel Corporation
— Charlotte Steel Mill Division
Wastewater Recycle System
Mecklenburg County
In accordance with your renewal request received June 4, 2001, we are forwarding herewith Permit No.
WQ0006060 dated August 31, 2001, to AmeriSteel Corporation- Charlotte Steel Mill Division for the continued
operation of the subject wastewater recycle system.
This permit shall be effective from the date of issuance until July 31, 2006, shall void Permit No.
WQ0006060 issued October 30, 1998, 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. y
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 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.
If you need additional information concerning this matter, please contact J R Joshi at [phone]
extension 363. y
Since e ,
J
regoryJ. Thorpe, Ph.D.
cc: Mecklenburg County Health Department
Mooresville Regional Office. Water Quality Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/10% post -consumer paper

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
AmeriSteel Corporation
Mecklenburg County
FOR THE
continued operation of a groundwater withdrawal and remediation system consisting of five (5) groundwater
recovery wells that can deliver two (2) gallons per minute per well and the operation of a leachate treatment system
consisting of a batch treatment system for the adjustment of pH and two (2) sand filters and a cartridge filter for the
removal of particulate material with the recovered groundwater and treated leachate being used as makeup water
for an existing closed loop contact cooling water recycle system that consists of oil/water separators, settling basins
and cooling towers with a combined capacity of approximately 189,000 gallons, and pumps to transfer the contact
cooling water in a closed loop from the cooling system to the mill and back. Contact cooling waters are pumped
through cooling towers for evaporative cooling and then pumped into the mill for reuse as contact cooling water.
The water is then recycled back through the contact cooling water recycle basin with makeup water coming from
the bleed off from non -contact cooling towers, the groundwater recovery system, the leachate treatment system and
collected stonnwater, well water and/or city water as required. Also for the operation of an existing closed loop
cooling system that consists of oil/water separators, settling basins and cooling towers with a combined capacity of
approximately 114,000 gallons, and pumps to transfer the contact cooling water in a closed loop from the cooling
system to the melt shop and back. Contact cooling waters are pumped through cooling towers for evaporative
cooling and then pumped into the melt shop for reuse as contact cooling water. The water is then recycled back
through the contact cooling water recycle pond with makeup water coming from the bleed off from non -contact
cooling towers and collected stormwater, well water and/or city water as required. All systems covered by this
permit shall operate with no discharge of wastes to surface waters, pursuant to a renewal request received June 4,
2001, 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 July 31, 2006, shall void Permit No.
WQ0006060 issued October 30, 1998, 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.
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.
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. 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.
11. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper operation
of the subject facilities.
12. 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.
13. 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.
14. 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).
15. 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.
16. 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.
17. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.

18. 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.
Persons reporting such occurrences by telephone shall also file a written report in letter form within five 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.
19. ' 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 orb eater 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 8G .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 8G .0202.
20, The Permittee, at least six 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 appropriatc.
Permit issued this the thiry-first day of August, 2001
NORT AROLIN ENV ONMENTAL MANAGEMENT COMMISSION
r'
1
AGregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0006060