WQ0006060_Final Permit_20030723

Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, A.E., Director
Division of Water Quality
July 23, 2003
Mr. Anthony S. Read. Vice -President
Gerdau Ameristeel US, Inc.
P. O. Box 481980
Charlotte, North Carolina 28269
Subject: Permit No. WQ0006060 (Modification)
Gerdau Ameristeel US, Inc.
Charlotte Steel Mill
Wastewater Recycle System
Mecklenburg County
Dear Mr. Read:
In accordance with your request for modification received May 23, 2003, we are forwarding
herewith Permit No. WQ0006060, dated July 23, 2003, to Gerdau Ameristeel US, Inc. for the continued
operation of the subject wastewater recycle system. This modification is issued because the company
changed names from AmeriSteel Corporation to Gerdau AmeriSteel US, Inc.
This permit shall be effective from the date of issuance until July 31, 2006, shall void Permit No.
WQ0006060 issued August 31, 2001, 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, 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 27699-671.4. Unless such demands are made this permit shall be final and binding.
Non -Discharge Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
DENR Customer Service Center
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If you need additional information concerning this matter, please contact Bennie Goetze, Jr., P.
E. at [phone] extension 375.
Sincerely,
T(Y- Alan W. Klimek, P.E.
cc_ Mecklenburg County Health Department
Mecklenburg County Water Quality Program
Mooresville Regional Office, Water Quality Section
Technical Assistance and Certification Unit
Water Quality Central Files
NDPU Files
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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
Gerdau AmeriSteel US, Inc
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 storrnwater, 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, serving the Charlotte Steel Mill, shall operate with no
discharge of wastes to the surface waters, pursuant to the application received May 23, 2003, and subsequent
additional information received by the Division, 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 August 31, 2001, 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.
It. 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 Ieast 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.
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20. 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 23rd day of July, 2003
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Alan W. Klimek, P.E., Director
Division. of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0006060

16. 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.
17. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
Iife 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.;
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 Response
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.
19. 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.