WQ0006060_Final Permit_19960830

"e+la`v of North Carolina
CGpartment of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
August 30, 1996
Mr. henry H. Herin, Mill Manager
Ameristeel Corporation
P.O. Box 560847
Charlotte, NC 28256-0847
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C) E 1-i COI FI
Subject: Permit No. WQ0006060
Ameristeel Corporation
Charlotte Steel Mill Division
Wastewater Recycle System
Mecklenburg County
Dear Mr. Herin:
1n accordance with your application received May 29, 1996, we are forwarding herewith Permit
No. WQ0006060, dated August 30, 1996, to Ameristeel Corporation for the continued operation of the
subject wastewater recycle system. This renewal includes changing the name of the applicant from Florida
Steel Corp to Ameristeel Corporation.
This permit shall be effective from the date of issuance until July 31, 2001, shall void Permit No.
WQ0006060 issued March 18, 1992, 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, 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 contact Andy Oakley at (919)
733-5083 extension 533.
Sincerely,
aA �_af\
A. Preston Ioward, Jr., .E.
cc: Mecklenburg County Health Department
Mooresville Regional Office, Groundwater Section
Mooresville Regional Office, Water Quality Section
Training and Certification Unit
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] i=AX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

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
Ameristeel Corporation
Mecklenburg County
FOR THE
continued operation of a groundwater withdrawal and remediation system consisting of eleven
groundwater remediation wells that can deliver two gallons per minute per well with the recovered waters
being used as makeup water for an existing recycle closed loop cooling system consisting of two equal
parallel oil/water separators having a combined capacity of 113,700 gallons, dual sludge settling basins
with combined capacity of 75,400 gallons (soda ash added to basins for pH adjustment), cooling towers,
then waters are sent through mill as process water and then recycled back through oil/water separators and
sludge basins with extra makeup water from the wells to serve Ameristeel Corporation, with no discharge
of wastes to the surface waters, pursuant to the application received May 29, 1996, 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 July 31, 1996, shall void Permit No.
WQ0006060 issued March 18, 1992, and shall be subject to the following specified conditions and
limitations:
1. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
2. The facilities shall be properly maintained and operated at all times.
3. 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 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.
4. 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.

5 . 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
Water Quality.
6. 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.
7. 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.
8. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
9. Any monitoring deemed necessary by the Division of Water Quality to insure surface and
ground water protection will be established and an acceptable sampling reporting schedule
shall be followed.
10. Adequate inspection, maintenance, and cleaning shall be provided by the Pere- tee to
insure proper operation of the subject facilities.
11. 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
Water Quality or other permitting authority, upon request.
12. Any duly authorized officer, employee, or representative of the Division of Water Quality
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.
13. The annual administering and compliance fee must be paid by the Perri ittee within thirty
(30) days after being billed by the Division. Failure to pay the fee accordingly may cause
the Division to initiate action to revolve this permit as specified by 15A NCAC 2H .0205
(c)(4).
14. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Water Quality in accordance with
North Carolina General Statute 143-215.6(a) to 143-215.6(c).
15. 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.
16. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
2

17. 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 or proposed to be taken to ensure that the problem does not recur.
18. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
19. 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.
20. 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.

. 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 30th day of August, 1996
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A. Preston award, Jr., P.E1, Director /
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0006060

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MATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
e of Facility: Iz, J �
or or Contact Psrspn:
Lbiling Address:
County: Telephone:.za ) �-9 /' - D 3 6
Present Classification:.. ---Now Facility xisting Facility
PdPDE,S fir. No. NCoo Norldisc. Per. Fia.WQQ Health Dept.Per No
Rated by: Telephone: �7 1 3 4/ ?ate: Iqi�
Reviewed by: Heatltth Dept, Telephone:
—Regional Off ice Telephone:
Central Office Telephone:
ORC: /3� �' D/1 _ Grade: Telephone:
Check Classification(s): Subsurface Spray Irrigation~ Land Application
Wastewater Ciassif"tion: (Circle One) U II 111 N Total Points: A//f]
pal; _.. ,1CM " ties We V
�.w�� s,�� �. ..71 I: . l.. =►I :�_: 1.. M .::w- �. ! . �.��. . 1�.. `• �JI. �.:. 7t-71 �s.►�_�'11.: �.. ! %1. _. •
IUNSLFFACE CLASSFIt:J1MN
(dwK* as units OW apply)
1 ssgtk tanks
2._---ptrrnp tanks
>i mx or pump-da3ing sfrt•ms
t and Mors
s.gr.as* traplirdero wor
6 _oLwster saparasom
7`-9raivky subwrlwoe treatment &-od d a:
•. prrasurs subsurface trammwrk and digx":
O P PAY t TK)N O_ASWMAT1 N
(dd*ck as units em spra)r)
1�prwiiminary vvatrnwrd (definition no. 32 )
a�taeooral
2,.._ *"Alc tanks
s,_pur„ p tares
b-----,ptrnps
aB_@and tutors
7. prsas• lrapAn wraaplor
l�ai.rwater separatom
e. dislMectkm
10_dwmk* addl km for nutriertWpas aoalroi
11, _-_--spray lrrioion d washotraler
In addition to the above classifications, pretreatment of wastewater In excess of these components shell
be rated using the point rating system and will require an operator with an approprists dual rartitication.
LAND APPLICAT)Cfy1RESI1)WLS ClASS MATION (A *&" ** b panne hoiden)
1. Land applicalion d bkeordL, raskUkk or ooniaawrwlod sok m a desVled else.
WASTEWATER TItEATL49gT FACUTY Q.ASSFIGTM
The toatowhV aygems " be nm pned a Class t daaslfkatian, majau ttw flow Is of a skrAlicard quantity or the Ucfv logy b Unusaully
owpiex, to npuim owW6wmdicn by efw Commission on a mace-by{ase basis: (-hook I Appnpi de)
1, CLAwader Ssparalor Systems consisting only of pkyslcat separation, purnpe and disposal;
1,_..r..Septic Tw*Maid Fier Sys*m wrWstkV dandy d septic tanks. daekV appw*Lw, purr►pa,aand fikers, Ok"aticn
and drsd dsdwva;
Swva *y of akwLry trssmeed, `gam, pup. dskdedkm, nwaesary dmwrJcol tasirnent fr
aaas ofunnd direct dscimmpe;
Goaedaoap Ptac7de Sydrurns;
&--Groudwslar RemwdWkm "rms oon:isift only of oLA*Ww sefasr•atsrs, pumps, sk-drfppirg, carbon edsarptio , diskrrl*Ot on
and d waat;
uro aperatkca vAth dlx:h s to surrum witless;
.—waior Pk" s&x$ge NvvmW "back -wash waSw Usairnard:
& 6sdood prvcwssk V oord Eoft at scrvert ft end dlsposai.
iC. 03%l*4wTtty d6tlMwpkV "am, vAth the exception of Aerobic Treadmeo Urdu, *6 be dasstr4d I psrmdtsd attar July 1,
1903 or s uapan knp dbn by the DNi sion, i V found that the s7-sism is not Wng adequaadOy opwad4�d or maVtab&d. 40ch
sysloms wV be nolafrod of the dassA"Km5on or radassrxa►gon by the Corsxnis.slon, In wrgft.

0
(15) EYetraftlysfc ►rods hoe rmovkp Irtasd Sass Yom NOW thein the w d bnaelocthve ki sdw morr6wrsos:
(141 Far Prw. A process Vw%W mchishYONI' for per" dowaomg awwdpe:
(17) Foam Separation. The planned &whinge of watowisr or wateweor of l"N s a swears, at rrrwanp mama" amo*v s of dteergen hu"ruts though
Mo Introduction of air in the form of fns bubbba; also CRW team fractionation;
(lit) Gk RrtevaL The prooss, Of rarrwl 0n and ouer heavy R*wW rrrlsbr frorn weak, W.
nh whoa Tart A dap has awry wastewater lush consisting of an upper ssdimrsawan comber and a ho wr skrgy ctpetion de hater.
Po) arnmaned flew kisawrecen. A devise whits I dicawft and head now of wow;
gt ) len Exchange. A d+.mkW process n Mddt W Ihornawed dM~ an adrr n
a .
2! LaawdaoI pI I :
Yii.1 p jnwhAa~ptebio for � d whodpe esswalhed by � d in ),sludge
1) of wi haw � to red wed y ale yl on 4e awfaw. r by swwnara nraon
jTwasad @lien. The pnssss of spraying awed wastewater show a kind oras or ower rtrhot or application of rYYwawrow ■ Y d area as a
Mlw M ftnel �al M Ilaawrnen; .
� hSertasswrc A low apsed, coakt ad/ l adrwaaf s4 wYfing drum liar apralnS uro0er g*r'Yl tertalbrw s a pthlaltkg r;tathatl h nmmlnp
mulperrthd art ham aitkan;
) MWOasfbn ►lacca The bYdrmfoal wnlrlabn of vesWYad owsepen Wwort and rgenk Mogen) a wdrod t4gan «wally esraol;
1 NMoommn Stage. A Operate map o wa.owstr inwtnrrs deeignod his M � purp ss d convertin Arturo li nbapen b rstrah nitnapen:
Phosphate
Flo aasval SbYpkLL The hvnmW of phpaphvua Yom wnwoator by an ak/roaic pewee designed w shderco bawy uptake of phosphorus
P�wMeO hold kip Ped bbwlrp socisn 7 waatm n .4h aYfltclers dearlbn oma b sow stfkng d tYry suspended watch:
04) Pea Araiom (Cascade) AA pwfahlhp mofod by dissolved while r added t ftshbefil DA. r for any rine , gravity
waAos of Maps r was; The flow eocv across the ■ oxygen Y added b ft sffiu the
by lotion of hNW. Barky mann d M.trp down
aquetman; the, aero Pens an aaalpned� even though Oht Y an w ndol um st a kiYy dtri bye ad tfr cep briks of a dihi d dr erM; requires ro operator
PD) Powdered a Gen JW Aeweed Carbon Fasd. A blopl ysic l croon prow LiIs ftm~bbbacaf wdNYyorganic aGaorPwn by tang powdered or
activated ssAm; Virgin r agerertad carbon Y food controlled Yee to s/etern;
11 Proration A lark mnasnAdsd to piovba so asks pder to pkwry thwam kis;
PZ) PraNJrury Uro Un1 operations In Oe tnamaM1 such process, suas screening and tenrrtHdbn. M WW&M 10 kW for .haws" Mpr operations:
1 Ytluthl Pwbwerrn.
M) Pro-ueauten t1rk i duswrL The oar dl bnY p of a ewe or b .euro taobn d ucharp., to wnove or b rruwafts wbstaroft 0*rkiurh to sowers and
weaman firoce suet r to atlod a putd adualon in had an fr wwatmen Process whidh Y opersed by to same poverring body W she wastewater
Westerners plan bong rood:
M ►rrtralnerw PMWWN Industrial •rata be a Skarn or EPA ragAred program to Rslve ports; on the rating tined;
Pa) hnary CW10an. The fM ;dap trdb Owugh ohld woarwtr Y passed an a edeamen arta low dr purpoa of w Oil g web" and sspaMod
asft end SOD which it asamloted with ft waft;
(fi) Pumps. AS tdluera, sutra and npkin Wrrp; .
(M) Rtlrdon DYYie ton r aerSation process uw4xv davkoa WMYq duvYM r /erne wys;
(!yl Wvry Osrrasla A ►scan Waass in whldh a heavy oenarttvatl polo Y preaurYad through a wanOnre W" teal/ park "M fnm
suspended soft;
Pf) Rotang Biological Coroaaora. A Ofd bbkaglea growth pAeaft In which wastewater flown Brough crus in which a oaah of Pont* su ornerped caouW
shorts am waled;
00) Stud fTitaw:
W inkirMwe t Wclogb FOrdbn or eftlwn folorring sales: tans, Ypo". ass warm other troamM process n ~ further Dbdewrrpaltbn Y
atpwcad to product desired orenuen
b; hlytak badahg haft on those Ohre are crrpvon d gpWw and have a Musing low Oprtw (loss Weloo
n ):
b) Recirculating bldogkak - the a.m. typo d .turd that s ached In subparagraph Pt) (a) t nk Rut with the added sspabaky to W, 001wr+ back
though ft ward tor,
Nps Sand a b0xe6kloda Flaw A polishing pans by which ohs art fm4s low scr ieved thrugh a l f0reduction of suspended soft,
hl low hos - gravity. fydtusuay baled bar with gees p raw in the loo ft drove vmwh mage;
1«S high b CLar"asurs. tank which tow�da� � budn0 wed n wo 0.w Ogre wrpa: At any rate, dos wrnp raft hos sand these Ogre:
Nbiological kis of trwm ed pall and whcl hes the purpose d rsrrnovI slurs associated with the
blolovicitJ
oan w
atmaas;
M Separate Sludge Raaertbn A pan d the mesa ana06adwh prooass when the activated sludge Y harstanwd b a to it and saratac Osltaw noun p k
as lino Coma bash:
µo) Septic Tat A Who"" same rush in which atlod ak dpe Y In staged with the ewaeeater fowanp dvough the tut: ~ not be alpaabY ass
&==stun TM �a � ross Mktg opacity d 2A00 gabs r kiu wfid+ discharge b . NtMcatbn UW;
prough the adnriy c"orgLrAne, which wWr:h� kir uatd hwangand t sludge r Wa4Y4 4rtffYd, rrhirraCsd r mnwratl tato trussed .able tapartb Rasher
(0) Mine Drying ret. An area orrprka rearal or rtfktl layer of porous nsarfsY wpm whkh dgsted sewage awdp. Y dried by OYepe and
lawspostalm ;
(ft) Skudge Eksrrrien A proast of Wrdpe mrdllxing In whid certain mrrYuans an rrnoved by elrcefikoo washing. wM Yash waw r putt effacer:
((7) Sludge Gs lAIStabn The process d wain rwags gas for the purpose d h m*V buildings, diving angbkit, ase::
(atj Sludge hbldn0 Tut (Aerwed and hwnaahadI. A ort d@wd hr «roll wastewater wwatnrrl phem to comanhp a Asser In dict sludge may be
Ypt YWh, and s prralars wWwwh gloss w a &It% nrcad (La. tudpe tiryn0 bids): This may be done by adding a wtW ar»un or air ►npy a kwp the
Amiga bash, kin not rrateuYy an smwn fuf weed be nriut,d to adhere arDiCaatbn of organ aetbr. A neraarted tart wadd simply be wad to
aacerf Wag. prior b d.rat.rtq and would rot abed hong partoda (aavrwf days of dot~) without rsauffng oder preAl -;
(p) Skrdpe Incinerators. A furnaco doslPad to bvm sludge and to nmws u mosaun and ambuaDY martell ad reduce the sludge to a aMf ON
wen a nt6ludw S; That tabilization be deo by H r*AVrramd}�A � ss�t�mskt N byhed�lgeos adora+a and pNaac6ls. and a md+w ate Patlnge^Y ri^Ym
f 1) Sludge Th Adarer. A type d sedktrrusan kink in ahidh the aludge Y prmnad in ettY and thicken trough a0adlen and /My:
0 `StdRutlon Lagorc A type d widakin �w n which bhologiol celdaYn d Motor th
orgark mar affected by rwwal lwwer of oxygen e weir Yam
Pfa &I ,rrg irk;
Str6y Powe Supply. On of or portable oloaAcel go -'n a4A paw it;
Staec sores. A stationary own dsipred to remove soft. Including nonOb6ywd" particulate onsubb weft, exprdsd solids and WD
"htaT.Rrry 7 Twp. d a
twam.ne':
r sropbyed lr to purpose;t0i� saearn6ry reth Y prtmaAy for to puepses d spurn poYhhtg; A asQknp fspoan r sed r edea free
Mj ThenwM Pollution Crad DoAm. A deb pwlatrnp kir the uwnfer of had tars a 14d IbM1p in tuba a arocer Aid suast ft Vibm r vas vrsa;
W atsr Mare of rowtadnp iriuli bmparssas;
S7) Thermal Sludge Conddorr. A owwAixing process by which het Y aided for a protracted period d glow r ntlev" fled dswaseramy of sludge by also
501AW1s and hydrw" d to anafr and non N" hydrated 44P panels";
Pt Task fAweta Those rased r mn6htbre of Wets. toduty aY..s.o anp "ma which new 66chrse cal wpm egwuM bpssom Yurlatbn
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