WQ0009909_Final Permit_19941011

0tate of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
October 11, 1994
Mr. Albert Kula
Safe and Environmental Manager
Kobe Copper Products, Incorporated
Post Office Box 160
Pine Hall, North Carolina 27042
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Subject: Permit No. WQ0009909
Kobe Copper Products, Inc.
Quench Water Storage & Treatment
Wastewater Recycle System
Stokes County
Dear Mr. Kula:
In accordance with your application received August 23, 1994, we are forwarding herewith Permit
No. WQ0009909, dated October 11, 1994 to Kobe Copper Products, Incorporated for the construction
and operation of the subject wastewater recycle system.
Please be advised that Kobe Copper Industries, Incorporated must contact the Winston-Salem
Regional Office, Groundwater and Water Quality Sections prior to the closure of the existing lined pit that
receives the casting pit effluent.
This permit shall be effective from the date of issuance until September 30, 1999, 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.
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

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 [phone].
Sincerely,
0tC
A. Prest Howard, Jr., P.E.
cc: Stokes County Health Department
Winston-Salem Regional Office, Water Quality
Winston-Salem Regional Office, Groundwater Section
Jack Floyd, Groundwater Section, Central Office
Training and Certification Unit
Facilities Assessment 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
Kobe Copper Products, Incorporated
Stokes County
me ' 'E
construction and operation of a 130,000 GPD wastewater recycle system consisting of mixers in the
existing concrete casting pit, three (3) existing 75 hp pumps, a clarifier with an attached two chamber flash
mixing/flocculation tank approximately 440 ft2, and a feed rate of 100 to 150 gpm, a 10 gpm pump to
constantly deliver the underflow from the clarifier to the filtration system which consists of a concentration
tank, a tubular filtration module, a flush tank, a cleaning tank and a dewatering filter press. The clarifier
effluent will be delivered to the existing cooling towers, and the construction of two (2) 68,000 gallon
storage tanks to hold the effluent from the casting pit during maintenance operations to serve as Kobe
Copper Products, Incorporated's Quench Water treatment and storage facility, with no discharge of wastes
to the surface waters, pursuant to the application received August 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 September 30, 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 Winston-Salem 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 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. 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.
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 of
Environmental Management or other permitting authority, upon request.
15. 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.
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).
2

17. 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).
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. Sample the soil and water for potential contamination in the vicinity of the lagoon to be
dismantled. If contamination has occurred, the a Corrective Action Plan is to be
implemented, in accordance with 15 A NCAC 2L .0106.
21. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
22. Noncompliance Notification:
The Permittee shall report by telephone to the Winston-Salem 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 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.
23. 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 1 facility at
least weekly and each CIass 11, 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. Once
the facility is classified, the Permittee must submit a letter to the Certification Commission
which designates the operator in responsible charge within thirty days after the wastewater
treatment facilities are 50% complete.

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.
Permit issued this the 11th day of October, 1994
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
n t
A. Preston Poward, Jr., P ., Director
sion of nvironmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0009909
4

Permit No. WQ0009909
October 11, 1994
ENGINEER'S CERTIEKATION
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,
Project Name
Location
for the
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
5
Registration No.

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RATING SCALE FOR CLASSIFICATION OF WATER
l POLLUTION CONTROL SYSTEMS
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me of Facility: � o � e �`� �`- �%� o � `� S �---
Owner or Contact Person: 'e /'
Mailing Address: 0 . 9.1 v . C' 2--
County: _sakes _ _Telep one: l�/� -2-7- 6b11
Present Classification- A1,4 New Facility Existing Facility
NPDES Per. No. N oo Nondisc. Per. No.WQ LIU�'� Health Dept.Per No -
Rated by: _ ,� r ss Telephone:� .- t r✓) 6S 'oc
Reviewed by: Health Dept. Telephone-
-Regional Office Telephone: ` � ?��,-7
Central Office Telephone:
ORC: I _s"2q,u2 Grade: Telephone
Check Classification(s): Subsurface Spray Irrigation Land Application
Wastewater Classification: (Circle One) C" II III IV Total Points:
a 5 wig1 0 'ice Mul I 22712MOW141 X is `a1 kIs :ir :► ia11 a' :�1 i\ Willi. ii:t� ~1 \Tits
f�Ja. as i ::. 1 Ii : Iu+`+a1 IEi 1�1 1011
tR�O ... d✓i-W 1a A 01 :►• b 1- �. Vie• its\ 6 1 •
2MA a; : i A .0.
SIJf3SllF�FACE C1 A.SSI FiCATON
(check all units that apply)
1—septic tanks
_—pump tanks
siphon or pump -dosing systems
4 sand filters
5. grease 1raprnferceptor
5 oiUwafer separators
7, gravity subsurface treafinenl and disposal:
8, pressure subsurface treatment and disposal
In addition to the above classifications,
be rated using the point rating system
SPRAY tF1R)GAT1lCN C! 1.5SiFICATK]N
(check all units that apply)
i, preliminary treatment (definition no. 32 )
2- lagoons
3, seplic tanks
4 pump tanks
5- pumps
6. sand fihers
7. grease irapintercaplor
8 oil/water separators
>a disinfection
10, chemical addition for nul6ent/alg8e control
11. spray irrigation of wastewater
pretreatment of wastewater In excess of these components :hall
and will tequira an operator with an appropriate dual certillcatlon.
AND APPLICATION/RESfDUALS CLASSIFICAT)ON (Applies onty to permit holder)
1. _Land application of biosotids, residuals ar contarninafed soils on a designated site.
WASTEWATER TREATMIENT FAC4t11Y CLASStF)CAT CN
The following systems shall be assigned a Class I classification, i[nIUS the flow Is of a significant quantity or the tech^•ciogy is unusually
complex, to require oonsideralion by the Commission on a case -by -case basis: (Check d ApproQrlale)
1 Git/waler Sep ralor Systems consisting only of physical reparafion, pumps and disposal:
2 Seplic Tank Sand Fitter Systems consisting only of septic lanks, dosing appa.ralus, pumps,sand fi ers, disir-!ection
and direct discharge;
3—Lagoon Systems consisting only of preliminary treatment, lagoons, pumps, disinfection, necessary chemical irealment for
algae or nutrient control, and direct discharge;
4. Closed -loop Recycle Systems;
5 —Groundwater Remediation Systems consisting only of olVwaler separators, pumps, air -stripping, carbon ads: rption, disinfe-dion
and dispos.J;
6.- Aquacullur© operations with dischargo to surtax+ waters;
—Water P!ar t s!Ldge handling and batik -wash water irealment;
rS. Seafood processing consisting of screening and disposal. �
;inglo-family disch<vging systems, will) 1ho ercopGon of Aerobic Troalmonl knits, will bo cta:sifie-j if pear'.-t-d tiller July 1,
1903 or it upon ln;p cdion by tho Division, h is lound that the sysicrr is nol wing adoqunlcdy operalod or rrY 'wined. Such
systems will bo nolilied ut rho clysif'cation or reclassification by 1ho Cowm:scion, in writing.