NC0089109_Permit (Issuance)_20131206

NPDES DOCUHENT :SCANNING COVER SHEET
NPDES Permit:
NC0089109
Document Type:
(17**74‘)PerrilitIss
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Meeting Notes
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
December 6, 2013
This document is printed on reuse paper - igrzore any
content on the reYerse side

ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Water Quality Programs
Pat McCrory Thomas A. Reeder John E. Skvarla, III
Governor Director Secretary
December 6, 2013
Mr. Anthony Staley, Plant Manager
Horsehead Metal Products Inc.
484 Hicks Grove Road
Mooresboro, North Carolina 28114
Dear Mr. Staley:
Subject Issuance of NPDES Permit
Permit NC0089109
Rutherford County Production
Facility
Rutherford County
Facility Class I
Division personnel have reviewed and approved your application for a renewal of the subject
permit. Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of
Agreement between North Carolina and the U.S. Environmental Protection Agency dated October 15,
2007 (or as subsequently amended).
The final permit contains no significant changes from your current permit.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30)
days following receipt of this letter. This request must be in the form of a written petition, conforming
to Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative
Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such demand is made,
this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division
. may require modification or revocation and reissuance of the permit. This permit does not affect the legal
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone]
Internet www.ncwateraualitv.orq
Nose Carolina
7Vaturaiij
An Equal Opportunity 1 Affirmative Action Employer

requirements to obtain other permits which may be required by the Division of Water Resources or permits
required by the Division of Land Resources, the Coastal Area Management Act or any other Federal or
Local governmental permit that may be required. If you have any questions concerning this permit, please
contact Sergei Chernikov at telephone number [phone].
Sincerely,
5Thomas A. Reeder
cc: Central Files
NPDES Files
Asheville Regional Office / Surface Water Protection Section
ESS/Aquatic Toxicology Unit (e-copy)

Permit NC0089109
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER RESOURCES
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1,
other lawful standards and regulations promulgated and adopted by the North Carolina
Environmental Management Commission, and the Federal Water Pollution Control Act, as
amended,
Horsehead Metal Products Inc.
is hereby authorized to discharge wastewater from a facility located at
Rutherford County Production Facility
Forest City
Rutherford County
to receiving waters designated as the Broad River in the Broad River Basin in accordance with
effluent limitations, monitoring requirements, and other applicable conditions set forth in Parts
I, II, III and IV hereof.
This permit shall become effective January 1, 2014.
This permit and authorization to discharge shall expire at midnight on July 31, 2018.
Signed this day December 6, 2013.
6i,
Thomas A. Reeder, Director
Division of Water Resources
By Authority of the Environmental Management Commission
Page 1 of 4

Permit NC0089109
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
Horsehead Metal Products Inc. is hereby authorized to:
1. After constructing the wastewater treatment facility, operate it in accordance
with the existing wastewater treatment system consisting of the following
components:
➢ Automatic sampler
➢ Instrumented flow measurement, and
➢ Diffuser
The facility is located near Forest City, Rutherford County; and
2. Discharge from said treatment works at the location specified on the attached
map into the Broad River which is classified C waters in the Broad River Basin.
Page 2 of 4

Permit NC0089109
Part I
A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee
is authorized to discharge from outfall(s) serial number 001. Such discharges shall be limited and
monitored by the Permittee as specified below:
E
CIS- �ACRISTICS,
Y ` �.1'IITS Y ` .."F.
.. •1 _ a . r
�N`0� i'1'OING`REQJREIVIENTS ""
' : .: `
i ,K S1
I Moon ' .._•
a , , tilt'
Avera e
g:
7. r '
l7a>�y
Maximum
ii
�eas�ei ent;.
_.
.. �. a�
, Saan�p er
F
Type
".z Y y1'
Sample
r r „
Location1
- �=-
requency
Flow (MGD)
0.62
Continuous
Recording
I or E
Total Suspended Solids
Monthly
Composite
E
NH3-N
Quarterly
Composite
E
Total Aluminum
Quarterly
Composite
E
Antimony
Quarterly
Composite
E
Arsenic
Quarterly
Composite
E
Total Cadmium
350 ug/L
2,143 ug/L
Monthly
Composite
E
Chlorides
Quarterly
Composite
E
Total Chromium
Quarterly
Composite
E
Total Cobalt
Quarterly
Composite
E
Total Copper
Quarterly
Composite
E
Fluoride
315.8 mg/L
315.8 mg/L
Monthly
Composite
E
Total Iron
Quarterly
Composite
E
Total Lead
4,386 ug/L
4,829 ug/L
Monthly
Composite
E
Total Nickel
Monthly
Composite
E
Total Tin
Quarterly
Composite
E
Total Zinc
Quarterly
Composite
E
pH2
Weekly
Grab
E
Chronic Toxicity3
Quarterly
Composite
E
Turbidity4
Monthly
Grab
E, U, D
NOTES:
1.
Sample Locations: I - Influent, E - Effluent, U - upstream (50 ft upstream of the
discharge), D - downstream (50 ft downstream of the discharge). •
2. The pH shall not be less than 6.0 standard units or greater than 9.0 standard units.
3. Chronic Toxicity (Ceriodaphnia) P/F ® 0.57%; Jan., April, July and October; See
condition A(2) of the Supplement to Effluent Limitations and Monitoring Section of this
permit.
4 The discharge from this facility shall not cause turbidity in the receiving stream to
exceed 50 NTU. If the instream turbidity exceeds 50 NTU due to natural background
conditions, the discharge cannot cause turbidity to increase in the receiving stream.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR FOAM VISIBLE IN OTHER THAN
TRACE AMOUNTS.
Page 3 of 4

Permit NC0089109
A (2). CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QUARTERLY)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in the "North
Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised November 1995, or subsequent
versions.
The effluent concentration at which there may be no observable inhibition of reproduction or significant
mortality is 0.57% (defined as treatment two in the procedure document). The permit holder shall perform
quarterly monitoring using this procedure to establish compliance with the permit condition. The tests will
be performed during the months of January, April, July and October. Effluent sampling for this testing
shall be performed at the NPDES permitted final effluent discharge below all treatment processes.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the month in which it was performed, using the parameter code TGP3B.
Additionally, DWR Form AT-1 (original) is to be sent to the following address:
Attention: North Carolina Division of Water Resources
Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data. Total residual chlorine of
the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the
waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name, permit number, pipe number, county, and the month/year of the report
with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the
Environmental Sciences Branch at the address cited above. Should any single quarterly monitoring
indicate a failure to meet specified limits, then monthly monitoring will begin immediately until such time
that a single test is passed. Upon passing, this monthly test requirement will revert to quarterly in the
months specified above. Should the permittee fail to monitor during a month in which toxicity monitoring
is required, then monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing, this monthly test requirement will revert to quarterly in the months specified above.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division
of Water Resources indicate potential impacts to the receiving stream, this permit may be re -opened and
modified to include alternate monitoring requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of
such monitoring shall be included in the calculation & reporting of the data submitted on the.DMR
& all AT Forms submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival, minimum control organism reproduction, and appropriate
environmental controls, shall constitute an invalid test and will require immediate follow-up
testing to be completed no later than the last day of the month following the month of the initial
monitoring.
Page 4 of 4

vi It
b= r�r
; t r
��' ,Tk6
yi
. ' `
, ���� ,�
iJ
ri
1 /�
•i' y l--. 1,
jl; "--�
yy -'
''
re �,, „� l,l� / I `/�T`'
1A
-
1 y1�
Cud,1.�,-
/r1J
�t_�� �
��
A 'I /I �`:,
} J
-
,, .
J,
f
i
_
J,'
I l
` . A.
1 L r 1l
�.• 7t, J
I�
lt��' kn�
eek-�,\
i� t�i /.' /-�
-: I : `
-. C 5-.r.���.
`,`L \)4
.\
xt
1 7 iiF
0.
!!:�
•
•
—
'I
?i
)
l `� /U�
�l ) i '
t; t ti`G
} - i
o.
SCALE: 1" = 3000'
Jam;
°
�Utf� l Q� 1
\) i�
�`s
���
-_ -
_
,' -,.te�.� /i -
,
��
;. _
-�v tt.
it
_ '
' ����
14 _"
}/ �' 1` l'
co ,_,]-\ i
, 'i •
r��, ,-
a�-fin ,t� p
1
, / " '- '-•
7
—1- ) e- i
.:`It_,_
ar, ;,
,
�r/ III
� ,
t
:..-.
i �� �' `/^J1(
,r•_ /�P (O2
I .n-`, r li.
i
�')
! 11��, 7
1 \ ?"<-
r' Y
t ' OQY.-1
•; �' QR�
r
r t /
J (/ - `,•
` IFS
i` . 1
\� �I''l
`
r•
-
•, f ��s
(- )+, /\�^
•-
('
4^ ,tt�o
_ ,_-,� _ SQUTH
SCUm
CARQL!NA
'r
',
/'
J „
c
'J
"i\
..ram �1
\\; 7 �- —
- J
•
_ r,'
/4
I /„.—,:, ,
..-
1\ Lrl.... ..--1.tr
�`��
. $ '9
--K- .7-1 1.,...:,''-'\ m
,._
:. • 6 .
" c..,1----\--: 'A ,
t�t'�O Ar
' -2 ) Z 1
72))
' \ i 1 ‘\4\\---- \ --)
1 1
rpT:
,k1 .
• ip ..' C,
•
\' 4
\ , -- --c—,,—
.Il\
'
,fi'(..:, . •.:' '•
IT.111-alp}. • .)
Latitude: 35°12'3" Sub -Basin: 03-08-02
Facility
Longitude: 81°51'3"
x
Quad #: F11SW
Location
Stream Class: C
Receiving Stream: Broad River
Horschcad Corporation
Permitted Flow: 0.62 MGD
North
NC0089109
Rutherford County Production Facility

PUBLIC NOTICE
North Carolina Environmental Management
Commission/NPDES Unit
1617 Mail Service Center AFFIDAVIT OF PUBLICATION
Raleigh, NC 27699-1617
Notice of Intent to Issue a NPDES Wastewater Permit STATE OF NORTH CAROLINA
The North Carolina Environmental Management Commission R UTH E R FO R D COUNTY
proposes to issue a NPDES wastewater discharge permit to
the person(s) listed below. Written comments regarding the
proposed permit will be accepted until 30 days after the tdersigned, a Notary Public of said County and State, duly
publish date of this notice. The Director of the NC Division of ;d, qualified, and authorized by law to administer oaths, personally
Water Quality (DWQ) may hold a public hearing should there
be a significant degree of public interest. Please mail
comments and/or information requests to DWQ at the above
address. Interested persons may visit the DWQ at 512 N. Bobbie Greene
Salisbury Street, Raleigh, NC to review information on file.
Additional information on NPDES permits and
this notice may be found on our website:rst duly sworn, deposes and says: that they are
http://portal.ncdenr.org/web/wq/swp/ps/npdes/calendar, or by
calling [phone]. The Horsehead Metal Products, Inc.
requested a renewal of permit NC0089109 for Rutherford Customer Service Representative
County Production Facility in Rutherford County; this facility
discharge is treated industrial wastewater to Broad River, ter, publisher, or other officer or employee authorized to make this
Broad River Basin. a,,1.11 FHE DAILY COURIER, a newspaper published, issued and entered as
second class mail In the town of FOREST CITY, In said County and State; that they
are authorized to make this affidavit and sworn statement; that the notice or other
legal advertisement, a true copy of which is attached hereto, was published in THE
DAILY COURIER on the following dates:
August 29, 2013
and that said newspaper in which such notice, paper, document, or legal
advertisement was published was, at the time of each and every such publication, a
newspaper meeting all of the requirements and qualifications of Section 1-597 of the
General Statutes of North Carolina and was a qualified newspaper within the meaning
of Section 1-597 of the General Statutes of North Carolina.
This the 29th day of August, 2013.
Bobbie Greene, Customer Service Representative
Sworn to and subscribed before me this the 29th day of August, 2013
l
, (Notary Public)
My commission expires: February 18, 2017.

Chernikov, Sergei
From:
Sent:
To:
Cc:
Subject:
Attachments:
Frazier, Wanda
Monday, August 26, 2013 5:06 PM
Chernikov, Sergei
Cranford, Chuck; Wiggs, Linda
Horsehead Holding Corporation WWTP NC0089109 Rutherford County permit renewal
a cover page 2013.doc
Hi Sergei,
Even though I have not received a draft permit from you, I am sending ARO's recommendation to renew this permit.
Construction status:
This facility is still under construction for the zinc manufacturing facility.
The rains have caused a lot of trouble for their construction crews, but they are continuing progress, none the less.
ARO recommends renewal of the permit for Horsehead Holding Corporation Rutherford County Production. Facility
WWTP NC0089109.
FYI:
Corporate Facility contact:
Darin Cooper
Project Manager
Horsehead Corporation
4955 Steubenville Pike, Suite 405
Pittsburgh, PA 15205
On -site:
Jim Harris
Environmental Manager
Horsehead Metal Products, Inc.
484 Hicks Grove Road
Mooresboro, NC 28114
C 828.748.5283
O 828.919.3139
F 828.245.4237
[e-mail]
(See attached facility info)
Thanks,
Wanda
1

Facility information
NPDES permit #:
Facility name:
WWTP class:
WWTP type:
Activities:
Annual Ave. Flow:
A to C(s):
Collection System:
Sludge Management:
Stormwater:
WWTP location:
Responsible official:
Responsible " 's title:,
Mailing address:
NC0089109 Rutherford County
Horsehead Holding Corporation WWTP
Physical Chemical
0.62 MGD (100% industrial / commercial) zinc
processing washwater (start-up: ~ Sept 2013)
Industrial & commercial machinery
manufacturing;
Inorganic chemical manufacturing;
Metal products manufacturing;
Non-ferrous metals manufacturing
SIC: 3341 Secondary Smelting & Refining
MGD (3 year average: 2010-2012)
Authorization to Construct issued (date) for
(description) ...
WQCSDOOXXX
(or list as: no permit # - < 12 connections)
Commercial hauler to City of ? WWTP.
NCS000562 Individual stormwater discharge
Effective 4-1-13
Tim Fox & Jonathan Stepp: 4-1-13 CEI
Hwy 221; Forest City 28043
Darin Cooper
Project Manager
Horsehead Corporation
4955 Steubenville Pike, Suite 405;
Pittsburgh, PA 15205

Phone numbers
724-773-2223
828-748-5283
828-
Darin Cooper - Project Manager
Jim Harris — (site manager)
Charlie Howell
Operator information
WWTP ORC: Name — Grade cert. & type - Cert. #
WWTP back-up ORC(s): Name — Grade cert. & type - Cert. #
Coll. Sys. ORC: Name — Grade cert. & type - Cert. #
Coll. Sys. Back-up ORC(s): Name — Grade cert. & type - Cert. #
Permit information
Date issued:
Expiration date:
Renewal:
Reviewer:
Stream information
Stream:
River basin:
Sub -basin:
Stream Index No.:
Hydrologic Unit Code:
Quad:
Grid:
lnstream Waste Conc.:
Toxicity Testing Conc.:
Toxicity Monitoring:
Drainage area sq mi:
Stream classification:
Average stream flow:
Summer 7Q10 cfs:
Winter 7Q10 cfs:
30Q2 cfs:
Latitude:
Longitude:
Outfall(s):
11-11-11
7-31-13
Rcvd 1-4-13
Sergei Chernikov
Broad River
Broad River Basin
03-08-02
9-(36.5)
C
cfs
35.12.03
81.51.03
001
Other information
Driving directions to facility:
(test organism: )

NCDENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
Horsehead Metal Products Inc.
NC0089109
Facility Information
(1.) Facility Name:
Rutherford County Production Facility
(2.) Permitted Flow (MGD):
0.62
(6.) County:
Rutherford
(3.) Facility Class:
II
(7.) Regional Office:
Asheville
(4.) Pretreatment Program:
I N ;' - \
(8.) USGS Topo Quad:
Fi 1 SW
(5.) Permit Status:
Renewal
(9.) USGS Quad Name:
Stream Characteristics
(1.) Receiving Stream:
Broad River
(7.) Drainage Area_(!ni2):
575
(2.) Sub -basin:
03-08-02
(8.) Summer 7Q10 (cfs):
167
(3.) Stream Index Number:
9-(36.5)
(9.) Winter 7Q10 (cfs):
334
(4.) Stream Classification: !
C
(10.) 30Q2 (cfs):
403
(5.) 303(d) Status:
[ Not listed
(11.) Average Flow (cfs):
914
(6.) 305(b) Status: 1
(12.) IWC %:
0.5
Summary
This is a renewal of the permit for Horsehead Metal Products Inc. The facility is currently
under construction, it is located in the southern portion of the Rutherford County. The
facility will use the impure zinc oxide that is generated from the recycled EAF dust in other
Horsehead facilities. The EAF dust is a zinc containing waste generated by the North
American mini mills. The facility will produce approximately 148,000 tons of high quality
prime -Western grade Zinc metal. The process will include zinc oxide leaching, extraction of
zinc with an organic ligand and electrowinning. The facility will achieve significant degree of
recycling of the reagents that are used in the process. This would be a first facility of this
type in the USA, and there are no effluent guidelines for Zinc recycling facilities.
The EAA was submitted by the McGill Associates on behalf of the Horsehead Corporation.
The EAA was approved on July 22 2011, it allows discharge of 0.62 MGD treated industrial
wastewater. The wastewater generated by the facility is essentially a clean brine solution that
has a high concentration of chlorides (19,680 mg/L). Potable water and sanitary sewer
service will be provided by the Forrest City. The facility is still under construction.
RPA
The RPA was conducted when the application for a new permit was received. The
application identified the number of pollutants that might be present in the discharge. The
RPA (reasonable potential analysis) was conducted for these pollutants: iron, chlorides,
fluoride, tin, arsenic, zinc, nickel, cobalt, copper, cadmium, lead, aluminum, chromium, and
antimony. RPA was not conducted during this renewal since the facility is still under
construction.
WET
The whole effluent toxicity testing was assigned in accordance with 15A NCAC 2B.0508

NPDES Permit Fact Sheet — 08/27/13 Horsehead Metal Products Inc.
Page 2 NC0089109
PERMIT LIMITS
• The limits for Total Cadmium, Fluoride, and Total Lead were established as a result
of the Reasonable Potential Analysis of the effluent data. These limits are necessary
to prevent contravention of the state water quality standards and the EPA criteria in
the receiving water body.
• The pH limits and turbidity limits are based on the state water quality standards.
• The whole effluent toxicity testing was assigned in accordance with 15A NCAC
2B.0508
Proposed Schedule for Permit Issuance
Draft Permit to Public Notice:
Permit Scheduled to Issue:
September 10, 2013 (est.)
November 4, 2013 (est.)
State Contact Information
If you have any questions on any of the above information or on the attached permit, please
contact Sergei Chernikov at [phone], or [e-mail].
Regional Office Comments:
Name: Date:

484 HICKS GROVE ROAD WWW.HORSEHEAD.NET
MOORESBORO. NC 28114
December 20, 2012
John Hennessy
North Carolina Department of Environment
& Natural Resources
Division of Water Quality
512 North Salisbury Street
9th Floor - Archdale Building
Raleigh, North Carolina 27604
Dear Mr. Hennessy:
HoR"SE,HE
CORPORATION
Leading the World in Zinc Recycling
Re: NPDES Permit No. NC0089109
Renewal Application
Horsehead Metal Products, Inc.
Rutherford County, North Carolina
Please find enclosed three (3) copies of an Application for an NPDES Permit
Renewal for Permit No. NC0089109. We are hereby requesting renewal of the permit.
The facility is currently under construction and no discharges have occurred under this
permit to date. Please note that we are requesting a change in Owner and Operator name
to Horsehead Metal Products, Inc. All application information should be considered
Business Confidential.
Thanks for your assistance on this important project. If you have any questions
please don't hesitate to contact me or our engineer, David Honeycu • , PE at 828-252-
0575 or email at [e-mail].
Sincerely,
HO
An i' • Staley
Plant Manager
Encl.
cc: Tim Basilone, Horsehead Corporation
Tom Belnick, Division of Water Quality
David Honeycutt, PE, McGill Associates, P.A.
Forrest Westall, PE, McGill Associates, P.A.
PRODUCTS, INC.

NPDES PERMIT APPLICATION = SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number 1NC0089109
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
Please print or type.
Horsehead Metal Products, Inc.
Horsehead Metal Products, Inc.
484 Hicks Grove Road
Mooresboro
North Carolina/28114
724.773.2223
412.788.4526
[e-mail]
2. Location of facility producing discharge:
Check here if same as above CXI
Street Address or State Road
City
State / Zip Code
County
Rutherford
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Horsehead Metal Products, Inc.
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
484 Hicks Grove Road
Mooresboro
North Carolina/28114
724.773.2223
412.788.4526
4. Ownership Status:
Federal ❑ State ❑
Private ® Public ❑
Page 1 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
5. Standard Industrial Classification (SIC) code(s): 3341
6. Number of employees: Approx. 250
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
Wastewater is generated during the zinc production processes including leaching, extraction,
stripping and electowinning. The series of technologies used to produce zinc from this
proposed facility provides a high degree of metals removal from the wastewater stream,
resulting in a discharge with low levels of contamination as compared to more traditional
production facilities. Because of the extensive efforts to remove all metals from the process
flow stream, the process itself provides a high degree of treatment. The effluent from these
processes can be characterized as a clear brine solution.
8. Is facility covered under federal effluent limitation guidelines? No ® Yes ❑
If yes, specify the category?
9. Principal product(s) produced: SHG Zinc
Principal raw material(s) consumed: Zinc Oxide
Briefly describe the manufacturing processtes):
The process consists of Waelz Oxide leaching, extraction, 'stripping, and then electrowinning. This
facility will constitute the application of several technologies that will allow zinc metal to be captured
from other metal production facilities. The technologies and the configuration of the plant is
considered business confidential information.
Page 2 of 5
C-Ml 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
n over the last three years)
�Lw�
vyvv.J ry w.. r.+w. w.. ..................r..�. - . -- --- ---- -✓ r
Product Produced or Raw Material
Consumed
(AVERAGE)
- - -- - - -
Product Produced or Raw Material
Consumed
(PEAK)
per Day
per Month
per Year
Zinc Oxide - 232,000 Short Tons
Consumed, Galvanizers Skimmings 26,500
Short Tons
11. Frequency of discharge: Continuous ® Intermittent 0
If intermittent:
Days per week discharge occurs: Duration:
12. Types of wastewater discharged to surface waters only
Discharge
Flow
(GALLONS PER DAY)
Sanitary - monthly average
Utility water, etc. - monthly average
Process water - monthly average
620,000 (includes other process -related wastewaters
as described in the attached application materials)
Stormwater - monthly average
Other - monthly average
Explain:
Monthly Average
total discharge (all types)
620,000
13. Number of separate discharge points: 1 Outfall Identification number(s) 001
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Broad River
Page 3 of 5
C-Ml 10/08

'4
NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data [for new or proposed discharges]
Provide data for the parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
NOTE: Permittees requesting renewal should complete the table ONLY for the parameters
currentisy mun&w W4.4. 147 ma ts i wra Leo. ... 4.. A...A...
Parameter
v ,y•+-+' •+ ✓ -/./
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
N/A
Chemical Oxygen Demand (COD)
N/A
Total Organic Carbon
N/A
Total Suspended Solids
50*
mg/1
Ammonia as N
N/A
Temperature (Summer)
45*
35-45*
degrees C
Temperature (Winter)
45*
35-45*
degrees C
pH
9*
6-9*
SU
Fecal Coliform (If sanitary waste is
present)
N/A
Total Residual Chlorine (if chlorine is
used)
N/A
•
*-- Projected values, facility is proposed and actual data is not available.
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type
Permit Number Type
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES X Dredge or fill (Section 404 or CWA)
PSD (CAA) Other
Non -attainment program (CAA)
Permit Number
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Refer to .discharge parameters provided in previous application package. No changes to
these projected values are known at this time.
Page 4 of 5
C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Anthony Staley Plant Manager
Printed name,af4" rson Si g Title
Signature o Ail)liian
Date
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of- the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 5 of 5
C-MI 10108

it7414k
(PD/1
lq(01,
A SL;/Iti
PROPOSED WASTEWATER
DISCHARGE LOCATION
}14(LATITUDE N 35° 122.6,
,1(7.-LONGITUDE W 81° 51' 3.1")
'V
NO;144ROUTA
SOUTHCAROUNA
r
FIGURE III-2
PROPOSED DISCHARGE LOCATION MAP
HORSEHEAD CORPORATION

AVA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Charles Wakild, P.E. Dee Freeman
Governor Director Secretary
Mr. Darin Cooper
Horsehead Corporation
4955 Steubenville Pike, Suite 405
Pittsburgh, PA 15205
March 2, 2012
Subject: Waiver of Monthly Reporting Requirement
NPDES Permit NC0089109
Rutherford County Production Facility
Rutherford County
Dear Mr. Cooper:
The Division has reviewed your request to suspend submission of monthly Discharge Monitoring Reports
(DMRs). The request was submitted by Forrest Westall of McGill Associates.
After considering the recommendations of the staff in the Asheville Regional Office, I have agreed to waive
the requirement to submit monthly DMRs for the subject facility, effective January 1, 2012. The DMRs up
through (and including) December 2011 should be submitted as usual.
Be advised that if and when any wastewater discharge occurs, the discharge must be monitored as per the
terms of the NPDES permit and other applicable rules or statutes. Please keep the Asheville Regional
Office apprised of any pertinent developments that arise regarding this facility, especially if the discharge
is re -activated.
While requirements for operator visitation, monitoring and reporting are being waived, you are still
required to pay the Annual Administering and Compliance Monitoring Fee that is associated with this and
all NPDES permits.
If you have any questions, or if you wish to request rescission of either permit, contact Charles H. Weaver
at 919 807-6391.
Charles Wakild, P.E.
cc: Central Files
Asheville Regional Office / Chuck Cranford
NPDES Files
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
512 North Salisbury Street, Raleigh, North Carolina 27604
Phone: [phone] / FAX [phone] / Internet: www.ncwaterquality.org
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper
NorthCarolina
Naturally

Weaver, Charles
From: Cranford, Chuck
Sent: Tuesday, February 28, 2012 9:32 AM
To: Weaver, Charles
Subject: RE: NPDES Process WW Permit, Horsehead Corporation, Rutherford County NC0089109
Sounds fine Charles.
************************************************************
Chuck Cranford
Supervisor, Surface Water Protection Section
Division of Water Quality
Asheville Regional Office
2090 U.S. Highway 70
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
[e-mail]
E-mail correspondence to and from this address may be subject to the
North Carolina Public Records Law and may be disclosed to third parties.
From: Weaver, Charles
Sent: Tuesday, February 28, 2012 9:17 AM
To: Cranford, Chuck
Subject: FW: NPDES Process WW Permit, Horsehead Corporation, Rutherford County NC0089109
Chuck — we receive requests like this one from time to time. We get regional approval before acting on them.
Does the ARO have any problems with the proposed monitoring waiver?
If not, I'll send the permittee an official waiver letter.
Thanks,
CHW
From: Guerra, Bob
Sent: Tuesday, February 28, 2012 7:15 AM
To: [e-mail]; Weaver, Charles
Cc: 'Basilone Tim'
Subject: RE: NPDES Process WW Permit, Horsehead Corporation, Rutherford County NC0089109
Thank you for the information. I am forwarding your request to suspend monitoring at the facility from 01/2012 until
3/2013. At that time you will contact DWQ and update the status of the construction of the facility.
From: Forrest Westall [mailto:[e-mail]]
Sent: Monday, February 27, 2012 3:45 PM
To: Guerra, Bob
Cc: 'Basilone Tim'
Subject: NPDES Process WW Permit, Horsehead Corporation, Rutherford County NC0089109
1

TOWN OF WARSAW NPDES PERMIT NC0021903 RENEWAL APPLICATION
Part B. 3. Process Flow Schematic Description
A Process Schematic is provided in 11" x 17" format. A more simplified flow diagram is also provided
in 8.5" x 11" format. The more simplified format also illustrates the constructed but not operated
reclaimed water element of the WWTP.
The town of Warsaw WWTP is designed for an average daily influent flow of 0.915 MGD. This flow is
routed through a mechanical bar screen, which has a manual bypass bar screen as a backup. The full flow
is then routed to the influent pump station. This pump station is equipped with three 800 gpm pumps.
Any two of the pumps can pump 1,600 gpm with the third pump out of service. Flow at 1,600 gpm is
directed to a 12' x 12' aerated grit removal unit with dual blowers. The degritted flow is then directed to
a flow splitter box, which uses weirs to split the flow equally to three equal oxidation ditches. This
splitter box also receives sidestreams from return activated sludge pumps and the filter backwash. Each
oxidation ditch has a volume of approximately 457,500 gallons. This provides approximately 36 hours of
detention time in the oxidation ditches. The WWTP also has three chemical feed pumps, which allow the
use of chemicals such as alum, ferric chloride and polymers to aid in solids settling and phosphorus
removal if needed. Oxidation Ditch No. 1 is the original ditch. Its flow is directed to a flow splitter box
located between two existing 30' diameter secondary clarifiers, each having a10' sidewater depth. Flow
from Oxidation Ditch No. 2 is directed to a 40' diameter Clarifier No. 3, with a 14' sidewater depth.
Flow from Oxidation Ditch No. 3 is directed to a 40' diameter Clarifier No. 4, with a 14' sidewater depth.
Effluent then flows from the clarifiers to another flow splitter box where the flows are divided equally
into two 144 square foot tertiary filters. The filtered effluent goes into a clear well where it is chlorinated
and is available for backwashing the filter. From the clear well, effluent flows to the chlorine contact
tank, to allow adequate time for disinfection to occur. The disinfected effluent then travels to the post
aeration tank, with two floating aerators, which raise the dissolved oxygen level. Sulfur dioxide is used to
reduce the chlorine residual. Sludge is daily wasted to an aerobic digester. Sludge is thickened, digested,
and then transferred to the aerobic sludge holding tank. The thickened digested sludge is then land
applied by a contract hauler. In the event of a power outage, the entire WWTP has standby power
available with an automatic transfer switch.
Wf D10XX_GEMD100X_MSW1D1005_CORRES_MSW\CGM12011\WARSAW NPDES RENEWAL\DESCRIPTION OF PROCESS FLOW
SCHEMATIC.DOC

Hi Bob,
As we just discussed, Horsehead Corporation's Rutherford County Facility is under construction and will not come on line
and start discharging process wastewater (WW) until, at the earliest, spring of 2013. Mr. Tim Basilone, VP for
Environmental Affairs with the company, spoke to you about this situation and is faxing you a DMR for the month of
December 2011 verifying there was no discharge and that the facility is under construction. Tim has asked that I contact
you on behalf of Horsehead to request that the DMR monitoring for the facility be suspended until March of 2013. At the
time the facility begins operation and has a process WW discharge, DMRs will be submitted in accordance with the
requirements of the reference permit. If operation is delayed beyond March 2013 the company will contact the Division to
note this and will discuss with you the expected start-up date and take whatever action is necessary to fully comply with
the requirements of this permit. I have copied Tim with this e-mail and have asked him to send you a confirmation note
that this request has come directly from the permit holder.
Please confirm with Tim and I that BIMS has been modified to reflect the suspension of monitoring request. If you have
any questions about this request, please do not hesitate to contact me.
Thanks Bob,
Forrest
Forrest R. Westall, Sr., PE
Principal
McGill Associates, P.A.
38 Orange Street I Asheville, NC 28801
Phone: [phone] I Fax: [phone]
Email: [e-mail] I Website: www.mcgillengineers.com
2

Permit NC0003573
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is authorized
to discharge from Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified
below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
'Type
Sample
Location
Flow (MGD)
2.0
Continuous
Recording
Effluent
,140D5> 20° C
182.6 lbs/day
484.7 lbs/day
3/Week
Composite
Effluent
Total Suspended Solids
303.1 lbs/day
981.5 lbs/day
3/Week
Composite
Effluent
'Temperature
Weekly
Grab
Effluent
Grease
Monthly
Grab
Effluent
-104
Between 6.0 and 9.0 Standard Units
3/Week
Grab
Effluent
40 CFR 414 Subpart I
See Condition A. (2)
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.