NC0000353_Permit (Issuance)_20040623

NPDES DOCUMENT :SCANNING COVER SHEET
NPDES Permit:
NC0000353
The Feldspar Corporation
.
Document Type:
ua
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
June 23, 2004
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State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
June 23, 2004
Mr. Thomas Freeman
The Feldspar Corporation
P.O. Box 99
Spruce Pine, North Carolina 28777
NCDENR
Subject: NPDES Permit Issuance
NPDES Permit NC0000353
The Feldspar Corporation
Mitchell County
Dear Mr. Freeman:
Division personnel have reviewed and approved your application for 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 May 9, 1994 (or as subsequently amended.)
This permit authorizes Feldspar Corporation to discharge up to 3.5 MGD of treated
wastewater from the Feldspar Plant to the North Toe River, a class C Trout water in the
French Broad River Basin. The permit includes discharge limitations and/or monitoring
for flow, total fluoride, total suspended solids (TSS), turbidity, pH, chloride, and chronic
toxicity.
The following modifications have been made to the final permit:
• Effluent limitations for total residual chlorine of 28 ug/1 have been added to
outfalls 002 and 003. These limits reflect the Division's current policy for
protection against chlorine toxicity instream and shall become effective upon
completion of the installation of a disinfection system but no later than 18
months from permit issuance. If a method different than
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone]/FAX [phone]
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chlorination/dechlorination is used, the total residual chlorine limit will not be
applicable.
• Additional monitoring requirements and special conditions for the
stormwater discharge portion of the Feldspar Corporation Plant have been
added to this permit per the request of the facility.
In addition, DWQ has completed a reasonable potential analysis on data from the
recently submitted chemical analysis report and has determined that no additional
effluent limitations or monitoring for any other parameters are needed in the Feldspar
Corporation 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 a demand is made, this permit
shall be final and binding.
Please take notice that this permit is not transferable. The Division may require
modification revocation and reissuance of the permit. This permit does not affect the
legal requirements to obtain other permits, which may be required by the Division of
Water Quality, or permits required by the Division of Land Resources, Coastal Area
Management Act, or any other Federal or Local governmental permits may be required.
If you have any questions or need additional information, please contact Ms.
Jacquelyn Nowell at telephone number [phone], extension 512.
Sincerely,
ORIGINAL SIGNED BY
Mark McIntire
Alan W. Klimek, P.E.
Attachments
cc: Asheville Regional Office/Water Quality Section
EPA Region IV/Attn. Roosevelt Childress
Aquatic Toxicology
Central Files
NPDES File

Permit NC0000353
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions 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,
The Feldspar Corporation
is hereby authorized to discharge wastewater from a facility located at
The Feldspar Corporation
NCSR 1121
Spruce Pine
Mitchell County
to receiving waters designated as the North Toe River in the French River Basin in accordance with effluent
limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective August 1, 2004
This permit and authorization to discharge shall expire at midnight on February 28, 2006.
Signed this day June 23, 2004
ORIGINAL SIGNED BY
Mark McIntire
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0000353
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and as
of this 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.
The Feldspar Corporation is hereby authorized to:
1. Continue operation of a 3.5 MGD wastewater treatment facility consisting of:
• three clarifiers,
• polymer feed system,
• Lime feed system for pH adjustment,
• Vacuum filters,
• Emico clarifier/thickener,
• Pump station emergency generator,
• flow measuring and totalizing equipment and
• two recycle pumps.
The facility is located at The Feldspar Corporation off NCSR 1121 south of Spruce Pine in
Mitchell County.
2. Discharge treated wastewater from said treatment works through outfall 001 and non -
contact cooling water from outfalls 002 and 003 [at the locations specified on the attached
map] into the North Toe River, which is classified C Trout waters, in the French Broad
River Basin.

Facility Information
Lat/Long: 35°54' 16" 82°03' 47" — 001;
35°54' 17" 82°03' 42" - 003
Quad #: D1ONE
Receiving Stream: North Toe River
Permitted Flow: 3.5 MGD
35°54' 17" 82°03' 40" - 002
Subbasixi: 040306
Stream Class: C-Trout
North
The Feldspar Corporation .
NC0000353
Mitchell County

Permit NC0000353
PART I., SECTION A.
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [001]
During the period beginning on the effective date of the permit and lasting until Unimin Corporation -Crystal
Operation (NC0084620) initiates direct discharge to the North Toe River or expiration, the Permittee is authorized
to discharge process wastewater 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
Measuremenr
Sample Type
Sample
Frequency
Location'
Flow
3.5 MGD
Continuous
Recording
Influent or
Effluent
Total Fluoride
225 pounds/day
448 pounds/day
Daily
Composite
Effluent, U, D
Total Suspended Solids
1568 pounds/day
3137 pounds/day
Daily
Composite
Effluent
Settleable Solids
Daily
Grab
Effluent
Turbidity2
Daily
Grab
Effluent, U, D
pH3
Daily
Grab
Effluent, U, D
Chloride'
Quarterly
Composite
Effluent
Chronic Toxicity5
Quarterly
Composite
Effluent
Notes:
1. U: upstream at the Altapass Road highway bridge. D: downstream at the footbridge in Spruce Pine.
Instream samples shall be grab samples collected 3/week.
2. This discharge shall not increase the turbidity of the receiving waters more than 10 NTU. If the turbidity
exceeds 10 NTU due to natural background conditions, the discharge shall not cause any increase in turbidity
of the receiving water.
3. The pH shall not be less than 6.0 standard units nor greater than 10.0 standard units.
4. Chloride shall be monitored quarterly during the same months as toxicity testing.
5. Chronic Toxicity (Ceriodaphnia) Pass/Fail at 11.0%: January, April, July and October [see A. (5)].
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0000353
A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [001]
During the period beginning when Unimin Corporation -Crystal Operation (NC0084620) initiates direct discharge
to the North Toe River and lasting until expiration, the Permittee is authorized to discharge process wastewater
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
Measuremen.
Sample Typo
Sample
Frequency
Location'
Flow
3.5 MGD
Continuous
Recording
Influent or
Effluent
Total Fluoride
174 pounds/day
348 pounds/day
Daily
Composite
Effluent, U, D
Total Suspended Solids
1568 pounds/day
3137 pounds/day
Daily
Composite
Effluent
Settleable Solids
Daily
Grab
Effluent
Turbidity2
Daily
Grab
Effluent, U, D
pH3
Daily
Grab
Effluent, U, D
Chloride4
Quarterly
Composite
Effluent
Chronic Toxicity5
Quarterly
Composite
Effluent
Notes:
1. U: upstream at the Altapass Road highway bridge. D: downstream at the footbridge in Spruce Pine.
Instream samples shall be grab samples collected 3/week.
2. This discharge shall not increase the turbidity of the receiving waters more than 10 NTU. If the turbidity
exceeds 10 NTU due to natural background conditions, the discharge shall not cause any increase in turbidity
of the receiving water.
3. The pH shall not be less than 6.0 standard units nor greater than 10.0 standard units.
4. Chloride shall be monitored quarterly during the same months as toxicity testing.
5. Chronic Toxicity (Ceriodaphnia) Pass/Fail at 11.0%: January, April, July and October [see A. (5)].
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0000353
A. (3) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [002]
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge non -contact cooling water from outfall 002 (Fine Grind and Plant Number 1). Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
PARAMETER
Monthly
Daily
Measurement
Sample
Sample
Average
Maximum
Frequency
Type
Location'
Flow
Monthly
Recording
Influent or Effluent
Temperature
2
2
Monthly
Grab
Effluent
Total Residual Chlorine3
28 ug/1
Monthly
Grab
Effluent, U, D
pH
>6.0 and <9.0 standard units
Monthly
Grab
Effluent
Notes:
1. U: upstream, D: downstream. Instream samples shall be grab samples collected 3/week.
2. The temperature of the effluent shall not cause an increase in the temperature of the reciving stream of more
than 0.5 degrees C and in no case cause the ambient water remperature to exceed 20.0 degrees C.
3. Limits and monitoring requirements only apply if chlorine is added to the non -contact cooling water.
Chlorine limit becomes effective 18 months from issuance date of the permit (February 1, 2006).
There shall be no discharge of floating solids or visible foam in other than trace amounts.
A. (4) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS [003]
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge non -contact cooling water from outfall 003 (Fine Grind and Plant Number 1). Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
PARAMETER
Monthly
Daily
Measurement
Sample
Sample Location'
Average
Maximum
Frequency
Type
Flow
Monthly
Recording
Influent or Effluent
Temperature
2
2
Monthly
Grab
E
Total Residual Chlorine3
28 µg/1
Monthly
Grab
Effluent, U, D
pH
>6.0 and <9.0 standard units
Monthly
Grab
E
Notes:
1. U: upstream, D: downstream. Instream samples shall be grab samples collected 3/week.
2. The temperature of the effluent shall not cause an increase in the temperature of the receiving stream of more
than 0.5 degrees C and in no case cause the ambient water temperature to exceed 20.0 degrees C.
3. Chlorine limit becomes effective 18 months from issuance date of the permit (February 1, 2006). Limits and
monitoring requirements only apply if chlorine is added to the non -contact cooling water.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0000353
A. (5) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 11.0%.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina
Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. 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.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then
multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North
Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable
impairment of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes,
and further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring
Form (MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and
THP3B for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: North Carolina Division of Water Quality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30 days after the
end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response
data, and be certified by laboratory supervisor and ORC or approved designate signature. 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 the Permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required
during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water Quality
indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring
requirements or limits.
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.

Permit NC0000353
A. (6) BIOCIDES
There shall be no chromium, zinc or copper added to the treatment system except as pre -approved
additives to biocidal compounds.
The Permittee shall obtain approval from the Division's Aquatic Toxicology Unit prior to the use of any
biocide (not previously approved by the Division) in the effluent discharged under this permit.
Approval for use of any biocide not previously approved should be requested at least 90 days in
advance of any planned usage.
Contact the Aquatic Toxicology Unit for detailed instructions on requesting approval of biocides:
NC DENR / DWQ / Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
A. (7) WASTEWATER DIVERSION
Diversion or bypassing of untreated wastewater from the treatment facility is prohibited.
A. (8) TURBIDITY REOPENER
This permit shall be modified, or revoked and reissued to incorporate new turbidity effluent limitations
in the event that violations of the turbidity standard of the North Carolina Water Quality Standard
occur as a result of this discharge.
A. (9) SOLIDS REMOVAL
Solids removed or resulting from the wastewater treatment process shall be contained and disposed of
in such a manner as to prevent any contamination of the surface waters of the State.
A. (10) FLUORIDE REOPENER
This permit shall be modified, or revoked and reissued to incorporate new fluoride effluent limitations
in the event that acute or chronic bioassay testing or other studies results in a change in the North
Carolina Water Quality Standard for fluoride.
A. (11) PERMIT MODIFICATIONS
This permit shall be modified, or revoked and reissued to incorporate new limitations in the event that
production changes are requested or should any new fluoride using discharge request to locate on the
North Toe River.

Permit NC0000353
PART I., SECTION B.
STORMWATER MONITORING, CONTROLS AND LIMITATIONS FOR PERMITTED DISCHARGES
FINAL LIMITATIONS AND CONTROLS FOR STORMWATER DISCHARGES
During the period beginning on the effective date of the permit and lasting until expiration, the
Permittee is authorized to discharge stormwater associated with industrial activity. Such discharges
shall be controlled, limited and monitored as specified below.
1. Stormwater Pollution Prevention Plans
The Permittee shall develop a Stormwater Pollution Prevention Plan, herein after referred to as the
Plan. The Plan shall be considered public information in accordance with Part II, Standard Conditions,
Section E.10. of this permit. The Plan shall include, at a minimum, the following items:
a. Site Plan: The site plan shall provide a description of the physical facility and the potential
pollutant sources which may be expected to contribute to contamination of regulated
stormwater discharges. The site plan shall contain the following:
(1) A general location map (USGS quadrangle map, or appropriately drafted equivalent map), showing the
facility's location in relation to transportation routes and surface waters, and the name of the receiving
water(s) to which the stormwater outfall(s) discharges. If the discharge is to a municipal separate storm
sewer system, the name of the municipality and the ultimate receiving waters, and accurate latitude and
longitude of the point(s) of discharge must be shown.
(2) A narrative description of storage practices, loading and unloading activities, outdoor process areas, dust or
particulate generating or control processes, and waste disposal practices.
(3)
A site map (or series of maps) drawn to scale indicating the location of industrial activities (including
storage of materials, disposal areas, process areas, and loading and unloading areas), drainage structures,
drainage areas for each outfall and activities occurring in the drainage area, building locations and
impervious surfaces, existing BMPs, and the percentage of each drainage area that is impervious. For each
outfall, a narrative description of the potential pollutants which could be expected to be present in the
regulated stormwater discharge.
(4) A list of significant spills or leaks of pollutants that have occurred at the facility during the 3 previous years
and any corrective actions taken to mitigate spill impacts.
(5) Certification that the stormwater outfalls have been evaluated for the presence of non-stormwater
discharges. The certification statement will be signed in accordance with the requirements found in Part II,
Standard Conditions, Section B.11.
b. Stormwater Management Plan: The stormwater management plan shall contain a narrative
description of the materials management practices employed which control or minimize the
exposure of significant materials to stormwater, including structural and non-structural
measures. The stormwater management plan, at a minimum, shall incorporate the following:
(1) A study addressing the technical and economic feasibility of changing the methods of operations and/or
storage practices to eliminate or reduce exposure of materials and processes to stormwater. Wherever
practical the Permittee should consider covering storage areas, material handling operations, manufacturing

Permit NC0000353
or fueling operations to prevent materials exposure to stormwater. In areas where elimination of exposure
is not practical, the stormwater management plan shall document the feasibility of diverting the stormwater
runoff away from areas of potential contamination.
(2) A schedule to provide secondary containment for bulk storage of liquid materials, storage of Section 313 of
Title III of the Superfund Amendments and Reauthorization Act (SARA) water priority chemicals, or
storage of hazardous materials to prevent leaks and spills from contaminating stormwater runoff. If the
secondary containment devices are connected directly to stormwater conveyance systems, the connection
shall be controlled by manually activated valves or other similar devices [which shall be secured with a
locking mechanism] and any stormwater that accumulates in the containment area shall be at a minimum
visually observed prior to release of the accumulated stormwater. Accumulated stormwater shall be
released if found to be uncontaminated. Records documenting the individual making the observation, the
description of the accumulated stormwater and the date and time of the release shall be kept for a period of
five years.
(3)
A narrative description of Best Management Practices (BMPs) to be considered such as, but not limited to,
oil and grease separation, debris control, vegetative filter strips, infiltration and stormwater detention or
retention, where necessary. The need for structural BMPs shall be based on the assessment of potential of
sources contributing significant quantities of pollutants to stormwater discharges and data collected through
monitoring of stormwater discharges.
(4) Inspection schedules of stormwater conveyances and controls and measures to be taken to limit or prevent
erosion associated with the stormwater systems.
c. Spill Prevention and Response Plan: The Spill Prevention and Response Plan shall incorporate
a risk assessment of potential pollutant sources based on a materials inventory of the facility.
Facility personnel (or team) responsible for implementing the plan shall be identified in the
plan. A responsible person shall be on -site at all times during facility operations that have the
potential to contaminate stormwater runoff through spills or exposure of materials associated
with the facility operations.
d. Preventative Maintenance and Good Housekeeping Program: A preventative maintenance
program shall be developed. The program shall document schedules of inspections and
maintenance activities of stormwater control systems, plant equipment and systems. Inspection
of material handling areas and regular cleaning schedules of these areas shall be incorporated
into the program.
e. Training schedules shall be developed and training provided at a minimum on an annual basis
on proper spill response and cleanup procedures and preventative maintenance activities for all
personnel involved in any of the facility's operations that have the potential to contaminate
stormwater runoff. Facility personnel (or team) responsible for implementing the training shall
be identified in the plan.
f. The Stormwater Pollution Prevention Plan shall identify a specific position(s) responsible for
the overall coordination, development, implementation, and revision to the Plan.
Responsibilities for all components of the Plan shall be documented and position(s) assignments
provided.
g. Plan Amendment: The Permittee shall amend the Plan whenever there is a change in design,
construction, operation, or maintenance which has a significant effect on the potential for the

Permit NC0000353
discharge of pollutants via a point source to surface waters. At a minimum, the Stormwater
Pollution Prevention Plan shall be reviewed and updated on an annual basis.
The Director may notify the Permittee when the Plan does not meet one or more of the
minimum requirements of the permit. Within 30 days of such notice, the Permittee shall submit
a time schedule to the Director for modifying the Plan to meet minimum requirements. The
Permittee shall provide certification in writing (in accordance with Part II, Standard Conditions,
Section B.11.) to the Director that the changes have been made.
h. Facility Inspections: Inspections of the facility and all stormwater systems shall occur at a
minimum on a semiannual schedule, once in the fall (September - November) and once during
the spring (April - June). The inspection and any subsequent maintenance activities performed
shall be documented, recording date and time of inspection, individual(s) making the
inspection and a narrative description of the facility's stormwater control systems, plant
equipment and systems. Records of these inspections shall be incorporated into the Stormwater
Pollution Prevention Plan.
Visual monitoring as required in Part I, Section B.3.b. shall be performed in addition to facility
inspections.
i. Implementation: Implementation of the Plan shall include documentation of all monitoring,
measurements, inspections, maintenance activities and training provided to employees,
including the log of the sampling data. Activities taken to implement BMPs associated with the
industrial activities, including vehicle maintenance activities, must also be recorded. All
required documentation shall be kept on -site for a period of five years and made available to
the Director or his authorized representative immediately upon request.
2. Minimum Monitoring and Reporting Requirements
Minimum monitoring and reporting requirements are as follows unless otherwise approved in writing
by the Director of the Division of Water Quality:
a. If a facility has multiple discharge locations with substantially identical stormwater discharges
that are required to be sampled, the Permittee may petition the Director for representative
outfall status. If it is established that the stormwater discharges are substantially identical and
the Permittee is granted representative outfall status, then sampling requirements may be
performed at a reduced number of outfalls.
b. Qualitative monitoring shall be performed at all stormwater discharge outfall locations
regardless of representative outfall status. All visual monitoring shall be documented and
records maintained with the Stormwater Pollution Prevention Plan. The initial visual
monitoring event shall be performed simultaneously with the first analytical monitoring event
and documentation of only this initial visual monitoring event shall be submitted along with
the required analytical monitoring submittal.
c. For purposes of the stormwater sampling required in this permit, all samples shall be collected
from a discharge resulting from a representative storm event (See definitions in Part III,

Permit NC0000353
Standard Conditions). Failure to monitor storm events in accordance with the specified
frequency shall constitute a violation of this permit.
• Analytical monitoring for a retention pond designed to contain the 10-year design storm without discharging is
not required. Qualitative monitoring is the only monitoring requirement.
• Analytical and qualitative monitoring are not required from a retention pond designed to contain the 25-year,
24-hour storm without discharging since the pond is considered a non -discharging stormwater control.
d. Samples analyzed in accordance with the terms of this permit shall be submitted on forms
approved by the Director no later than January 31 for the previous year in which sampling was
required to be performed.
e. Analytical results from sampling during the final year of the permit term shall be submitted
with the permit renewal application.
f. Any other point source discharge to surface waters of the state is prohibited unless it is an
allowable non-stormwater discharge or is covered by another permit, authorization or
approval.
If the storm event monitored and reported in accordance with this permit coincides with a non-
stormwater discharge, the Permittee shall separately monitor and report all parameters as
required under the non-stormwater portion of this permit and provide this information with the
stormwater discharge monitoring report.
3. STORMWATER MONITORING REQUIREMENTS
a. Analytical Monitoring.
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee
is authorized to discharge from outfall 002 - stormwater from process wastewater areas and adjoining
stormwater collection areas. Process wastewater shall not be discharged from outfall 002. Stormwater
discharges shall be limited and monitored by the Permittee as specified below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Daily
Measurement
Sample
Sample
Average
Maximum
Frequency
Type
Location'
Flow
**
**
Effluent
Total Rainfall (inches)
**
Event Duration (minutes)
**
Total Suspended Solids (mg/I)
Annual
Grab
Effluent
Settleable Solids (m1/1)
Annual
Grab
Effluent
Turbidity (NTU)
Annual
Grab
Effluent
pH (SU)
Annual
Grab
Effluent
**
The total precipitation, storm duration and total flow must be monitored for each sampled
representative storm event. Total flow shall be either; (a) measured continuously, (b) calculated based
on the amount of area draining to the outfall, the amount of built -upon (impervious) area and the total
amount of rainfall, or (c) estimated by the measurement of flow at 20-minute intervals during the rain
event.

Permit NC0000353
b. Qualitative Monitoring
Qualitative monitoring requires a visual or other observation of each stormwater outfall,
regardless of representative outfalI status, for the purpose of evaluating the effectiveness of the
Stormwater Pollution Prevention Plan and assessing new sources of stormwater pollution. No
analytical tests are required. Visual monitoring of stormwater outfalls does not need to be
performed during a representative storm event.
Parameter
Frequency)
Monitoring Type2
Monitoring Location
Color
Semi-annual
Visual
Each Stormwater Discharge Outfall
Odor
Semi-annual
Observation
Each Stormwater Discharge Outfall
Clarity
Semi-annual
Visual
Each Stormwater Discharge Outfall
Floating Solids
Semi-annual
Visual
Each Stormwater Discharge Outfall
Suspended Solids
Semi-annual
Visual
Each Stormwater Discharge Outfall
Foam
Semi-annual
Visual
Each Stormwater Discharge Outfall
Oil Sheen
Semi-annual
Visual
Each Stormwater Discharge Outfall
Other obvious indicators of
stormwater pollution
Semi-annual
Visual
Each Stormwater Discharge Outfall
1. Frequency: The first visual monitoring event during the term of the permit must be performed during the
initial analytical monitoring event. All subsequent visual monitoring will be performed twice per year,
once in the spring and once in the fall.
2. Monitoring Type: Monitoring requires a qualitative observation of each stormwater outfall. No analytical
testing or sampling is required.
PART I., SECTION C.
SCHEDULE OF COMPLIANCE
1. The Permittee shall comply with stormwater monitoring requirements and controls specified
for stormwater discharges in accordance with the following schedule:
The Stormwater Pollution Prevention Plan shall be developed and implemented within 12
months of the effective date of this permit. Secondary containment, as specified in Part III,
Section A.19. of this permit, shall be accomplished within 12 months of the effective date of this
permit.
2. The Permittee shall at all times provide the operation and maintenance necessary to operate the
permitted stormwater controls at optimum efficiency.

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0000353
Facility Information
Applicant/Facility Name:
The Feldspar Corporation
Applicant Address:
P.O. Box 99 Spruce Pine NC 28777
Facility Address:
530 Altapass Road Spruce Pine NC 28777
Permitted Flow
3.5 MGD
Type of Waste:
Industrial
Facility/Permit Status:
Renewal
Facility Classification
Physical/Chemical Class II
County:
Mitchell
Miscellaneous
Receiving Stream:
North Toe River
Regional Office:
Asheville
Stream Classification:
C Trout
USGS Topo Quad:
D1ONE
303(d) Listed?:
No
Permit Writer:
Jackie Nowell
Subbasin:
04-03-06
Date:
4/8/2004
Drainage Area (mi2):
126
.411.
•
Summer 7Q10 (cfs)
43
Winter 7Q10 (cfs):
55
Average Flow (cfs):
260
IWC (%):
11%
Primary SIC Code:
1499 (Mining)
SUMMARY OF FACILITY INFORMATION AND WASTELOAD ALLOCATION
The Feldspar Corporation is requesting a permit renewal for its industrial minerals processing
facility. The facility is permitted to discharge into the North Toe River, class C-Trout waters, in
French Broad River Basin. Currently the Unimin Corp. -Crystal Plant (NC0084620) effluent
discharge also goes to the Feldspar Corporation WWTP. Outfall 001 discharges the treated process
water and outfalls 002 and 003 discharge cooling water.
(see attached memo on North Toe Mines)
The existing wastewater treatment plant consists of:
• three clarifiers,
• polymer feed system,
• Lime feed system for pH adjustment,
• Vacuum filters,
• Emico clarifier/thickener,
• Pump station emergency generator,
• flow measuring and totalizing equipment and
• two recycle pumps.
The existing limits
Pollutant
Flow
Total Suspended
Residue
Total Fluoride
Settleable Solids
Turbidity
Chloride
pH
Chronic Toxicity
for the renewal permit are as follows:
Mo. Avg. Da. Max.
3.5 MGD
1568 lbs/day 313J. lbs/day
225 lbs/day
Daily monitoring
Daily monitoring
Qrtrly monitoring
6-10 SU
11%
448 lbs/day
) t l'1
((is1d"f
6( tirof
The Feldspar Corporation .t; actsheet
NPDES Renewal
Page 1

If Unimin Corp. -Crystal Plant starts direct discharge to North Toe River, the limits for
Feldspar Corp. are as follows. There is a reduction in total fluoride that can be
discharged:
Pollutant Mo. Avg. Da. Max.
Flow 3.5 MGD
Total Suspended 1568 lbs/day 3131 lbs/day
Residue
Total Fluoride 174 lbs/day 348 lbs/day
Settleable Solids Daily monitoring
Turbidity Daily monitoring
Chloride Qrtrly monitorini
pH 6-10 SU
Chronic Toxicity 11%
RECEIVING STREAM INFORMATION:
The North Toe River is not listed on North Carolina's 2002 303(d) list.
INSTREAM MONITORING:
Upstream: Upstream at Altapass Road bridge
Downstream: Downstream at footbridge in Spruce Pine
Parameters: Fluoride, Turbidity, pH,
(see attached North Toe River dischargers memo)
TOXICITY TEST RESULTS:
Quarterly Chronic P/F, 11% Ceriodaphnia test. JAN APR JUL OCT
Facility's compliance with toxicity limit has been excellent. Since 2000, they have passed all chronic
tests. There was one late test in April 2003 followed by a pass in May. 2003.
Recommendation: Renewal of quarterly chronic test @ 11%
PRIORITY POLLUTANT ANALYSIS RESULTS:
Facility has not submitted an updated PPA as yet. They are still awaiting test results. Upon receipt
of data, NCDWQ will review and determine if permit needs to be modified for the addition of limits or
monitoring requirements.
COMPLIANCE REVIEW:
Facility has been in compliance with all permit limits consistently with the exception of three
exceedences of the pH limit of 6-10 SU in July, September and October 2001.
PROPOSED CHANGES:
• No changes recommended
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: 04/14/2004
Permit Scheduled to Issue: 06/07/2004
Projected Effective Date of Permit: 07/01/2004
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please contact
Jackie Nowell at [phone] ext. 512.
NAME.
DATE: Ott
The Feldspar Corporation .Fact:sheet
NPI)ES Renewal
Page

REGIONAL OFFICE COMMENT:
re vie wJ /. dra ravletiai j'tm d ir�t
Care raliDi 7h-C 04 di.SCrep any ioltd s /Lt Zeo/ /yiayi /h
�or 7 I Sits- v&e4 kecs 71-1c / c' SI1444 ti6wS 3131 /b d
y
GiA1 lB �f'�'�lt� �� mi %i s .4 c►j /M i i4—i k &tirtgl f 6off e 3) A C' 1
S_IrowS 3/3 7 /6.5 /d / com,,ind p.e,i/n, 6.4 ,cssazd wk.7 )
d;Scre e IS Ciari/)ed
NPDES SUPERVISOR COMMENT:
NAME: DATE:
The Feldspar Corporation .Factsheei:
NPDES Renewal
Page 3

Permit Number: NC0000353
ce-)! (
PART II
STORMWATER MONITORIN
DISCHARGES
, CONTROLS AND LIMITATIONS FOR PERMTI-1'ED
SECTION A: FINAL LIMITA IONS AND CONTROLS FOR STORMWATER DISCHARGES
During the period beginning on he effective date of the permit and lasting until expiration, the permittee
is authorized to discharge - : • : stormwater associated with industrial activity. Such discharges
shall be controlled, limited and monitored as specified below.
1. Stormwater Pollution Prevention Plans
The permittee shall develop a Stormwater Pollution Prevention Plan, herein after referred to as the Plan.
The Plan shall be considered public information in accordance with Part III, Standard Conditions, Section
E;10. of this permit. The Plan shall include, at a minimum, the following items:
a. Site Plan: The site plan shall provide a description of the physical facility and the
potential pollutant sources which may be expected to contribute to contamination of
regulated stormwater discharges. The site plan shall contain the following:
(1) A general location map (USGS quadrangle map, or appropriately drafted
equivalent map), showing the facility's location in relation to transportation
routes and surface waters, and the name of the receiving water(s) to which the
stormwater outfall(s) discharges. If the discharge is to a municipal separate
storm sewer system, the name of the municipality and the ultimate receiving
waters, and accurate latitude and longitude of the point(s) of discharge must be
shown.
(2) A narrative description of storage practices, loading and unloading activities,
outdoor process areas, dust or particulate generating or control processes, and
waste disposal practices.
(3) A site map (or series of maps) drawn to scale 'indicating di¢.
location of industrial activities (including storage of materials, disposal areas,
process areas, and loading and unloading areas), drainage structures, drainage
areas for each outfall and activitieseoccurring in the drainage area, building
locations and impervious surfacesAthe percentage of each drainage area that is
impervious. For each outfall, a narrative description of the potential pollutants
which could be expected to be present in the regulated stormwater discharge.
(4) A list of significant spills or leaks of pollutants that have occurred at the facility
during the 3 previous years and any corrective actions taken to mitigate spill
impacts.
(5)
Certification that the stormwater outfalls have been evaluated for the presence of
non-stormwater discharges. The certification statement will be signed in
accordance with the requirements found i ar , Standard Conditions, Section
8 con7•r," uy yowl tetmi f or ev, d f /op

Permit Number: NC0000353
b. Stormwater Management Plan: The stormwater management plan shall contain a
narrative description of the materials management practices employed which control or
minimize the exposure of significant materials to stormwater, including structural and
non-structural measures. The stormwater management plan, at a minimum, shall
incorporate the following: r? e f't ca j
(1) A study addressing the technical and economic feasib' ity of changing the
methods of operations and/or storage practices to eli nate or reduce exposure
of materials and processes to stormwater. Wherever/praGticable the permittee
should consider covering storage areas, material handling operations,
manufacturing or fueling operations to prevent materials exc 6/
stormwater. In areas where elimination of exposure is no4reeiiczrble, the
stormwater management plan shall document the feasibility of diverting the
stormwater runoff away from areas of potential contamination.
c.
(2) A schedule to provide secondary containment for bulk storage of liquid
materials, storage of Section 313 of Title III of the Superfund Amendments and
Reauthorization Act (SARA) water priority chemicals, or storage of hazardous
materials to prevent leaks and spills from contaminating stormwater runoff. If
the secondary containment devices are connected directly to stormwater
conveyance systems, the connection shall be controlled by manually activated
valves or other similar devices [which shall be secured with a locking
mechanism] and any stormwater that accumulates in the containment area shall
be at a minimum visually observed prior to release of the accumulated
Stormwater. Accumulated stormwater shall be released if found to be
uncontaminated. Records documenting the individual making the observation,
the description of the accumulated stormwater and the date and time of the
release shall be kept for a period of five years.
(3)
A narrative description of Best Management Practices (BMPs) to be considered
such as, but not limited to, oil and grease separation, debris control, vegetative
filter strips, infiltration and stormwater detention or retention, where necessary.
The need for structural BMPs shall be based on the assessment of potential of
sources contributing significant quantities of pollutants to stormwater discharges
and data collected through monitoring of stormwater discharges.
(4) Inspection schedules of stormwater conveyances and controls and measures to
be taken to limit or prevent erosion associated with the stormwater systems.
Spill Prevention and Response Plan: The Spill Prevention and Response Plan shall incorporate a
risk assessment of potential pollutant sources based on a materials inventory of the facility.
Facility personnel (or team) responsible for implementing the plan shall be identified in the plan.
A responsible person shall be on -site at all times during facility operations that have the potential
to contaminate stormwater runoff through spills or exposure of materials associated with the
facility operations.
d. Preventative Maintenance and Good Housekeeping Program: A preventative maintenance
program shall be developed. The program shall document schedules of inspections and
maintenance activities of stormwater control systems, plant equipment and systems. Inspection
of material handling areas and regular cleaning schedules of these areas shall be incorporated into
the program.
9

Permit Number: NC0000353
e. Training schedules shall be developed and training provided at a minimum on an annual basis on
proper spill response and cleanup procedures and preventative maintenance activities for all
personnel involved in any of the facility's operations that have the potential to contaminate
stormwater runoff. Facility personnel (or team) responsible for implementing the training shall
be identified in the plan.
f. The Stormwater Pollution Prevention Plan shall identify a specific position(s) responsible for the
overall coordination, development, implementation, and revision to the Plan. Responsibilities for
all components of the Plan shall be documented and position(s) assignments provided.
g.
Plan Amendment: The permittee shall amend the Plan whenever there is a change in design,
construction, operation, or maintenance which has a significant effect on the potential for the
discharge of pollutants via a point source to surface waters.
Plan shall be reviewed and updated on an annual basis.
Dy
The rector may notify the permittee when the Plan does not meet one or more of the minimum
requirements of the permit. Within 30 days of such notice, the permittee shall submit a time
schedule to the Director for modifying the Plan to meet minimum requirements. The ermittee
shall rovide certification in writing (in accordance wit(Part III, Standard Conditions, Sectio
-B.l 1.) o the Director that the changes have been made..--'� Ger214;r07 /ote c°r)ce
tte Stormwater Pollution Prevention
h. Facility Inspections: Inspections of the facility and all stormwater systems shall occur at a
minimum on a semiannual schedule, once in the fall (September - November) and once during the
spring (April - June). The inspection and any subsequent maintenance activities performed shall
__-- be documented, recording date and time of inspection, individual(s) making the inspection and a
narrative description of the facility's stormwater control systems, plant equipment and systems.
r04244, Records of these inspections shall be incorporated into the Stormwater Pollution Prevention Plan.
be e'k Visual monitoring as required irPart II, Section A.3.shall be performed in addition to
facility inspections.
- L — c,1476,: ' !c'4re.._ 4
Implementation: Implementation of the Plan shall include documentation of all
monitoring, measurements, inspections, maintenance activities and training provided to
employees, including the log of the sampling data. Activities taken to implement BMPs
associated with the industrial activities, including vehicle maintenance activities, must
also be recorded. All required documentation shall be kept on -site for a period of five
years and made available to the Director or his authorized representative immediately
upon request.
2. Minimum Monitoring and Reporting Requirements
Minimum monitoring and reporting requirements are as follows unless otherwise approved in writing by v'
the Director of the Division of Water Quality:
a. If a facility has multiple discharge locations with substantially identical stormwater
discharges that are required to be sampled, the permittee may petition the Director for
representative outfall status. If it is established that the stormwater discharges are
substantially identical and the permittee is granted representative outfall status, then
sampling requirements may be performed at a reduced number of outfalls.
/
10

(1:-eFr42/eS5 oT r6,QfPScop)fa71/V& Permit Number: NC0000353
d th/4/�
b. 'Litsial monitoring for • • ... { ._.:. - _
hall be performed at all stormwater discharge outfall location All visual
monitoring shall be documented and records maintained with the Stormwater Pollution
Prevention Plan. The initial visual monitoring event shall be performed simultaneously
with the first analytical monitoring event and documentation of only this initial visual
monitoring event shall be submitted along with the required analytical monitoring
submittal.
d.
011714// stt;s,--)
a��lyses
For purposes of the stormwatesampling required in this permit, all samples shall be
collected from a discharge resulting from a representative storm event (See definitions in
Part IIT; Standard Conditions). Failure to monitor storm events in accordance with th
_specified freq_uen-cy shall constitute a violation of this Eermitstows, water_r_una{f"j
�i�ntr�llec by a detenHnn_pond, th
• Analytical monitoring for a retention pond designed to contain the 10-year design storm (see-Part-
V117-13efirritionst without discharging is not required. Qualitative monitoring f , , T€a:
is the only monitoring requirements.
• Analytical and qualitative monitoring are not required from a retention pond designed to contain the
25-year, 24-hour storm without discharging s the pond is considered a •
non -discharging stormwater control. since
- to-kl?DES-requiremen
da-Seb a V1VraviuLl or al l Ci6[YlaIl)
Samples analyzed in accordance with the terms of this permit shall be submitted on
forms approved by the Director no later than January 31 for the previous year in which
sampling was required to be performed.
Analytical results from sampling during the final year of the permit term shall be
submitted with the permit renewal application.
This • - 't regulates stormwater discharges associated with industrial activity. Non - -
stormwater • ' arges which shall be allowed in the stormwater conyeyance system are:
(1) All other discharges th a - - thorized by -an NPDES permit.
(2) Foundation drains, air-coridittoner condensate dded chemicals, springs,
waterline andfir iydrant, water from fog drains, flows
and and's,-fire-fighting tr4ining a dike system testing. ,
(3),./.Discharges resulting from fire -fighting.
arian habits
If the storm event monitored and reported in accordance with this permit coincides with
a non-stormwater discharge, the permittee shall separately monitor and report all
parameters as required under the non-stormwater portion of this permit and provide
this information with the stormwater discharge monitoring report.
o�oa �r��i ,sD�i�s Su SPe �� so- AG)/4
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t Y?P it c I f e%
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" Froces areas" "Iahcl �d�,1vr6�ce areas''
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lc'ieral perw•c+ 0CCzoZ. I %e )en51.18
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areas' (5 awkward +o vne.
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top UIc :I ,. r .:....!
Permit Number: NC0000353
VC' hlcle
W�2o'1{ennce atwd5''
d 5
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.pR MONITORING REQUIREMENTS/IF-INAL
(a). nalytical Monitoring \\
During t e period beginning on th -eeffective date of t �ee permit and lasting until
expiration, the Permittee is authorized`t discharge fromhutTall 002 - stormwat
from process wastewater area and join ng stormwater coTtecti area - rocess
wastewater shall not be discharged from out a 00 . Stormwater discharges shall be
limited and monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
EFFLUENT LIMITATIONS
MONITORING
REQUIREMENTS
Monthly
Daily
Measurem e
Sample
Sample
Averae
Maximum
nt
PrPl711PrIONT
Type
Location
Flow
**
**
E
Total Rainfall (inches)
**
Event Duration (minutes)
**
Total Suspended
Residue (mg/I)
Annual
Grab
E
Settleable Solids (ml/I)
Annual
Grab
E
Turbidity (NTU)
Annual
Grab
E
pH (SU)
Annual
Grab
E
Fluoride (mg/I)
Annual
Grab
E
Chloride (mg/I)
Annual
Grab
E
Sample location: E - Effluent
lilPerp W! d -/t04)
12

Permit Number: NCOO00353
**
S PAP/4 d
For each representative storm event the total precipitation, storm duration and total
flow must be monitored. Total flow shall be either; (a) measured continuously, (b)
calculated based on the amount of area draining to the outfall, the amount of built -
upon (impervious) area and the total amount of rainfall, or (c) estimated by the
measurement of flow at 20 minute intervals during the rain event.
There shall ben discharge of floating solids or visible foam in other than trace amounts.
t_. S'-:,..1A/1-1. -4144:-1
,Azon.;i kie /71i�it-Q-t c-a' 1
r
13

Permit Number: NC0000353
4al,7f4h ve
b. —Visu i-Monitoring
a/'4)74tape
monitoring requires a giia ive visua)ine � of each stormwater outfall, regardless
of representative outfall status, for the purpose of evaluating the effectiveness of the
Stormwater Pollution Prevention Plan and assessing new sources of stormwater pollution. No
analytical tests are required. Visual monitoring of stormwater outfalls does not need to be
performed during a representative storm event.
Stormwater Discharge
Characteristics
Frequency)
Monitoring
Type2
Monitoring
Location3
Color
Semi-annual
Visual
SDO
Odor
Semi-annual
Observation
SDO
Clarity
Semi-annual
Visual
SDO
Floating Solids
Semi-annual
Visual
SDO
Suspended Solids
Semi-annual
Visual
SDO
Foam
Semi-annual
Visual
SDO
Oil Sheen
Semi-annual
Visual
SDO
Other obvious indicators of
stormwater pollution
Semi-annual
Visual
SDO
1 Frequency: The first visual monitoring event during the term of the permit must be
performed during the initial analytical monitoring event. All subsequent visual
monitoring will be performed twice per year, once in the spring and once in the fall.
2 Monitoring Type: Monitoring requires a qualitative observation of each stormwater
outfall. No analytical testing or sampling is required.
eac�
3 Sample Location Stormwater Discharge Outfall (SDO).
SECTION B: SCHEDULE OF COMPLIANCE
v 1. The permittee shall comply with stormwater monitoring requirements and controls
specified for stormwater discharges in accordance with the following schedule:
17
The Stormwater Pollution Prevention Plan shall be developed and implemented within
12 months of the effective date of this per
Secondary containment, as specified • , Part III, Section A.1')of this permit, shall be
accomplished within 12 months of the effective date of this permit.
2. I The permittee shall at all times provide the operatio and maintenance necessary to
1./ operate the permitted stormwater controls at optimu efficiency.
14
the are.
a&
4> rya
Oily S.
ey
0n-a"IVI14Cye

Jai o S % s.
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
W REGION 4
• ra.4)
e ATLANTA FEDERAL CENTER
= 61 FORSYTH STREET
PAo " ATLANTA, GEORGIA 303033960 _._
APR 2 8 2004
Ms. Jackie Nowell
North Carolina Department of Environment and
Natural Resources
Division of Water Quality
NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
r(g CEJ E
.�� APR 3 0 20 0�
SUBJ: Draft NPDES Permits
Unimin - Quartz/Feldspar Plant, Permit No. NC0000175
Feldspar - Permit No. NC0000353
K-T Feldspar Corp. - Permit No. NC0000400
�• ? R /'\TER �(, j,]•I '/
Pt
� I
1.
Dear Ms. Nowell:
In accordance with the EPA/NCDENR NPDES MOA, we have completed review of the draft
permits specified above and we have no comments or objections to their conditions. We request that
we be afforded an additional review opportunity only if significant changes are made to the draft
permit(s) prior to issuance or if significant comments objecting to the draft permit(s) are received.
Otherwise, please send us one copy of each final permit when issued.
If you have any questions, please call me at [phone].
Sincerely,
Marshall Hyatt, Environmental Scientist
Permits, Grants, and Technical Assistance Branch
Water Management Division
Internet Address (URL) • http://www.epa.gov
Recycled/Recyclable •Printed with Vegetable Oil Based Inks on Recycled Paper (Minimum 30% Postconsumet)

STATE OF
NORTH CAROLINA
ENVIRONMENTAL
MANAGEMENT
COMMISSION/
NPDES UNIT
1617 MAIL
SERVICE CENTER
RALEIGH NC27699-1617
NOTIFICATION OF
INTENT TO ISSUE A
NPDES PERT WASTEWATER
On the' basis of thorough
staff review and applica-
tion of NC General Statute
143.21, Public law 92-500
and other lawful stan-
dards, and regulations, the
North Carolina Environ-
mental Management
Commission proposes to
issue a National Pollutant
Discharge Elimination
System (NPDES) waste-
water discharge permit to
the person(s) listed below
effective 45 days from the
publish date of this notice.
Written comments regard-
ing the proposed permit
will be accepted until 30
days after the publish date
of this notice. All com-
ments received prior to
that date are considered in
the finaldeterminations
regarding the proposed
thNDsthe CiviinDirector Water
Quality may decide to hold
a public meeting for the
proposed permit should
the Division receive a sig-
nificant degree of public
interest.'
Copies of the draft permit
and other supporting in-
formation on file used to
determine conditions Pre -
wit in the draft permit are
available upon request
and payment of the costs
of reproduction. Mail
comments and/or requests
for information to the. NC
Division of Water.Quality
at the above address or
cahens
atIl [phone], ext. Valery ension
520. Please include the
NPDES- permit number
(attached), in any corm
munication : Interested
he
Divissiionmof Water.Quality
at 512 N. Salisbury Street.
Raleigh, NC 27604-1148 be-
tween the hours of 8:00 am
forn
and
matiioponn hi fi ereview in
The Town of Newland has
t Ile-NPDESS Permit
NC0021 a57. far its waste -
Water treatment facility
discharging to the- North
Toe .River, a C-Trout wa-
ter in the French Broad
River Basin. The facility is
currently permitted to dis-
charge up to 0.32 MOD
and, after expapsion, 06
MOD. Ammonia -nitrogen
and total residual chlorine
qual-
ityare limited-tiThis diisreny carge
may impact future alloca-
tion of the receiving
'stream.
NPDES Permit Number
NC0000175, Unimin Como-
' ration, Quarts Feldspar
Facility, Mitchell, County,
has applied for renewal of
its permit discharging
treated wastewater to the
FrennchTB Broad the
Currently fluoride and
total suspended solids are
water quality limited. This
discharge may affect fu-
Lure allocations in this por-
tion of the receiving
stream.
NPDES. Permit Number
N0000025S, The Feldspar
Corporation, Mitchell
County, has applied for
renewal of its permit dis-
charging . treated ' waste-
water and noncontact coat-
ingRiver n terhe o the
Brooad
River Basin. Currently
fluoride and total sus-
pended solids are water
quality limited. This dis-
charge rnay affect. future
aofltho e�recceiving stt reamr.
rc.
,.:,tic it
AFFIDAVIT OF PUBLICATION
BUNCOMBE COUNTY
SS.
NORTH CAROLINA
Before the undersigned, a Notary Public of said
County and State, duly commissioned, qualified and
authorized by law to administer oaths, personally
appeared Darryl Rhymes, who, being first duly
sworn, deposes and says: that he is the Legal
Billing Clerk of The Asheville Citizen -Times,
engaged in publication of a newspaper known as
The Asheville Citizen -Times, published, issued,
and entered as second class mail in the City of
Asheville, in said County and State; that he is
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 Asheville Citizen -
Times on the following date: April 17, 2004. And
that the said newspaper in which said notice, paper,
document or legal advertisement were published
were, at the time of each and every publication, a
newspaper meeting all of the requirements and
qualifications of Section 1-597 of the General
Statues of North Carolina and was a qualified
newspaper within the meaning of Section 1-597 of
the General Statues of North Carolina.
Signed this 19th day of April 2004
(Signature of perso along affidav'
Sworn to and subscribed before me the 19th day of
April 2004
(Notary Pu
My C
2008.
tic) I v
mission expires the 3rd day of Seel
ttttttttttttttt
�••, c NPDES Permit Number
•`_�` NC000040Q K-T Feldspar
Corporation, Mitchell
County, hos applied for
renewal of its permit for a
facility discharging
treated Industrial ,waste-
water to the North Toe
River in the French Broad
River Basin. Currently
fluorine and total sus-
pended solidsare water
quality limited:. This dis-
charge may affect future
allocations In the portion of
thereceiving stream.
April 17, 2004
(7004)

PUBLIC NOTICE
STATE OF
NORTH CAROLINA
ENVIRONMENTAL
MANAGEMENT
COMMISSION/NPDES UNIT
1617 MAIL SERVICE
CENTER
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT
TO ISSUE A NPDES
WASTEWATER PERMIT
On the basis of thorough staff
review and application of NC
General Statutes 143.21, Pub-
lic Law 92-500 and other lawful
standards and regulations, the
North Carolina Environmental
Management Commission pro-
poses to issue a National Pollu-
tant Discharge Elimination Sys-
tem (NPDES) wastewater dis-
charge permit to the person(s)
listed below effective 45 days
from the publish date of this no-
tice.
Written comments regarding the
proposed permit will be accept-
ed until 30 days after the pub-
lish date of this notice. All com-
ments received prior to that date
are considered in the final de-
terminations regarding the pro-
posed permit.The Director of the
NC Division of Water Quality
may decide to hold a public
meeting for the proposed permit
should the Division receive a sig-
nificant degree of public interest.
2
Copies of the draft permit and
other supporting information on
file used to determine conditions
present in the draft permit are
available upon request and pay-
ment of the costs of reproduc-
tion. Mail comments and/or re-
quests for information to the NC
Division of Water Quality at the
above address, or call Ms.
Valery Stephens at (919) 733-
5083, extension 520. Please in-
clude the NPDES permit num-
ber (attached) in any communi-
cation. Interested persons may
also visit the Division of Water
Quality at 512 N. Salisbury
Street, Raleigh, NC 27604-1148
between the hours of 8:00 a.m.
and 5:00 p.m. to review infor-
mation on file.
NPDES Permit Number
NC0000175, Unimin Corpora-
tion, Quartz Feldspar Facility,
Mitchell County, has applied for
renewal of its permit discharg-
ing treated wastewater to the
North Toe River in the French
Broad River Basin. Currently flu-
oride and total suspended solids
are water quality limited. This
discharge may affect future al-
locations in this portion of the re-
ceiving stream.
MITCHELI.
NEWS -JOURNAL
Cost of Advertisntcnt
Cost of Aft tdavit
S II
Total $ JJ"I 3. 1,0
STATE OF NORTH CAROLINA
COUNTY OF MbTCHELL
1, Nathaniel A. Ashurst. Publisher of the Mitchell News -Journal. a
newspaper published in Mitchell County, North Carolina, in
compliance with statutes G.S. I -597 of North Carolina, as amended in
1947 session of General Assembly, being duly sworn, certify that the
attached advertisement of
U)-ull,uf\ry
was duly published in the aforesaid paper once a week for
Iconsecutive week eginning with the issue date
(signed)
(0 •n ,Partner, Publisher or other
Employee Authorized to make the affidavit)da
Sworn to and subscribed before me this L--).--,✓laday of
20 O -
Notary Public for Mit.f ell County
North Carolina
My Commission expires 1 ��i ' h.Q L\
NPDES Permit Number
NC0000353, The Feldspar Cor-
poration, Mitchell County, has
applied for renewal of its permit
discharging treated wastewater
and noncontact cooling water to
the North Toe River in the
French Broad River Basin. Cur-
rently fluoride and total sus-
pended solids are water quality
limited. This discharge may af-
fect allocations in this portion of
the receiving stream.
NPDES Permit' Number
NC0000400, K-T Feldspar Cor-
poration, Mitchell County, has
applied for renewal of its permit
for a facility discharging treated
industrial wastewater to the
North Toe River in the French
Broad River Basin. Currently flu-
oride and total suspended solids
are water quality limited. This
discharge may affect future al-
locations in this portion of the re-
ceiving stream.
#5255 - 4/21/04
No, 5rL55
No.

TOXICANT ANALYSIS
Facility Name
NPDES #
Qw (MGD)
7Q 1Os (cfs)
IWC (%)
Rec'ving Stream
Stream Class
Feldspar Corp
NC0000353
3.5
43
11.20
North Toe River
C Trout
Chloride
Max. Pred Cw
Allowable Cw
Max. Value
Fluoride
Iron
FINAL RESULTS
45000
2053041.5
45000
Max. Pred Cw 12000
Allowable Cw 16067.3
Max. Value 12000
Max. Pred Cw 1300
Allowable Cw 8,926.27
Max. Value 1300
Nickel
Max. Pred Cw 19
Allowable Cw 785.5
Max. Value 19
Barium
Max. Pred Cw 11
Allowable Cw 8926.3
Max. Value 11
Manganese
Max. Pred Cw 210
Allowable Cw 1785.25
Max. Value 210
Nitrate N
Max. Pred Cw 190
Allowable Cw 89262.7
Max. Value 190
Copper
Max. Pred Cw 3
Allowable Cw 62.5
Max. Value 3
Sulfate
Max. Pred Cw 23000
Allowable Cw 2231566.8
Max. Value 23000
Zinc
Max. Pred Cw 110
Allowable Cw 446.3
Max. Value 110
Max. Pred Cw
Allowable Cw #VALUE!
Max. Value
Max. Pred Cw
Allowable Cw #VALUE!
0
0
0
1
Max. Value
0
amp
ana
ug/l
ug/l
ug/l
ug/l
ug/I
ugh
ug/I
ugh
ug/I
ug/I
ug/I
ug/I
ugh!
ug/I
ug/I
ug/I
ug/I
ug/I
ugh
ug/I
ugh
ugh
ugh
ugh
6/9/2004

NC draft rationale for fluoride mines
Subject: NC draft rationale for fluoride mines
Date: Thu, 25 Sep 2003 11:32:29 -0400
From: [e-mail]
To: [e-mail], [e-mail]
CC: [e-mail], [e-mail]
sorry for the delay in getting back to you. Chris Decker and I looked
at it. Based on the data provided and rationale, we can agree with your
conclusion that there is no need to change permit limits at this time.
1 of 1 12/10/03 5:29 PM

DIVISION OF WATER QUALITY
Point Source Branch
NPDES Unit
August 22, 2003
MEMORANDUM
To: Madolyn Dominy
Marshall Hyatt
EPA Region IV
Through: Dave Goodrich'`(J
144
From:
Jacquelyn M. NowellA
Subject: North Toe River Mining Dischargers
French Broad River Basin
Mitchell County, North Carolina
Background
There are six feldspar and quartz mines discharging into the North Toe River in the
French Broad River basin (subbasin 040306). The facilities are listed here in order, from
upstream to downstream:
• Unimin- Schoolhouse Facility (NC0000361) — 2.16 MGD
• Feldspar Mines (NC0000353) — 3.5 MGD
• Unimin-Crystal Facility (NC0084620) — 0.36 MGD
• K-T Feldspar Mines (NC0000400) — 1.73 MGD
• Unimin — Quartz Facility (NC0000175) — 3.6 MGD
• Unimin — Red Hill Facility (NC0085839) — 0.682 MGD
Please see the attached schematic that represents the mine locations on the North Toe
River. Most of these facilities have been discharging since the early 1980's. The
exception is the Red Hill Facility that started discharging in 1995 and is located
approximately 20 miles downstream of the other mines and is not relevant to this
discussion from the standpoint that no interaction occurs between this plant and any
other. Therefore, this discussion will only include the mines above the confluence of the
South Toe River. It should also be noted that the Unimin — Crystal Facility discharges
effluent into the Feldspar Mines facility. There is the possibility of a separate discharge
in the future; therefore the facility has received a fluoride allocation.
The primary area of concern is the discharge of fluoride from these facilities. The North
Carolina water quality standard for fluoride is 1.8 mg/l. The allowable fluoride loading
for the North Toe River was determined in 1986 and has been allocated to these mines as
a group instead of individual allocations. This approach of allocating the total fluoride
1

Unimin-
Red Hill
0.682 fic)
MGD
N
c
T
m
Unimin-
Quartz
3.6 MGD
i c0 G
¢
K-T Feldspar 1.73 MGD
North ��
roe
Rifrer
X
Unimin- Feldspar 3.5 MGD
Crystal
0.360 MGD
North Toe River
MINE DISCHARGES ON THE NORTH TOE RIVER
Unimin-
School
House
-Quartz
2.16 MGD
y

MINE DISCHARGES ON NORTH TOE RIVER
River Mile NPDES Permit number
41.5 X NC0000361- Unimin-Schoolhouse Quartz
33.8
NC0000353- The Feldspar Corp.
X( NC0084620- Unimin-Crystal
31.4 HWY 19
29.2 X NC0000400- K-T Feldspar
28.6 X NC0000175- Unimin-Quartz
27.5 Ambient monitoring station
21.6 X South Toe River junction
6.0 X NC0085839- Unimin-Red Hill

load to a section of the North Toe River is similar to other methods used by the Division,
including nutrient control strategies in the Neuse and Tar -Pamlico River basins. Similar
to a "bubble permit"(used in the Air Quality program), some discharges may cause
localized impacts. However, the overall goal of the allocation method is to protect water
quality while allowing some flexibility for the dischargers to maintain compliance. The
Division and EPA have approved this approach for 17 years.
The total pounds per day of fluoride allocated are 574. The permitted fluoride
allocations for each of the mines is as follows:
Facility Name
Fluoride Monthly Average
(lbs/day)
Fluoride Daily Maximum
(lbs/day)
Unimin-Schoolhouse
109
218
Feldspar Mines
174
348
Unimin-Crystal
50
100
K-T Feldspar
132
264
Unimin-Quartz
109
436
Total Allocation
574
1366 - '
These allocations for the mines have been assigned upon all past permit renewals. This
fluoride loading of 574 lbs/day is based on:
1) a summer 7Q10 flow of 45 cfs in the North Toe River just below Little Bear Creek,
2) the current water quality standard for fluoride of 1.8 mg/1, and
3) a background fluoride concentration of 0.05 mg/1.
The 1985 wasteflows for three of the quartz processing mines were used to develop the
fluoride loading:
1) Feldspar @ 1985 Qw = 3.50 MGD
2) KT Feldspar @ 1985 Qw = 2.02 MGD
3) Unimin-Quartz @ 1985 Qw = 4.32 MGD
9.84 MGD = 15.25 cfs
Fluoride loading = (45 cfs + 15.25 cfs)(1.8 mg/1) — (45 cfs)(0.05 mg/1)
= (60.25)(1.8) — 2.25 cfs.mg/1
= 108.45 — 2.25 = 106.2 cfs.mg/1
= 106.2 cfs.mg/1* 5.39 = 572 lbs/day - 574 lbs/day
(Assume the difference is attributable to rounding)
Water Quality Evaluation
There are no federal effluent guidelines for mines that discharge fluoride. The purpose of
this memorandum is to evaluate water quality as it relates to previous permit decisions
and propose a 2003 permit strategy.
2

The Division uses a weight of evidence approach when assessing water quality. That is,
all available data are reviewed and evaluated to determine the appropriateness of certain
actions. There are three categories of information in this case:
• Instream biological assessments
• Whole -effluent toxicity testing
• Instream chemical data
Instream biological data are the most directly reliable measurements of stream health and
are, therefore, given the greatest consideration. Whole -effluent toxicity testing also is
given a lot of weight during deliberations. It is not a direct measurement of stream
conditions, but it is a direct measurement of the interaction between wastewater and
species that inhabit the stream or river. The Division also considers comparison of
physical or chemical measurements to existing water quality standards. In the presence
of all three categories of information, contraventions of water quality standards, although
considered serious, are given the least amount of weight. The reason for this is that
comparisons to numeric criteria (which are based on whole -effluent toxicity testing) are
indirect measurements of the biota in the stream. All of this information is valuable, but
North Carolina chooses to make a comprehensive critical evaluation of all available data.
Use Support
There are no segments of the North Toe River listed on the North Carolina 2003 303(d)
impaired stream list. There are approximately 556 miles of the North Toe River that are
rated fully supporting designated uses including the river reaches receiving effluent from
these mines.
Instream Biological Assessment
The benthic macroinvertebrate data for the North Toe River below all the quartz mines
demonstrate good water quality. The most recent evaluation was in 1997 at State Road
1162 at Penland, Mitchell County. This is located just 0.5 miles downstream of the
Unimin-Quartz discharge. There has been improvement in the biological rating over the
years from a poor rating in August 1988 to a good -fair rating in 1989 and 1992.
Macroinvertebrate data for the most upstream station above the quartz mines, North Toe
River at US19E at Ingalls, Avery County, indicate a rating of excellent water quality as of
July 1997. The table below indicates North Toe River biological monitoring stations and
their biological ratings during the 10 year period between 1987 and 1997.
'a�. i ti+ia F
ra
':�..
��..
r {•
_
� 'irk,.
�.
w�
.�k•
�L1`� i 1
North Toe R.,US 19E
at Ingalls
Good
Good
Good
Good
Excellent
North Toe R.,
SR1162, Penland
Fair
Poor
Good
—Fair
Good
-Fair
Good

Bioclassification Use Support Rating
Excellent Fully Supporting
Good Fully Supporting
Good -Fair Fully Supporting
Fair Partially Supporting
Poor Not Supporting
Whole Effluent Toxicity Testing
All the quartz mines have quarterly whole effluent toxicity tests based on the potential for
toxic effects on the receiving stream. (Please note that Unimin-Crystal has a toxicity
limit, however because it discharges into the Feldspar Mines WWTP, they do not conduct
individual toxicity tests.) Since 1998, there have been 91 tests conducted by the five
quartz mines with a 93% passing rate. There have only been 6 failures of all the tests
conducted in the past four years. The majority of the failures occurred at the same
facility. The Unimin-Schoolhouse plant accounted for four of the six failures. The cause
of this toxicity is unknown. However, it should be noted that Unimin-Schoolhouse been
compliant since August 2001.
Facility Name
Toxicity Limit
Number of
Toxicity Tests
since 1998
Number of
Failures
Unimin-Schoolhouse
10%
26
4
Feldspar Mines
11%
24
()
Unimin-Crystal
1.3%
-
-
K-T Feldspar
6%
19
1
Unimin-Quartz
11%
22
1
Instream Chemical Monitoring by Facilities
All the facilities conduct instream self -monitoring for turbidity, fluoride and pH, both
upstream and downstream of their outfalls. This is to help determine the effect of the
discharges on the water quality in the North Toe River. Instream fluoride data from the
time period of January 1999 to August 2002 were reviewed for the preceding five
facilities. During this time period, the monthly averages for instream fluoride have
shown no exceedances of the water quality standard either upstream or downstream of the
Unimin-Schoolhouse and Feldspar facilities. The average upstream value for the
Schoolhouse facility was 0.15 mg/I and the average downstream value was 0.26 mg/l.
The average upstream value for the Feldspar facility was 1.29 mg/I and the average
downstream value was 1.2 mg/1.
There were a total of 327 fluoride observations in the stream among these five
dischargers with 30 values >1.8 mg/l. This was 9% of the total monthly observations
with 91% within the standard. Most of the instream fluoride values > 1.8 mg/I standard
occurred upstream and downstream of the K-T Feldspar discharge. This, more than
likely, occurred as a result of the proximity of the Feldspar Mines discharge which is only
0.6 miles above the K-T Feldspar Mines discharge. The breakdown of instream
observations of values > 1.8 mg/1 are:
4

s
Number of
Monitoring Locations Number of Obs. values > 1.8 mg/1
Above Unimin Schoolhouse 43 0 0
Franklintown Bridge 43 0
Above Feldspar 37 0
Below Feldspar 38 0
Above K-T Feldspar 41 7
Below K-T Feldspar 42 15
Above Unimin-Quartz 42 5
SR 1162 at Penland Bridge 42 3
327 30
0
0
0
17%
36%
12%
7%
9%
Ambient Monitoring Data
The Division conducts ambient monitoring in the North Toe River at two sites. The first
station is at US Highway 19E near Ingalls, NC nearly 1 mile above the Unimin-
Schoolhouse Quartz mine. The second station is at State Road 1162 at Penland
approximately 0.8 miles below the Unimin-Quartz outfall. These stations are above the
most upstream mine and below the most downstream mine. Since January 1999, there
have been 30 samples of fluoride taken. There have been only 3 values > 1.8 mg/1 and
these occurred in February 2000, February 2001 and June 2001. This indicates that 90%
of the ambient samples in the past 4 years have been < 1.8 mg/1.
Discussion of Water Quality Information
An overall view of water quality in this segment of the North Toe River indicates that the
biological assessment shows improving water quality conditions. The toxicity data
indicates that the discharges are not toxic or causing toxicity instream. There is greater
than 90% compliance with the toxicity limits. Self monitoring instream data conducted
by the discharges does demonstrate that some instream fluoride standard exceedances
occur. The majority are below K-T Feldspar, and it is concluded that these occur because
the two dischargers are in such close proximity and North Carolina (with EPA approval)
has used a "bubble" permitting approach, which allows some localized impacts by design.
However, the average instream fluoride values collected between January 1999 and
August 2002 show that upstream and downstream of all the dischargers, the instream
fluoride average is below the standard of 1.8 mg/l.
DWO Recommendation
The Division recommends that the allocations for the North Toe River dischargers remain
the same. Water quality data show that there is no impairment in the stream, there have
been minimal toxicity problems, and the numeric water quality standard is being
protected > 90% of the time. It recommended that all the feldspar and quartz mines have
their permits reissued at the existing fluoride allocations.
Attachments
cc: Forrest Westall
Mike Parker
Matt Matthews
NPDES Files: NC0000175
NC0000400
NC0000353 NC0000361
NC0084620 NC0085839
5

Whole Effluent Toxicity Testing Self -Monitoring Summary
FACILITY REQUIREMENT
March 16, 2004
YEAR JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Fayetteville -Rockfish WWTP chr lim: 3.5%
NC0050105/001 Begin:1 I/1/2002 Frequency Q Jan Apr Jul Oct
County:Cumberland Region: FRO Subbasin: CPFI5
PF: 16.0 Special
7Q10: 675.0 IWC(%; 3.5
+ NonComp Single
M 2000 Pass - - Pass - - Pass - - Paso -
2001 Pass - - Pass - - Pass - - Pass -
2002 Pass - - Pass - - Fail >14 >14 Late Pass
2003 Pass - - Pass - - Pass - - Pass -
2004 Pass
Feldspar Corp. chr lim: 11 %
NC0000353/001 Begin.2/I/1997 Frequency Q P/F + Jan Apr Jul Oct
County:Mitchell Region: ARO Subbasin: FRB06
PF: 3.5 Special
7Q10: 43 IWC(% 11.18
+ NonComp Single
O 2000 NR/Lale
2001 Pass
2002 Pass
2003 Pass
2004 Pass
NR/Pass
Pass - - Pass
Pass - - Pass
Pass - - Pass
Lato Pass - Pass
- - Pass AP -
- - NRJPass -
- - NR Pass
- - Pass -
Fieldcrest Mills chr lira: 90% 2000 - H Pass - Pass - - H - - H
NC0004286/001 Begin:10/1/1999 Frequency Q P/F + Feb May Aug Nov + NonComp Single 2001 - H Pass - H - - H Pass - Pass
County:Rowan Region: MRO Subbasin: YADO4 2002 - Pass - - H Pass - H - Pass NR/H
PF: 0.05 Special 2003 - Pass - Pass H - - H - - H
7Q10: 0.0 IWC(%; 100 2004 -
First Union Commons chr lim: 90%
NC0086886/001 Begin:4/1/2001 Frequency Q Mar Jun Sep Dec + NonComp Single
County:Mecklenburg Region: MRO Subbasin: CTB34
PF: 0.086 Special
7010: 0.85 IWC(%; 100
2000 -
2001 -
2002 -
2003 -
2004 <45
- - Fa- il Pa- ss Fa- il <45
- Pass - - NR/Pass -
- NRIPass NR NR/Pass NR/Pass -
54- .1
Pa- ss - - Pa- ss
NR/Fail(Sig) NR/92. 5 NR/>100 NR/Pass
Pass - - Fail
Flakt Products, Inc. chr lim: 4.5% 2000 - - Pass - - Pass - - Pass - - H
NC0085871/001 Begin:8/1/1999 Frequency Q P/F + Mar Jun Sep Dec + NonComp Single 2001 Late - Pass - - NR/Pass - - Pass - - Pass
County:Forsyth Region: WSRO Subbasin: YADO4 2002 - - Pass - - Pass - - Pass - - Pass
PF: 0.0864 Special 2003 - - Pass - - Pass - - Pass - - Pass
7Q10:2.9 IWC(%;4.5 2004 -
Flint Hills Resources, LLP 24hr p/f ac lim: 90% 2000 Pass - - Pass - - Pass - - NR/Pass
NC0076732/001 Begin:10/1/1996 Frequency Q + Jan Apr Jul Oct NonComp Single 2001 Pass - - Pass - - Pass - - Pass
County:New Hanover Region: WIRO Subbasin: CPFI7 2002 Pass - - >ISO - Pass Pass - - Pass
PF: 0.1 Special 2003 Pass - - Pass - - Pass - - Pass
7Q10: Tidal IWC(%;NA 2004 Pass
Forest City WWTP chr lim: 18%
NC0025984/001 Begin: 1/1/2004 Frequency Q P/F + Jan Apr Jul Oct
County:Rutherford Region: ARO Subbasin: BRD02
PF: 4.95 Special
7Q10: 34.8 IWC(%; 18.0
+ NonComp Single
0 2000 Pass - - Pass - - Pass - - Pass
2001 Pass - - Fall >35 29.6 Pass - - Pass
2002 Fail 10.8 27.4,21.2 Pass - - Pass - - Pass
2003 Pass - - Pass,>72 - - Pass - - Pass
2004 Paas
Forest City-Rlverstonc Ind Park WWTP Acute P/F Lim: 90% Fathead
NC0087084/001 Begin:I/I/2004 Frequency Q P/F + Mar Jun Sep Dec + NonComp Single
County: Rutherford Region: ARO Subbasin: BRD02
PF: 0.1 Special
7Q10: 195 IWC(%;0.08
2000 -
2001 -
2002 -
2003 -
2004 -
- N - - N - - H - - H
Fort Bragg WWTP/001 chr lim: 26% 2000 Pass - - Pass - - Pass - - Pass
NC0003964/001 Begin:8/1/2001 Frequency Q Jan Apr Jul Oct + NonComp Single 2001 Pass - - NR - Pass Pass - - Pass
County:Cumberland Region: FRO Subbasin: CPFI4 2002 Pass - - Pass - - Pass - - Pass
PF: 8.0 Special 2003 Pass - - Pass - - Pass - - Pass
7Q10: 35.8 IWC(%;26 2004 Pass
Fortron Industries/001 chr lim: 0.9% 2000 - Pass - - Pass - - Pass - - Pass
NC0082295/00I Begin8/1/1997 Frequency Q P/F + Feb May Aug Nov + NonCompSingk 2001 - Pass - - Pass - - Pass - - Pass
County:New Hanover Region: WIRO Subbasin: CPFI7 2002 - Pass - - Pass - - Pass - - Pass
PF: 0.245 Special 2003 - Pass - - Pass - - Pass - - Pass
7010: 910 IWC(%; 1.16 2004 -
Franklin Co. WASA chr lim: 49% (1.0 MGD), 74 % (3.0 MGD) 2000 Pass - - NR/Pass - - Pass - - Pass
NC00693I1/001 Begin:l/l/2001 FrequencyQ Jan Apr Jul Oct + NonComp Single 2001 Pass - - Pass - - Pass - - Pass
County:Franklin Region: RRO Subbasin: TAROt 2002 Pass - - Fall 34.6 62.6 Fail 62.6 62.6 62.6
PF: 1.0 Special 2003 pass,>100 - - Pass - - Pass - - Pass
7Q10: 1.6 IWC(%;49 2004 Pass
9 Pre 2000 Data Available
LEGEND:
PERM = Permit Requirement LET = Administrative Letter - Target Frequency = Monitoring frequency: Q- Quarterly; M- Monthly; BM- Bimonthly; SA- Semiannually; A- Annually; OWD- Only when discharging; D- Discontinued monitoring requirement
Begin = First month required 7Q10 = Receiving stream low now criterion (efs += quarterly monitoring increases to monthly upon failure or N Months that testing must occur - ex. Jan, Apr, Jul, Oct NonComp = Current Compliance Requirement
PF = Permitted Bow (MGD) [WC% = Instream waste concentrati P/F = Pass/Fail test AC = Acute CHR = Chronic
Data Notation: f - Fathead Minnow; • - Ceriodaphnia sp.; my - Mysid shrimp; ChV - Chronic value; P - Mortality of stated percentage at highest concentration; at - Performed by DWQ Aquatic Tox Unit; bt - Bad test
Reporting Notation: -- = Data not required; NR - Not reporte Facility Activity Status: I - Inactive, N • Newly Issued(To construct); H - Active but not discharging; t-More data available for month in question; • = ORC signature needed
20

TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
Attention: Charles Weaver
DATE: August 13, 2001
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY Mitchell
PERMIT NUMBER NC0000353
PART I - GENERAL INFORMATION
1. Facility and Address: The Feldspar Corporation
Post Office Box 99
530 Altapass Road
Spruce Pine, North Carolina 28777
2. Date of Investigation: June 5, 2001
3. Report Prepared By:
Michael R. Parker
Environmental Chemist
rT,
4. Persons Contacted and Telephone Number: Thomas Freeman, Manager
Environmental Services
828/765-8955
5. Directions to Site: From the intersection of U.S. Highway 19E and
NCSR 1121 in Spruce Pine, N.C., travel east on NCSR 1121
approximately 0.4 mile. The Feldspar Corporation is located on
the right side of the highway and the wastewater treatment
facility is located behind the manufacturing plant near the river.
The offices are located on the left side of NCSR 1121.
6. Discharge Point(s), List for all discharge points:
Latitude: 001 35° 54' 16" Longitude: 82° 03' 47"
002 35° 54' 17" 82° 03' 40"
003 35° 54' 17" 82° 03' 42"
Attach a USGS map extract and indicate treatment facility site and
discharge points on map.
U.S.G.S. Quad No. DlONE U.S.G.S. Quad Name Spruce Pine, N.C.
7. Size (land available for expansion and upgrading): % acre
8. Topography (relationship to flood plain included): The wastewater
treatment facility is located approximately 40 feet above the
river and is not subject to flooding.
9. Location of nearest dwelling: Greater than 500 feet.

`
10. Receiving stream or affected surface waters: North Toe River
a. Classification: C-trout
b. River Basin and Subbasin No.: 030406
c. Describe receiving stream features and pertinent downstream
uses: fishing, wading, fish and wildlife propagation,
canoeing, industrial water supply, irrigation.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. Type of wastewater: % Domestic
100 % Industrial
a. Volume of Wastewater: 3.5 MGD (Design Capacity)
b. Types and quantities of industrial wastewater: Wastewater is
from the processing of ore to produce feldspar, mica, quartz
and sand.
c. Prevalent toxic constituents in wastewater: Chloride,
Fluoride.
d. Pretreatment Program (POTWs only): NA
2. Production rates (industrial discharges only) in pounds per day:
a. Highest month in the past 12 months: tons/day
b. Highest year in the past 5 years: lbs/day
3. Description of industrial process (for industries only) and
applicable CFR Part and Subpart: The crushing of raw ore and
sending it through the various flotation processes for product
separation. In accordance with 40 CFR Part 436 Subpart I -Mica and
Sericite Subcategory has been reserved and Subpart AI -Feldspar
Subcategory has also been reserved. No effluent guidelines have
been published.
4. Type of treatment (specify whether proposed or existing): 001-The
existing wastewater treatment process consist of a 3.5 MGD
inorganic solids wastewater treatment system with lime feed
systems for pH adjustment, polymer feed systems, vacuum filters,
three clarifiers, Emico clarifier/thickner and associated piping
and ancillary equipment, pump station emergency generator, flow
measuring and totalizing equipment and two recycle pumps.
Discharges 002 & 003 are non -contact cooling water.
5. Sludge handling and disposal scheme: Sludge from the wastewater
treatment facility is landfilled on properties around Mitchell
County, with approval of the Division of Land Resources, Land
Quality Section.
6. Treatment plant classification (attach completed rating sheet):
Class II Physical/Chemical.

7. SIC Codes (s) : 3295
Wastewater Code (s) :
Primary 41 Secondary 14
Main Treatment Unit Code: 51002
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant funds
(municipals only)?
2. Special monitoring requests: Monitoring should be left as in the
existing NPDES Permit.
3. Additional effluent limits requests:
4. Other:
PART IV - EVALUATION AND RECOMMENDATIONS
It is recommended that the permit be permit be issued with the
existing limits and monitoring requirements.
The Feldspar Corporation has requested renewal of NPDES Permit
Number No. NC0000353 for the continued discharge of industrial
process wastewater from the production of feldspar, mica and sand
at their plant at Spruce Pine, North Carolina.
There are no effluent guidelines for this industry and the
effluent limitations were developed using production and process
information and the North Carolina Water Quality Standard of 1.8
mg/l. There are four other companies, K-T Feldspar Corporation,
Unimin Corporation -Quartz, Unimin Corporation -Crystal and Unimin
Corporation -Schoolhouse Quartz Operation which have similar
industrial processes and wastewater characteristics. Each company
discharges or proposes to discharge fluorides to the North Toe
River. It has been determined that there is a maximum
assimilative capacity of 574 lbs/day of fluoride in the North Toe
River at the mouth of Little Bear Creek. All five permits are
interdependent on each other because the total assimilative
capacity of the fluoride is allocated between the five industries
and all permits should be issued at the same time.
The discharges from 002 and 003 is non contact cooling water.
At the time of the staff report an new clarifier/thickner is being
installed at the wastewater treatment facility. Two new vacuum
filters are also being installed to replace the existing units.
Also, at the main wastewater lift station a second pump and
emergency generator is being installed. There have been no
changes in the wastewater characteristics or discharge since the
permit was last issued.
There have been several exceedances for fluoride and pH over the
past three years. The new wastewater treatment units should help
with these permit violations. Notices of violation were sent for
these minor violations.
At this writing The Feldspar Corporation has not submitted the APA
data but will submit the data when analyses is complete.

It is recommended that the permit be permit be issued with the
existing limits and monitoring requirements. Also, stormwater
monitoring should be included in the permit.
Signature of Report
110 (.4
1 „
reparer
Water Quality Regional Supervisor
Date

TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
Attention: Charles Weaver
DATE: August 9, 2001
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY Mitchell
PERMIT NUMBER NC0000353
PART I - GENERAL INFORMATION
1. Facility and Address: The Feldspar Corporation,
----
Post Office Box 99
530 Altapass Road
Spruce Pine, North Carolina,�
2. Date of Investigation: June 5, 2001
3. Report Prepared By:
Michael R. Parker
Environmental Chemist
28777
N
O
4. Persons Contacted and Telephone Number: Thomas Freeman -;-Manager
Environmental Services
828/765-8955
5. Directions to Site: From the intersection of U.S. Highway 19E and
NCSR 1121 in Spruce Pine, N.C., travel east on NCSR 1121
approximately 0.4 mile. The Feldspar Corporation is located on
the right side of the highway and the wastewater treatment
facility is located behind the manufacturing plant near the river.
The offices are located on the left side of NCSR 1121.
6. Discharge Point(s), List for all discharge points:
Latitude: 001 35° 54' 16" Longitude: 82° 03' 47"
002 35° 54' 17" 82° 03' 40"
003 35° 54' 17" 82° 03' 42"
Attach a USGS map extract and indicate treatment facility site and
discharge points on map.
U.S.G.S. Quad No. D10NE U.S.G.S. Quad Name Spruce Pine, N.C.
7. Size (land available for expansion and upgrading): % acre
8. Topography (relationship to flood plain included): The wastewater
treatment facility is located approximately 40 feet above the
river and is not subject to flooding.
9. Location of nearest dwelling: Greater than 500 feet.

10. Receiving stream or affected surface waters: North Toe River
a. Classification: C-trout
b. River Basin and Subbasin No.: 030406
c. Describe receiving stream features and pertinent downstream
uses: fishing, wading, fish and wildlife propagation,
canoeing, industrial water supply, irrigation.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. Type of wastewater: % Domestic
100 % Industrial
a. Volume of Wastewater: 3.5 MGD (Design Capacity)
b. Types and quantities of industrial wastewater: Wastewater is
from the processing of ore to produce feldspar, mica, quartz
and sand.
c. Prevalent toxic constituents in wastewater: Chloride,
Fluoride.
d. Pretreatment Program (POTWs only): NA
2. Production rates (industrial discharges only) in pounds per day:
a. Highest month in the past 12 months: tons/day
b. Highest year in the past 5 years: lbs/day
3. Description of industrial process (for industries only) and
applicable CFR Part and Subpart: The crushing of raw ore and
sending it through the various flotation processes for product
separation. In accordance with 40 CFR Part 436 Subpart I -Mica and
Sericite Subcategory has been reserved and Subpart AI -Feldspar
Subcategory has also been reserved. No effluent guidelines have
been published.
4. Type of treatment (specify whether proposed or existing): 001-The
existing wastewater treatment process consist of a 3.5 MGD
inorganic solids wastewater treatment system with lime feed
systems for pH adjustment, polymer feed systems, vacuum filters,
three clarifiers, Emico clarifier/thickner and associated piping
and ancillary equipment, pump station emergency generator, flow
measuring and totalizing equipment and two recycle pumps.
Discharges 002 & 003 are non -contact cooling water.
5. Sludge handling and disposal scheme: Sludge from the wastewater
treatment facility is landfilled on properties around Mitchell
County, with approval of the Division of Land Resources, Land
Quality Section.
6. Treatment plant classification (attach completed rating sheet):
Class II Physical/Chemical.

7. SIC Codes (s) : 3295
Wastewater Code(s): Primary 41 Secondary 14
Main Treatment Unit Code: 51002
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant funds
(municipals only)?
2. Special monitoring requests: Monitoring should be left as in the
existing NPDES Permit.
3. Additional effluent limits requests:
4. Other:
PART IV - EVALUATION AND RECOMMENDATIONS
It is recommended that the permit be permit be issued with the
existing limits and monitoring requirements.
The Feldspar Corporation has requested renewal of NPDES Permit
Number No. NC0000353 for the continued discharge of industrial
process wastewater from the production of feldspar, mica and sand
at their plant at Spruce Pine, North Carolina.
There are no effluent guidelines for this industry and the
effluent limitations were developed using production and process
information and the North Carolina Water Quality Standard of 1.8
mg/l. There are four other companies, K-T Feldspar Corporation,
Unimin Corporation -Quartz, Unimin Corporation -Crystal and Unimin
Corporation -Schoolhouse Quartz Operation which have similar
industrial processes and wastewater characteristics. Each company
discharges or proposes to discharge fluorides to the North Toe
River. It has been determined that there is a maximum
assimilative capacity of 574 lbs/day of fluoride in the North Toe
River at the mouth of Little Bear Creek. All five permits are
interdependent on each other because the total assimilative
capacity of the fluoride is allocated between the five industries
and all permits should be issued at the same time.
The discharges from 002 and 003 is non contact cooling water.
At the time of the staff report an new clarifier/thickner is being
installed at the wastewater treatment facility. Two new vacuum
filters are also being installed to replace the existing units.
Also, at the main wastewater lift station a second pump and
emergency generator is being installed. There have been no
changes in the wastewater characteristics or discharge since the
permit was last issued.
There have been several exceedances for fluoride and pH over the
past three years. The new wastewater treatment units should help
with these permit violations. Notices of violation were sent for
these minor violations.
At this writing The Feldspar Corporation has not submitted the APA
data but will submit the data when analyses is complete.

It is recommended that the permit be permit be issued with the
existing limits and monitoring requirements.
Signature of Report P parer
ater Quality Regional/Supervisor
Date U

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
North
€t-
E
Printed from USGS Map
Spruce Pine - Quad
Copyright (C) 1997. MQptadi. Inc.

THE /ds
RA T/ON ap
CORPO
A subsidiary of
Corporation
N.C. Division of Water Quality
NPDES Compliance Group
1617 Mail Service Center
Raleigh, NC 27699-1617
Post Office Box 99, Spruce Pine, NC 28777
[phone] FAX: [phone]
July 18,2001
Subject Permittee Name Change
The Feldspar Corporation
NPDES Permit No. NC0000353
Spruce Pine, Mitchell County
To Whom It May Concern,
This correspondence is to inform your office of a change in management at Spruce Pine
operations of The Feldspar Corporation.
Effective July15, 2001 Mr. Barry Brogdon bacame the new Plant Manager at the Spruce
Pine operations. The Spruce Pine operations include the processing facility and Altapass
Mine on Altapass Road, the Chalk Mt. Mine located on highway 19E and the Sullins -
Wiseman Mine located on Sullins Branch Road.
Mr. Brogdon will be the designated permittee on all permits and will have the authority to
sign for permits and other forms of State issued requests, etc. Mr. Brogdon replaces
Davis Marek and R.William Ellis in this position.
If you have further questions please contact either Mr. Brogdon or myself at 828-765-
5500.
Sincerely,
The Feld . ar Co ration
om.: Tom) Freeman
Manager — Environmental Services
CC: CVK, BB, RWE, & Files
Land Quality, Air Quality, Water Quality
�,l'�i 'G `LuUI

THE /dS ar"
CORPORA
A subsidiary of =d Corporation
Ms. Valery Stephens
NC DENR / Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Post Office Box 99, Spruce Pine, NC 28777
[phone] FAX: [phone]
July 3, 2001
Subject: NPDES Permit renewal
The Feldspar Corporation
Spruce Pine, Mitchell County
NPDES # NC0000353
Dear Ms. Stephens,
Please find attached the permit renewal request for the Company listed above. With this
letter and attached forms The Feldspar Corporation requests that NPDES permit #
NC0000353 be renewed.
The renewal package is complete to the best of my knowledge but with the ATC and the
facility upgrade in progress it was difficult to know what to send, without sending too
much.
Please list me as your contact due to the resignation of the Plant Manager who signed this
and will be leaving within the month. Feel free to contact me concerning any questions
or request for additional information you may have. I can be reached at 828-765-5500
during normal business hours.
Sincerely,
The Feldspar Corporation
Thomas (om) Freeman
'Manager of Environmental Services
CC: RWE, CVK & Files

Reference: The Feldspar Corporation, Spruce Pine, NC
NPDES No. NC0000353
Supplemental Documentation
Present Operating Status:
The Feldspar Corporations, Wastewater Treatment Facility operates at or
below capacity and is at present in compliance with the requirements of the
NPDES Permit.
The present system has been built over the last 40+ years as the plant has
expanded in size and production of finish products. The 35'diameter, 8'
deep clarifier (57,726 gal. capacity) and a disk filter was placed into service
in the early sixties and a 40' diameter, 10' deep clarifier (94,247 gal.
capacity) and another disk filter was placed in service in 1972. A 55'
clarifier, 12' deep (213,824 gal. Capacity) was placed into service in 1986
along with two 18,000-gallon equalization tanks.
Potential Facility Changes:
The plant is now undergoing an upgrade that includes like for like
replacement of the disk filters, electrical and a new building. Attached is a
letter to Mike Parker of the Asheville regional office.
The Feldspar Corporation applied March for Authorization to Construct
(ATC) a new Eimco, Clarifier and Thickener (E-CAT) and a stand-by pump
and generator for a tailings tank located near the North Toe River. The ATC
was approved on June 29, 2001 and the equipment has been ordered to allow
construction before cold weather and years end.
Schematic of wastewater flow:
Please see attached flow drawing.
Location Map:
Please see attached USGS print-outs.
Production Data:
Applicable production date as required by 40 CFR does not apply to this
facility.
Priority Pollutant Analysis:
PPA results will be forwarded when completed.

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
Ur
Post Office Box 99, Spruce Pine, NC 28777
A subsidiary of G' Corporation [phone] FAX: [phone]
April 3, 2001
Mr. Mike Parker
NCDENR, Division of Water Quality
59 Woodfin Place
Asheville, NC 28801
Subject: Wastewater Plant up -grade
The Feldspar Corporation
Spruce Pine, Mitchell County
NPDES Permit No. NC 0000353
Dear Mr. Parker,
This letter is a follow-up to our conversations over the last several months about the need
to replace the building and certain equipment at the wastewater treatment plant here at
The Feldspar Corporation's, Spruce Pine, NC location.
We are currently awaiting approval of an authorization for expenditures (AFE) that will
allow funding for this facility up -grade. The big items include the addition of a stand-by
pump and generator for the tailings tank located at the river bridge and the addition of an
Eimco E-CAT clarifier and thickener. An authorization to construct (ATC) covering
these items has already been sent to the Raleigh Water Quality office for approval. The
AFE will also cover other improvements such as an upgrade of the electrical system and
replacement of certain equipment items. The electrical system at the wastewater plant
was installed in sections from the 1960's until the present. New motor control centers
will be installed to replace the existing electrical system.

The Feldspar Corporation
.Spruce Pine, NC
Mitchell County
NPDES # NC0000353
The Doff Oliver and Denver disk filters are worn and will be replaced with Eimco disk
filters. The Eimco filters will also allow us to stock spare parts for one filter rather than
two. Placement of the new Eimco filters will be configured to allow plant operations to
continue during installation. Conveying systems and other items associated with the disk
filters will be added and modified, as necessary, to allow for continued plant operations
during equipment placement.
Due to age, the buildings of the wastewater treatment plant will be replaced with a steel
frame and sheet metal structure requiring temporary removal of the plant operators'
office and lab. The lab will be split into two parts: one will be located in the temporary
plant operators' office in the parking area of plant number two and the other will be
located in the research lab near the main office. Grab samples will be analyzed and
stored at the lab located in the temporary operators' office. Composite samples will be
analyzed and stored in the temporary lab located in the research lab. The new office and
lab will house a state of the art operating system that will allow the plant to be operated
from a PC using electronic instrumentation and information.
We are excited about our facility upgrade and the added treatment capacities it will
provide. This modification of our wastewater facility should provide adequate treatment
capabilities for years to come. Please contact me if you have any questions or require
additional information. I can be reached at 828-765-5500.
Sincerely,
The Feldspar Corporation
/
Thomas ( om) Freeman
Manager of Environmental Services
CC: CVK, RWE, RAC, Files

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353 ;par
..L/II/%j/l 1•IILIJ
Post Office Box 99, Spruce Pine, NC 28777
A subsidiary of am Corporation [phone] FAX: [phone]
N.C. Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Authorization to Construct
The Feldspar Corporation
Spruce Pine, Mitchell County
NPDES Permit No. NC 0000353
Dear Sirs,
The Feldspar Corporation, by this correspondence, requests approval of the.attached
Authorization to Construct (ATC). The authorization to construct will allow The
Feldspar Corporation to upgrade the Spruce. Pine. processing.plants wastewater treatment
facilities.
The ATC requests the addition of major components. (1). Aduel pumping system with
stand-by generator; (2) The addition of a Clarifier / Thickener. (Eimco E-CAT) for
improved clarification and solids handling capacity.
Pump System with Stand-by Generator
Wastewater (tailings) from Plant No. 1 flows by gravity to a.tank.(commonly known as
the tailings tank) located near the North Toe River. The wastewater is then pumped from
this collection tank to the wastewater treatment plant_. Afailure of the existing

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
tt1 %. s Wequext tester
pumping system (mechanical, electrical.,..etc._). has_the...potential._to release wastewater to
the North Toe River. This system was built in 1960 as part of a solids collection system
to prevent the plant effluent from being_straightpiped_.to. the. stream.
To provide a working system that represents the best available control technology will
requires the addition of a second pump with..the_ability. to. supply alternate. electrical
power to the pumping system. Electrical power failures are the most likely contributor to
a potential spill. Plant No. 1 has the potential_togenerate 1800 gallons of wastewater per
minute and, because the system is gravity fed, drainage from the plant can continue after
the pump has stopped. Sensors will automatically. activate.the.stand-by generator in the
event of a power failure or if the wastewater level rises in the tank for any reason.
Alarms will alert the plant operator if.the..stand by. generator_ is. activated_. The alarm will
also be indicated on a PC located in the wastewater treatment plant operations room.
Plant operators will be able to open and close_valves,..start.and. stop pump. motors, and test
the generator from the operations room.
The duel pump set-up is to provide redundancy to assure_ adequate pumpingcapacities of
the flows expected from Plant No. I under all circumstances, as well as facilitate pump
maintenance.
Addition of Clarifier / Thickener
The original wastewater plant was. constnucted_in.the.19.60's. and subsequently. expanded
with evolving permit requirements, laws, regulations, and production demands. This
worked very well until an upgrade o£.our.No_Lplant_provided.a sharp increase.in
production tonnages and use of feedstock. Two years ago our engineering group began
looking into how we could effectively increase._the...capacity of our wastewater treatment
facility. Due to the location of our plants, Altapass Road and the North Toe River, the
first obstacle to overcome was the placement...o£.the...additional clarifier.

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
ATC Request Letter
After researching the location of the new. equipmentr.we. were. faced with finding a
wastewater treatment unit that would fit in a very small footprint. We found through
research that Eimco (a division of Baker .Hughes)..had..b.ought.the rights to a South
African patented treatment system that combines thickening and clarification. This unit
is known as the Eimco — Clarifier and Thickener (E.-.CAT).. Eighty-two units are now
operating in six countries with excellent results. The E-CAT has the benefits of a high
rate thickener with a footprint 10% the. size. o.£a_conventionaLclarifier, making. it the
perfect fit for our needs.
In the spring of 1998 Eimco and The Feldspar..Corp.oration.performed a series of pilot
plant test at The Feldspar Corporation's Spruce Pine Facility. This was the first study
performed in the United States and Gerrit. du. Plessis, Eimco's.E-CAT expert was flown
in from South Africa to conduct the test. After operating the pilot plant for eight days,
the desired results were achieved. In. the.Fall. of.2.000,..L was. able to observe the potential
of the E-CAT during a visit to Val D'or, Canada, where Agnico-Eagle, a gold mining and
refining facility has 6 E-CATs in use. They. needed_si ..12.0'diameter conventional
clarifiers to treat the waste streams and chose the six E-CATs for their footprint. We
talked with other facilities that have E-CAT.s. and_they all. stated that the E-CAT is
working above and beyond their expectations. Based on the good pilot plant results here
and the favorable experience of those who. have recently employed this technology we
are now ready to place a 10-meter E-CAT into operation at the Spruce Pine facility.
Construction activities to be covered..by_ the ATC. as. pertains_to the placing. of the E-CAT
are as follows:
Construction of the E-CAT
Construction of the associated collection and distribution boxes
Construction of the associated pumping and piping
Connecting and interfacing with existing system
Electrical service, distribution and instrumentation

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
ATC Request Letter
Please find attached the information and.related_materials..necessary for your approval of
our request for Authorization to Construct. This modification of our facility should
provide adequate treatment capabilities for. years..ta Come_. We await you approval to
proceed.
Sincerely,
The Feldsp . Corporatio
Manager of Environmental Services
Randy A. Carpenter, PE
Consulting Engineer
CC: CVK, RAC, Files

The Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
CONSTRUCTION SEQUENCE PLAN
Both the placement of a second pump and the construction of the Eimco E-CAT clarifier
are add-ons to the present system and are not expected cause any interruptions in
operations.
The collection tank near the river will be upgraded by adding a back-up pump and a
stand-by generator as follows:
• Apply to Water Quality section for Authorization to Construct and receive
approval.
• The pump house will be enlarged to accommodate the secondary pump by
pouring a concrete floor in the expansion area. The wood frame building will
them be expanded.
• The new 8X8 ASH (Allen Sherman Hoff) slurry pump (pump no. 2), supplied
with a 100 HP motor will be installed.
• Pump no. 2 supply line from the tank will be added along with the automated
valve and plumbed to the new pump.
• The discharge of pump no.2 will be plumbed into the existing piping leading to
the wastewater plant and supplied with an automated valve.
• The original pump (pump no. 1) will be fitted with automated valves and new
lines and readied for service.
• Final electrical hook-up to the new automated switches, valves, and stand by
generator will complete this part of the project.
The construction of the building will be done as weather permits and the equipment and
electrical hook-ups will be made on repair days. We have historically shut all operations
down on Mondays (or Tuesdays) of each week for repairs that cannot be made while the
plant is in operation. This allows for repairs and installation of major equipment and
electrical components such as the ones discussed above.

Thy Feldspar Corporation
Spruce Pine, NC
Mitchell County
NPDES # NC0000353
The construction of the Eimco E-CAT will be scheduled as follows:
• Apply to Water Quality section for Authorization to Construct and receive
approval.
• Order E-Cat from Eimco and issue purchase.
• Prepare area for E-CAT concrete footer, foundation and associated splitter box
support, and pour concrete.
• Construct connecting stairway for E-CAT and splitter box and begin (dry)
plumbing.
• Construction of E-CAT by Eimco construction crew.
• Installation of electrical components and instrumentation.
• Final plumbing tie-ins to splitter box, underflow pumps, and disk filters.
• The 40' and 35' clarifiers will be left to operate as they do now until the E-CAT is
fully operational as a standalone unit.

The,Feldspar Corporation
S4ruce Pine, NC
Mitchell County
NPDES # NC0000353
Wastewater Flow with E-Cat installed
Non Fluoride Wastewater flows
PI nt#1 1600gpm
n
Plintff2 900gpm
Plont#3 g000pm
FP Waoh 100gpm
loogpi 1- - - -FP Recycle Washwater- -►
Plantttl
n
i0
•iVy
Sam Box
•
40' clarifier
10' deep
A1500gpm 4
4 Plantit2
Influent
Effluent
Undertlow
Recycle
Existing Pipin
New Piping
Pipe Size
Legend
n
E-CAT
10 meter
4X3
Denver
c)
Fluoride Wastewater flows
1oosPen -A
Pkxtt#1 A ; ►
Plont#2 �9pm /" \
► Fluoride _ wide
PlantA3 wpm � 4 t
/�_ ;' Treabsient . Treatment
.� ' - .
Crystal 200gpm A ..
vv�
4rn
Spillway
(}
11111111
Disk Fitter
()
Hauled to landfill
n
12\
V
•
Sputter Box
88
Galigher
55' clarifier
17 deep
Hauled to landfill
A • ► Effluent to receiving stream
1
-* 200gpm Pl, nt 1 ►
Recycle
35' clarifier
8' deep

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Feldspar Corporation
Spruce Pine, NC
Mitchell County
z NPDES # NC0000353
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