NC0000353_Permit (Issuance)_19961216

NPDES DOCUHIENT SCANNIN`: COVER SHEET
NPDES Permit:
NC0000353
The Feldspar Corporation
Document Type:
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:
December 16, 1996
This document is printed on reuse paper - ignore any
comer t on the re' rersse !side

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
December 16,1996
Mr. David Marek
The Feldspar Corporation
P.O. Box 99
Spruce Pine, North Carolina 28777
11 "A
C)EHNFi
Subject: NPDES Permit Issuance
Permit No. NC0000353
The Feldspar Corporation
Mitchell County
Dear Mr. Marek:
In accordance with the application for a discharge permit received on July 2, 1996, the Division is
forwarding herewith the subject NPDES 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 US
Environmental Protection Agency dated December 6,1983.
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, Post Office Drawer
27447, Raleigh, North Carolina 27611-7447. Unless such demand is made, this decision shall be final and
binding.
Please take notice this permit is not transferable. Part II, E.4. addresses the requirements to be followed
in case of change in ownership or control of this discharge.
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 permit that may be required.
If you have any questions concerning this permit, please contact Paul Clark at telephone number (919) 733-
5083, extension 580.
Sincerely,
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E.
cc: Central Files
Asheville Regional Office
Mr. Roosevelt Childress, EPA
Permits and Engineering Unit
Facility Assessment Unit
Aquatic Survey & Toxicology Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled / 10% post -consumer paper

Permit No. NC0000353
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
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 Broad River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts I,
II, III, and IV hereof.
The permit shall become effective February 1, 1997
This permit and the authorization to discharge shall expire at midnight on December 31, 2001
Signed this day December 16, 1996
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

SUPPLEMENT TO PERMIT COVER SHEET
The Feldspar Corporation
is hereby authorized to:
Permit No. NC0000353
1. Continue to operate a 3.5 MGD wastewater treatment facility (outfall 001) consisting of a
treatment process with lime and acid feed systems for pH adjustment, polymer feed systems,
cyclone separator, vacuum filters, three clarifiers, flow measuring and totalizing equipment
and recycle pumps and continue to discharge non -contact cooling water from outfalls 002
and 003 located at the Feldspar Corporation, NCSR 1121, in Spruce Pine, Mitchell County
(See Part III of this permit), and
2. Discharge wastewater from said treatment works 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.

•
•
N
•
•
•
•
i. r.Ffsc
•
,��
IIlam'-' \ ~L� \
I.....) /.
%
001 Latitude 35°54'16" 002 Latitude 35°54'17" 003 Latitude 34°54'17"
Longitude R2°03'47" Longitude R2°03'40"
ROAD CLASSIFICATION
PRIMARY HIGHWAY
HARD SURFACE
LIGHT -DUTY ROAD, HARD OR
IMPROVED SURFACE
SECONDARY HIGHWAY
HARD SURFACE =MCI UNIMPROVED ROAD
Map # D1ONE
Stream Class
Discharge Class
Receiving Stream
Sub -basin 040306
C-Trout
North Toe River
Design Q 3.5 MOD Permit expires 12/31/01
Longitude 82°03'42"
as l`
SCALE 1:24 000
0 1 MILE
0 7000 FEET
1 0 1 KILOMETER
CONTOUR INTERVAL 40 FEET
The Feldspar Corporation
NC0000353
Mitchell County

A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0000353
During the period beginning on the effective date of the permit and lasting until Unirnim Corporation - Crystal Operation (NC0084620) initiates direct discharge, ,
the Permittee is authorized to discharge from outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location1
Flow
3.5 MGD
Continuous
Recording
I or E
Total Suspended Residue
1568 lbs/day
3137 lbs/day
Daily
Composite
E
Total Fluoride
225 lbs/day
448 lbs/day
Daily
Composite
E, U, D
Settleable Solids
Daily
Grab
E
Turbidity 2
Daily
Grab
E, U, D
pH 3
Daily
Grab
E, U, D
Chloride ^
Quarterly
Composite
E
Chronic Toxicity 5
Quarterly
Composite
E
Notes:
Sample locations: E - Effluent, I - Influent, U - Upstream at Altapass Road highway bridge, D - Downstream at footbridge in Spruce Pine. Instream samples
shall be grab samples and shall be conducted 3/week.
2 The discharge shall not cause the turbidity of the receiving water to exceed 10 NTU. If the turbidity exceeds these levels due to natural background
conditions, the discharge level cannot cause any increase in the turbidity of the receiving water.
3 The pH shall not be less than 6.0 standard units nor greater than 10.0 standard units.
° Chloride shall be monitored quarterly during the same months as toxicity testing.
5 Chronic Toxicity (Ceriodaphnia) P/F at 11 %; January, April, July, and October; See Part III Condition E.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0000353
During the period beginning when Unimim Corporation - Crystal Operation (NC0084620) initiates direct discharge and lasting until expiration, the Permittee is
authorized to discharge from outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location1
Flow
3.5 MGD
Continuous
Recording
I or E
Total Suspended Residue
1568 lbs/day
3137 lbs/day
Daily
Composite
E
Total Fluoride
174 lbs/day
348 lbs/day
Daily
Composite
E, U, D
Settleable Solids
Daily
Grab
E
Turbidity 2
Daily
Grab
E, U, D
pH 3
Daily
Grab
E, U, D
Chloride 4
Quarterly
Composite
E
Chronic Toxicity 5
Quarterly
Composite
E
Notes:
Sample locations: E - Effluent, I - Influent, U - Upstream at Altapass Road highway bridge, D - Downstream at footbrige in Spruce Pine. lnstream samples
shall be grab samples and shall be conducted 3/week.
2 The discharge shall not cause the turbidity of the receiving water to exceed 10 NTU. If the turbidity exceeds these levels due to natural background
conditions, the discharge level cannot cause any increase in the 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) P/F at 11 %; January, April, July, and October; See Part III Condition E.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0000353
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 serial number 002. Such discharges shall be limited and monitored by the Permittee as specified below:
(Fine Grind and Plant Number 1)
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location1
Flow
Monthly
Recording
I or E
Temperature
Monthly
Grab
E
Total Residual Chlorine 3
Monthly
Grab
E, U, D
Notes:
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL
COMPOUNDS.
' Sample locations: E - Effluent, I - Influent, U - Upstream, D - Downstream.
2 The temperature of the effluent shall not to cause an increase in the temperature of the receiving stream of more than 0.5°C and in no case cause the
ambient water temperature to exceed 20.0°C.
3 Monitoring requirements only apply if chlorine is added to the non -contact cooling water.
The permittee shall obtain authorization for the Division of Water Quality prior to utilizing any biocide in the non -contact cooling water (See Part III Condition F of
this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 units and shall be monitored monthly at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0000353
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 serial number 003. Such discharges shall be limited and monitored by the Permittee as specified below:
(Fine Grind and Plant Number 1)
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location'
Flow
Monthly
Recording
I or E
Temperature
`
z
Monthly
Grab
E
Total Residual Chlorine 3
Monthly
Grab
E, U, D
Notes:
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL
COMPOUNDS.
' Sample locations: E - Effluent, I - Influent, U - Upstream, D - Downstream.
2 The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 0.5°C and in no case
cause the ambient water temperature to exceed 20.0°C.0-c
3 Monitoring requirements only apply if chlorine is added to the non -contact cooling water.
The permittee shall obtain authorization for the Division of Water Quality prior to utilizing any biocide in the non -contact cooling water (See Part III Condition F of
this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 units and shall be monitored monthly at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Part III Permit No. NC0000353
E. CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The permittee is required to perform the toxicity test as specified below.
The effluent discharge shall at no time exhibit chronic toxicity using test procedures
outlined in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure,"
Revised November 1995, or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction
or significant mortality is 11% (defined as treatment two in the procedure document). The
permit holder shall perform quarterly monitoring using this procedure to establish
compliance with the permit condition. The tests will be performed during the months of
January, April, July, and October. Effluent sampling for this testing shall be performed at
the NPDES permitted final effluent discharge below all treatment processes.
All toxicity testing results required as part of this permit condition will be entered on the
Effluent Discharge Monitoring Form (MR-1) for the month in which it was performed,
using the parameter code TGP3B. Additionally, DWQ Form AT-1 (original) is to be sent to
the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Water Quality
4401 Reedy Creek Road
Raleigh, North Carolina 27607
Test data shall be complete and accurate and include all supporting chemical/physical
measurements performed in association with the toxicity tests, as well as all dose/response
data. Total residual chlorine of the effluent toxicity sample must be measured and reported
if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity
monitoring is required, the permittee will complete the information located at the top of the
aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number,
county, and the month/year of the report with the notation of "No Flow" in the comment
area of the form. The report shall be submitted to the Environmental Sciences Branch at the
address cited above.
Should any single quarterly monitoring indicate a failure to meet specified limits, then
monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing, this monthly test requirement will revert to quarterly in the months specified
above.
Should the permittee fail to monitor during a month in which toxicity monitoring is
required, then monthly monitoring will begin immediately until such time that a single test
is passed. Upon passing, this monthly test requirement will revert to quarterly in the
months specified above.
Should any test data from this monitoring requirement or tests performed by the North
Carolina Division of Water 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.
F. In the event that violations of the turbidity standard of the North Carolina Water Quality
Standards occur as a result of this discharge, this permit shall be modified, or alternately,
revoked and reissued to incorporate limitations sufficient to protect the receiving waters.
G. 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.
H. 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.
I. This permit shall be modified, or revoked and reissued to incorporate new limitations in
the event that production changes are requested by any of the existing fluoride using
industries or should any new fluoride using discharge request to locate on the North Toe
River.

D[VTSIQN OF WA thiR QUALITY
October 14,1996
Plemonausiurn
To: Forest Westill
Mike Parker
Prom: Susan A. Wi lso
Paul Claric(e,
Subject: MiininS Pi iuities oil the North Tbc River
Please review the enclosed • Ilement, effluent sheets, and conditions (minus any
storinwater language, if app .le) regarding the renewal of mining/processing
f hitter loud on the North Toe River in the French Broad River Basin. The following
summarizes the P&E's review of these facilities:
• Nachanges are proposed to the fluoride loadings at each facility [ref. SW'I's Ietia
6f2l /951, The P&Bitinit would lice to be involved in the future re -allocation
development of fluoride at these facilities.
• PM recommends effluent monitoring frequencies ('T'P, TSS) of weekly for fall lies
<1 MG); daily for facilities > I MGD [most facilities reflect this frequency).
• P&B tends that imstream monitoring be weekly for facilities <I MOD; Vweelc
for facilities > 1 MGI). This should provide the Division ample data, to view daring
the next permit cycle. [Sorts: facilities currently have daily is tream monitoring).
• As.recommeaded by your dace, chloride monitoring has been implemented quarterly
(during the an months as toxicity. testing).
• Efaue nt setdeable solids, pH, and turbidity monitoring have been continued on a daily
frequency.
/0//1//1
Regi
7Permfts Engineering:
Date: 0 - ( - ! (,
!/74

MINING FACILITIES ON THE NORTH TOE RIVER
Permit Limits and Monitoring Requirements
Facility
NPDES No,
PF
Unimin Schoolhouse Qtz.
NC0000361
Feldspar
NC0000353
Mon. avg. Dail. max. Freq.
Unimin Crystal
NC0084620
Mon. avg. Dail. max. Freq.
K-T Feldspar
NC00004O0
Mon. avg. Dail. max. Freq.
(MGD)
TF (#/day)
2.16
109
218
daily
3.5
174
348
daily
0.173
50 100 weekly
1.73
132 264 weekly
TF (mg/1)
TSS (11/day)
TSS
6.1
450
12.1
721
daily
6
1568
12
3137
daily
35
86.6
70
173.2 weekly
9. I
1240
18.2
2480
weekly
(mg/l)
SS
pH (SU)
Turh(NTU)
Tox
"
25
40
monitor
6-10
10
P/F 10%
daily
daily
daily
Qtrly
54
108
monitor
6-10
10
P/F 1 1 %
daily
daily
daily
Qtrly
60
120
monitor daily
6-10 daily
10 daily
LC50>65%Qtrly
86
172
monitor
6- I 0
10
P/F 6%
dail
daily
daily
Qtrly
TF,Turb
(daily)
TF,Turb,
pH
(daily)
TF (wkly)
Turb,
pH (daily)
TF,Turb,
pH
(daily--
3/week)
Facility
NPDES No
PF (MGD)
TF (#/day)
TF (mg/1)
TSS (#/day)
TSS (mg/1)
SS
pH (SU)
'1'url)(N'1'U)
Tox
U,D
Unimin Qtz
NC0000175
Mon. avg. Dail. max. Fre
3.6
218 436 daily
7.3 14.5
1320 2640 daily
44 88
monitor daily
6-10 daily
10 daily
P/F 1 1 % Qtrly
d
TF,Turb
pH
(daily --
3/week)
Unimin Qtz (processing - new)
NC0085839
Mon. avg. Dail max. Freq.
0.682
200 4(X) weekl
35 70
142 284 week)
25 50
monitor daily
6-10 daily
10 weekly
P/F 1.15% Qtrl
TF,Turb
(weekly)
y
y
THIS 1S THE CURRENT MONITORING AND LIMIT SCHEME FOR THE MINING FACILITIES AS OF 10/96.
October 16, 1996

MINING FACILITIES, NORTH TOE RIVER
NOTES TO FILE
NC0084620 (Unimin Crystal). Located at River Mile 33.8, this facility
currently discharges to the Feldspar plant (NC0000353). UNIMIN requested
an increase in flow from 0.173 MGD to 0.36 MGD for incidental wastewater
associated with the process. The facility is to begin discharging directly via this
permit in the near future. The increase in flow increased the IWC, and
consequently, the toxicity testing percentage.
IWC based on 7Q10s = 41 cfs and 0.36 MGD permitted flow. (IWC = 1.3%)
This is classified as a 'MINOR' permit.
There has been no direct discharge from this outfall, therefore no instream data
have been taken.
[See memo to ARO 10/ 14/ 96 ]
/44.4
October 15, 1996

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P,E., Director
Asheville Regional Office
MEMORANDUM
TO:
THROUGH:
FROM:
SUBJECT:
the
ATA
DEHNR
WATER QUALITY SECTION
August 15, 1996
Dave Goodrich
Permits and Engineeri
Forrest R. Westa
Regional Water Qu
Mike Parker !'' 7
Environmental Chemist
g Unit
Supervisor
Staff Reports
Feldspar Mining Company's
Avery and Mitchell County's
I have completed the staff reports
following facilities:
The Feldspar Corporation
K-T Feldspar Corporation
Unimin Corporation -Schoolhouse
Unimin Corporation -Crystal
Unimin Corporation -Quartz
and recommendations
NPDES
NPDES
NPDES
NPDES
NPDES
Permit
Permit
Permit
Permit
Permit
No.
No.
No.
No.
No.
for
NC0000353
NC0000400
NC0000361
NC0084620
NC0000175
It is requested that all of these permits be sent co public
notice and issued al: the same time with the same expiration
dates. As you know all of these permit are interdependent on
each other because of the fluoride allocation in the North Toe
River. The total allocation of fluoride (574 lbs/day) is
allocated between these companies.
Also, please refer to the attached letter dated June 21,
1995, to Representative Charles Buchanan from Steve Tedder,
advising that the fluoride allocation will not be reduced when
the permits are reissued.
Interchange Building, 59 Woodfin Place
Asheville, North Carolina 28801
Voice 704-251-6208
N7.*?C
Reduce Reuse Recycle
FAX [phone]
An Equal Opportunity/Affirmative Action Employer
50% recycles/ 10% post -consumer paper

wR'
Dave Goodrich Memo
August 15, 1996
Page Two
Additionally, chlorides have been noted in the results of
the Annual Pollutant Analysis data provided by these companies.
It may need to be added to the permits as a new parameter. If it
is decided to be added it is recommended that monitoring onlybe
conducted until we have adequate data to determine it limits are
necessary.
If you have questions or would like to discuss the staff
reports, please call me at 704-251-6208.

SOC PRIORITY PROJECT: Yes No X
IF YES, SOC NUMBER
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Susan Wilson
DATE: August 14, 1996
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY Mitchell
PERMIT NUMBER NC0084620
PART I - GENERAL INFORMATION
1. Facility and Address:
2. Date of Investigation:
Unimin Corporation -Crystal
Post Office Box 588
Spruce Pine, North Carolina 28777
January 27, 1995
3. Report Prepared By: Michael R. Parker
4. Persons Contacted and Telephone Number: Roy Riddle
'' 704/765-4383
5. Directions to Site:From the intersection of North Carolina
Highway 226 and North Carolina Secondary Road 1117, travel
east on NCSR 1117 approximately 0.55 mile. Turn north onto
private gravel road to Unimin Crystal Plant.
6. Discharge Point(s), List for all discharge points:
Latitude: 35°54'16"
Longitude: 82°03'46"
Attach a USGS map extract and indicate treatment facility site and
discharge point on map.
U.S.G.S. Quad No.D10NE U.S.G.S. Quad Name Spruce Pine, N. C.
7. Site size and expansion area consistent with application?
X Yes No If No, explain:
8. Topography (relationship to flood plain included):
Facility will not be subject to flooding.
Page 1

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.: FBR 06
c. Describe receiving stream features and pertinent downstream
uses: fishing, wading, canoeing, fish and wildlife
propagation, agricultural, industrial water supply.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted 0.360 MGD (Ultimate
Design Capacity)
b. What is the current permitted capacity of the Wastewater
Treatment facility? 0.173 MGD
c. Actual treatment capacity of the current facility (current
design capacity. 0.720 MGD
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two years:
January 9, 1995
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: The existing
wastewater treatment facilities consist of an equalization
tank, lime feed system, chemical additions, sludge thickener,
drum filter with vacuum system, sludge conveyer, pH
monitoring equipment, flow recorder and totalizer, (4) fiber
glass tanks for neutralization and effluent flow
equalization, pumps, piping and appurtenacnes. Pumps and
piping to The Feldspar Corporation will be left in place in
case there is a malfunction at Unimin Corporation's
wastewater treatment facility.
f. Please provide a description of proposed wastewater treatment
facilities: NA
g-
Possible toxic impacts to surface waters: None anticipated.
h. Pretreatment Program (POTWs only):
in development approved
should be required not needed
2. Residuals handling and utilization/disposal scheme:
a. If residuals are being land applied, please specify DEM
Permit Number
Residuals Contractor
Telephone Number
b. Residuals stabilization: PSRP PFRP
OTHER
Page 2

C. Landfill: Residuals removed from this facility will be taken
to Unimin's Quartz Operations landfill.
d. Other disposal/utilization scheme (Specify): Sludge removed
from this facility will be taken to the landfill at Unimin
Corporation's Quartz Operations.
3. Treatment plant classification (attach completed rating sheet):
Class II.
4. SIC Codes(s) :1499
Primary 41 Secondary
Main Treatment Unit Code: 51602
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds
or are any public monies involved. (municipals only)?
2. Special monitoring or limitations (including toxicity). requests:
3. Important SOC, JOC, or Compliance Schedule dates: (Please
indicate)
Submission of Plans and Specifications
Begin Construction
Complete Construction
Date
4. Alternative Analysis Evaluation: Has the facility evaluated all
of the non -discharge options available. Please provide regional
perspective for each option evaluated.
Spray Irrigation: Not feasible due to area required.
Connection to Regional Sewer System: Mining wastewater is not
acceptable.
Subsurface: No enough area.
Other disposal options:
5. Other Special Items:
Page 3

•
ti
PART IV - EVALUATION AND RECOMMENDATIONS-
Unimin Corporation has made application for renewal of NPDES
Permit No. NO0084620. The company is asking that the flow be
increased from 0.173 MGD to 0.360 MGD with no increase in the
pollutant loading. The effluent limits for fluoride and TSS are
to remain the same as the existing permit. The company indicates
that their normal flow has increased to this amount and the sketch
attached to the application indicates that the wastewater
treatment capacity is 500 GPM or 0.750 MGD.
The APA indicates that chlorides are high in the effluent,
measured at 760 mg/1, we may want to include this parameter in the
permit; possibly monitoring only at weekly intervals.
There are no effluent guidelines for this industry and the
effluent limits were developed using production and process
information and the North Carolina Water Quality Standard for
fluoride of 1.8 mg/l. It has been determined there is a maximum
assimilative capacity of 574 lbs/day of fluoride in the North Toe
River at the mouth of Little Bear Creek. The 574 lbs/day of
fluoride are divided between four other dischargers, Unimin
Corporation -Schoolhouse Quartz Operation, K-T Feldspar
Corporation, The Feldspar Corporation and Unimin Corporation -
Quartz Operation, all of which have similar industrial processes
and wastewater characteristics. Each company discharges or
proppses to discharge fluorides to the North Toe River. All of
the permits for these companies are interdependent on each other
because of the total assimilative capacity of the fluoride is
allocated between these five industries and all of the permits
should be issued at the same time.
It is recommended that the permit be issued.
v
efs
Si ature of Report P eparer
Water/
Regional Supervisor
///
f6
Dame
Page 4

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
June 21, 1995
Representative Charles Buchanan
Route 1, Box 273
Green Mountain, North Carolina 28740
Re: Fluoride
Dear Representative Buchanan:
�1 HNR
This correspondence is to clarify our position and hopefully to address concerns expressed by several
feldspar and quartz processing operations near Spruce Pine concerning fluoride limitations within their
NPDES permits.
The Water Quality Section of the Division of Environmental Management has worked closely with the
mining facilities on the fluoride allocation issue for several years. In 1985 we worked with the mining
operations to allocate the available assimilative capacity of the North Toe River in consultation with the
mining interests in that area.
The industries have expressed concerns that we may modify the allocations upon permit renewal in
1996. Although an error in mass calculations has been noted, I can assure you that there will not be a
reduction in allowable pounds allocated to these facilities for fluoride upon permit re -issuance. We will
continue to monitor the situation as the allocation for fluoride has been exhausted in the North Toe River
near Spruce Pine.
I have relayed this information previously to Unimin Corporation and to Charles Case and Lucius
Pullen.
If there are additional questions, please do not hesitate to call.
SWT: ps
cc: Forrest Westall
Don Safrit
Steve W. Tedder, Chief
r-Nater Quality Section
,
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

DIVISION OF WATER QUALITY
October 14, 1996
Memorandum
To:
Forrest Westall
Mike Parker
From: Susan A. Wilson
Paul Clark
Subject: Mining Facilities on the North Toe River
Please review the enclosed effluent sheets regarding the renewal of the mining/processing
facilities located on the North Toe River in the French Broad River Basin. The following
summarizes the P&E's review of these facilities:
• No changes are proposed to the fluoride loadings at each facility [ref. SWT's letter
6/21/95]. The P&E Unit would like to be involved in the future re -allocation
development of fluoride at these facilities.
• P&E recommends effluent monitoring frequencies (TF, TSS) of weekly for facilities
<1 MGD; daily for facilities > 1 MGD [most facilities reflect this frequency].
• P&E recommends that instream monitoring be weekly for facilities <1 MGD; 3/week
for facilities > 1 MGD. This should provide the Division ample data to review during
the next permit cycle. [Some facilities currently have daily instream monitoring].
• As recommended by your office, chloride monitoring has been implemented quarterly
(during the same months as toxicity testing).
• Effluent settleable solids, pH, and turbidity monitoring has been continued on a daily
frequency.
Reviewed by
Regional Supervisor: Date:
Permits & Engineering: Date:

MINING FACILITIES, NORTH TOE RIVER
FACILITIES:
NC0000361 (Schoolhouse Quartz). Located at River Mile 41.5, this is
the first mine discharge of the five within close proximity. This facility was
recently permitted to construct a tertiary treatment system to meet a fluoride limit
of 109 lbs/day. The UNIMIN facility NC0000175 traded 109 Ibs/day fluoride
load to the Schoolhouse facility. which subsequently reduced its existing load
of 219 lbs/day to 109 lbs/day.
Stormwater is covered under GP NCG020112.
NC0000353 (The Feldspar Corporation). Located at River Mile 33.8,
this facility has phased effluent limits. After Unimin Crystal begins to
discharge directly to North Toe River, Feldspar's total fluoride monthly average
limit will decrease from 225 to 174 lbs/day. As noted in Mike Parker's
staff report (7/18/96), the facility has never discharged from
outfalls 002 and 003 (both of which are non -contact cooling water
discharges). Please investigate the possibility of terminating one
or both of these outfalls since it appears the facility is not
discharging from these outfalls.
Stormwater is covered under general permits: NCG020256 and NCG020257.
NC0084620 (Unimin Crystal). Located at River Mile 33.8, this facility
currently discharges to the Feldspar plant (NC0000353). UNIMIN requested
an increase in flow from 0.173 MGD to 0.36 MGD for incidental wastewater
associated with the process. The facility is to begin discharging directly via this
permit in the near future. The increase in flow increased the IWC, and
consequently, the toxicity testing percentage.
NC0000400 (K-T Feldspar Corporation). Located at River Mile 29.2,
this facility does not have a non -contact cooling water discharge. The
Biocide Condition will be omitted from this permit, unless the
region provides a reason for retaining this condition. Review of
instream monitoring data for the period January 1993 through July 1996
indicated six violations of the fluoride water quality standard at the downstream
station. Feldspar facility (NC0000353) did not have any violations over the
same time period.
Stormwater is covered under general permits: NCG020273 and NCG020274.
NC0000175 (Unimin Quartz). Located at River Mile 28.6, this facility is
the last mine of the five in close proximity. This facility was recently permitted
to construct a tertiary treatment system to meet a fluoride limit of 109 lbs/day
[see note under NC0000361].
Stormwater is covered under the NPDES permit.

Sludge (Solids) Management Plan
The Feldspar Corporations Wastewater Plant thickens and dewaters all solids (99.9% using
standard efficiency calculations) from the mineral processing plants. The solids are thickened in 3
clarifiers and then pumped to a disk filter for dewatering. The dewatered solids are then conveyed
out to stockpiles to be hauled to disposal areas or to be sold as raw materials for the ceramics
industry. The solids are referred to in the mining industry as tailings and are actually a feldspatic
sand ( feldspar, quartz, mica, garnet and clay) We are presently seeking more customers for this
product but the lack of natural gas in our area limits us to markets that require shipping cost which
effects the market value of the product.
All landfill areas over I acre in size are regulated under the Land Quality Section and have a Soil
and Erosion Control Plan filled and approved before any fill is placed. These fill sites are
constructed to prevent the materials from leaving the site via runoff flows and are inspected after
each runoff producing rainfall and no less than once per week.
Sites less than 1 acre in size are regulated by the company with mandatory controls and
preventative measures in place before any material is landfilled. All property owners who have
solids placed on their property must sign an agreement with the company specifying
responsibilities.
Once the solids are placed and proper grades are established topsoil is placed and the areas are
seeded and stabilized. Because of the excellent compaction of these solids over 40% of the
Iandfills constructed in the last 10 years have been used for commercial purposes.

r-4 0 A A A s'� J`—� u a i•i a1TYa •,
October 7, 1996
The Feldspar Corporation has applied for renewal of their NPDES permit to discharge 3.5
MGD treated industrial wastewater.
The WWTP consists of treatment process with lime and acid feed systems for pH
adjustment, polymer feed systems, cyclone separator, vacuum filters, three clarifiers, flow
measuring and totalizing equipment and recycle pumps.
Air compressors are permitted to discharge non -contact cooling water from outfalls 002 and
003. There has been no discharge from either of these outfalls over the past several years.
A proposed upgrade at the facility would include improvements which would allow
discharge from these two outfalls to begin.
Wastewater from Plant #1 is stripped of solids which are stored for resue. Process water is
recycled in both plants for re -use. Fluoride and non -fluoride wastew waters are separated
for maximum fluoride removal. pH adjustment is used for maximum fluoride removal and
neutralization. Coagulation is made possbile using flocculant plymer aided by lime
addition. solids are thickened in claridiers and pumped to a vacuum filter for dewatering.
Waste tailings are sold as raw materials to anotehr compay with the remainder land filled.
There are no effluent guidelines for this industry and the effluent limits were developed
using production and process information and the NC Water Quality Standard for fluoride
of 1.8 mg/1. There are four other companies, The Feldspar Corporation, Unimin
Corporation -Mica Operations, Unimin Corporation -Quartz Operations, and Unimin
Corporation -Crystal which have similar industrial processes and wastewater characteristics.
Each coi Lij)any 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, which is the most downstream point
fluoride is discharged. All five permits are interdependent on each other because the total
assimilative capacity for the fluoride is allocated between the five industries and all permits
should be issued at the same time.
WLA Summary
The attached summary documents the effluent limits and monitoring requirements'
development for the five mining facilities that discharge into the North Toe River. This
summary specifically addresses process wastewater limits and monitoring requirements
development.
The facility conducts a quarterly chronic pass/fail toxicity test with a 11% limit and has
consistently passed their toxicity tests since July 1994.
Feldspar has two general stormwater permits NCG020256 and NCG020257. Thus, the
stormwater discharge does not have to be incorporated into the process wastewater
discharge permit (as has been done with one of the Unimin facilities).

saaanosaa Ira'' i uaua Ada I
`luauauOJIAu3 l
2U OJeO UPON eielS
cc,M"-"rl,i�NCE EVALUATION ANALYSIS REPoar
PAGE
PERMIT--NC0000353 PIPE--001 REPORT PERIOD: 9506-9605 LOC---E
FACILITY --FELDSPAR CORP. / SPRUCE PINE DESIGN FLOW-- 3.5000 CLASS--3
LOCATION --SPRUCE PINE REGION/COUNTY--01 MITCHELL
50050 00530 TGP3B 00076 00400 00545 00951
MONTH Q/MGD RES/TSS CERI7DPF TURBIDTY PH RES/SET FLUORIDE
LIMIT F 3.5000 F 1568.0 NOL NOL 10.0 6.0 NOL F224.000
95/06 2.7720 1285.0 16.60 9.5-6.2 .0 203.057
95/07 2.6683 1109.2 1 13.77 8.5-6.0 .0 237.782F
95/08 2.6100 1160.6 14.90 9.8-6.3 .0 207.485
95/09 2.6293 1091.4 11.40 9.0-3.3F .0 225.217F
95/10 2.5193 1135.9 1 15.67 7.4-6.2 .0 176.635
95/11 2.6440 1129.0 11.73 7.2-6.3 0 203.643
95/12 2.7467 1040.7 11.45 7.3-6.4 .0 172.203
96/01 2.5548 1159.6 1 16.70 7.6-6.4 .0 191.674
96/02 2.9248 1390.1 20.24 8.2-6.5 .0 222.253
96/03 2.7167 1237.2 19.12 7.4-6.6 .0 202.287
96/04 2.9553 1338.8 1 14.93 7.6-6.7 .0 220.589
AVERAGE 2.7037 1188.8 1 15.13 .0 205.711
MAXIMUM 3.5600 2126.7 1 70.00 9.810 1.5 1571.923
MINIMUM 1.1500 71.7 1 4.00 3.390 .000
UNIT MGD LBS/DAY PASS/FAI NTU SU ML/L LBS/DAY

ANC t::VA LUATION ANALYSIS REPORT
07/03/96
PAGE 1
PERMIT--NC0000353 PIPE--001 REPORT PERIOD: 9406-9505 LOC---E
FACILITY --FELDSPAR CORP. / SPRUCE PINE DESIGN FLOW-- 3.5000 CLASS--3
LOCATION --SPRUCE PINE REGION/COUNTY--01 MITCHELL
50050 00530 TGP3B 00076 00400 00545 00951
MONTH Q/MGD RES/TSS CERI7DPF TURBIDTY PH RES/SET FLUORIDE
LIMIT F 3.5000 F 1568.0 NOL NOL 10.0 6.0 NOL F224.000
94/06 2.8278 1241.8 16.50 7.5-6.0 .0 198.122
94/07 2.5683 1165.4 1 13.45 9.7-6.3 .0 176.297
94/08 3.0651 1382.8 16.48 8.7-5.9F .0 208..588
94/09 3.2126 1402.7 17.76 7.0-5.8F .0 223.494
94/10 3.0145 1241.9 1 17.41 7.4-6.0 .0 199.416
94/11 3.0880 1340.0 19.33 8.8-6.2 .0 216.724
94/12 2.4664 1082.7 12.55 7.2-6.2 .0 171.222
95/01 2.4045 1073.2 15.32 7.7-6.4 .0 168.626
95/02 2.7371 1312.7 18.39 7.7-6.4 .0 201.269
95/03 2.7480 1256.4 17.96 8.2-6.3 .0 8.400
95/04 2.7026 1191.2 1 10.50 8.3-6.6 .0 185.100
95/05 2.8238 1216.2 11.45 8.0-6.4 .0 198.113
AVERAGE 2.8048 1242.2 1 15.59 .0 179.614
MAXIMUM 3.9700 2909.3 1 75.00 9.700 .5 334.601
MINIMUM .0200 .6 1 .10 5.850 .016
UNIT MGD LBS/DAY PASS/FAI NTU SU ML/L LBS/DAY

!� A (2-1S 1-LL;L:['
NC0000353
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
APPLICATION FOR
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
PERMIT TO DISCHARGE TREATED WASTEWATER
Application No. NC0000353 Date: 10/16/96
1. SYNOPSIS OF APPLICATION
Applicant's Name
The Feldspar Corporation
Applicant's Address
1040 Crown Point Parkway - Suite 270
Atlanta, GA 30338
Facility Address
P.O. Box 99
530 Altapass Road
Spruce Pine, NC 28777
Type of Operation
Process includes milling, processing, and flotation of ore to produce feldspar, mica, and
quartz. Mica and sand are by-products of the feldspar flotation process.
Design Capacity of Facility
3.5 MGD
Applicant's Receiving Water
Receiving Stream: North Toe River
Classification: C-Tr
Sub -Basin: 04-03-06
See Attachment A for a map showing the discharge location(s).
Page 1

1=t�L-1��l-iLl_ l
NC0000353
Description of Wastewater Treatment Facilities
A 3.5 MGD wastewater treatment facility (outfall 001) consisting of a treatment process
with lime and acid feed systems for pH adjustment, polymer feed systems, cyclone
separator, vacuum filters, three clarifiers, flow measuring and totalizing equipment and
recycle pumps. There is also discharge of non -contact cooling water from outfalls 002 and
003.
Type of Wastewater (as reported by applicant).
100 % Industrial
2. PROPOSED EFFLUENT LIMITATIONS
See attached copy of Effluent Page(s) from Draft Permit.
3. MONITORING REQUIREMENTS
The applicant will be required to monitor regularly for flow and those parameters
limited in Section 2 above with sufficient frequency to ensure compliance with the
permit conditions. Frequency, methods of sampling, and report dates will be
specified in the final permit.
4. EFFECTIVE DATE OF PROPOSED EFFLUENT LIMITS
(AND COMPLIANCE SCHEDULE IF APPLICABLE)
The limits become effective on the date of permit issuance.
5. PROPOSED SPECIAL CONDITIONS WHICH WILL HAVE A SIGNIFICANT
IMPACT ON THE DISCHARGE
Chronic Toxicity
Fluoride Re -opener
Page 2

1=ACf�Pl1iL:"1'
N C00003 5 3
6. BASIS FOR PROPOSED EFFLUENT LIMITS
There are no federal guidelines for processing of ore for quartz and feldspar. The
fluoride limit is based on allocated load to the five mining facilities which produce
quartz (in close proximity). The total load from all plants is based on protection of
an instream fluoride level of 1.8 mg/l. Total suspended solids is based on
treatability levels from the WWTP and BPJ. North Carolina has no water quality
standard for total suspended solids.
Chloride is a by-product from the precipitation process and has been recommended
for quarterly monitoring (there is no NC water quality standard for chloride, but
there is an action level).
The toxicity testing requirement is placed on all major facilities and other facilities
with complex wastestreams (Departmental memo 7/22/87). The toxicity limit is
based on the instream waste concentration under 7Q10 conditions.
The pH limit was based on the water quality standards contained in NCAC 2B
.0211.
Turbidity and settleable solids monitoring are included due to the potential for solids
from the ore processing and the wastewater treatment process to be in the effluent.
7. REQUESTED VARIANCES OR ALTERNATIVES TO REQUIRED
STANDARDS
None
8. DISCUSSION OF PREVIOUS NPDES PERMIT CONDITIONS
The previous effluent sheet/limits are attached. No major changes have been made
to the permit.
The NPDES Permit expires on: 12/31/2001
Page 3

1'AC I'S1-i1LL-r
NC0000353
9 . THE ADMINISTRATIVE RECORD
The administrative record, including application, draft permit. fact sheet, public
notice, comments received, and additional information is available by writing the
Division of Water Quality, Water Quality Section, P. O. Box 29535,
Raleigh, North Carolina 27626-0535. The above documents are available for
review and copying at the Archdale Building, 9th Floor, Water Quality Section,
Permits and Engineering Unit, 512 North Salisbury Street, Raleigh, North Carolina
27611 between the hours of 8:00 a.m. and 5:00 p.m. Monday through Friday.
Copies will be provided at a charge of 10 cents per page.
10. STATE CONTACT
Additional information concerning the permit application may be obtained at the
above address during the hours stated in item No. 9 by contacting: Paul Clark at
[phone], extension 580.
11. PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice - 10/23/96
Permit Scheduled to Issue - 12/9/96
12. PROCEDURES FOR THE FORMULATION OF FINAL DETERMINATIONS
a. Comment Period
The Division of Water Quality proposed to issue an NPDES Permit to this applicant
subject to the effluent limitations and special conditions outlined above. These
determinations are tentative and are open to comment from the public.
Interested persons are invited to submit written comments on the permit application
or on the Division of Water Quality's proposed determinations to the
following address:
DIVISION OF WATER QUALITY
WATER QUALITY SECTION
POST OFFICE BOX 29535
RALEIGH, NORTH CAROLINA 27626-0535
Page 4

NC0000353
All comments received within thirty days following the date of public notice will be
considered in the formulation of final determinations with regard to this application.
b. Public Hearing
The director of the Division of Water Quality may hold a public hearing if there is a
significant degree of public interest in a proposed permit or group of permits.
Public notice of such a hearing will be circulated in newspapers in the geographical
area of the discharge and to those on the Division of Water Quality's mailing list at
least thirty days prior to the hearing.
c. Appeal Hearings
An applicant whose permit is denied, or is granted subject to conditions he deems
unacceptable, shall have the right to a hearing before the Commission upon making
written demand to the Director within 30 days following issuance or denial of the
permit.
d. Issuance of the permit when no hearing is held
If no public hearing or appeal hearing is held, and after review of the comments
received, the Division of Water Quality's determinations are substantially
unchanged, the permit will be issued and become effective immediately. This will
be the final action of the Division of Water Quality.
If a hearing is not held, but there have been substantial changes, public notice of the
Division of Water Quality's revised determinations will be made. Following a 30-
day comment period, the permit will be issued and will become effective
immediately. This will be the final action of the Division of Water Quality unless a
public or appeal hearing is granted.
Page 5

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Asheville Regional Office
MEMORANDUM
TO:
THROUGH:
FROM:
SUBJECT:
ATA
EDEEHMF
WATER QUALITY SECTION
August 15, 1996
Dave Goodrich
Permits and Engineeri
Forrest R. Westa
Regional Water Qu
Mike Parker !''
Environmental Chemist
g Unit
27 Supervisor
Staff Reports
Feldspar Mining Company's
Avery and Mitchell County's
I have completed the staff reports and
the following facilities:
The Feldspar Corporation
K-T Feldspar Corporation
Unimin Corporation -Schoolhouse
Unimin Corporation -Crystal
Unimin Corporation -Quartz
NPDES
NPDES
NPDES
NPDES
NPDES
recommendations for
Permit
Permit
Permit
Permit
Permit
No.
No.
No.
No.
No.
NC0000353
NCO000400
NC0000361
NC0084620
NC_0000175
It is requested that all of these permits be sent to public
notice and issued at the same time with the same expiration
dates. As you know all of these permit are interdependent on
each other because of the fluoride allocation in the North Toe
River. The total allocation of fluoride (574 lbs/day) is
allocated between these companies.
Also, please refer to the attached letter dated June 21,
1995, to Representative Charles Buchanan from Steve Tedder,
advising that the fluoride allocation will not be reduced when
the permits are reissued.
Interchange Building, 59 Woodfin Place
Asheville, North Carolina 28801
Voice 704-251-6208
Reduce Reuse Raeycta
FAX [phone]
An Equal Opportunity/Affirmative. Action Employer
50% recycles/10% post -consumer paper

Dave Goodrich Memo
August 15, 1996
Page Two
Additionally, chlorides have been noted in the results of
the Annual Pollutant Analysis data provided by these com anies.
It may need to be added to the permits as a new parameter. If it
is decided to be added it is recommended that monitoring onlybe
conducted until we have adequate data to determine it limits are
necessary.
If you have questions or would like to discuss the staff
reports, please call me at 704-251-6208.

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
June 21, 1995
Representative Charles Buchanan
Route 1, Box 273
Green Mountain, North Carolina 28740
Re: Fluoride
Dear Representative Buchanan:
.4 I I
DI HNI�
This correspondence is to clarify our position and hopefully to address concerns expressed by several
feldspar and quartz processing operations near Spruce Pine concerning fluoride limitations within their
NPDES permits.
The Water Quality Section of the Division of Environmental Management has worked closely with the
mining facilities on the fluoride allocation issue for several years. In 1985 we worked with the mining
operations to allocate the available assimilative capacity of the North Toe River in consultation with the
mining interests in that area.
„, The industries have expressed concerns that we may modify the allocations upon permit renewal in
1996. Although an error in mass calculations has been noted, I can assure you that there will not be a
reduction in allowable pounds allocated to these facilities for fluoride upon permit re -issuance. We will
continue to monitor the situation as the allocation for fluoride has been exhausted in the North Toe River
near Spruce Pine.
I have relayed this information previously to Unimin Corporation and to Charles Case and Lucius
Pullen.
If there are additional questions, please do not hesitate to call.
SWT: ps
cc: Forrest Wes tall
Don Safrit
Steve W. Tedder, Chief
..--,::Water Quality Section
1.)'
i� \Q ,
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10°/0 post -consumer paper

TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
Attention: Paul Clark
DATE: July 23, 1996
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
Spruce Pine, North Carolina 28777
2. Date of Investigation: July 18, 1996
3. Report Prepared By: Michael R. Parker
4. Persons Contacted and Telephone Number: Thomas Freeman
704/765-8955
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.
6. Discharge Point(s), List for all discharge points:
Latitude: 001 350 54' 16" Longitude: 820 03' 47"
002 35 54 17"82 03' 40"
003 350 54' 17" 820 03' 42"
Attach a USGS map extract and indicate treatment facility site and
discharge points on map.
U.S.G.S. Quad No. D1ONE 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.
Page 1

10. Receiving stream or affected surface waters: North Toe River
a. Classification: C-trout 04 b. River Basin and Subbasin No.: 03 04 OG
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: 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: 900 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 and acid
feed systems for pH adjustment, polymer feed systems, cyclone
separator, vacuum filters, three clarifiers, flow measuring and
totalizing equipment and recycle pumps. 002 & 003 non -contact
cooling water.
5. Sludge handling and disposal scheme: Sludge from the wastewater
treatment facility is landfilled with approval of the Division of
Land Resources, Land Quality Section.
Page 2

1
6. Treatment plant classification (attach completed
Class III. p eted rating sheet):
7. SIC Codes (s) : 3295
Wastewater Code(s): Primary 41
Main Treatment Unit Code: 5Secondary 14
1002
PART III - OTHER PERTINENT INFORMATION
1. Is this facility
(municipals only),being constructed with Construction Grant funds
2. Special monitoring re
existing NPDES Permit.
Monitoring should be left as in the
z'mit.
3. Additional effluent limits requests:
4. Other:
PART IV - EVALUATION AND RECOMMENDATIONS
The Feldspar Corporation has
Number NC0000353orrequested renewal
Nmrwastewater from ththe continued discharge fNindustrialr
processat their production of mica ndsand
plant at Spruce Pine, North Carolinaldspar, and sand
There are no effluent
twere guidelines for this industry
limitations
and the Northreroevelopedeusing production andana the effluent
are fourhothr Cacorolina
Qualityprocess information
K-T FeldsparStandard of 1.8 Unimin There
Corporation -Quartz, Unimin Corporation-Crystal
or Corp
nimin
Corporation -Schoolhouse poration-Cr staltind,
industrial processes characteristics.and wastewz ater havesimilardischarges or proposes to discharge Each River. It has been g fluorides to the North Toe
River.determined that there is a
capacity of of 74 Bear lbs/dayof eek fluoride inmaximum River iatltheve
eachmouth
otherofLittle because the total all five
the North Toe at the
All five permits are interdependentfhoi on
is allocated between the five industrieseandissued at the same time.capacity of the fluoride
all permits should be
The
Feldspar dspar Corporation has never dischar
t003.
gel from discharges 002
There have been no changes in the discharge or
treatment facility since the the It is recommended that the permit was last issuedWastewater
It xiecomg limits and mopermit be issued for
the APA The Feldspar Corporationfive years with
receivedthnshow Acdatade forithe Feldspar We but the not
included as a newdischarge. Chlordema other
recommended. parameter in this permit. Y need to be
Monthly monitoring is
Page 3

Xl‘e°L l'‘%'----
Sigh ature of Report eparer
ater Qu ity Regional Supervisor
Date
Page 4

RATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
Name of Facility:
e,1.4
Owner or Contact Person: 1.
Mailing Address: P D . �o
x 9 ? 5e' - -- Q... /N er !L9777
County: Ai:4-eJ erf J Telephone: 7'54 2GS =- S5`6 6
Present Classification: Z New Facility Existing Facility v'
NPDES Per. No. NC00 040SSU Nondisc. Per. No.WQ Health Dept.Per No.
Rated by: j � � 1 I . J2Ac. lc,-... Telephone: 74 7,t1_47d' Date: 7/2zf 52
Reviewed by: Health Dept. • " Telephone:
-Pniz f r Z.-Wry
ORC:
Check Classification(s): _ Subsurface
Wastewater Classification: (Circle One) I Il
Regional Office Telephone: am.-2.A-ij tc'
Central Office Telephone:
Grade: Telephone:
Spra Irrigation Land Application
IV Total Points: s9
IN -PLANT PROCESSES AND RELATED CONTROL EOUIPMENT WHICH 6RE A VNTEGRAI PART OF INDUSTRIAL PRQDUCTI N SHALL NOT
CONSIDERED WASTE TREATMENT FOR THE PURPOSE OF CLASSIFICATION. ALSO SEPTIC TANK SYSTEMS CONSISTING ONLY OF SEPTIC TANK
AND GRAVITY NITRIFICATION LINES ARE EXEMPT FROM CLLSSiFICATION,
SUBSURFACE CLASSIFICATION
(check all units that apply)
1. septic tanks
2. pump tanks
3.siphon or pump -dosing systems
4. sand filters
5. grease trap/interceptor
6_ oil/water separators
7 gravity subsurface treatment and disposal:
8. pressure subsurface treatment and disposal:
in addition to the above
be rated using the point
rating system and will require an operator with an appropriate
LAND APPLICATiON/RESIDUALS CLASSIFICATION (Applies only to permit holder)
1. Land application of biosolids, residuals or contaminated soils on a designated site.
SPRAY IRRIGATION CLASSIFICATION
(check all units that apply)
1. preliminary treatment (definition no. 32 )
2. lagoons
3. septic tanks
4. pump tanks
5. pumps
6. sand filters
7. grease trap/interceptor
8. oil/water separators
9. disinfection
10. chemical addition for nutrient/algae control
11. spray irrigation of wastewater
classifications, pretreatment of wastewater in excess of these components shall
dual certification.
WASTEWATER TREATMENT FACILITY CLASSIFICATION
The following systems shall be assigned a Class I classification, ynless the flow is of a significant quantity or the technology is unusually
complex, to require consideration by the Commission on a case -by -case basis: (Check if Appropriate)
1 O€/water Separator Systems consisting only of physical separation, pumps and disposal;
2. Septic Tank/Sand Filter Systems consisting only of septic tanks, dosing apparatus, pumps,sand filters, disinfection
and direct discharge;
3. Lagoon Systems consisting only of preliminary treatment, lagoons, pumps, disinfection, necessary chemical treatment for
algae or nutrient control, and direct discharge;
4. Closed -loop Recycle Systems;
5. Groundwater Remediatlon Systems consisting only of on/water separators, pumps, air -stripping, carbon adsorption, disinfection
and disposal;
6. Aquaculture operations with discharge to surface waters;
7Water Plant sludge handling and back -wash water treatment;
8. Seafood processing consisting of screening and disposal.
9. Single-family discharging systems, with the exception of Aerobic Treatment Units, will be classified if permitted after July 1,
1993 or if upon inspection by the Division, it is found that the system is not being adequately operated or maintained. Such
systems will be notified of the classification or reclassification by the Commission, in writing.

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(I) Post Aeration - cascade
(al) Reverse Osmosis
diffused or mechanical 0
2
(n) Sand or Mixed -Media Fitters • low rate 5
(o) Treatment processes for removal of metal or cyanide high rate 2
(P) treatment processes for removal of toxic materials other than metal or cyanide .5
(7) SWDGE TREATMENT
15
(a) Sludge Digestion Tank - Heated (anaerobic) 15
Aerobic 10
Unheated (anaerobic) S
(b) Sludge Stabilization (chemical or thermal) .5
(c) Sludge Drying Beds • Gravity
Vacuum Assisted .5
(d) Sludge Elutriation 5
(e) Sludge Conditioner (chemical or thermal) 5
(i) Sludge Thickener (gravity) .5
(9) Dissolved Air Rotation Unit [not applicable to a unit rated as (3)(i)) .5
(h) Sludge Gas Utilization (including gas storage) 8
(I) Sludge Holding Tank - Aerated .5
Non -aerated 5
()) Sludge incinerator (not including activated carbon regeneration) 2
(k) (8)
Vacuum Filter, Centrifuge, or Filter Press or other similar dewatering devices
...10
(a)
RESIDUALS UTILIZATION/DISPOSAL (including incinerated ash)
Lagoons
(b) Land Application (surface and subsurface) (see definition 22a) 2
by contracting to a land application operator or landfill operator who holds the land application permit
or landfill permit
•
(9) (DISIsFECTICN
c) Dedicated Landfill(buriai) by the permittee of the wastewater treatment facility
(a) Chlorination
(b) Dechlorination 5
(c) Ozone 5
(d) Radiation 5
(10) CHEMICAL ADDITION SYSTEM(S) ( see definition No. 9) (not applicable to chemical additions rated as item 3 .5
List
. (6)(a)• �6)(,(7)(b). (7)(e). (9a). (9)(b) or (9)(c) 5 points each: ()C)).
(11) MISCELLANEOUS UNiTS/PROCESSES
(a) Holding Ponds. Holding Tanks or Settling Ponds for Organic or Toxic Materials including wastes from mining
operations containing nitrogen or phosphorus compounds In amounts significantly greater than is common
for domestic wastewater
(b) Effluent Flow Equalization (not applicable to storage basins which are inherent In land application 4
(c) Stage Discharge (notapplicable to storage basins inherent In landapplication systems....
(d) Pumps
g systems)..».»».»»...»..
(e) Stand -By Power Supply »��
(f) Thermal Pollution Control Device
Class 1
TOTAL POINTS
OSSIFICATION
Class II 5-25 Points
Class if! 26-50 Points
Class IV51.65 Points
66-Up Points
5
3
3
Facilities having a rating of one through four points, inclusive, do not require a certified operator.
Facilities having an activated sludge process will be assigned a minimum classification of Class Ii.
Facilities having treatment processes for the removal of metal or cyanide will be assigned a minimum classification of Class II.
Facilities having treatment processes for the biological removal of phosphorus will be assigned a minimum classification of Class ill.
.0004 DEFINITIONS
The following definitions shall apply throughout this Subchapter.
(1) Activated Carbon Beds. A physical/chemical method for reducing soluble organic material from wastewater effluent; The column -type beds used In this
method will have a flow rate varying from two to eight gallons per minute per
may not be regenerated on the wastewater treatment plant she; P square foot and may be either upflow or downflow carbon beds. Carbon may or
(2) Aerated Lagoons. A basin in which all solids are maintained in suspension and by which biological oxidation or organic matter Is reduced through artifici
ally
ally
accelerated transfer of oxygen on a flow -through basis;
(3) Aeration. A process of bringing about intimate contact between air or high u oxygen in a lI uid b
Aeration. An activated sludge process utilizing a minimum hydraulic detention time of 18 hours. q y spraying, agitation or diffusion;(3a) Extended
(4) Agriculturally managed site. Any site on which a crop is produced, managed, and harvested (Crop includes grasses.
(5) Air Stripping. A process by which the ammonium ion is first convened to dissolved ammonia (pH adjustmet) witthe tartmc a then released to the
atmosphere by physical means; or other similar processes which remove petroleum products such as benzene, toluene, and xylem;
(6) Carbon Regeneration. The regeneration of exhausted carbon by the use of a furnace to provide extremely high temperatures which volatilize and oxidize the
absorbed impurities;
(7) Carbonaceous Stage. A stage of wastewater treatment designed to achieve 'second
(8) Centrifuge, A mechanical device in which centrifugal force is used to separate solids from liquids or to effluent limits;
parate liquids of (9) Chemical Addition Systems- The addition of chemical(s) to wastewater at an application point for purposes of Improving solidf different
removalapH adjustment.
alkalinity control, etc.; the capability to experiment with different chemicals and different
system; the capability to add chemical(s) to dual units will be rated as one system; application points to chemical achieveta specific application will bents for ff one
purposes will result in the systems being rated as separate systems; ' capability to add a at a different points for different
(10) Chemical Sludge Conditioning. The addition of a chemical compound such as lime. tonic chloride, or a
Its application to a dewatering device;polymer to wet sludge to coalesce the mass prior to
(11) Closed Cycle Systems. Use of holding ponds or holding tanks for containment of wastewater containing inorganic. non -toxic materials from sand ravel
crushed stone or other similar operations. Such systems shall carry a maximum of twopoints
(12) Combined Removal of Carbonaceous BOO and Nitrogenous Removal by Nitrification- siregardless
el stage system required red to achieve permit effluent limits on BOD
and ammonia nitrogen within the same biological reactor.any facilities or appurtenances;
(13) Dechlorinatlon. The partial or complete reduction of residual chlorine in a itoutd 1w any nk.....t....i -- _,__._ _.
(14) Denhrtticatten ar" .e..e -rt. - _

♦
se of ion -selective bn•exchange membranes;
(15) F terrA. proceoperated mrocess for echanically for artally dewatering Ionized satts from water sludge;
(16)Flom Press.Pwastewater or wastewater effluent as a means of removing excessive amounts of detergent materials through
1) Foam Separation. The planned frothing of
the introduction air In the Corm of fine bubbles; also chared heavy
vymct fractionation; l matter
f from
west and a lower sludge digestion chamber.
(18) Imhoff Removal.
an.Thep two story
removing grit
tank consisting l mineral after tram cation chamberhter.
(19) Imhoff Tank. Al deep
(20)te of flow;
1Instrumented
ng Flow chemicalment. A device in which which
indicates and
different molecules are exchanged;
(21 ) Ion Exchange in on the surface or by subsurface injection
(22) Land application: disposal method by which wet sludge may be applied to land either by spraying (a) Sludge Disposal. A final sludge lisp
(i.e.. chisel plow); [not applicable for types of sludge described In (11) of this Rule); application of wastewater onto a land area as a
(b) Treated Effluent. The process of spraying treated wastewater onto a land area or other methods of app � polishing method for removing
means of final disposal or treatment; conditions as a po 9
(23) Mlcroscreen. A low speed, continuously back -washed. rotating drum fitter operating under gravity (usuallynitrate);
supended sands from effluent; to oxidized nitrogen .
en ammonia and organic nitrogen)
(24)te
5Nitrification Stage. The biochemical of wastewateronversion ureatment nitrogen (
crate stage of treatment designed for the specific Japrtuo�spro�sosndasisrgiedrtc ammonia
luxury uptake of phosphorus
9
(26) Nitrogenous Stage. A separate
The removal of phosphorus from wastewater by
(26) Phosphate Removal. Bblog' suspended solids;
(27)by Polishing microorganisms; following secondary treatment with sufficient detenton time to allow settling of finely
6r Pond. A holding o pondgravity means flowing down a
� dissolved oxygen is added to the °ffluerd by non e h sic al. graade requires men so of flowing
2B) Post Aerator. Aeration following conventional secondary treatment units to Increase effluent D.O. ortor any other purpose;
sari Post tepstor. iCascadel A polishing method by s or weirs moves in a fairly thin layer and the op
series of steps or welts; The flow occurring across the step to meeting the limits of the discharge permit;
biophysical carbon process that utilizes biological activity and organiceabsorption by using powdered or
(30) adjustment; thus. zero pGranuointsareActivated
Carbon
even though this is an essential step g
granular) Powdered a carbon; Viirrgin or regenerated carbon is feed controlled into the sytem;
activated carbon;
(31j Preaeratlon. A tank constructed to provide aeration prior to primary treatment;
Unit operations in the treatment process. such as screening and comminution. that prepare the liquor for subsequent s major
o sewers operations;
(32) Preliminary Units. U
(33) industrial Pretreatment.pe bytovemin bodyas the wastewater
(a) Pr
e-treatment Unit. tndustrial. The conditioning of a waste at its source PefoCeresdislarrg h , to remove
rod o to neutralize
neu r lize substances In u
treatment processes or to effect a partial reduction in load on the
treatment plant being rated; to receive points on the rating sheet;
b) Pre-treatment Program. industrial - must be agate or EPA required program P use of removing settleable and suspended
(34) Primary Clartfiers. The first settling tanks through which wastewater is passed In a treatment works for the purpose
solids and BOD which is associated with the solids
(35) Pumps. All influent. effluent and in -pant pumps;
, ultraviolet or gamma rays; pre liquid tree from
(36) Radiation. Disinfection or sterilization process utilizing devices emitting
(37)Reverse Osmosis. A treatmerd process In which a heavy contaminated liquid is pressurized through a membrane forming series arty of re liquially tree from circular
3pendad solids; process in which wastewater flows through tanks in why
(38) Rotating Biological Contractors. A fixed biological growth p
surfaces are rotated; process In which further bbdecormposftlon is
(39() Intermittent
Filters:(aslagoons, or some other treatment p blod less than one);
expected to to produce
du a desired
Filtrationeueof effluent fooadl ng rates
t s tanks. lag P ac and have a resulting low gprn/st
on these eraare h(39)(a)of this Rule with the added capability to reftycte effluent back
t probtiol d � �he effluents;
type al sandofitterr as defined In Subp rs graphto
b) Recirculating 9 suspended solids;
through the sand fitter. polishing process by welch effluent limits are achieved through a further reduction of
(40() to or Nllxed•lNey,a Fitters. Apo 9 m►st;
(a) tow rate —gravity. hydraulically loaded filter with loading rates in the one to three gprmist era range; rate. the loading rate will exceed three gp
(b) eco daty --lariiffiers.0 A• tank which of foloadllows the bioler ogical with
unit gof treatment plant and which has the purpo
se of removinggsludges associated with the
(41) Secondary C
tt
biological treatment units;
Sludge Reaeration. A part of the contact stabilization process where the activated sludge is transferred to a tank and aerate beeforetirreatur for
(42) Separate9eng through the tank; shallapplicable to the contact basin;
(43)septic
Septic Tank. A single -story settling tank in which settled itysludgef 2.000 gallons or less which �8 ei r ��en d; into more stable organic matter
(44)ic tank systems serving single Ywhichheorganicaor volatile matter and sludge is gasified. liquefied.
Sludge Digestion. The pro by tanks; a sludgeIs dried by drainage and
through the activity of living organisms. which Includes aerated hotting
(45) Sludge Drying Beds. An area comprising natural or artificial layers of porous materials upon which digested s N0 washin wtth trash water or plant effluent;
evaporation; removed
(46) Sludge Elutrfatlon. A process of sludge conditioning In which certain ��of heating buildings. driving engines. etc.;
(47) Sludge Holding
Utilization. The processaeof using sewage gas for the pure adding a email amount of airsimplyto the
e Holdi Tank (Aerated and Nonaerated). A tank utilized for smalledwastewater treatment
l aa�� �1�� not containing a digester In which sludge maybe
(48) Slung ngtter. A be usedk to
sled efre.. and but not necessarily
verily an n prior tot a drying method (i•e• slung drying
ud a trash. not necessarily an amount that would be requiredto
severe! days
ysi of
1 stabilization
organic
awithomtrt resulting odor problems; sludge to a sterile ash;
sludge and reduce the
decant sludge n prior to dew attiring and would not allow long patio
(49) Sludge Stabilization
A homed designed bAm process and to e ttreateasludgectlesss combustible
putrescblels and to reduce the pathogenic organism
(50) content;
This
Stabzatton (Chemical aid Thermal). ttmeenthlorfne dosing. or by heat treatment;
con) Slu Sludge
may be done type pHj to settle g oxygen to the water from
(51) Stabge Thickener. A typeof of oxidation
lagoonn In which biological oxidation of or organic matter iseffectedby cken gnaturalttranstion re ofofo ge
(52) Stabilization Lagoon. A oxidatbn in
air (not a polishing pond);
(53) Stand -By Power Supply. On site or portable electrical generating equipment;
Static Screens. A stationary screen designed to remove solids. Including non -biodegradable particulate plowable solids, suspended °O lids nd OD
coal litter
rest systems; A settling lagoon reduction) trom municipal
tme tat and stage
of
treawasttment
ingaseco a which is primarily for the purpose of effluent polishing;
(55) Tertiary Treatment. A, stage of treatment following secondary
(56hthe employed thin purpose;
Poled for Control pose; A device providing for the transfer of heat trot a fluid flowing to tubes to another fluid outside the tjlbe tlyof sludge by the
or vice versa;
or Thermal liquid temperatures;
(57) other means of regulating iq
Thermal Sludge Conditioner. A conditioning process by d tact heat oe padicles� a protracted period of time to improvea�n exposure. t<tgestlon. tnhaatlon
clb€ oxic and rials. Thor of the smaller obi more highly by win and u death, osure. • bee Ion. In
(58) Toxic Materials. Those wastes or corrtbinatlons of wastes. trtcluding disease -causing agertts which after discharge p P
or assimilation into any organism, either directly from the environment or indirectly by ingestion through food chains, in al genetic mutations. physiological malfunctions (including malfunctio chromium. mercury, physical
ha ical arse at zinc• such
chitra organisms
ins t their
offzene
abnormalities. cancer. ge by of illustration and not Limitation: load, cadmium.
(ONCB). Toxic materials include. nCBy) and dtchtorodlphenyi trlchtoroethane (DDT); and any other materials that have or may hereafter be deters
have
(ONCB). polychlorinated bl hen !s PCBs,
toxic properties;
Trickling
of a material such as broken stone or rock over which wastewater is distributed; A high rate %ridding
f 59) Trfc ne Filter. oA bed atb treatment 0t unit consisting
filter is one which operated at between 10 and 30 mgd per acre. A low rate trickling filter is one which is designed to operate at one to four mg p
r acre;
ed Tower). A tug flow type of operation in which wastewateows down method may produce h successive layeersrt f media
quality etrato material; or my beams
ma) r at 15 re Filter (Pack I ptug
is removed continually by the active biological fixed growth In each successive layer.ge riot to disposal
adapted to produce a nitrified effluent;
61 Vacuum Filter. Centrifuges. or Fitter Presses. Devices which are designed to remove excess water from either digested or undigested sludge p
or further treatment.

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001 Latitude 35°541R" 002 Latitude 35°54'17" 003 Latitude 34°54'17"
Longitude R2°03'47"
ROAD CLASSIFICATION
PRIMARY HIGHWAY
HARD SURFACE
LIGHT -DUTY ROAD. HARD OR
IMPROVED SURFACE
SECONDARY HIGHWAY
HARD SURFACE Ci UNIMPROVED ROAD
Map # D1ONE Sub -basin 040306
Stream Class C-Trout
Discharge Class 41 14
Receiving Stream North Toe River
Design Q 3.5 MGD Permit expires 12/31/01
Longitude R2°03140" Longitude 82°03'42"
SCALE 1:24 000
1 MILE
7000 FEET
1 KILOMETER
CONTOUR INTERVAL 40 FEET
The Feldspar Corporation
NC0000353
Mitchell County

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
MEMORANDUM
TO:
THROUGH:
FROM:
SUBJECT:
ATMwig,
DEHNR
WATER QUALITY SECTION
February 13, 1995
Dana Bolden
Permits and Engineering
Forrest R. Westall
Regional Water Qua Supervisor
Michael R. Parker 62
Environmental Chemist
NPDES Staff Reports
The Feldspar Corporation
Unimin Corporation -Crystal
Mitchell County
NC0000353
NC0084620
Attached to this memo are NPDES staff reports for the
subject facilities. Unimin Corporation -Crystal Operations
wastewater is currently being treated by The Feldspar Corporation
and is proposing to discharge. Unimin Corporation and The
Feldspar Corporation have entered into an agreement in which The
Feldspar Corporation will give up 50 lbs of fluoride and Unimin
Corporation will assume this 50 lbs and discharge this amount.
There will not be a change in the total amount of fluorides being
discharged to the North Toe River. We have discussed all of
these limits with Unimin Corporation and they are agreeable to
them.
If you have questions or if I can be of assistance, please
call me at 704/251-6208.
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
Attention: Dana Bolden
DATE: February 6, 1995
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
Spruce Pine, North Carolina 28777
2. Date of Investigation: January 27, 1995
3. Report Prepared By: Michael R. Parker
4. Persons Contacted and Telephone Number: Thomas Freeman
704/765-9051
5. Directions to Site: From the intersection of U.S. Highway 19E acid
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.
6. Discharge Point(s), List for all discharge points:
Latitude: 001 350 54' 16" Longitude: 820 0347"�
002 35 54' 17" 82 03'40"
003 350 54' 17" 820 03' 42"
Attach a USGS map extract and indicate treatment facility site and
discharge points on map.
U.S.G.S. Quad No. D1ONE U.S.G.S. Quad Name Spruce Pine, N.C.
7. Size (land available for expansion and upgrading): 1/2 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.
Page 1

10. Receiving stream or affected surface waters: North Toe River
a. Classification: C-trout
b. River Basin and Subbasin No.: 03 04 06
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: 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: 434.63 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 and acid
feed systems for pH adjustment, polymer feed systems, cyclone
separator, vacuum filters, three clarifiers, flow measuring and
totalizing equipment and recycle pumps. 002 & 003 non -contact
cooling water.
5. Sludge handling and disposal scheme: Sludge from the wastewater
treatment facility is landfilled with approval of the Division of
Land Resources, Land Quality Section.
Page 2

6. Treatment plant classification (attach completed rating sheet):
Class III.
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:
3. Additional effluent limits requests:
4. Other:
PART IV - EVALUATION AND RECOMMENDATIONS
The Feldspar Corporation has requested modification of NPDES
Permit Number No. NC0000353. The Feldspar and Unimin Corporation
have entered into an agreement in which The Feldspar Corporation
will give up 50 lbs of its current fluoride allocation and give
that allocation to Unimin Corporation for use at its Crystal
Operations. A copy of the agreement is attached to the report.
Two separate effluent limits pages should be included in The
Feldspar Corporation's permit. The first page should say "During
the period beginning on the effective date of this permit and
lasting until Unimin Corporation -Crystal Operations begin
discharging,". The effluent limits should be as they now exist.
The second page should say "During the period beginning when
Unimin Corporation -Crystal Operations begin discharging and last
until expiration,". The effluent limits on this page should be
modified with the fluoride reduced by 50 lbs monthly average and
100 lbs daily maximum.
Draft copies of the effluent pages are
information.
A copy of the letter requesting permit
attached to this staff report.
attached for your
modification is also
It is recommended that the permit be issued.
Page 3

Signature of Report Preparer
ater Quality R gional Supervisor
Date
Page 4

die c44/24:03 AwC.
A. (). EFFLUENT LIMITATIONS AND MONITORING REQ NTS FINAL Permit No. NC0000353
During the period beginningiA e.) &vew+a-ayj 1 bf ! c I lasting until expiration, the PCrmittee is authorized to discharge from
outfall(s) serial number 001. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic. Discharge Limitetlona Monitoring Requirements
Lbs/day Units (specify Measurement Semple *Sample
Mon. Avg, Daily Max Mon. Avg.. Daily Max. frequency Type Location
Flow 3.5 MGD Daily Continuous I or E
Settleable Solids Daily Grab E
Turbidity •' Daily Grab E,U,D
Total Suspended Residue 1568.0 3137.0 Daily Composite E
Fluorides /7V1.0 346.0 Daily Composite E,U,D
Chronic Toxicity*** Quarterly Composite E
* Sample locations: E - Effluent, U - Upstream at Station number 56, D - Downstream at Station number 59.
Daily stream sampling frequency may be reduced to three times per week All stream samples may be grab samples.
**This discharge shall not increase the turbidity of the receiving stream more than 10 NTU. If the turbidity exceeds 10 NTU due to natural
conditions, the discharge shall not cause any increase in the turbidity.
*** Chronic Toxicity (Ceriodaphnia) P/F at 11%, January, April, July, October, See Part III, condition E.
The pH shall not be less than 6.0 standard units nor greater than 10.0 standard units and shall be monitored Daily at the effluent, Upstream and
Downstream by grab samples.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREME AL Permit No. NC0000353
During the period beginning on the effective date of the permit and lasting until , the Permittee is authorized to discharge from
outfall(s) serial number 001. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic. Discharge Limitations Monitoring Requirements
Lbs/day Units (specify
Measurement Samole tumid"
Mon. Avg. Daily Mal MonMo�.AM pally Max, Frequency Tine Locatlop
Flow 3.5 MOD Daily Continuous I or E
Settleable Solids Daily Grab E
Turbidity •' Daily Grab E.U,D
Total Suspended Residue 1568.0 3137.0 Daily Composite E
Fluorides 224.0 448.0 Daily Composite E,U,D
Chronic Toxicity*** Quarterly Composite E
* Sample locations: E - Effluent, U - Upstream at Station number 56, D - Downstream at Station number 59.
Daily stream sampling frequency may be reduced to three times per week. All stream samples may be grab samples.
**This discharge shall not increasethe turbidity of the receiving stream more than 10 NTU. If the turbidity exceeds 10 NTU due to natural
conditions, the discharge shall not cause any increase in the turbidity.
*** Chronic Toxicity (Ceriodaphnia) P/F at 11%, January, April, July, October, See Part III, condition E.
The pH shall not be less than 6.0 standard units nor greater than 10.0 standard units and shall be monitored Daily at the effluent, Upstream and
Downstream by grab samples.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Name of Facility: ' _/ 69J4%iC...
Owner or Contact Person: avl, ei D. A / NA✓
Mailing Address: ea. ?aX 69 Sr1Z1A4 ,r,e,,
County: !1-f £faa. V Telephone: 70 -- 74 S`-- zr/
Present Classification: New Facility Existing Facility
NPDES Per. No. NCoo,2v3 -3 Nondisc. Per. No.WQ Health Dept.Per No.
Rated by: /l f e �,ee.l T...,Aii.,L�1. Telephone: 70400~1,ZOB Date: 2/!�/g.5
Reviewed by: Health Dept.
RATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
I— d
tifrid
•0 -
C. rzw.A.
Check Classification(s): Subsurface
Wastewater Classification: (Circle One)
A/c- - 71
Regional Office
Central Office
Grade: +
I I
Spra rrigation
IV
Telephone:
Telephone: Toy 2.S/-Geer
Telephone:
Telephone:744 7/J' .' cbr�/
Land Applic lion
Total Points: 6 C)
J-PLANT PROCESSES AND RELATED CONTROL EOU[PMENT WHICH ARE AN INTEGRAL PART OF INDUSTRIAL PRODUCTION SHALL NOT BB
CONSIDERED WASTE TREATMENT FOR THE PURPOSE OF CLASSIFICATION. ALSO SEPTIC TANK SYSTIZIS CONSISTING ONLY OF SEPTIC TANK
AND GRAVITY NITRIFICATION LINES ARE EXEMPT FROM CLASSIFICATION,
SUBSURFACE CLASSIFICATION
(check all units that apply)
1. septic tanks
2. pump tanks
3. siphon or pump -dosing systems
4.sand filters
5. grease trapfinterceptor
6oil/water separators
7. gravity subsurface treatment and disposal:
8. pressure subsurface treatment and disposal:
SPRAY IRRIGATION CLASSIFICATION
(check all units that apply)
1._ preliminary treatment (definition no. 32 )
2. lagoons
3. septic tanks
4. pump tanks
5. pumps
6sand filters
7 grease trap/interceptor
8. oil/water separators
9. disinfection
10. chemical addition for nutrient/algae control
11. spray irrigation of wastewater
in addition to the above classifications, pretreatment of wastewater in excess of these components shell
be rated using the point rating system and will require an operator with an appropriate dual certification.
LAND APPLICATION/RESIDUALS CLASSIFICATION (Applies only to permit holder)
1. Land application of biosolids, residuals or contaminated soils on a designated site.
WASTEWATER TREATMENT FACILITY CLASSIFICATION
The following systems shall be assigned a Class I classification. unless the flow is of a significant quantity or the technology is unusually
complex, to require consideration by the Commission on a case -by -case basis: (Check If Appropriate)
1. Oil/water Separator Systems consisting only of physical separation, pumps and disposal;
2. Septic Tank/Sand Filter Systems consisting only of septic tanks, dosing apparatus, pumps,sand fitters, disinfection
and direct discharge;
3. Lagoon Systems consisting only of preliminary treatment, lagoons. pumps, disinfection, necessary chemical treatment for
algae or nutrient control, and direct discharge;
4. Closed -loop Recycle Systems;
5. Groundwater Remediation Systems consisting only of oil/water separators, pumps, air -stripping, carbon adsorption, disinfection
and disposal;
6. Aquacutture operations with discharge to surface waters;
7Water Plant sludge handling and back -wash water treatment;
8. Seafood processing consisting of screening and disposal.
9. Single-family discharging systems, with the exception of Aerobic Treatment Units, will be dassified if permitted after July 1,
1993 or if upon Inspection by the Division, it is found that the system is not being adequately operated or maintained. Such
systems will be notified of the classification or reclassification by the Commission, in writing.

The following scale is used for rating wastewater treatment facilities: (circle appropriate points)
ITEM POINTS
(1) Industrial Pretreatment Units or Industrial Pretreatment Program (see definition No. 33) 4
(2) DESIGN FLOW OF PLANT IN gpd (not applicable to non -contaminated cooling waters. sludge handling facilities for
water purification plants, totally closed cycle systems(see definition No. 11), and facilities consisting only of item
(4)(d) or Items (4)(d) and (11)(d)J
0 - 20.000 1
20,001 - 50.000 2
50,001 - 100.000 .3
100,001 - 250.000.. 4
250,001 - 500,000 5
500.001 - 1,000.000 .8
1,000.001 - 2,000.000 10
2.000.001 (and up) rate 1 poll% additional for each 200,000 gpd capacity up to a maximum of ...�g
Design Row (gpd) 3y I'M Oav
(3) PRELIMINARY UNiTS/PROCESSES (see definition No.32)
(a) Bar Screens 1
Or
(b) Mechanical Screens. Static Screens or Comminuting Devices 2
(c) Grit Removal 1
or
(d) Mechanical or Aerated Grit Removal 2
(e) Flow Measuring Device 1
or
( 114)
(i) Instrumented Flow Measurement
Preaeration
(h) influent Flow Equalization 2
(I) Grease or Oil Separators - Gravity 2
Mechanical .3
Dissolved Air Flotation .8
(1) Prechtorination .5
(4) PRIMARY TREATMENT UNRSIPROCESSES
(a) Septic Tank (see definition No. 43) 2
(b) Imhoff Tank. 5
(c) Primary Clariilers 5
(d) Settling Ponds or Settling Tanks for Inorganic Nontoxic Materials (sludge handling facilities for water
purification plants, sand, gravel, done. and other mining operations except recreational activities such as gem
or gold mining) 2
(5) SECONDARY TREATMENT UNITS/PROCESSES
(a) Carbonaceous Stage
(I) Aeration -High Purity Oxygen System 20
Diffused Air System 10
Mechanical Air System (fixed, floating or rotor) .8
Separate Sludge Reaeratlon .3
(11) Tridding Ricer
High Rate.........» 7
Standard Rate 5
Packed Tower 5
(III) Biological Aerated Filter or Aerated Biological Filter ..»...»».». .... ....... 10
(iv) Aerated Lagoons 10
(v) Rotating Biological Contactors 10
(v1) Sand Filters -intermittent biological 2
Recirculating biological 3
(vii) Stabilization Lagoons .5
(1) Single
(ix) stage system for combined carbonaceous removal of BOD and nitrogenous removal by
nitrification (see definition No. 12)(Points for this Item have to be in addition to items
(5)(a)(1) through (5)(a)(vl1l).
utilizing the extended aeration process (see definition No.3a) .2
utilizing other than the extended aeration process 8
(x) Nutrient adds -lions to enhance BOD removal 5
(xi) Biological Culture ('Super Bugs')additlon 5
(b) Nitrogenous Stage
(1) Aeration - High Purity Oxygen System .....................». 20
Diffused Air System
Mechanical Air System (fixed. floating or rotor) ..... »»...».................................................8
Separate Sludge Reaeration 3
(11) Trickling Filter -High Rate
Standard Rate
Packed Tower..
(111) Biological Aerated Filter or Aerated Biological Filter.—....._.—........_ ......... .....— .......... 1 0
(Iv) Rotating Biological Contactors 10
(v) Sand Filter - intermittent biological 2
Recirculating biological ... 3
5
TERTIARY OR ADVANCED TREATMENT lNRS'Pf OCESSES
(a) Activated Carbon Beds -
without carbon regeneration. .5
with carbon regeneration 15
(b) Powdered or Granular Activated Carbon Feed -
without carbon regeneration 5
with carbon regeneration 15
(c) Air stripping .5
(d) Denitriflcatlon Process 10
(e) Efectrodialysis ... 5
(I) Foam Separation5
(g) ton Exchange ... 5
(h) Land Application of Treated Effluent (see definition No. 22b) (not applicable for sand. gravel. stone
and other similar mining operations) by high rate Infiltration 4
(I) Microscreens 5
f1) Phosphorous Removal by Biological Processes (See definition No. 26) 20
(k) Polishing Ponds - without aeration. 2
with aeration .5
(8)
7
5
5

(I) Post Aeration - cascade 0
diffused or mechanical 2
(m) Reverse Osmosis .5
(n) Sand or Mixed -Media Fitters - low rate 2
high rate 5
(o) Treatment processes for removal of metal or cyanide 1 5
(p) treatment processes for removal of toxic materials other than metal or cyanide 1 5
(7) SLUOGE TREATMENT
(a) Sludge Digestion Tank - Healed (anaerobic) 10
Aerobic 5
Unheated (anaerobic) .3
(b) Sludge Stabilization (chemical or thermal) .5
(c) Sludge Drying Beds - Gravity 2
Vacuum Assisted 5
(d) Sludge Elutrlation 5
(e) Sludge Conditioner (chemical or thermal) .5
(I) Sludge Thickener (gravity) .5
(g) Dissolved Air Rotation Unit [not applicable to a unit rated as (3)(i)l 8
(h) Sludge Gas Utilization (including gas storage) 2
(I) Sludge Holding Tank - Aerated .5
Non -aerated 2
(j) Sludge Incinerator (not including activated carbon regeneration)
(k) Vacuum Filter. Centrifuge. or Filter Press or other similar dewatering devices
(8) RESIDUALS UTILIZATION/DISPOSAL (inducting incinerated ash)
(b) LandaLagoons 2
Application (surface and subsurface) (see definition 22a)
by contracting to a land application operator or landfill operator who holds the land application permit
or landfill permit
(c) Dedicated Landiill(burial) by the permittee of the wastewater treatment facility ....5
(9) OCSNFECTICN
(a) Chlorination .S
(b) Dechlorination .5
(c) Ozone .5
(d) Radiation .5
(10) CHEMICAL ADDITION SYSTEM(S) ( see definition No. 9) [not applicable to chemical additions rated as hem (3)0).
(5)(a)(xi). (6)(ak (6 (b). () b). (7)(e). (9a). (9)(b) or (9)(c) 5 points each:
List [i•�-
m
42:$
(11) MISCELLANEOUS UNITS/PROCESSES
(a) Holding Ponds. Holding Tanks or Settling Ponds for Organic or Toxic Materials including wastes from mining
operations containing nitrogen or phosphorus compounds in amounts significantly greater than is common
for domestic wastewater 4
(b) Effluent Row Equalization (not applicable to storage basins which are inherent In land application systems).....2
(c) Stage Discharge (not applicable to storage basins inherent in land application systems)...................... .......e1
/
(d)Pumps
Stand -By Power Supply
(e)I.3
Thermal Pollution Control Device .3
TOTAL POINTS
CLASSIFICATION
Class I. 5-25 Points
Class II 26-50 Points
Class Ig 51-65 Points
Class IV 66-Up Points
Facilities having a rating of one through four points. Inclusive. do not require a certified operator.
Facilities having an activated sludge process will be assigned a minimum classification of Class IL
Facilities having treatment processes for the removal of metal or cyanide will be assigned a minimum classification of Class II.
Facilities having treatment processes for the biological removal of phosphorus will be assigned a minimum classification of Class III.
A004 DEFINITIONS
The following definitions shall apply throughout this Subchapter.
(1) Activated Carbon Beds. A physlcaVchemical method for reducing soluble organic material from wastewater effluent; The column -type beds used in this
method will have a flow rate varying from two to eight gallons per minute per square foot and may be either upfiow or downflow carbon beds. Carbon may or
may not be regenerated on the wastewater treatment plant she;
(2) Aerated Lagoons. A basin in which all solids are maintained in suspension and by which biological oxidation or organic matter is reduced through artificially
accelerated transfer of oxygen on a flow -through basis;
(3) Aeration. A process of bringing about intimate contact between air or high purity oxygen In a liquid by spraying, agitation or diffusion;(3a) Extended
Aeration. An activated sludge process utilizing a minimum hydraulic detention time of 18 hours.
(4) Agriculturally managed site. Any she on which a crop Is produced. managed. and harvested (Crop includes grasses. grains. trees. etc.);
(5) Air Stripping. A process by which the ammonium ion is first converted to dissolved ammonia (pH adjustment) with the ammonia then released to the
atmosphere by physical means; or other similar processes which remove petroleum products such as benzene. toluene. and xylem;
(6) Carbon Regeneration. The regeneration of exhausted carbon by the use of a furnace to provide extremely high temperatures which volatilize and oxidize the
absorbed impurities;
(7) Carbonaceous Stage. A stage of wastewater treatment designed to achieve 'secondary' effluent limits;
(8) Centrifuge. A mechanical device In which centrifugal force Is used to separate solids from liquids or to separate liquids of different densities;
(9) Chemical Addition Systems- The addition of chemical(s) to wastewater at an application point for purposes of improving solids removal. pH adjustment.
alkalinity control, etc.; the capability to experiment with different chemicals and different application points to achieve a specific result will be considered one
system; the capability to add chemicals) to dual units will be rated as one system; capability to add a chemical at a different application points for different
purposes will result in the systems being rated as separate systems;
(10) Chemical Sludge Conditioning. The addition of a chemical compound such as lime. ionic chloride. or a polymer to wet sludge to coalesce the mass prior to
its application to a dewaterinig device;
(11) Closed Cycle Systems. Use of holding ponds or holding tanks for containment of wastewater containing Inorganic. non -toxic materials from sand, gravel.
crushed stone or other similar operations. Such systems shall carry a maximum of two points regardless of pumping facilities or any other appurtenances;
(12) Combined Removal of Carbonaceous BOO and Nitrogenous Removal by Nitrificatbn- A single stage system required to achieve permit effluent limits on BOD
and ammonia nitrogen within the same biological reactor
(13) Dechlorination. The partial or complete reduction of residual chlorine In a liquid by any chemical or physical process;

(15) Electrodialysls. Process for removing Ionized salts from water through the use of ion -selective lon•exchange membranes;
(16) Filter Press. A process operated mechanically for partially dewaiering sludge;
(17) Foam Separation. The planned frothing of wastewater or wastewater effluent as a means of removing excessive amounts of detergent materials through
the introduction of air in the form of fine bubbles; also called foam fractionation;
(18) Grit Removal. The process of removing grit and other heavy mineral matter from wastewater;
(19) Imhoff Tank. A deep two story wastewater tank consisting of an upper sedimentation chamber and a lower sludge digestion chamber.
(20) Instrumented Flow Measurement. A device which Indicates and records rate of flow;
(21) Ion Exchange. A chemical process in which ions from two different molecules are exchanged;
(22) land application:
(a) Sludge Disposal. A final sludge disposal method by which wet sludge may be applied to land either by spraying on the surface or by subsurface injection
(i.e., chisel plow); (not applicable for types of sludge described In (11) of this Rule);
(b) Treated Effluent. The process of spraying treated wastewater onto a land area or other methods of application of wastewater onto a land area as a
means of final disposal or treatment;
(23) Microscreen. A low speed. continuously back -washed, rotating drum fitter operating under gravity conditions as a polishing method for removing
suspended solids from effluent;
(24) Nitrification Process. The biochemical conversion of unoxidized nitrogen (ammonia and organic nitrogen) to oxidized nitrogen (usually nitrate);
(25) Nitrogenous Stage. A separate stage of wastewater treatment designed for the specific purpose of converting ammonia nitrogen to nitrate nitrogen;
(26) Phosphate Removal. Biological. The removal of phosphorus from wastewater by an ask/anoxic process designed to enhance luxury uptake of phosphorus
by the microorganisms;
(27) Polishing Pond. A holding pond following secondary treatment with sufficient detention time to allow settling of finely suspended solids;
(28) Post Aeration. Aeration following conventional secondary treatment units to increase effluent D.O. or for any other purpose;
(29) Post Aeration. (Cascade) A polishing method by which dissolved oxygen is added to the effluent by a nonmechanical. gravity means of flowing down a
series of steps or weirs; The flow oocuring across the steps or weirs moves in a fairly thin Iayer and the operation of the cascade requires no operator
adjustment; thus. zero points are assigned even though this 1s an essential step to meeting the limits of the discharge permit;
(30) Powdered to Granular Activated Carbon Feed. A biophysical carbon process that utilizes biological activity and organic absorption by using powdered or
granular activated carbon; Virgin or regenerated carbon is feed controlled Into the system;
(31) Preaeratlon. A tank constructed to provide aeration prior to primary treatment;
(32) Preliminary Units. Untt operations In the treatment process. such as screening and comminution. that prepare the liquor for subsequent major operations;
(33) Industrial Pretreatment.
(a) Pre-treatment Unit. Industrial. The conditioning of a waste at its source before discharge. to remove or to neutralize substances injurious to sewers and
treatment processes or to effect a partial reduction In Toad on the treatment process which is operated by the same governing body as the wastewater
treatment plant being rated;
b) Pre-treatment Program, Industrial • must be a State or EPA required program to receive points on the rating sheet;
(34) Primary Clarifiers. The first settling tanks through which wastewater is passed In a treatment works for the purpose of removing settleable and suspended
solids and BOD which is associated with the solids;
(35) Pumps. All influent. effluent and in -plant pumps;
(36) Radiation. Disinfection or sterilization process utilizing devices emitting ultraviolet or gamma rays;
(37) Reverse Osmosis. A treatment process In which a heavy contaminated Liquid Is pressurized through a membrane forming nary pure liquid free from
suspended solids;
(38) Rotating Biological Contractors. A fixed biological growth process in which wastewater flows through tanks in which a series of partially submerged circular
surfaces are rotated;
(39) Sand Filters:
(a) Intermittent Biological. Filtration of effluent following septic tanks, lagoons, or some other treatment process to which further biodecomposttion €s
expected to produce desired effluents; Hydraulic loading rates on these filters are computed in gpd/ac and have a resulting low gpm/sl (less than one);
b) Recirculating biological • the same type of sand filter as defined In Subparagraph (39) (a) of this Rub with the added capability to recycle effluent back
through the sand fitter;
(40) Sand or Mixed -Media Fitters. A polishing process by which effluent limits are achieved through a further reduction of suspended solids;
(a) low rate — gravity. hydraulically loaded fitter with loading rates In the one to three gpnvsf range;
(b) high rate — a pressure. hydraulically loaded filter with baring rates in the five gprmisf range; At any rate. the loading rate will exceed three gpm/sf;
(41) Secondary Clarifiers. A tank which follows the biological unit of treatment plant and which has the purpose of removing sludges associated wtth the
biological treatment untls;
(42) Separate Sludge Reaerationl. A pan of the contact stabilization process where the activated sludge Is transferred to a tank and aerated before returning it
to the contact basin;
(43) Septic Tank. A single -story settling tank In which settled sludge is in contact with the wastewater flowing through the tank; shall not be applicable for
septic tank systems serving single family residences having capacity of 2.000 gallons or less which discharge to a nitrification field;
(44) Sludge Digestion. The process by which organic or volatile matter and sludge is gasified. liquefied mineralized or converted into more stable organic matter
through the activity of living organisms. which Includes aerated hoidrtg tanks;
(45) Sludge Drying Beds. An area comprising natural or artificial layers of porous materials upon which digested sewage sludge is dried by drainage and
evaporation; .
(46) Sludge Etutriation. A process of sludge conditioning to which certain constituents are removed by successive washings with fresh water or plant effluent;
(47) Sludge Gas Utilization. The process of using sewage gas for the purpose of heating buildings. driving engirfes, etc.;
(48) Sludge Holding Tank (Aerated and Nonaerated). A tank utilized for small wastewater treatment plants not containing a digester In which sludge may be
kept fresh, and supernatant withdrawn prior to a drying method (Le. sludge drying beds); This may be done by adding a small amount of air simply to keep the
sludge fresh. but not necessarily an amount that would be required to achieve stabilization of organic matter. A nonaerated tank would simply be used to
decant sludge prior to dewatering and would not allow long periods (several days of detention) without resutling odor problems;
(49) Sludge Incinerators. A furnace designed to bum sludge and to remove all moisture and combustible materials and reduce the sludge to a sterile ash;
(50) Sludge Stabilization (Chemical or Thermal). A process to make treated sludge less odorous and putrescble, and to reduce the pathogenic organism
content; This may be done by pH adjustment. chlorin dosing, or by heat treatment;
(51) Sludge Thickener. A type of sedimentation tank in which the sludge is permitted to settle and thicken through agttation and gravity;
(52) Stabilization Lagoon. A type of oxidation lagoon In which biological oxidation of organic matter its effected by natural transfer of oxygen to the water from
air (not a polishing pond);
(53) Stand -By Power Supply. On site or portable electrical generating equipment;
(54) Static Screens. A stationary screen designed to remove solids. including non -biodegradable particulate (floatabte solids, suspended solids and BOD
reduction) from municipal and Industrial wastewater treatment systems;
(55) Tenlary Treatment. A stage of treatment following secondary which is primarily for the purpose of effluent polishing; A settling lagoon or sand or coal filter
might be employed for this purpose;
(56) Thermal Pollution Control Device. A device providing for the transfer of heat from a fluid flowing in tubes to another fluid outside the tubes. or vice versa;
or other means of regulating liquid temperatures;
(57) Thermal Sludge Conditioner. A conditioning process by which heat is added for a protracted period of time to Improve the dewaterabtiity of sludge by the
sotubitizing and hydrautizing of the smaller and more highly hydrated sludge particles;
(58) Toxic Materials. Those wastes or combinations of wastes. tncfudtrg disease-causlrg agents which after discharge and upon exposure. tngestton. Inhalation
or assimilation Into any organism, either directly from the environment or indirectly by ingestion through food chains. will cause death. disease. behavioral
abnormalities. cancer, genetic mutations. physiological malfunctions (including rlalfunctlons in reproduction) or physical deformations. In such organisms or their
offspring; Toxic materials Include. by way of Illustration and not limitation: lead. cadmium. chromium. mercury. vanadium. arsenic. zinc. ortho-nitro•chlorobenzene
(ONCE). polychlorinated bipheryls (PCBs) and dlchtorodlphenyl trichloroethane (DDT); and any other materials that have or may hereafter be determined to have
toxic properties;
(59) Trickling Flier. A biological treatment unit consisting of a material such as broken stone or rock over which wastewater Is distributed; A high rate trickling
fitter is one which operated at between 10 and 30 mgd per acre. A low rate trickling fitter Is one which is designed to operate at one to four mgd per acre;
(60) Trickling Fitter (Packed Tower). A plug flow type of operation In which wastewater flows down through successive layers of media or filtrate material; Organic
material is removed continually by the active biological fixed growth In each successive layer. This method may produce 'secondary' quality effluent. or may be
adapted to produce a nitrified effluent;
(61) Vacuum Filter. Centrifuges. or Fitter Presses. Devices which are designed to remove excess water from either digested or undigested sludge prior to disposal
or further treatment.

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•
THE r�
CORPORA i/ON
A subsidiary of Corporation
December 12, 1994
Post Office Box 99, Spruce Pine, NC 28777
[phone] FAX: [phone]
Mr. Mike Parker
Division of Environmental Management
Water Quality Section
59 Woodfin Place
Asheville, North Carolina
Dear Mr. Parker:
As you are aware, Unimin Corporation purchased the Crystal Plant from The
Feldspar Corporation in 1991. The Feldspar Corporation has been treating the
effluent from that plant since that time. As specified in the Operating
Agreement between the two companies (copy enclosed), Unimin has advised The
Feldspar Corporation that it wishes to construct its own waste water treatment
facility. As part of the Operating Agreement, The Feldspar Corporation is
obligated to offer to have our existing NPDES Permit amended to reduce our
average daily pounds per day of fluorides allowance by 50 pounds and to reduce
our daily maximum pounds per day of fluorides
allowance
byr100lel pounds which in order
to facilitate Unimin obtaining the maximumfluoride
Unimin is able to achieve in the permitting process.
ing
The Feldspar Corporation wishes to honor this
agreement
aforementionedtofferefort
make
modification. This letter is intended to that Unimin currently
the Crystal Plant only and is not for any other facility
operates in this area. The Feldspar Corporation
Unimin hasecompletedkeep
thethe
waete
above mentioned allocation until such ime
treatment facility for the Crystal Plant.
Once the Crystal Plant waste
treatment facility is complete, The Feldspar Corporation wouldenoilongerpbeate
er be
responsible in any way for the effluent from that facility.
with Unimin in every way during the transition period to protect the North Toe
River.
If you have any questions regarding this letter, please feel free to call me.
Thank you.
Sincerely yours,
THE FELDSPAR CORPORATION
John D. (Pete) Lawson
Vice President - Operations
JDL/h
Enclosure
cc: Charles Stover
DE 1 3 4994

27. Term. Unless terminated as otherwise provided
hereunder, this Agreement shall terminate on the date 99 years
after the date of this Agreement, and all the easements referred
to in Section 12 hereof shall likewise terminate on said date.
28. Fluoride Allocation. If, after receiving notice
UN imii4
under Section 6 hereof or after Purchaser gives Operator notice
that it wishes to construct its own waste treatment facility and
terminate this Agreement following completion of such facility
and the attainment of its own waste discharge permits, or
otherwise, Purchaser applies to the Department of Environment,
Health and Natural Resources, State of North Carolina (or
successor or replacement agency) for an NPDES permit or other
appropriate permit to discharge effluent into the North Toe
River, Operator shall offer to appropriate governmental permit
authorities to have the Existing NPDES Permit or the New NPDES
Permit amended to reduce Operator's average daily pounds per day
of fluorides allowance by 50 pounds and to reduce Operator's
daily maximum pounds per day of fluorides allowance by 100 pounds
in order to facilitate Purchaser obtaining the maximum fluoride
discharge level which Purchaser is able to achieve in the
permitting process. If, at the time Purchaser applies'for such
permit, the daily average pounds per day of fluorides permitted
A:\EXHIBITS - 3 5 -

r^
in the New NPDES Permit applicable to Operator shall be a number
other than 224 pounds, then the foregoing figure of 50 pounds
shall instead be 50 multiplied by a fraction of which the
numerator is .the daily average pounds per day of fluoride then
permitted under Operator's New NPDES Permit and the denominator
of which is 224. If, at the time Purchaser applies for such
permit, the daily maximum pounds per day of fluorides permitted
in the New NPDES Permit applicable to Operator shall be a number
other than 448 pounds, then the foregoing figure of 100 pounds
shall instead of 100 multiplied by a fraction of which the
numerator is the daily maximum pounds per day of fluoride then
permitted under Operator's New NPDES Permit and the denominator
of which is 448.
IN WITNESS WHEREOF, the parties hereto have executed
this Agreement under seal this day of , 1991.
By:
ATTEST:
Title:
(Corporate Seal)
UNIMIN CORPORATION
Title
A:\EXHIBIT8 - 36 -

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