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Home My WebLink AboutNC0000361_Compliance Evaluation Inspection_20220314DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A ROY COOPER Governor ELIZABETH S. BISER Secretary S. DANIEL SMITH DirectOr NORTH CAROLENA Environmental Qualify SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED. March 14, 2022 Jeffrey Ferguson P.E., Sustainability Manager Sibelco Schoolhouse Quartz facility E-mail: Jeff.Ferguson@sibelco.com SUBJECT: Compliance Inspection Report Schoolhouse Quartz facility NPDES WW Permit No. NC0000361 Avery County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Schoolhouse Quartz facility on 3/04/2022. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0000361. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". Please respond via e-mail to this office within 90 days of your receipt of this letter regarding your plans to be taken to address the following issue: • A proposed plan of action for solids removal from the Effluent Lagoon, including schedule milestones and how permit compliance will be maintained during the activity. If you should have any questions, please do not hesitate to contact Timothy Heim with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4500 or via email at tim.heim@ncdenr.gov. ATTACHMENTS Ec: LF, Rick Singleton, Jody McKinney Sincerely, �DocuSigned by: 111446 A 1 tk6144 082B1105A3CA418... Tim Heim, P.E., Environmental Engineer Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ D_EC� North Carolina Department of Environmental Quelfy I olvtslon of Water Resources Asheville Regional Office 12090 O.S. Highway 70 I Swannanoa, Noah Carolina 28778 828.296.4500 DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A United States Environmental Protection Agency EPA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection 1 IN I 2 IL I 3 I NC0000361 111 121 22/03/04 117 Type 1810I IIIIIIIIIII Inspector Fac Type 19I S I 2011 21IIIIII IIIIIIIIIIIIIIIIII I IIIIII P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 I 7° I I 711 172 I N I 73I 1 74 71 I I I I I I I I 180 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Schoolhouse Quartz facility US Hwy 19-E Spruce Pine NC 28777 Entry Time/Date 09:30AM 22/03/04 Permit Effective Date 12/06/01 Exit Time/Date 12:30PM 22/03/04 Permit Expiration Date 16/02/29 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Ricky L Singleton/ORC/828-765-4283/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Jeff Ferguson,136 Crystal Dr Spruce Pine NC 28777/Sustaninablity Manager/828-765-1114/8287650912 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Operations & Maintenar Facility Site Review Effluent/Receiving Wate Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Stephanie A Williams 9a,,A—„, x:u:,— DWR/ARO WQ/828-296-4500/ 3/14/2022 Timothy H Heim �po„s;g „,'F8C8JAFcc DWR/ARO WQ/828-296-4665/ 3/14/2022 T woflul him Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date 7Lnra7.; 3/14/2022 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A 31 NPDES yr/mo/day N C0000361 111 121 22/03/04 I17 Inspection Type 18LI (Cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Tim Heim and Stephanie Williams of the Asheville Regional Office performed a Compliance Inspection of the Facility on March 4, 2022. Rick Singleton (Environmental Supervisor/ORC) and Jody McKinney (Mineral Separation Manager/BORC.) were present and assisted with the inspection. The following items were noted at the time of the inspection: Pump (Sump) Station: The pump station where influent is pumped to the thickeners was undergoing maintenance on one pump at the time of the inspection. The fluoride and non -fluoride streams were co -mingling and a small amount of influent was flowing to the Emergency Pond via gravity. Operators stated that the fluoride and non -fluoride streams are segregated for process optimization only and co -mingling does not impact compliance. Thickeners (Primary Clarifiers): Both clarifiers were completed covered with a scum blanket at the time of the inspection, this is a normal impact of the treatment process for this type of physical chemical operation and does not indicate the same concerns it would in a biological treatment facility. A small volume of influent was splashing over the center well and by-passing optimal hydraulic flow through the clarifier baffles. Operators state that these units are scheduled to be covered as part of a planned future project. Consider adding secondary containment skids under the chemical totes in the chemical storage area of the thickener building. Emergency Lagoon: The emergency pond appears to receive regular flow as part of the treatment operation in order to divert and/or store flow requiring additional treatment. Consider a project to remove significant solids from this lagoon to optimize operational capacity. Effluent Lagoon: The effluent lagoon appears to have reached the upper limits of its solids storage capacity, and a minimal layer of supernatant was observed above the sludge blanket. Removal of solids and rehabilitation of the lagoon should be given priority. Failure to adequately manage solids in the lagoon could result in several detrimental impacts: reduced settling due to increased flow velocity in the preferential flow path, reduced lagoon volume for solids settling, and significantly increased potential for detriment to the receiving stream in the event of a breach or other unintended release of solids. Respond to the Regional Office with a proposed plan of action including schedule milestones and how permit compliance will be achieved during solids removal within 90 days or an NOD will be issued. Page# 2 DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A Permit: NC0000361 Inspection Date: 03/04/2022 Owner - Facility: Schoolhouse Quartz facility Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? • ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable II El El El Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Process control parameters include pH, TSS, and sludge depth/torque readings in the clarifiers. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? ■ ❑ ❑ ❑ Is the wet well free of excessive grease? • ❑ El El Are all pumps present? • El El El Are all pumps operable? ■ El ❑ ❑ Are float controls operable? • El El El Is SCADA telemetry available and operational? • El El El Is audible and visual alarm available and operational? El El • El Comment: The pump station where influent is pumped to the thickeners was undergoing maintenance on one pump at the time of the inspection. The fluoride and non -fluoride streams were co -mingling and a small amount of influent was flowing to the Emergency Pond via gravity. Operators stated that the fluoride and non -fluoride streams are segregated for process optimization only and co -mingling does not impact compliance. Primary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ • ❑ ❑ • ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A Permit: NC0000361 Inspection Date: 03/04/2022 Owner - Facility: Schoolhouse Quartz facility Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Comment: Both clarifiers were completed covered with a scum blanket at the time of the inspection, this is a normal impact of the treatment process for this type of physical chemical operation and does not indicate the same concerns it would in a biological treatment facility. A small volume of influent was splashing over the center well and by-passing optimal hydraulic flow through the clarifier baffles. Operators state that these units are scheduled to be covered as part of a planned future project. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Up flow Is the filter media present? • ❑ ❑ ❑ Is the filter surface free of clogging? • ❑ ❑ ❑ Is the filter free of growth? • ❑ ❑ ❑ Is the air scour operational? ❑ El • El Is the scouring acceptable? ❑ ❑ • ❑ Is the clear well free of excessive solids and filter media? • ❑ ❑ ❑ Comment: Lagoons Yes No NA NE Type of lagoons? Aerated # Number of lagoons in operation at time of visit? 2 Are lagoons operated in? Series # Is a re -circulation line present? • ❑ El El Is lagoon free of excessive floating materials? • El El El # Are baffles between ponds or effluent baffles adjustable? ❑ El • ❑ Are dike slopes clear of woody vegetation? ■ El El El Are weeds controlled around the edge of the lagoon? • El ❑ ❑ Are dikes free of seepage? • El El El Are dikes free of erosion? • El ❑ ❑ Are dikes free of burrowing animals? • El El El # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ■ El ❑ ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? El El ▪ El Is the lagoon surface free of weeds? ❑ • ❑ ❑ Is the lagoon free of short circuiting? El • El El Page# 4 DocuSign Envelope ID: 2C4B3CEE-D5CC-42C3-A92D-30D99D0E9E7A Permit: NC0000361 Inspection Date: 03/04/2022 Owner - Facility: Schoolhouse Quartz facility Inspection Type: Compliance Evaluation Lagoons Yes No NA NE Comment: Emergency Lagoon: The emergency pond appears to receive regular flow as part of the treatment operation in order to divert and/or store flow requiring additional treatment. Consider a project to remove significant solids from this lagoon to optimize operational capacity. Effluent Lagoon: The effluent lagoon appears to have reached the upper limits of its solids storage capacity, and a minimal layer of supernatant was observed above the sludge blanket. Removal of solids and rehabilitation of the lagoon should be given priority. Failure to adequately manage solids in the lagoon could result in several detrimental impacts, including: reduced settling due to increased flow velocity in the preferential flow path, reduced lagoon volume for solids settling, and significantly increased potential for detrimental impacts to the receiving stream in the event of a breach or other unintended release of solids. Page# 5