NC0035173_Permit (Issuance)_19970103

NPDES DOCUMENT SCANNING COVER :MEET
NC0035173
Wieland Copper WWTP
NPDES Permit:
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:
January 3, 1997
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Staff Review and Evaluation
NPDES Wastewater Permit
FACILITY INFORMATION
Facility Kobe Copper Products, Inc.
NPDES No. NC0035173, Outfalls 001 (dom), 003 (NCCW/blowdown)
Design Flow (MGD) 0.025 (001)
Facility Class II
STREAM CHARACTERISTICS _
Stream Name UT Dan River
Stream Class WS III
Sub -basin 030201
.l l
Drainage Area (mi2) 1.6
S7Q10 (cfs) 0.075
W7Q10 (cfs) 0.3
30Q2 (cfs)
IWC (%) 34
Proposed Changes
Parameters Affected
Basis for change(s)
monitoring at 003
copper
elevated instream conductivity
II IIconductivity
(eff)
VI If
Compliance Schedule:
Special Condition(s):
Permits & Engineering Comments:
Outfall 001 discharge consists of domestic wastewater from an extended aeration plant.
Outfall 003 consists of NCCW and cooling tower blowdown. Process water is recycled.
Kobe is well in compliance with its existing limits. The facility has had some inconsistent
results for toxicity testing (failed in January). The facility monitors for total copper and soluble
copper at outfall 001. Values for both are above what would be expected for a domestic
facility. Copper will continue to be monitored. Instream data indicate D.O's above 5 mg/1.
Some instream values for conductivity are well above expected levels. P&E recommends that
copper and conductivity monitoring be added to outfall 003 and other requirements remain the,.
same.
WIN h . rA(4.PYI/vvvc- vi&r- fief? -
Prepared by: Susan A. Wilson,
Regional Office Evaluation and Recommendations:

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
{� �/ January 3,1997
Mr: Ka4-6v�rn l01\0Ghi%
Kobe Copper Products, Inc.
P.O. Box 160
Pine Hall, North Carolina 27042
yo
Dear Mr. Shtmrate:
itITTA
E)EHNR
GIB{ 2-F
Subject: NPDES Permit Issuance
Permit No. NC0035173
Kobe Copper Products
Stokes County
In accordance with the application for a discharge permit received on June 17, 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 Susan Robson at telephone number (919)
733-5083, extension 551.
Sincerely,
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E.
cc: Central Files
Winston-Salem 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. NC0035173
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,
Kobe Copper Products, Incorporated
is hereby authorized to discharge wastewater from a facility located at
- S-HighwaY-3-14- 3990 (L 31l WV.
north of Pine Hall
Stokes County
4: ; '11T�
to receiving waters designated as an unnamed tributary to the Dan River in the Roanoke River
Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, III, and IV hereof.
This permit shall become effective February 1, 1997
This permit and authorization to discharge shall expire at midnight on January 31, 2002
Signed this day January 3, 1997
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0035173
SUPPLEMENT TO PERMIT COVER SHEET
Kobe Copper Products, Incorporated
is hereby authorized to:
1. Continue to operate an existing domestic wastewater treatment facility consisting of bar screen,
aeration basin, clarifier, tablet -type chlorinator, tablet -type de -chlorinator and aerobic digester
discharging via outfall °O1 and continue to discharge boiler blowdown, cooling tower
blowdown, and non -contact cooling water from outfall 003 (combines the discharges from
outfalls previously numbered 002 and 003) located at Kobe Copper Products , US Highway
311, north of Pine Hall, Stokes County (See Part III of this Permit), and
2. Discharge from said treatment works at the location specified on the attached map into an
unnamed tributary to the Dan River which is classified Class WS-III waters in the Roanoke
River Basin.

ROAD CLASSIFICATION
PRIMARY HIGHWAY
HARD SURFACE
SECONDARY HIGHWAY
HARD SURFACE
LIGHT•DUTY ROAD, HARD OR
IMPROVED SURFACE
UNIMPROVED ROAD = _ =
Latitude 36°20'58" Longitude 80°02'18"
Map # B18SE Sub -basin 03-02-01
Stream Class
WS-III
Discharge Class 02 17 14 16
Receiving Stream UT to Dan River
Design Q n ro5 MCn Permit expires 1/31/02
wnrxf.
.:Qaoauaxoe»az�
Kobe Copper Products,Inc.
NC0035173
Stokes County

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS SUMMER (April 1 - October 31) Permit No. NC0035173
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outlall(s) serial number 001. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics
Discharge Limitations
Monthly Avg.
Flow 0.025 MGD
BOD, 5 day, 20°C 20.0 mg/1
Total Suspended Residue 30.0 mg/I
NH3 as N 17.0 mg/I
Dissolved Oxygen**
Fecal Coliform (geometric mean) 200.0 /100 ml
Total Residual Chlorine
Temperature
Copper
Chronic Toxicity***
Weekly Avg.
Daily Max
30.0 mg/I
45.0 mg/I
Monitoring
Measurement
Frequency
Weekly
Weekly
Weekly
Weekly
Weekly
400.0 /100 ml Weekly
2/Week
Daily *
�,�OLe�ekly
Monthly
Quarterly
Requirements
Sample *Sample
e Location
Instantaneous
Grab
Grab
Grab
Grab
Grab
Grab
Grab
(r )
1 or E
E
E
E
E, U, D
E, U, D
E
E,U,D
Grab
Composite
E
E
* Sample locations: E - Effluent, I - Influent, U - Upstream 100 feet, D - Downstream 200 feet.
Instream samples shall be grab samples and shall be conducted weekly.
** The daily average dissolved oxygen effluent concentration shall not be less than 5.0 mg/l.
*** Chronic toxicity (Ceriodaphnia) P/F at 34%, January, April, July, and October; See Part III, Condition E.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored weekly 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 WINTER (November 1 - March 31) Permit No. NC0035173
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics
Discharge Limitations
Monthly Avg.
Flow 0.025 MGD
BOD, 5 day, 20°C 30.0 mg/I
Total Suspended Residue 30.0 mg/I
NH3asN
Dissolved Oxygen**
Fecal Coliform (geometric mean) 200.0 /100 ml
Total Residual Chlorine
Temperature
Clanduatigity.
Copper
Chronic Toxicity***
Weekly Avg.
Daily Max
45.0 mg/I
45.0 mg/I
Monitoring Requirements
Measurement Sample
Type
Frequency
Weekly
Weekly
Weekly
2/Month
Weekly
400.0 /100 ml Weekly
2/Week
Daily *
-Weekly-
Monthly
Quarterly
Instantaneous
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Composite
*Sample
Location
I or E
E
E
E
E, U, D
E, U, D
E
E, U, D
E
E
* Sample locations: E - Effluent, I - Influent, U - Upstream 100 feet, D Downstream 200 feet.
Instream samples shall be grab samples and shall be conducted weekly.
** The daily average dissolved oxygen effluent concentration shall not be less than 5.0 mg/1.
*** Chronic toxicity (Ceriodaphnia) P/F at 34%, January, April, July, and October; See Part III, Condition E.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored weekly 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. NC0035173
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 003 - COOLING TOWER BLOWDOWN AND NON -CONTACT COOLING WATER. Such discharges shall be
limited and monitored by the permittee as specified below:
Effluent Characteristics
Flow
Temperature
Total Residual Chlorine***
Oil and Grease
TSS
Copper
on ri
Discharge Limitations
Units (specify)
Mon. Avg. Daily Max Mon. Avg. Pally
Lbs/day
Monitoring
Measurement
Max. Frequency
Monthly
Monthly
Monthly
Monthly
Monthly
Requirements
Sample *Sample
Type Location
Instantaneous E
Grab E, U, D
Grab E
Grab E
Grab E
Monthly Grab
E
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, U - Upstream, D - Downstream
** The temperature of the effluent shall be such as not to cause an increase in the temperatureiof the receiving stream of more than 2.8°C and in
no case cause the ambient water temperature to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard 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. NC0035173
E. CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in:
1.) The North Carolina Ceriodaphnia chronic effluent bioassay procedure (North Carolina Chronic
Bioassay Procedure - Revised *September 1989) or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction or
significant mortality is 34% (defined as treatment two in the North Carolina procedure document).
The permit holder shall perform quarterly monitoring using this procedure to establish compliance
with the permit condition. The first test will be performed after thirty days from the effective date
of this permit 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, DEM Form AT-1 (original) is to be sent to the following address:
Attention:
Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 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 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 any test data from this monitoring requirement or tests performed by the North Carolina
Division of Environmental Management 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 and appropriate environmental controls, shall constitute an invalid test
and will require immediate retesting(within 30 days of initial monitoring event). Failure to submit
suitable test results will constitute noncompliance with monitoring requirements.
F. Biocide Condition
The permittee shall obtain authorization from the Division of Environmental Management prior to
utilizing any biocide in the cooling water. The permittee shall notify the Director in writing not
later than ninety (90) days prior to instituting use of any additional biocide used in cooling systems
which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map indicating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the biocide worksheet
Form 101 with Supplemental Metals Analysis worksheet.

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cc:
Permits and Engineering
Technical Support Branch
County Health Dept.
Central Files
WSRO
SOC PRIORITY PROJECT: Yes
No X
If Yes, SOC No.
To: Permits and_Engineering Unit
Water uality Section),
Attention: Susan Wilson -
Date: July 3, 1996
NPDES STAFF REPORT AND RECOMMENDATION
County Stokes
Permit No. NC0035173
PART I - GENERAL INFORMATION
1. Facility and Address: Kobe Copper Products, Inc.
Hwy 311
P. 0. Box 160
Pine Hall, N.C. 27042
2. Date of Investigation: 960702
3. Report Prepared by: David Russell, WSRO
4. Persons Contacted and Telephone Number: John
and Environmental Manager [phone]
Shumate, Safety
5. Directions to Site: From Winston-Salem travel Hwy 311 north
through Walnut Cove approximately 6 miles. The facility is
located on the right.
6. Discharge Points(s), List for all discharge
7.
8.
9.
points:
Latitude: 36° 20' 58" Longitude: 80° 02' 17"
Latitude: 36° 20' 45" Longitude: 80° 02' 43"
U.S.G.S. Quad No. B18SE U.S.G.S. Quad Name
Site size and expansion area consistent
X Yes No If No, explain:
Topography (relationship to flood plain
is located outside of any flood plain.
Location of nearest dwelling: Greater than 1000 feet
Dhc uir?e OOj
2;sue �,e
Belews Lake
with application?
included): The site
10. Receiving stream or affected surface waters:
River
UT to Dan

a. Classification WS III
b. River Basin and Subbasin No.: 030201
c. Describe receiving stream features and pertinent
downstream uses: The Dan River is a rural stream in
this area, the City of Eden's water intake is located
many miles downstream.
Part II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted: 0.025 MGD
(Ultimate Design Capacity)
Discharge 001 - Domestic
Discharge 00 - Cooling water
b. What is the current permitted capacity of the Waste
Water Treatment facility? 0.025 mgd
c. Actual treatment capacity of the current facility
(current design capacity)? 0.025 mgd
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years. None
e. Please provide a description of existing or
substantially constructed wastewater treatment
facilities; Existing: Bar screen, aeration basin,
clarifier, chlorination, de -chlorination, aerobic
digester
f. Please provide a description of proposed wastewater
treatment facilities. NA
g•
Possible toxic impacts to surface waters: None known.
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 No.
Residuals Contractor
Telephone No.
NPDES Permit Staff Report
Version 10/92
Page 2

b. Residuals stabilization: PSRP PFRP
Other
c. Landfill:
d. Other disposal/utilization scheme (Specify): Sludge
pumped by septic tank pumper.
3. Treatment plant c assification (attach completed rating
sheet) . III - Attached
_7 35 pfs.
4. SIC Code (s) : 3351 ��. 44(/
Primary 02 Secondary
Main Treatment Unit Code: 0 6 0 _ 7
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: Unknown as to whether spray irrigation
was evaluated.
Connection to Regional Sewer System: None available
Subsurface: Poor soil
Other disposal options:
5. Other Special Items:
NPDES Permit Staff Report
Version 10/92
air
Page 3
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PART IV - EVALUATION AND RECOMMENDATIONS
The facility has two discharge points. Discharge 001 is for
the 0.025 mgd domestic wastewater treatment system. The system
has shown consistent compliance.
Discharge 003 is for non -contact cooling water. The
discharge is a combination of what was at one time Discharge 002
and 003.
Recommend the permit be reissued with twodischarge points -
001 and 003.
ignature of report preparer
Water Quality Regional upervisor
Date
NPDES Permit Staff Report
Version 10/92
Page 4
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