NC0003875_Renewal (Application)_20170320

Water Resources
ENVIRONMENTAL DUALITY
March 30, 2017
Mr. Dennis Valentino, President
Elementis Chromium, Inc.
5408.Holly Shelter Road
Castle Hayne, NC 28429
Subject: Permit Renewal
Application No. NC0003875
Castle Hayne Plant
New Hanover County
Dear Mr. Valentino:
ROY COOPER
Governor
MICHAEL S. REGAN
Secretary
S. JAY ZIMMERMAN
Director
The Water Quality Permitting Section acknowledges receipt of your permit application and
supporting documentation received on March 20, 2017. The primary reviewer for this renewal
application is Sergei Chernikov.
The primary reviewer will review your application, and he will contact you if additional
information is required to complete your permit renewal. Per G.S. 150B-3 your current permit
does not expire until permit decision on the application is made. Continuation of the current permit
is contingent on timely and sufficient application for renewal of the current permit.
Please respond in a timely manner to requests for additional information necessary to
complete the permit application. If you have any additional questions concerning renewal of the
subject permit, please contact Sergei Chernikov at 919-807-6386 or [e-mail].
Sincerely,
7641" %Cie J"d
Wren Thedford
Wastewater Branch
cc: Central Files
NPDES
Wilmington Regional Office
State of North Carolina I Environmental Quality I Water Resources
1617 Mail Service Center I Raleigh, North Carolina 27699-1617
919-807-6300

Certified Mail — Return Receipt
March 15, 2017
NC DENR — DIVISION OF WATER QUALITY
WQ Permitting Section - NPDES
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: NPDES PERMIT RENEWAL
NC0003875 — ELEMENTIS CHROMIUM, INC CASTLE HAYNE PLANT
Dear Mr. Weaver:
RECEIVENAn
GUENWR
MAR 2 0 2017
WaterQuality
POrMitting Section
Enclosed please find the original and two copies of the completed NPDES Permit Application for renewal of this
facility's NPDES permit, Permit Number NC0003875. Our current permit expires at midnight on January 31, 2018.
Elementis Chromium, Inc (Elementis) hereby respectively requests renewal of NPDES Permit Number NC0003875
for the above referenced facility.
Elementis manufactures sodium dichromate, chromic acid, sodium sulfate anhydrous, and salt cake at its Castle
Hayne facility and is subject to 40 CFR 415.
Please note that there have been no changes at the facility since issuance of the last permit. However, the facility has
submitted a permit application modification, which was received by the Division on June 2, 2016. The modification
included the addition of an outfall that consists of treated quarry water supernatant with a limit of 576,000 gallons per
day. Additionally, Elementis submitted a subsequent notification regarding Outfall 002. Elementis intends to
connect the sanitary wastewater treatment plant effluent to the headworks of the industrial wastewater treatment
plant. In recognition of this change in operation, Elementis requests that Outfall 002 be changed to an internal
monitoring point with the same monitoring requirements and limitations currently listed for outfall 002. The average
flow from the sanitary treatment plant constitutes less than 1% of the total flow discharged from this facility.
Connection of 002 effluent to the industrial wastewater treatment plant can be accommodated without an increase in
the permitted flow for Outfall 001.
Thank you for your efforts with this renewal. If you have any questions or concerns, please do not hesitate to contact
me at [phone].
Sincerely
441*0<
AalvinOverca/sh
Regulatory Manager
Enclosures
Elementis Chromium LP
5408 Holly Shelter Road
Castle Hayne, NC 28429
Telephone: [phone]
Facsimile: [phone]

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number INCO003875
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
Please print or type.
Elementis Chromium Inc
Elementis Chromium Castle Hayne Plant
5408 Holly Shelter Rd
Castle Hayne
NC / 28429
910-675-7229
910-675-7201
[e-mail]
2. Location of facility producing discharge:
Check here if same as above
Street Address or State Road
City
State / Zip Code
County
3. Operator Information:.
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Elementis Chromium
Mailing Address 5408 Holly Shelter Rd
City Castle Hayne
State / Zip Code NC / 29429
Telephone Number 910-675-7229
Fax Number 910-675-7201
4. Ownership Status:
Federal ❑ State ❑ Private ® Public ❑
Page 1 of 7 C -MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
5. Standard Industrial Classification (SIC) code(s): 2819
6. Number of employees: 112
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
See attachments titled narrative description of wastewater treatment plant and narrative
description of domestic wastewater treatment plant.
S. Is facility covered under federal effluent limitation guidelines? No ❑ Yes
If yes, specify the category? Sodium Dichromate and Sodium Sulfate Production Subcategory of
Inorganic Chemicals. Manufacturing (40 CFR Part 415 Subpart O)
9. Principal product(s) produced: Sodium Dichromate, Chromic Acid, Sodium Sulfate Anvdrous
Principal raw material(s) consumed: Chromium Ore, Soda Ash, Lime and Sulfuric Acid
Briefly describe the manufacturing process(es):
Elementis produces sodium dichromate, chromic acid, and sodium sulfate from chromite ore, soda
ash, lime and sulfuric acid. Chromite ore is first sent through a dryer and then pulverized to a powder
in one (1) of four (4) on-site ball mills. The pulverized ore is combined with lime, sodium carbonate
(soda ash), and recycle residue prior to being fed to one (1) of three (3) on-site kilns. The ore mixture is
heated to approximately 2000 degrees Fahrenheit in the kiln. This treatment oxidizes the chromite
ore, converting the majority of the chromium in the ore from trivalent to hexavalent chromium. The
roasted mixture of pulverized ore, lime, recycled residue, and soda ash is quenched and leached with
water in tanks, producing a sodium chromate solution and solid ore residues.
After leaching, the mixture is sent through hydroclones to separate the sodium chromate solution from
unconverted ore residue. The unconverted ore (recycle residue and post leach ore residue) is sent to
the recycle residue process to be returned to the process to make up 50% of the initial kiln feed
mixture.
After the hydroclones, the leached sodium chromate mixture is neutralized with sulfuric acid or
chrome contaminated acid generated from the chromic acid process from a 12 to 13 pH to a pH of 8.5.
After neutralization, the mixture is sent through a primary and secondary rotary reject filter to
separate the sodium chromate solution from the waste solid residue (reject residue or spent post
neutralization ore residue). This reject residue is sent directly to the #3 Repulp Tank which operates
as a holding tank prior to being sent to the wastewater treatment system.
The sodium chromate is then sent through a calcium precipitator, a filter, and an acidifier where
sulfuric acid and soda ash are added to reduce the pH to 5 and precipitate the remaining ore residues
to convert the sodium chromate solution to sodium dichromate. The sodium dichromate is evaporated
after leaving the acidifier and sent through a final filtering process.
The liquid sodium dichromate is either crystallized to form a sodium dichromate solid crystal product
Page 2 of 7 C -MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
or remains as liquid sodium dichromate and is piped to the chromic acid process to make chromic
acid.
Chromic Acid
The sodium dichromate liquid, with an 85% concentration, is reacted with sulfuric acid to produce
chromic acid. After reacting, the chromic acid solution is filtered, melted, and rolled to produce the
chromic acid in solid flake form. The air pollution control system in the chromic acid process is
associated with the filtering, melting, conveyancing, and packaging processes. The melting and
filtering processing is connected to the Main Scrubber and the conveyancing and packaging process is
connected to the Packaging Scrubber. Both the Main Scrubber and the Packaging Scrubber is
connected to the Brownian Demister before being vented to the atmosphere. The wastewater that exits
the Packaging Scrubber is reused in the Neutralization square tank in the production of sodium
dichromate. The wastewater from the Main Scrubber is sent to the #3 Repulp tank prior to being sent
to the wastewater treatment system. There is a wastewater that is generated in the Brownian Demister
Unit that is sent to the #3 Repulp tank prior to being sent to the wastewater treatment system.
Sodium Sulfa
After the acidifier in the production of sodium dichromate, the product stream is evaporated and
centrifuged to separate sodium sulfate (saltcake) from the sodium dichromate solution. The sodium
sulfate saltcake is sent to a salt cake purification unit for purification and then sold as purified sodium
sulfate anhydrous. The wastewater residue from the saltcake purification unit is reinserted to the
manufacturing process at the leach and filter unit.
Page 3 of 7 C -MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
(List specific amounts consumed and/or units of production over the last three nears)
11. Frequency of discharge: Continuous
If intermittent:
Days per week discharge occurs:
Intermittent ❑
Duration:
12. Types of wastewater discharged to surface waters only
Discharge
Sodium Dichromate Production
AVERAGE
Sodium Dichromate Production
PEAK
per Day
244 tons/day
375 tons/day
per Month
7404 tons/month
8800 tons/month
per Year
88,885 tons/year
92,150 tons/year
11. Frequency of discharge: Continuous
If intermittent:
Days per week discharge occurs:
Intermittent ❑
Duration:
12. Types of wastewater discharged to surface waters only
Discharge
Flow
GALLONS PER DAY
Sanitary - monthly average
5,300 (average flow 2012 - 2016)
Utility water, etc. - monthly average
Process water - monthly average
625,975 (average flow 2012 - 2016)
Stormwater - monthly average
Other - monthly average
Explain:
Monthly Average
total discharge (all types)
631,275 (average flow 2012 - 2016)
13. Number of separate discharge points: 2 Outfall Identification number(s) 001 and 002
NOTE: A permit modification was submitted to add a third discharge point (Outfall 003) and send the
effluent from the sanitary plant (outfall 002) to the headworks of the industrial waste treatment
facility, which would eliminate outfall 002.
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Northeast Cape Fear River (lat - 34 deg 22 min 34 sec, long - 77 deg 51 min, 55 sec
Page 4 of 7 C -MI 10108

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data [for new or proposed discharges]
Provide data for the parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
NOTE: Permittees requesting renewal should complete the table ONLY for the parameters
currently monitored. Summarize the past 3 years of effluent data.
001 Outfall Mau 2014 throuah Mau 2016
Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
11
2.06
mg/l
Chemical Oxygen Demand (COD)
N/A
N/A
N/A
Total Organic Carbon
N/A
N/A
N/A
Total Suspended Solids
61.8
35.9
lbs/day
Ammonia as N
7.8
4.14
mg/l
Temperature (Summer)
37
32
°C
Temperature (Winter)
31
21.5
°C
pH
7.5
6.9
Std units
Fecal Coliform (If sanitary waste is
present)
N/A
N/A
N/A
Total Residual Chlorine (if chlorine is
used)
N/A
N/A
N/A
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type Permit Number Type Permit Number
Hazardous Waste (RCRA)
UIC (SDWA)
NPDES
PSD (CAA)
NCD057454670 NESHAPS (CAA)
N/A
NC0003875
3712900055
Non -attainment program (CAA) N/A
N/A
Ocean Dumping (MPRSA) N/A
Dredge or fill (Section 404 or CWA) N/A
Other - Title V Air Permit 02937T36
Other - NPDES Stormwater Permit NCS000003
Page 5 of 7 C -MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Chromium - typical less than detection, max 0.265 lb/day - source chromium manufact.
Nickel - typical less than detection, max 0.37 lb/day
Cadmium - no detection in last 3 years - source chromite ore
Copper - average 21.2 ug/l, max 31 ug/1- source chromite ore
Mercury - average 10.8 ng/1, max 30 ng/1- source chromite ore, river water, sulfuric acid
Lead - no detection last 3 years - source chromite ore
Silver - no detection last 3 years - source chromite ore
Zinc - average 17.5 ug/1, max 20 ug/1- source chromite ore
Phosphorus - average 0.175 mg/l, max 0.21 mg/l
Page 6 of 7 C -MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Calvin Overcash Regulatory Manager
Printed name of Person Signing Title
Signature of Applicant
Date
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 7 of 7 C -MI 10/08

Elements 3 -yr Produciton
2014
201,r
2016
Month
Tons Dichromate
Daily Avg (tons) Annual Average (Tons)
Jan
5982
193
Feb
6687
239
Mar
8379
270
Apr
8652
288
May
8794
284
June
8433
281
July
7943
256
Aug
8607
278
Sept
8564
285
Oct
8595
277
Nov
5412
180
Dec
6100
197 92150
Jan
6546
211
Feb
6767
242
Mar
8504
274
Apr
8410
280
May
7875
254
June
7783
259
July
8302
268
Aug
6820
220
Sept
7601
253
Oct
7342
237
Nov
6724
224
Dec
6188
200 88862
Jan
6307
203
Feb
7153
255
Mar
8612
278
Apr
5285
176
May
6857
221
June
7323
244
July
6258
202
Aug
7643
247
Sept
7895
263
Oct
5837
188
Nov
7826
261
Dec
Monthly Average
Monthly Max
Daily Average
Annual Average
8647
7407
8794
279 85644
244
88885

ELEMENTIS CHROMIUM SLUDGE MANAGEMENT PLAN
Date: March 15, 2017
Prepared by Sean Coury— Elementis Chromium Industrial Plant ORC
The sludge generated in Elementis Chromium's industrial wastewater treatment process is sent
as slurry to the "quarry" under Occidental Chemical Corporation's Surface Disposal of Residual
Solids Permit No. WQ0001492. Elementis Chromium holds a license agreement with
Occidental Chemical Corporation to dispose of the solids discharged to the "Quarry". Specific
regulatory requirements are stipulated in the permit. They include maintaining two feet of
freeboard, monitoring the waste using the TCLP test, and maintaining inspection logs, etc. This
activity is 503 exempt.
The sludge generated from the domestic wastewater treatment process is removed for land
application at a permitted site (WQ0000455) by Lewis Farms. Vector control is accomplished by
having Lewis Farms add lime to the truck load of sludge and follow the DENR procedure to
maintain a high pH prior to Land Application. Annual samples of the sludge are collected and
analyzed as required by Lewis Farms' Permit. Typically 4,000 to 8,000 gallons of sludge are
removed annually.

NARRATIVE DESCRIPTION OF INDUSTRIAL WASTEWATER TREATMENT
Wastewater slurry from the #2 repulp tank in the neutralization production area and waste water
from the recycle production area enters the wastewater treatment process via the 80,000 gallon
wastewater collection tank. Pickle liquor (ferrous chloride reducing agent) and/or sulfur dioxide
are added to begin the reduction of hexavalent chromium to trivalent chromium.
Wastewater slurry is pumped from the waste collection tank to one of three 24,000 gallon
reactors. Pickle liquor is added to the reactor to complete the reduction of hexavalent chromium
to trivalent chromium. When the reduction is complete, lime slurry is added to the reactor to
raise the pH so that chromium, iron, and other metals will precipitate from the treated wastewater
solution.
Contaminated water wastes from groundwater recovery wells, containment areas, production
area sumps, etc. enter the wastewater treatment process via the 10,000 gallon sump surge tank.
The sump surge tank is pumped to the 12,000 gallon water batch reactor. Pickle liquor is added
to the reactor to reduce the hexavalent chromium to trivalent chromium. When the reduction is
complete, lime slurry is added to raise the pH, to precipitate metals.
All four reactors are pumped to the 103,000 gallon treatment surge tank. This tank allows a
continuous feed of the treated wastewater batches into the chloride removal
(countercurrent washing) circuit.
The treatment surge tank is pumped to the 4,700 gallon feed reslurry tank. This feed reslurry tank
is the starting point for two parallel washing circuits. One circuit washes soluble solids from light
solids. The other circuit washes soluble solids from heavy solids.
The light circuit has three 95,000 gallon clarifiers, and two 3,200 gallon light reslurry tanks.
The heavies circuit has three hydroclones, and two 1,100 gallon light reslurry tanks.
Both washing circuits wash soluble solids away from the insoluble solids. The liquid proceeds
from three to two to one and eventually becomes the effluent to the river, while the washed
residual solids go from one to two to three and eventually to a surface impoundment.
The underflow (residual solids) from the third stage of each washing circuit enters the 3,950
gallon sludge hold tank. Crushed limestone is added to the treated waste slurry in the sludge hold
tank to decrease the solubility and mobility of metals in the residual solids. The treated slurry is
then pumped to the 10,000 gallon sludge retention tank where either river water, or quarry return
water is added for transport to the surface impoundment. The residual solids are pumped via
conveyance piping to the surface impoundment. Please see the attached, signed Sludge
Management Plan for details.
The liquid overflow from the first stage clarifier goes to the 10,000 gallon overflow tank. The
overflow tank feeds one of the three, eleven foot diameter, 800 GPM capacity sand filters. The
polished water from the sand filters is the 001 effluent to the river. The maximum permitted
monthly average flow of this stream is 0.785 MGD.

NARRATIVE DESCRIPTION OF DOMESTIC WASTEWATER TREATMENT
Domestic wastewater from showers, sinks, and restrooms enters the wastewater treatment
process via the 5,000 gallon equalization tank. The equalization tank is continuously aerated.
The flow from the equalization tank is split and pumped to two parallel extended aeration
package plants; each plant has a 10,000 gpd treatment capacity.
Plant one has two 5,000 gallon aeration compartments, while plant two has one 10,000 gallon
aeration compartment, but the operation is essentially the same. The treatment units share five
blowers. One is used for the equalization tank. Two are used for the aeration compartments and
air lifts, and two are spares.
The flow precedes from the aeration compartments to the clarifiers. The overflow from the
clarifiers feed tablet chlorinators.' Each plant has a chlorine contact tank sized to provide a
minimum of thirty minutes contact time at 10,000 gallons per day. The water from each of the
plants' chlorine contact chambers is the 002 effluent to the river. After the chlorine contact
chamber, dechlorination is achieved by metering liquid sodium metabisulfite into the effluent
stream. The maximum permitted monthly average flow of this stream is 0.020 MGD. The
facility is in the process of converting from chlorine disinfection to ultraviolet disinfection. The
equipment is in the process of being installed and tested and should be in operation by the end of
August 2012.
Wasted sludge is sent to a digester for further aeration. Plant one has a 1,500 gallon digester and
Plant two has a 3,000 gallon digester.
Lime is added to digested sludge for vector control and is land -farmed by Lewis Farms. Please
see the attached, signed Sludge Management Plan for details.
A 3.0 liter diesel backup generator auto starts during power interruptions, supplying electricity to
operate the treatment plants, pumps, lights, etc.

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