NC0089109_Renewal Application_20180327

ROY COOPER
MECHAEL S.REGAN
Secreta
Water Resources LLA CULPEPPER
ENViRONMEINTAL Q49AUTY IF3terim Director
March 27, 2018
Robert Williamson, General Manager
American Zinc Products LLC
484 Hicks Grove Rd
Mooresboro, NC 28114
Subject: Permit Renewal
Application No. NC0089109
American Zinc Products, LLC
Rutherford County
Dear Applicant:
The Water Quality Permitting Section acknowledges the March 26, 2018 receipt of your permit renewal application and
supporting documentation. Your application will be assigned to a permit writer within the Section's NPDES WW
permitting branch. 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.
The permit writer will contact you if additional information is required to complete your permit renewal. Please respond
in a timely manner to requests for additional information necessary to allow a complete review of the application and
renewal of the permit.
Information regarding the status of your renewal application can be found online using the Department of Environmental
Quality's Environmental Application Tracker at:
https://deq.nc.gov/permits-regulations/permit-guidance/environmental-application-tracker
If you have any additional questions about the permit, please contact the primary reviewer of the application using the
links available within the Application Tracker.
S''inc��erely,
���Ul '`r
Wren Thedford
Administrative Assistant
Water Quality Permitting Section
ec: WQPS Laserfiche File w/application (ARO)
State of North Carolina I Enviromnental Quality I Water Resources
1617 Mail Service Center I Raleigh,North Carolina 27699-1617
919-807-6300

TIMOTHY R.BASILONE
AMERIVice President-Environmental Affairs
AZ
� Z NEC RECYCAN CLING 4955 Steubenville Pike T 724-773-2223 www azr corn
Suite 405 F 412-788-4526 tbasrlone@azrcom
Delivering a Sustainable Future Pittsburgh,PA 15205
A.At =fin L P9A,4 � �-�3a�.� ��.,�r,.,., ,:,.�., Wu�.
VIA EMAIL AND OVERNIGHT MAIL
January 30,2018
Dr.Sergei Chernikov, Ph.D.
Environmental Engineer II
North Carolina Dept.of Environment
&Natural Resources
Division of Water Quality
{
9th Floor—Archdale Building
512 N Salisbury StreetRECE EDIDE VIR
Raleigh, NC 27604
MAR 6 2010
RE: NPDES—Effluent Permit Renewal Application
American Zinc Products LLC Water Resources
Permit NC0089109 perrmtting Section
Dear Dr.Chernikov:
Please find enclosed three copies of the application and supporting information for timely renewal of
the above referenced NPDES Permit for the American Zinc Products LLC("AZP",f/k/a Horsehead Metal
Products LLC)facility in Mooresboro, North Carolina.
Please note that all application information should be considered Confidential Business Information.
Information contained in the application is based on recent monthly effluent discharge monitoring
information submitted over the past 24 months.
AZP would like to meet with you to discuss the permit application and anticipated activities at the
facility during the next 12-18 months. I will call you within the next week to schedule a mutually
convenient time to meet at your office. If you have any questions, please contact me.
Sincerely,
K 0e—e-Xxe
Timothy . Basilone
Enc.

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 NC0089109
Please print or type.
1. Contact Information:
Owner Name American Zinc Products LLC
Facility Name American Zinc Products LLC
Mailing Address 484 Hicks Grove Road
City Mooresboro
State / Zip Code North Carolina, 28114
Telephone Number 724-773-2223
Fax Number 412-788-4526
e-mail Address [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:
Narne 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 N/A
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
Page 1 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
4. Ownership Status:
Federal 0 State 0 Private ® Public ❑
5. Standard Industrial Classification (SIC) code(s): 3341
6. Number of employees: 35; approximately 300 when fully staffed
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.
There is no wastewater treatment system. Removal of metals and other constituents
from effluent water is inherent to the metal production process, as described in
Section 9 below.
8. Is facility covered under federal effluent limitation guidelines? No ® Yes ❑ �
If yes, specify the category?
9. Principal product(s) produced: Special High-Grade ("SHG") Zinc Metal and other metal
commodities.
Principal raw material(s) consumed: Waelz Oxide (a/k/a Crude Zinc Oxide)
Briefly describe the manufacturing process(es):
The manufacturing process consists of an integrated system of leaching, extraction,
stripping, and electrowinning processes. Feed, including metal bearing oxides and other raw
materials, are managed in solution throughout the process, and metal products are removed
as precipitates, concentrates, and SHG Zinc Metal. Metal bearing Waelz Oxide feed is
produced at parent company-owned facilities. The specific technologies and configuration of
the operation are confidential business information.
In January 2016, the facility curtailed zinc production. Process design and operational
changes will be under consideration over the forthcoming 12 - 18 months. (j
Information provided in this permit renewal application reflects effluent discharge
monitoring data provided in monthly discharge monitoring reports (DMR's) submitted to the
Department over the past 24 months. This historic information reflects the volume and
nature of constituents anticipated in discharge under current operations.
Page 2 of C-M110108

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 years)
Product Produced or Raw Material Product Produced or Raw Material
Consumed Consumed
(AVERAGE) (PEAK)
per Day
per Month
per Year
11. Frequency of discharge: Continuous ❑ Intermittent IE
If intermittent:
Days per week discharge occurs: Average 12 days/month Duration: 24 hours/day
12. Types of wastewater discharged to surface waters only
Discharge Flow
(GALLONS PER DAY)
Sanitary- monthly average
Utility water, etc. - monthly average
Process water - monthly average 192,842 gallons / day (12 days / month average)
Stormwater-monthly average
Other-monthly average
Explain: •
Monthly Average
total discharge (all types) 192,842 gallons / day (12 days / month average)
13. Number of separate discharge points: 1 Outfall Identification number(s): 001
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Broad River
Page 3 of 5 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.
Parameter Daily Monthly Units of
Maximum Average Measurement
-
Biochemical Oxygen Demand (BOD5) N/A {
Chemical Oxygen Demand (COD) N/A
Total Organic Carbon N/A
SEE ATTACHED
NARRATIVE,
TABLES,AND
Total Suspended Solids* FIGURES
Ammonia as N N/A
Temperature (Summer) N/A
Temperature (Winter) N/A
pH*
Fecal Coliform (If sanitary waste is N/A
present)
Total Residual Chlorine (if chlorine is N/A
used)
16. List all permits,construction approvals and/or applications (check all that apply and provide permit
numbers or check none ye not applicable):
Type Permit Number Type Permit Number
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES X Dredge or fill (Section 404 or CWA)
PSD (CAA) Other
Non-attainment program (CAA)
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Attached is information describing the anticipated constituents and average
concentrations in effluent water discharged from the facility.
SEE TABLE 4, FIGURES 1 AND 2, AND THE NARRATIVE, ATTACHED
Page 4 of 5 C-MI 10/08

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
I
18. Is this facility located on Indian country? (check one)
Yes ❑ No El
ji
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.
Rob Williamson General Manager
Printed name of Person igning Title
(..„...---7 -71)
>/Zq/r4
Signature of App scant 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 6 of 5 C-MI 10108

Supplemental Information
Mooresboro Effluent Permit Renewal Application
Permit NC0089109
This renewal permit application is submitted timely for renewal of the effluent discharge permit
for the AZR Mooresboro,NC facility (Permit Number NC0089109).
Information provided in this permit renewal application reflects effluent discharge monitoring
data provided in monthly discharge monitoring reports(DMRs) submitted to the Department
ovet the past 24 months. This information reflects the nature of effluent discharge water based
on current operations.
A summary of historic effluent information is provided below, and data from Monthly DMR's
for the past 24 months is provided on the attached Tables and Figures.
Discharge Volume
In January 2016, the facility curtailed zinc production, and the associated effluent discharge rate
over the past 24 months has fluctuated, averaging 192,842 gallons on a daily average basis,
which is approximately 2.34 million gallons/month total discharge(Table 1). The current
permitted average discharge volume is 800,000 gallons/day.
Intermittent flow has occurred at an average of around 12 days per month over the past 24
months. It is anticipated that operations at the current level will continue while process design
and operation changes are considered over the forthcoming 12— 18 months. The average daily
effluent flow of 800,000 gallons should be maintained in the renewed permit.
Constituent Discharge Concentration and Mass
Information on DMR's submitted to the Department over the past 24 months indicates that
permit limits were not exceeded for any parameters. There was one chronic toxicity test,
occurring in January 2016, which failed. A test was conducted the following month which was
shown to pass. All other tests passed for chronic toxicity.
Information from DMR's, including monthly average concentrations for constituents having
chronic discharge limits, and monthly effluent flow information is provided on Table 1.
Constituents noted on Table 1 have a sampling frequency of 2/Month.
Information from DMR's, including daily maximum concentrations for constituents with acute
discharge limits is provided on Table 2.
Table 3 includes monthly average and daily maximum concentrations for constituents without
limits and that were monitored on a quarterly or monthly frequency, except for pH which is
monitored daily and has a limit of 6—9 standard units,chronic toxicity which is pass/fail, and
turbidity having a contribution limit to the stream of 50 NTU.

r .
Table 4 provides information on various constituents as to the anticipated average concentration
in effluent discharge water.
Cadmium
Cadmium discharge is limited in the current permit to 0.270 Mg/L(ppm). At an average
discharge rate of 800,000 gallons/day, based on this concentration limit 54.83 pounds/month
of cadmium can be discharged within limits to the Broad River in effluent water, provided the
daily average concentration for the month does not exceed 0.270 ppm, and the maximum daily
concentration does not exceed 1.66 ppm(Table 1).
Over the past 24 months, the average monthly cadmium concentration was 0.0802 ppm. This
concentration is well below the permit limit for cadmium at 0.270 ppm. At the current average
daily effluent discharge rate of 192,842 gallons/day, an average of 1.62 pounds/month of
cadmium was discharged over the past 24 months. This amount of cadmium is well below the
mass at the chronic permit limit described above,at 54.83 pounds/month.
The Maximum Effluent Concentration Limit was calculated using the Departments Reasonable
Potential Analysis(RPA)worksheet. Based on stream characteristics for the Broad River, an
average of 800,000 gallons/day discharge rate, a water hardness of 2,500 ppm, and using 0.100
ppm for the anticipated cadmium concentration,the calculated maximum effluent concentration
for chronic toxicity is 0.121 ppm. This limit is conservative considering it is based on the
permitted discharge rate (800,000 gallons/day average)as opposed to the actual discharge rate
(192,000 gallons/day average),which is much lower. Additionally, a higher anticipated
cadmium concentration of 0.100 ppm was used in the calculation,which is 25%higher than the
average cadmium concentration in effluent water over the past 24 months of 0.0802 ppm.
Finally,flow is intermittent, averaging 12 days/month,which consequently reduces the
likelihood of the calculated limit for the average monthly concentration being exceeded.
Based on the calculated Maximum Effluent Concentration Limit, at an average of 800,000
gallons/day discharge volume the mass of cadmium that could be discharged within the
calculated limit is 25 pounds/month. The current monthly average discharge rate of 1.62
pounds/month is well below the calculated limit on a mass basis.
Table 2 provides information on maximum cadmium concentrations in effluent flow over the
past 24 months, the current acute toxicity permit limit, and the calculated maximum acute
toxicity permit limit using the RPA. Using the maximum discharge concentrations over the past
24 months,the average of maximum monthly cadmium concentrations was 0.1453 ppm, and the
maximum of all daily cadmium concentrations recorded is 0.260 ppm. These concentrations are
both well below the 1.66 ppm limit in the current permit, and is below the daily maximum
(acute)limit of 0.63 ppm for cadmium calculated using the RPA.
2

Lead
Lead discharge is limited in the current permit to 3.37 ppm. At an average discharge rate of
800,000 gallons/day, based on this concentration limit 684.32 pounds/month of lead can be
discharged within limits to the Broad River in effluent water,provided the daily average
concentration for the month does not exceed 3.37 ppm, and the maximum daily concentration
does not exceed 3.75 ppm (Table 1).
Over the past 24 months, the average monthly lead concentration was 0.0072 ppm. This
concentration is well below the permit limit for lead at 3.37 ppm. At the current average daily
effluent discharge rate of 192,842 gallons/day,an average of 0.23 pounds/month of lead was
discharged over the past 24 months. This amount of lead is well below the mass at the chronic
permit limit described above, at 684.32 pounds/month.
The Maximum Effluent Concentration Limit was calculated using the Departments RPA
worksheet. Based on stream characteristics for the Broad River, an average of 800,000 gallons/
day discharge rate, a water hardness of 2,500 ppm,and using 0.500 ppm for the anticipated lead
concentration,the calculated maximum effluent concentration for chronic toxicity is 0.737 ppm.
This limit is conservative considering it is based on the permitted discharge rate (800,000 gallons
/day average)as opposed to the actual discharge rate(192,000 gallons/day average),which is
much lower. Additionally, a higher anticipated lead concentration of 0.500 ppm was used in the
calculation,which is significantly higher than the average lead concentration in effluent water
over the past 24 months of 0.0072 ppm. Finally, flow is intermittent, averaging 12 days/month,
which reduces the likelihood of the calculated limit for the average monthly concentration being
exceeded
Based on the calculated Maximum Effluent Concentration Limit, at an average of 800,000
gallons/day discharge volume the mass of lead that could be discharged within the calculated
limit is 150 pounds/month. The current monthly average discharge rate of 0 23 pounds/month
is well below the calculated limit on a mass basis.
Table 2 provides information on maximum lead concentrations in effluent flow over the past 24
months,the current acute toxicity permit limit, and the calculated maximum acute toxicity permit
limit using the RPA. Using the maximum discharge concentrations over the past 24 months,the
average of maximum monthly lead concentrations was 0.0096 ppm, and the maximum of all
daily lead concentrations recorded is 0.174 ppm. These concentrations are both well below the
3.75 ppm limit in the current permit, and is below the daily maximum (acute) limit of 17.07 ppm
for lead calculated using the RPA.
Summary
Figure 1 and Figure 2 summarize recent mass discharge levels for cadmium and lead,including
the mass discharge on an average monthly basis over the past 24 months, and mass limits for the
current permit limit and the anticipated limit based on the RPA,respectively. As shown on these
figures, under the current operating conditions and based on information over the past 24
{
3

months,cadmium and lead discharges on a monthly mass basis are well below the calculated
RPA maximum chronic and acute toxicity limit values for effluent discharge to the Broad River.
AZR is submitting this renewal application for renewal of the effluent discharge permit based on
effluent information contained in the DMR's submitted over the past 24 months. Anticipated
constituents and concentrations are provided in Table 4. Effluent water hardness determined
over the past 24 months of approximately 2,500 should be used for RPA calculations. The
current permit discharge volume should be maintained on an average daily discharge of 800,000
gallons/day.
11
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TABLE 2
MONTHLY DISCHARGE INFORMATION-MAXIMUM CONSTITUENT CONCENTRATION ,
COMPARISON WITH CURRENT PERMIT LIMITS
AND CALCULATED MAXIMUM DAILY(ACUTE)EFFLUENT LIMITS
Monthly Maximum Concentrations(Mg/L)
YEAR MONTH Cd Cr Pb Zn F TSS
January 0.114 0.011 0 1.44 31.5 12
February 0.128 0.0057 0.0055 5.56 12.9 11.2
March 0.174 0 0.174 1.21 0 7.6
April 0 075 0 0 1 6 8 16 2
May 0.035 0 0.0052 0.64 6 6 12.2
June 0.099 0 0 1.6 9 2 15.5 ,
N July 0.1 0 0 1.5 9 1 6.5
August 0.228 0 0.006 4.4 10.3 11.8
September 0.14 0 0.0055 4.66 7.7 5.7
October 0.069 0 0 3.74 6 0
November 0.068 0 0 3.7 4.7 0
December 0.094 0 0 4.43 5.2 0 ,
January 0.12 0 0 6.56 5.3 0
February 0.083 0 0.0066 9 5.2 3
March 0.057 0 0 4 2 8.2 4.3
April 0 08 0 0 4.53 7.1 3.8
May 0.038 0 0.011 2.23 4.6 0
r^, June 0 057 5 0 2.8 5.7 3
IN July 0.078 0.0055 0.005 2.28 6.8 9.6
August 0.13 0 0 10.5 6.7 5.4
September 0.26 0 0.0054 3.9 5.2 6
October 0.12 0 0.0051 7.24 5 2.5
November 0.72 0.076 0 34.5 7.5 0
December 0.42 0 0 2 52 0
MONTHLY
AVERAGE 1, 04453._ _W ,4,„_12,EL00,8,6 5.17 , .Ng 5.68
Current Permit(Acute) Limit(Daily Maximum Concentration-Mg/L)
Cd Cr Pb Zn F TSS
1'66 113.6 336 No Limit 243.2 No Limit
Calculated(Acute)Limit(Daily Maximum Concentration-Mg/L)
Cd Cr Pb Zn F TSS
0..0 17007
*Calculated using hardness of 2,500 for effluent water,and 25 for upstream
hardness,and at 800,000 gallons/day average flow.
"0"value means not detected.
Cl ,,:,1„ ,.a » Parameter with Permit Limit

TABLE 3
MONTHLY DISCHARGE INFORMATION-OTHER MONITORED CONSTITUENTS
DAILY MAXIMUM AND AVERAGE MONTHLY CONSTITUENT CONCENTRATION
Constituent Units Maximum Average
NH3-N Mg/L 0 12 0.017
Total Aluminum Mg/L 0.151 0.0713
Total Antimony Mg/L 0 0445 0.0125
Total Arsenic Mg/L Not Detected Not Detected
Chlorides Mg/L 4700 1440
Total Cobalt Mg/L 0 0072 0.001
Total Copper Mg/L 0.0238 0.0034
Total Fluoride Mg/L 31.5 25.3
Total Iron Mg/L 110 15.7
Total Nickel Mg/L 0.0071 0.0028
Total Tin Mg/L 0 0068 0 001
pH standard units 6 6-8.3 6 5-7.3
Chronic Toxicity Pass/Fail Failed 1 Time in 8 Monitored Periods
Effluent Turbidity NTU 13.8 3
Upstream Turbidity NTU 83.4 17
Downstream Turbidity NTU 87 3 17

TABLE 4
ANTICIPATED CONSTITUENTS-AVERAGE CONCENTRATION
Constituent Mg/L
Chlorides 17,000
Fluoride 20
Iron 0.0157
Tin 0.001
Arsenic 0.25
Zinc 4.00
Nickel 0.150
Cobalt 0.001
Copper 0.160
Cadmium 0.100
Lead 0.500
Aluminum 0.151
Chromium 0.004
Antimony 0.250 j

Figure 1
Cadmium Mass Discharge
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Figure 2
Lead Mass Discharge
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700
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c
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a 400
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Monthly Mass Discharged -- —Permitted Monthly Mass -- RPA Calculated Allowable Max Monthly Mass
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