WQ0003699_Final Permit_19990126

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
January 26, 1999
Jeff Van Jahnke
Zemex Mica Corporation
P.O. Box 277
Spruce Pine, North Carolina 28777
4 •
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0003699
Zemex Mica Corporation
Bear Creels Plant
Wastewater Recycle System
Mitchell County
Dear Mr. Jahnke:
In accordance with your application received September 23, 1998, we are forwarding herewith Permit No.
WQ0003699, dated January 26, 1999, to the Zemex Mica Corporation for the construction and operation of the
subject wastewater recycle system. The modification to this permit is the construction and operation of two 1.195
million -gallon settling basins with two 1,500 GPM pumps. Upon startup operation of the new system, the existing
recycle ponds will be terminated from service.
This permit shall be effective from the date of issuance until December 31, 2003, shall void Permit No.
WQ0003699 issued April 22, 1998, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this permit. Failure to establish an adequate
system for collecting and maintaining the required operational information will result in future compliance
problems.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes,
and filed with the Office of Administrative Hearings, P.O. Drawer 27447, Raleigh, NC 27611-7447. Unless such
demands are made this permit shall be final and binding.
PO Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled110% post -consumer paper

One set of approved plans and specifications is being forwarded to you. If you need additional information
concerning this matter, please contact;?b'o at (9I9) 733-5083 extensj4 533.
Sincerely
A. Preston Howard, Jr., P.E.
cc: Mitchell County Health Department
Asheville Regional Office, Water Quality Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and
other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Zemex Mica Corporation
Mitchell County
FOR THE
continued operation of a 18,000 GPD wastewater recycle system consisting of a filter press, three inorganic solids
settling ponds in parallel, a fine settling basin, a 200 GPM return pump, a 5,000 gallon pressurized storage tank, a
chemical feed system, and all associated piping valves, controls and appurtenances to serve the Bear Creek Plant,
with no discharge of wastes to the surface waters, pursuant to the application received September 29, 1998, and in
conformity with the project plan, specifications, and other supporting data subsequently filed and approved by the
Department of Environment and Natural Resources and considered a part of this permit, and
construction and operation of a 900,000 GPD wastewater recycle system consisting of two settling basins with a
combined capacity of 1.195 million -gallons, two 1,500 GPM pumps, and all associated piping valves, controls and
appurtenances to serve the Bear Creek Plant, with no discharge of wastes to the surface waters, pursuant to the
application received September 29, 1998, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and Natural Resources and
considered a part of this permit. Upon startup operation of the new system, the existing recycle ponds in the
previous paragraph will be terminated from service.
This permit shall be effective from the date of issuance until December 31, 2003, shall void Permit No.
WQ0003699 issued April 22, 1998, and shall be subject to the following specified conditions and limitations:
I. This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application and
other supporting data.
The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there is
a name change of the Permittee, a formal permit request must be submitted to the Division of Water Quality
(Division) accompanied by an application fee, documentation from the parties involved, and other supporting
materials as may be appropriate. The approval of the request will be considered on its merits and may or may
not be approved.

Upon completion of construction and prior to operation of this permitted facility, a certification must be
received from a professional engineer certifying that the permitted facility has been installed in accordance
with this permit, the approved plans and specifications, and other supporting materials. If this project is to be
completed in phases and partially certified, you shall retain the responsibility to track further construction
a roved under the same ermit, and shall provide a final certificate of completion once the entire project has
been completed. Mail the Certification to the Non -Discharge Permitting Unit, P.O. Box 29535, Raleigh, NC
27626-0535.
6. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those actions that may be required by this
Division, such as the construction of additional or replacement treatment or disposal facilities.
The Asheville Regional Office, telephone number [phone], shall be notified at least forty-eight (48)
hours in advance of operation of the installed facilities so that an in-place inspection can be made. Such
notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m. until 5:00
p.m. on Monday through Friday, excluding State Holidays.
The residuals generated from these treatment facilities must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the Division.
9. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface or
groundwaters resulting from the operation of this facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the discharge
of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the settling basins shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division to insure surface and ground water protection will be
established and an acceptable sampling reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper operation
of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent malfunctions and
deterioration, operator errors and discharges which may cause or lead to the release of wastes to the
environment, a threat to human health, or a nuisance. The Permittee shall maintain an inspection log or
summary including at least the date and time of inspection, observations made, and any maintenance, repairs,
or corrective actions taken by the Permittee. This log of inspections shall be maintained by the Permittee for
a period of three years from the date of the inspection and shall be made available to the Division or other
permitting authority, upon request.
16. Any duly authorized officer, employee, or representative of the Division may, upon presentation of
credentials, enter and inspect any property, premises or place on or related to the recycle system at any
reasonable time for the purpose of determining compliance with this permit, may inspect or copy any records
that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
17. The annual administering and compliance fee must be paid by the Permittee within thirty (30) days after
being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate action to
revoke this permit as specified by 15A NCAC 2H .0205 (c)(4).

18. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to an
enforcement action by the Division in accordance with North Carolina General Statute 143-215.6A to 143-
215.6C.
19. The issuance of this permit does not preclude the Permittee from complying with any and all statutes, rules,
regulations, or ordinances which may be imposed by other government agencies (local, state, and federal)
which have jurisdiction.
20. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
Iife of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office, telephone number [phone],
as soon as possible, but in no case more than 24 hours or on the next working day following the occurrence or
first knowledge of the occurrence of any of the following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of significant amounts
of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents of a basin
or tank, the known passage of a slug of hazardous substance through the facility, or any other unusual
circumstances;
L Any process unit failure, due to known or unknown reasons, that renders the facility incapable of
adequate wastewater treatment, such as mechanical or electrical failures of pumps, aerators, compressors,
etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility; or
d. Any time that self-monitoring information indicates that the facility is not in compliance with its permit
limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter form within
five (5) days following first knowledge of the occurrence. This report must outline the actions taken
or proposed to be taken to ensure that the problem does not recur.
23. The lagoon shall have a liner of natural material at least one (2) foot in thickness (as specified by the design
engineer), compacted to 95% proctor standard dry density and installed and compacted in layers no thicker
than six inches, with a hydraulic conductivity no greater than 1 x 10-6 centimeters per second. Following
installation and inspection of the lagoon liner, and prior to waste disposal operations, verification of the
liner's compliance with hydraulic conductivity and thickness specifications must be provided by the project
engineer to the Groundwater Section, N.C. Division of Water Quality, P.O. Box 29578, Raleigh, N.C. 27626-
0578.
24. The COMPLIANCE BOUNDRY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and standards. The Compliance Boundary for the disposal system individually
permitted after December 31, 1983 is established at either (1) 250 feet from the waste disposal area, or (2)
within 50 feet of the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to immediate remediation
action in addition to the penalty provisions applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the disposal system
midway between the Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of
standards at the Review Boundary shall require remediation action on the part of the permittee.

25. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its extension. Upon
receipt of the request, the Commission will review the adequacy of the facilities described therein, and if
warranted, will extend the permit for such period of time and under such conditions and limitations as it may
deem appropriate.
Permit issued this the twenty-sixth day of January, 1999
;NORXTKHOL,/27ALINMANAGEMENT COMMISSION
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0003699
4

Permit No. WQ0003699
January 26, 1999
ENGINEER'S CERTIFICATION
Partial Final
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the project,
Project Name
Location and County
for the Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation of
the construction such that the construction was observed to be built within substantial compliance and intent of this
permit, the approved plans and specifications, and other supporting materials.
Signature
Date
Registration No.

UNITED STATES �� =n U-�'ADEPARTMENT OF THE INTERIORGEOLOGICAL SURVEY
82°07'30" 399000- E. 400oc
401 �2/yleX
200
39H

RATING SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
Name of
Owner or
Mailing Address: V-0- ZSaA_ X 77 5P194 4- Al C 7I/
County: —mss.// - Telephone: -GBS — 4G Z/ .
Present Classification: New Facility Existing Facility
NPDES Per. No. NC00 Nondisc. Per. No.WQ 9 Health Dept.Per No.
Rated by: ,`c-�.o�- IZ• Telephone /ZJ'l 1GZ08 Date:V OF—
�Y?�
Reviewed by: Health Dept. Telephone:
<1�r 0 �-� Regional Office Telephone: 2.1- zSl-GtnLo
-- Central Office Telephone:
ORC: Grade: Telephone:
Check Classification(s): Subs a Spray Irrigation Land Application
Wastewater Classification: (Circle One it III IV Total Points:
SUBSURFACE CIASSIFICATION
SPRAY IRRIGATION CLASSIFICATION
(check all units that apply)
(check all units that apply)
1. septic tanks
1.
preliminary treatment (definition no. 32 }
2. pump tanks
2.
lagoons
3. siphon or pump -dosing systems
3.
septic tanks
4. sand filters
4.
pump tanks
5. grease trapAnterceptor
5,
pumps
6_ oil/water separators
6.
sand filters
7. gravity subsurface treatment and disposal:
7.
grease trapAnterceptor
8. pressure subsurface treatment and disposal:
8.
oil/water separators
9.
disinfection
10.
chemical addition for nutrientlalgae 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 b'rosolids, residuals or contaminated soils on a designated site.
WASTEWATER TREATMENT FACILITY CLASSIFICATION
The following systems shall be assigned a Class I classification, unlacc the flow is of a significant quantity or the technology is unusually
complex, to require consideration by the Commission on a case -by -ase basis: (Check if Appropriate)
i. Oil/wafer Separator Systems consisting only of physical separation, pumps and disposal;
2. septic Tank/Sand f=ilter 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;
3. Groundwater Remediation Systems consisting only of o"ater separators, pumps, air -stripping, carbon adsorption, disinfection
and dispo a);
6, AquacuRure operations with discharge to surface waters;
7. Water Plant sludge handling and back -wash water treatment;
8. Seafood processing consisting of screening and disposal.
4. Single-family discharging systems, with the exception of Aerobic Treatment Units, will be classified 9 permitted after July 1,
1493 or 4 upon inspection by the Division, h 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.

(15) Electrodlalysis. Process for removing Ionized salts from water through the use of Ian -selective len-exchange membranes;
(16) Filter Press. A process operated mechanically for partially dewatering 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 farm of line bubbles; also called foam fractionation;
(18) Grh 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 applfcallon:
(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 filter operating under gravity conditions as a polishing method for removing
suspended soilds 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 nhrate nitrogen;
(26) Phosphate Removal, Biological. The removal of phosphorus from wastewater by an oxicdanox€c 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 AeratforL 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 flawing down a
series of steps or weirs; The flow occurring across the steps or weirs moves in a fairly thin layer and the operation of the cascade requires no operator
adjustment; thus, zero points are assigned even though this is an essential step to meeting the limits of the discharge permit;
(30) Powdered to Granular Activated Carbon Feed. A biophysical carbon process that utiflzos biological activity and organic absorption by using powdered or
granular activated carbon; Virgin or regenerated carbon is feed controlled into the system;
(31) Preaeration. A tank constructed to provide aeration prior to primary treatment;
(32) Preliminary Units. Unit operations in the trealmert 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 bad on the treatment process which is operated by the same governing body as the wastewater
treatment plant being rated;
b) Pre-treatrrsnt Program, Industrial - must be a State or EPA required program to receive points on the rating shoot;
(34) Primary Clarifiers. The first settling tanks through which wastewater is passed In a Ireatment 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 -plan 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 nearty pure flqu;d free from
suspended solids;
(38) Rotal Ing Biological Contractors. A fixed biological growth process in which wastewater flows through tanks In which a series of partially submerged circa lar
surfaces are rotated;
(39) Sand Ffterc:
(a) Intermittent Bioioglcal. FWation of effluent following septic tanks, lagoons, or some other treatment process In which further b€odecomposhlon is
expected to produce desired effluents; Hydraulic loading rates on these fihers are computed In gpd/ac and have a resuhing low gpm/sf (less than one);
b) RecircuWIng biological - the same type of sand filter as defined In Subparagraph (39) (a) of this Rule with the added capabil ty to recycle effluent back
through the sand filter,
(40) Sand or Mixed-Medla Fitters. A poilshing process by which effluent limits are achieved through a further reduction of suspended solids;
(a) low rate — gravity, hydraulically loaded filler with loading rates In the one to three gprnrst range;
(b) high rate — a pressure, hydraufically loaded filter with loading rates in the five gpm/sl range; At any rate, the loading rate will exceed three gpnYsl;
(d1) Secondary Clarifiers. A tank which follows the biological unit of treatment plant and which has the purpose of removing sludges associated with the
biological treatment units;
(42) Separate Sludge Reaeration. A part of the contact stabilization process where the activated sludge Is transferred to a tank and aerated before returning h
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 holding 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 Elutriation A process of sludge conditioning In which certain consthuerts are removed by successive washings with fresh water or plant effluent;
(47) Sludge Gas Utll€zation. The process of using sewage gas for the purpose of heating buildings, driving engiries, etc.;
(ds) 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 (i.e. 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 stabillzallon of organic matter. A nonaerated lank would simply be used to
decant sludge prior to dewatering and would not allow long periods (several days of detention) without resulting odor problems;
(49) Sludge incinerators. A furnace designed io bum sludge and to remove all moisture and combustble materials and reduce the sludge to a sterilo ash;
(50) Sludge Stabilization (Chemical or Thermal). A process to make treated sludge less odorous and putrescible, and to reduce the pathogenic organism
content; This may be done by pH adjustment, chlorine dosing, or by heat treatment;
(51) Sludge Thickener. A type of sedimentation tank In which the sludge is permitted to settle and thicken through agitation and gravity;
(52) Stabilization Lagoon. A type of oxidation lagoon In which bioiogicai oxidation of organic matter Is 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 nonrbiodegradable particulate (floatable solids, suspended solids and BOD
reduction) from municipal and Industrial wastewater treatment systems;
(55) Tertiary Treatment. A stage of treatment following secondary which is primarily for the purpose of effluent polishing; A settling lagoon or card or coal fifer
might be employed for this purpose;
(56) Thermal Pollution Control Device. A device providing for the transfer of hem 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 ccndhfoning process by which heat Is added for a protracted period of time to improve the dewaterabtlfy of sludge by the
solubilizing and hydraulizing of the smaller and more highly hydrated sludge particles;
(58) Toxic Materials. Those wastes or combinations of wastes, Including disease -causing agents which after discharge and upon exposure, Ingestion, inhalation
or assimilation Into any organism, either directly from the environment or Indirectfy by Ingestion through food chains, will cause death, disease, behavioral
abnormalities, cancer, genetic mutations, physiological malfuncilons (Including malfunctions In reproduction) or physical deformations. In such organisms or their
offspring; Toxic materials include, by way of Illustration and cot limitation: lead, cadmlum, chromium, mercury, vanadium, arsenic, zlnc, ortho-nitro-chlorobenzene
(ONCB), polychlorinated biphenyls (PCBs) and dichiorodiphonyl trichiomethane (DDT); and any other materials that have or may hereafter be determined to have
toxic properties;
(59) Trickling Filter. A biological treatment unit consisting of a material such as broken stone or rock over which wastewater is distributed; A high rata trickling
fifer is one which operated at between 10 and 30 mgd per acre. A law rate trickling filter is one which is designed to operate at one to four mgd per acre;
(60) Trickling Flier (Packed Tower). A plug flow type of operation In which wastewater flows down through success" 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 nitrilled effluent;
(61) Vacuum Fifter, Centrifuges, or Filter Presses, Devices which are designad to remove excess water from either digested or undigested sludge prior to disposal
or further treatment.