WQ0004821_Final Permit_19910419

�V
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
William W. Cobey, Jr., Secretary
Mr. Jerry Call
Post Office Box 296
Little Switzerland, North Carolina 28749
Dear Mr. Call:
George T. Everett, Ph.D.
Director
April 19, 1991
L'
5
Subject: Permit No. WQ0004821
Rio Doce Mine
Closed Loop Recycle
Mitchell County
In accordance with your application received March 14, 1991, we are forwarding herewith
Permit No. WQ0004821, dated April 19, 1991, to Jerry Call for the construction and operation of
a closed loop recycle facility.
This permit shall be effective from the date of issuance until March 31, 1996, 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 to you,
you have the right to request an adjudicatory hearing upon written request within 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.
One set of approved plans and specifications is being forwarded to you. If you need
additional information concerning this matter, please contact Mr. Mark Hawes at 919/ 733-5083.
Sincerely,
4�ege T. Ev rett
cc: Mitchell County Health Department
Asheville Regional Office
Training and Certification Unit
Pollulion Prevention Pays
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH 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
JERRY CALL
Mitchell Coun ty'
4
FOR THE
construction and operation of a 20,000 gpd closed loop Recycle system consisting of a 960 gallon
sedimentation tank with four 240 gallon compartments and a 40 gpm recycle pump and all the
associated piping, valves, and appurtenances to serve the Rio 1poce Mine with no discharge of
wastes to the surface waters, pursuant to the application received March 14, 1991 and in
conformity with the project plan, specifications, and other supporting data subsequently filed and
approved by the Department of Environment, Health and Natural Resources and considered a part
of this permit.
This permit shall be effective from the date of issuance until March 31, 1996, and shall be
subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, 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.
3. 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 Environmental Management 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.
S. 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. Mail the Certification to the Permits and Engineering Unit, P.O. Box
27687, Raleigh, NC 27611.
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 as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.

7. The Asheville Regional Office, phone no. [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.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
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. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be' established and an acceptable sampling
reporting schedule shall be followed.
13. Adequate inspection, maintenance, and clean'in'g shall be provided by the Permittee to
insure proper operation of the subject facilities.
14. 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 keep 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 upon request to
- the Division of Environmental Management or other permitting authority.
15. Any duly authorized officer, employee, or representative of the Division of Environmental
Management 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 kept under the terms and conditions of this permit; or may obtain samples of
groundwater, surface water, or leachate.
16. 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 15 NCAC 2H .0205
(c)(4).
17. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6.
18. 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.
19. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
2

20. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office,
telephone no. [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.
b. Any process unit failure, due to known or unknown reasons, that render 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. {
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 15 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.
21. A leakage test shall be performed on the septic tank and dosing tank to insure that any
exfiltration occurs at a rate which does not exceed twenty (20) gallons per twenty-four (24)
hour per 1,000 gallons of tank capacity. The engineer's certification will serve as proof
of compliance with this condition.
22. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified waster treatment plant operator to be in responsible charge of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to the classification .assigned to the wastewater treatment facilities by the
Certification Commission. Once the facility is classified, the Permittee must submit a letter
to the Certification Commission which designates the operator in responsible charge.
23. 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 19th day of April, 1991
NORTH CAROLINA. ENVIRONMENTAL MANAGEMENT COMMISSION
j-� George T. Evereti, D ct
UDivision of Envlronm Management
By Authority of the Environmental Management Commission
Permit No. WQ0004821
91

Permit No. WQ0004821
April 19, 1.991
Engineer's Certification
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, for the
Project Name Location
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 the approved plans and specifications.
Signature
Date
i
:11
Registration No

LITTLE SWITZERLAND QUAL
7.5 MINUTE SEF�iES (TOPOCKAP-
- . SPRUCE PlvE 3-5 Ml 2'30" � ��l � - °�8 _
am A
r 'Q a f .` I �asoo. .. �.
per �in'i 25 5\ '.����d��aee
11Lower Pind
Tun elddiI
Yla 6r Ga' f F-----
22 c�'lPrk` dY Tun ~V r �`1 f
In
ROY SO
Tnel o- %
un
J ,
Pepper Certo, Ch
oil
} �-;✓ � I' ''. l.� :err .r �e •.< (' ,ice_ - = - _- � � �.'� N
,� !t` \,_ til 1 ' �' ���.. � l - -� \• ��' 4
nope Iun'. �- d
tnn` n�ob T
I rd shburn=del
cern
n �
r

(MISCELLANBOUS UNITS CONTINUED) POINTS
(c) Holding Pond for Effluent Flow Equalization and/or
Stage Discharge . . . . . . . . . . . . . . . . . . 5
d Effluent Pumps. . . . . . , . . . . . . , . 3
c In -Plant Pumps (including air lifts): 2
f Stand -By Power Supply . . . . . . . . . . 3
g Thermal Pollution Control Device 3
h Treatment Processes for Removal of Metal or Cyanide and
.other Toxic Materials . . . . . . . . . . . . . . . 30
Total Points Z
CLASSIFICATION
Class I . . . . . . . . . . . . . . . 5 - 25 Points
o Class II . . . . . . . . . . . . . . . 26 - 50 Points
Class III . . . . . . . . . . . . . . . 51 - 65 Points
Class IY . . . . . . . . . . . . 66 Up Points
Facilities having a rating of one through four points, inclusive,
do not require a certified operator. Classification of all other
facilities requires a comparable grade operator in responsible charge.
-4-
North Carolina
Division of Fnvircrmental Management
Checklist of. Facility Components
To be Used In Determing Facility Classification
All Information will be printed:
Name of Plant i Ca —D cc- e kki
County
Owner or Contact Person �•�{�-{ �lO.� "7U4 �nSJRC�
r- © C Telephone
Mai 11 ng Address t' Q-,�l�'"[i� �M.i i'L"L'^QL�
Street or P.O.ox No. J0wn or Lity ZlEt,1 4
Permit Number Information Construction Status
HPOES Permit No. Please Ched;
Existing Facility _
Date Issued Upgraded Facility _
New Facility
State Permit No.� 4 ezk If Upgraded or New-Ta-c-lli ty, Give:
�^, 50% Completion Date
Date Issued l� l� ��-`� IGO% Completion Date
Rated by ��l/l��"S Regional Office -M Date JZ n,
Operator in Responsible Charge Gra
Design Flow of Plant in GPD Plant Class
ITEM
POINTS
(1)
PRETREATMENT UNITS (see definition No. 34) , , . , , , , , 2
2)
DESIGN FLOW OF PLANT IN GPD (not applicable to non -
contaminated cooling waters and non -discharging systems)
0 -- 20,000 . . . . . . . . . . . . . . . . . . 1
20,001 -- 50,000 . . . . . . . . . . . . . . . . 2
50,001 -- 100,000 . . . . . . . . . . . . . . . . . 3
100,001 -- 250.000 . . . . . . . . . . . . . . . . . . 4
250,001 -- 500,000 . . . . . . . . . . . . . . . . . . 5
500.001 -- 1.000,000 . . . . . . . . . . . . . . . . . . a
11000,001 -- 2.000,000 10
. . . . . . . . . . . . . . .
2,000,001 (and up) - rate 1 point additi.n.i for each 200.000
GPO capacity up to a ma XImuo of . . . 30
Design Flow (GPD):
(3)
PRELIMINARY UNITS (see definition
a Influent Pumps (including air lift) . . . . . . . . . 3
bBar Screens . . . . . . . . . . . . . . . . . . . . . 1
or
(c) Mechanical Screens, Static Screens or Coarminuting
.
Devices . . . . . . . . . . . . . . . . . . . . 2
.(d) Grit Removal or. . . . . . . . . I
(e) Mechanical or Aerated Grit Removal . . . . . . 2
f) Flow Measuring Device or 1
{g) Instrumented Flow Measurement . . . . . . . . . . . . 2
Effective
1/1/83

(4)
(5)
(6)
ITEM
POINTS
NPreaeration
or Equalization . . . . . . . . . . . .
I
5
Grease or Oil Separators -- Gravity . . . . . . . .
Z
(not applicable for facilities under 10(a) . . . .
Mechanical. . . . . . .
3
Aerated . . . . . . . .
5
(j)
Chemical Conditioning . . . . . . . . . . . . .
5
PRIMARY TREATMENT UNITS
1)
Septic Tank (see deflnitlon No. 44) . . . . . . . .
2
b
lal
Imhoff Tank .
3
c
Primary Clarifiers (including sludge air lifts) . .
5
d
Settling Ponds or Settling Tanks for Inorganic Non -
Toxic Materials Involving a Discharge to the Surface
5
waters (sand, gravel, stone, and other mining operations
Pre -Package Unit for Removal of 011 and Grease
30
except recreational activities such as gem or gold
a)
Reverse Osmosis
raining) . . . . . . . . . . . . . . . . . . . . . ..
10
SECONDARY TREATMENT UNITS
Sand or Mixed -Media Filters -- Low Rate . . . . ..
(a)
Carbonaceous Stage
High Rate . . . ..
(i) Aeration - High Purity Oxygen System . . . .
20
SLUDGE TREATMENT
Diffused Air System . . . ... . . . . . .
10
(a)
Mechanical Air System (fixed, floating or rotor)
8
Separate Sludge Reaeration . . . .
3
5
(ii) Trickling Filter - High Rate . . . . . .
7
Unheated
Standard Rate . . . . . .
5
iib}
Packed Tower . . . . . . .
5
(iii) Aerated Lagoons . . .10
Sludge Drying Beds . . . . . . . . . . . . . • , ,
2
(iv Rotating Biological Contactors (biodisc). . .
10
Sludge Elutriation . . . . . .
(v Sand Filters (intermittent biological) . . .
2
(e)
(ri) Stabilization Lagoons with Outlet to Stream .
5
(Vii Clarifier (including sludge air lifts). . . .
5
(b)
Nitrogenous Stage
(g)
Sludge Gas Utilization (including gas storage). . .
(1) Aeration - High Purity Oxygen System. . . . .
20
h
Diffused Air Systems.. .
10
Mechanical Air System (fixed, floating, or rotor)8
Non-aerated . . .
Separate Sludge Reaeration . , . . . . . . .
3
(i)
(ii) Trickling Filter - High Rate . . . . . . . .
7
Standard Rate . . . . . .
5
10
Packed Tower. . . . .
5
Vacuum Filter, Centrifuge or Filter Press .
(iii Rotating Biological Contactors (biodisc) . .
10
. . .
SLUDGE DISPOSAL (including incinerated ash)
(iv Sand Filter (intermittent biological). . . .
2
a
(v Clarifier (including sludge air lifts) . . .
5
TERTIARY OR ADVANCED TREATMENT UNITS
b
(a)
Activated Carbon Beds - Without Carbon regeneration
5
With Carbon regeneration.
15
(b)
Powdered or Granular Activated Carbon Feed - Without
Landfilled (burial) . . . . . . . . . . . .
5
Carbon regeneration
5
With Carbon regeneration.
15
c)
Ammonia Stripping . . . . . . . . . . . . . . . .
18
d�
Chemical Additions . , , , , ,
5
e
Drenitrificatl on P w cess (separate process).
10
f)
Electrodialysis
5
g
Foamy Separation . . . . . . . . . . . . . . . . .
5
(h)
Ion Exchange . . . . . . . . . . . . . . . . .
5
:'s
ITEM POINTS
{i)
Land Application (see definition No. 23b) . . . . .
5
(not applicable for facilities under 10(a) . . . .
Microscreens5
�J)
k)
Phosphorus Removal . ..... , , ,
20
1)
Polishing Ponds- Without aeration . . . . . . . .
2
With aerations . . . . . . . . , .
5
(m)
Post Aeration - Cascade . . . . . . . . . . . . . .
0
Diffused or Mechanical
5
(n)
Pre -Package Unit for Removal of 011 and Grease
30
a)
Reverse Osmosis
5
(p)
Sand or Mixed -Media Filters -- Low Rate . . . . ..
2
High Rate . . . ..
5
(7)
SLUDGE TREATMENT
(a)
Sludge Digestion Tank -- Heated . . . . . . . . . .
10
Aerobic . . . . . . . . .
5
Unheated
3
iib}
Sludge Stabilization (chemical or thermal)
to
(c
Sludge Drying Beds . . . . . . . . . . . . . • , ,
2
((d}
Sludge Elutriation . . . . . .
5
(e)
Sludge Conditioner (chemical or thermal) , , . . ,
5
f)
Sludge Thickener
2
(g)
Sludge Gas Utilization (including gas storage). . .
2
h
Sludge Holding Tank -- Aerated . . . . .
5
Non-aerated . . .
2
(i)
Sludge Incinerator (not including activated carbon
regeneration . . . . . . . .
10
(j)
Vacuum Filter, Centrifuge or Filter Press .
10
(8)
. . .
SLUDGE DISPOSAL (including incinerated ash)
a
Lagoons
2
b
Land Application (surface and subsurface) (see def.
23a) . . . . . . . . . . . . .
to
(c)
Landfilled (burial) . . . . . . . . . . . .
5
(9)
DISINFECTION
a)
Fre . . . . . .
1
bf
.
Intermediate . . . . . . . . . . .
2-.
C)
Post . .
3
Dechlorination. . . . . . . . . . . . . .
5
(e)
Chlorine or Ozone Generation . .5
. . .
(f)
Radiation . . . . . . . . . . . . . . .
3
(10)
MISCELLANEOUS
UNITS
(a)
Molding Ponds or Holding Tanks for Inorganic, Non-toxic
Materials with no Discharge to the Surface Waters
(Sludge handling facilities for water purification
plants, sand, gravel, crushed stone and other similar
operations --see definition No. 10)
(b)
Holding Ponds or Holding Tanks for Organic or Toxic
MaLertals with no Discharge to the surface. Wates,
4
(Any pump, valve, or other mechanical control subject
to failure creating a potential for bypass or discharge
from the holding ponds or tanks will necessitate a
minimum classification of Class 1 requiring a certified
operator),