WQ0000603_Final Permit_19930407

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor
April 7, 1993
Gary D. Loflin, Vice President
APAC-Tennessee, Inc.
Harrison Division
Post Office Box 359
Alcoa, Tennessee 37701
Dear Mr. Loflin:
Jonathan B. Howes, Secretary
Subject: Permit No. WQ0000603
APAC-Tennessee, Inc.
Harrison Division
Dillsboro Quarry - Sand Plant and
Stone Washing Plant
Wastewater Recycle System
Jackson County
In accordance with your application received March 11, 1993, we are forwarding herewith Permit
No. WQ0000603, dated April 7, 1993, to APAC-Tennessee, Inc., Harrison Division for the continued
operation of the subject recycle wastewater treatment facility extension. This permit includes the renewal
of both the sand washing recycle system and the stone washing recycle system.
This permit shall be effective from the date of issuance until March 31, 1998, shall void Pemrit
No. WQ0000603 issued November 23, 1988, shall void Permit No. 2449 issued December 31, 1977 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.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
704/251-6208 919/486-1541 704/663-1699 919/571-4700 919/946-6481 919/395-3900 919/896-7007
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

If you need additional information concerning this matter, please contact l+ SI chael D. Allen at
[phone].
Sincerely,
A. Prest Howard, Jr., P.E.
Director
cc: Jackson County Health Department
Asheville Regional Office
Training and Certification
Facilities Assessment Unit

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
APAC-Tennessee, Inc.
Harrison Division
Jackson County
W6041-69-1-0
.
continued operation of a 80,000 GPD wastewater recycle system consisting of two (2) lagoons in series
(total capacity of 555,000 gallons) and a 400 GPM recirculating pumping station and the continued
operation of a 98,000 GPD stone washing recycle sytem consisting of three (3) compartment concrete
gravity settling basins and a 400 GPM recirculation pump with repumping of the clarified washwater back
into the process to serve Dillsboro Quarry Sand Plant with no discharge of wastes to the surface waters,
pursuant to the application received March 11, 1993, 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, 1998, shall void Pemrit
No. WQ0000603 issued November 23, 1988, shall void Permit No. 2449 issued December 31, 1977 and
shall be subject to the following specified conditions and limitations:
This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved pians, 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.

5. 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.
6. 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.
7. 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.
8. 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.
9. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
10. Freeboard in the lagoons shall not be less than two feet at any time.
11. 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.
12. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
13. 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.
14. 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.
15. 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 .0245
(c)(4)•
16. 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 143-215.6A to 143-215.6C.
17. 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.
18. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.

19. 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.
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
farm 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.
20. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and N facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
21. 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 7th day of April, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
L'j' — �0 - ninq
A. Preston oward, Jr., .E., Director
Division of'Environmental Management
By Authority of the Environmental Management Commission
Permit No. WQWW603

166-s jL-- FS-56
NORTH CAROLINA
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Name of Plant:
Owner or Contact Person:_
Mailing Address: .
---------------
County: %h ~� Telephone:�6 J - k S - 3 to
NPDES Permit No. NC00 Nondisc. Per, No. 009 6000CV T
IssueDate:-9.r r. LeC.✓a Expiration Date:
Existing Facility y/ _ _W New Facility
Rated . By: k-IE . A J yr�y r, Date: tot
Reviewed (Train. & Cert.) Reg. Office—
Reviewed (Train. & Cert.) Central Office
ORC
Plant Class: (circle one) O
2
ITEM POINTS
3
(1) Industrial Pretreatment Units and/or
20
Industrial Pretreatment Program
10
(see definition No. 33)
4
(2) QE,9!Q FLOW OF PLANT W GPD
8
(not applicable to non -contaminated cooling waters, sludge
handling facilities for water purification plants, totally
(ii) Trickling Filter
closed cycle systems (dei. No. 11), and facilities
High Rate ...................
consisting only of Item (4) (d) or Items (4) (d) and (11) (d))
0 20,000 ..................1.......
1
20,001 50,000 ..........................
2
50,001 -- 100,000.... ......................
3
100.001 -- 250,000 ..........................
4
250.001 - 500,000 ..........................
5
500,001-•1,Ooo,000..........................
8
1,000,001 •- 2,000,000 ........................
10
2,000,001 (and up) - rate 1 point additional for each
10
200,000 gpd capacity up to a
maximum of 30
8
Design Flow (gpd) :
3
(3) PRELIMINARY UNITS (see definition no. 32)
(a) Bar Screens ................................
1
or
5
(b) Mechanical Screens, Static Screens or
5
Comminuting Devices ........... .............
2
(c) Grit Removal ...............................
1
or
10
(d) Mechanical or Aerated Grit Removal ...........
2
(e) Flow Measuring Device .......................
1
0
3
(I) Instrumented Flow Measurement ..............
2
(g) PreaeraUon .. . . . ...........................
2
(h) Influent Flow Equalization ...................
2
(i) Grease or Oil Separators - Gravity ..........
2
Mechanical..,.......
3
Dissolved Air Flotation
8
(j} Prechforination ..............................
5
PRIMARY TREATMENT UNITS
(a) Septic Tank (see definition no. 43) .............. 2
(b) Imhoff Tank ................................. 5
(c) Primary Clarifiers .......... I ........ I ........ 5
(d) Settling Ponds or Settling Tanks for Inorganic
Non-loxic Materials (sludge handling facilities
for waler purification plants. sand, gravel,
stone, and other mining operations except
recreational activities such as gem or gold
mining) .. O
Grade
II ill IV Total Points 5
(5) SECONDARY TREATMENT UNITS
2
(a) Carbonaceous Stage
3
(i)Aeration - High Purity Oxygen System .....
20
Diffused Ajr System ...........
10
Mechanical Air System (fixed,
floating or rotor) ..............
8
Separate Sludge Reaeration .....
3
(ii) Trickling Filter
High Rate ...................
7
Standard Rate ............ . ..
5
Packed Tower...............
5
(iii) Biological Aerated Filler or Aerated
5
Biological Filter ......................
10
(iv) Aerated Lagoons ..................... .
10
(v) Rotating Biological Conlactors ..........
10
(vi) Sand Filters -
intermittent biological .. ..
2
recirculating biological .....
3
(vii) Slabi€:nation Lagoons ............ . ......
5
(viii)Clarifier ..............................
5
(ix) Single stage system for combined
carbonaceous removal of BOD and
nitrogenous removal by nitrification
(see dei. No. 12) (Points for this item
have to be in addition to items (5) (a)
(i) through (5) (a) (viii) .................
8
(x) Nutrient additions to enhance BOD
removal ...............................
5
(xi) Biological Culture ("Super Bugs') addition
to enhance organic compound removal .....
5
(b) Nitrogenous Stage
(i) Aeration - High Purity Oxygen System . ....
20
Diffused Air System ...........
10
Mechanical Air System (fixed,
floating, or rotor) ...... ......
8
Separate Sludge Reaeration .....
3
(ii) Trickling Filter -
High Rate ..............
7
Standard Rate ............
5
Packed Tower............
5
(iii) Biological Aerated Filler or Aerated
Bio€ogicat Filler .........................
10
(iv) Rotating Biological Conlactors ............
10
(v) Sand Filler-
inlermiftenl biological -
2
recircu:ating biological
3
(vi) claril ei
5

I TERTIARY OR ADVANCED Tn[ATMENT UN11
(a) activated C. Ftions Beds -
witho0 carton regeneration....... .. . ... .. .
v,ith carbon regeneralion .......... _ .... . .
(b) powdered or Granular Activated Carbon, Feed -
without carbon regeneration ................ .
with carbon regeneration .......... . ....... .
(c) Air Stripping ............................ .
(d) Denitrification Process (separate process) . . . . .
(e) Electrodialysis ............................. .
(f) Foam Separation ............................ .
(g) Ion Exchange .............................
(h) Land Application of Treated Ellluenl
(see definition no, 22b) (not applicable for
sand, gravel, clone and other similar mining
operations)
(i) on agriculturally managed Biles (See del.
fdo.4)...................................
(ii) by high rale infiltration on non -agriculturally
managed sites (includes rotary distributors
and similar fixed nozzle systems) .......... .
(iii) by subsurface disposal (includes low pressuri
pipe systems and gravity systems except at
plants consisting of septic lank and nitrifica-
tion lines only) ............................ .
(i) Microscreens....... ..........................
(j) phosphorus Remoial by Biological Processes
(See def. No. 26) ........................... .
(k) polishing Ponds - without aeration ...... .
with aeration ..........
(1) Post Aeration - cascade ..............
diffused or mechanical .. .
(m) Reverse Osmosis ...............................
(n) Sand or Mixed -Media Filters - low rate .......... .
high rale ......... .
(o) Treatment processes for removal of metal or
cyanide---• ................................
(p) Treatment processes for removal of toxic
materials other than metal or cyanide ........ .
LUDGE TREATMENT
(10) C:I LMIC AL A001110W SYSTCM (S) (See definit-an IJo 9)
5 (not applicahle, to chernical ndditions rated as item
1 5 (3) (1). (5) (a) (x i). (6) (a). (6) (b), (7) (b)• (7) (e),
(9) (a). (9) (b), or (9) (c) 5 points each: Lisl'
5
15
5
10
5
5
5
10
4
5
20
2
5
0
5
5
2
5
15
15
(a) Sludge Digestion Tank - Heated ...............
Aerobic ...............
Unhealed ...... ...... .
(b) Sludge Stabilization (chemical or thermal) . ... .. .
(c) Sludge Drying Beds - Gravity .................
Vacuum Assisted .......
(d) Sludge Elutrialion ............................ .
(e) Sludge Conditioner (chemical or thermal) ....... .
(f) Sludge Thickener (gravity) ..................... .
(g) Dissolved Air Flotation Unit
(not applicable to a unit rates as (3) (i) ........ .
(h) Sludge Gas Utilization (including gas storage) . .. .
(i) Sludge molding Tank - Aerated ................
Non-aerated ............
{j} Sludge Incinerator - (not including activated
carbon regeneration) .... .
10
5
3
5
2
5
5
5
5
B
2
5
2
10
(k) Vacuum Filter, Centrifuge or Filter Press or other
Holding Ponds, Holding Tanks or Settling Ponds
similar dewatering devices ............. I ......
10
SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons ........................................
2
(b) Land Application (surface and subsurface)
(see definition 22a)
-where the facility holds the land app. permit ..
10
-by contracling to a land application operator who
(b)
holds the land application permit ................
2
-land application of sludge by a contractor who does
basins which are inherent in land application systems).
not hold the permit for the wastewater treatment
(c)
facility where the sludge is generated - - - - - - - - -
10
(c) Landfilled (burial) .............................
5
;NFECTION
(d)
(a) Chlorination ........
(b) Dechlorinz!Gon ........................
5
(c) Ozone.- ..5
...
(f)
(d) RZd4laon ..
5
5
5
5
5
01) MISCELLANEOUS UNITS
(a)
Holding Ponds, Holding Tanks or Settling Ponds
for Organic or Toxic Materials including wastes
from mining operations containing nitrogen and/or
phosphorous compounds in amounts significantly
greater than is common for domestic wastewater ..........
4
(b)
Effluent Flow Equalization (not applicable to storage
basins which are inherent in land application systems).
2
(c)
Stage Discharge (not applicable to storage basins
inherent in land application systems .......................................
5
(d)
Pumps.—_- ................ ....... _........... _......... _.... ............................ �....
(e)
Stand-by Power Supply..................................................................
(f)
Thermal Pollution Control Device:............................................
3
TOTAL POINTS `!
CLASSIFICATION
Class I ..... ...... ............................. __..____ 5 - 25 Points
ass .......................................... _ 26- 50 Points
Class III ------- ---.......................-------------../ 51- 65 Points
Class IV ... ............................. .......... __..- ---- ._ 66- Lip 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.
Facilities having an activated sludge process will be assigned
a minimum classification of Class 11.
Facilities having treatment processes for the removal of metal
or cyanide will be assigned a minimum classification of Class 11.
Facilities having treatment processes for the biological removal
of phosphorus will be assigned a minimum classification of Class
Ill.
In -plan] processes and related control equipment which are an
integral part of industrial production shall not be considered waste
treatment. Likewise, discharges of wastewater from residences
having a design flow of 1,000 gpd or less, shall not be subject to
rating.
ADDITIONAL COMMENT,: