WQ0008987_AROCompleteFile_20190207

,,-North Carolina
,drtment of Environment,
,zalth and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
June 10, 1994
Mr. Greg Woody, Production Superintendent
Aspect Minerals, Incorporated
Post Office Box 277
Spruce Pine, North Carolina 28777
Dear Mr. Woody:
JUN 17
lllllSION GF Ett91i#iiP iG .�L"t k : .
MOBRESVILLE RE9rt3lMl.el]EE
Subject: Permit No. WQ0008987
Aspect Minerals, Incorporated
South Toe River Plant
Wastewater Recycle System
Yancey County
In accordance with your application received February 8, 1994, we are forwarding herewith Permit
No. WQ0008987, dated June 10, 1994, to Aspect Minerals, Incorporated for the construction and
operation of the subject wastewater recycle system.
This permit shall be effective from the date of issuance until May 31, 1999, 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.
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Ms. Angela Y. Griffin at [phone].
cc: Yancey County Health Department
Mooresville Regional Office, Water Qu
Mooresville Regional Office, Groundwa r`
Engineering & Environmental Science C m
Training and Certification Unit
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535
An Equal Opportunity Affirmative Action Employer
Sincerely,
1.O , � �d�2.JlY.�
A. Presto Howard, Jr,�.P.E.
if
AN 2 41994 '
ction
iiw2310
Telephone [phone] FAX [phone]
50% recycled/ 10% post -consumer paper
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NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH > P;3_AL,ny
Au b«
RECYCLE SYSTEM PERMIT
Jud 17 1�9q,j
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
Aspect Minerals, Incorporated
Yancey County
FOR THE
construction and operation of a 965,000 GPD wastewater recycle system consisting of a recirculation
pump, a 20 foot diameter solids thickener, a chemical feed system, a vacuum drum filter, and a 472,060
gallon "upslope" pond to serve Aspect Minerals, Incorporated's South Toe River Plant with no discharge
of wastes to the surface waters, pursuant to the application received February 8, 1994, 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 May 31, 1999, 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 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.
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. 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. Mail the Certification to the Water Quality
Permits and Engineering Unit,P.O. Box 29535, Raleigh, NC 27626-0535.
1

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.
7. The Mooresville Regional Office, telephone number (704) 663-.1699, 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 residuals generated from these treatment facilities must be disposed 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. Freeboard in the "upslope pond shall not be less than two feet at any time.
13. 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.
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 of
Environmental Management or other permitting authority, upon request.
16. 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
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 of Environmental Management in
accordance with North Carolina General Statute 143-215.6(a) to 143-215.6(c).
2

19. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, ruleg, 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 life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Mooresville 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 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 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.
22. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
23. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in
15A NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary is
for the disposal system constructed after December 31, 1983 is established at either (1) 250
feet from the waste disposal area, or (2) 50 feet within 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 systems 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.
3

24. 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 IV 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.
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 10th day of June, 1994
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
6 0.C -M( Q�L L
A. Preston Ijoward, Jr., P.E. Director '
Division of Mvironmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0008987
C!

Permit No. WQ0008987
June 10, 1994
L',.TrTNFFjt C �
r. nTiFirATIOI�I
G1\ 11
as a duly registered Professional Engineer
construction of tl
r 1 (periodically, weekly, full time)
Carolina, having been authorized to observe (p
for
Location
r project,
project Name
e best of my abilities, due care and diligence was used in the o'
t Permittee hereby state that, to the oiling materials•
such that the construction was observed
otherlsuppthin substantial comp
of the constructions roved plans and specifications,
intent of this permit, the app
Registration No. �--
Signature
Date
C� P
�l
5
......_........

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DIVISION OF ENVIRONMENTAL MANAGEMENT
GROUNDWATER SECTION
June 2, 1994
MEMORANDUM
TO: Carolyn McCaskill
THROUGH: Bob Cheek A -n c.,
FROM: Brian Wagner 13—
SUBJECT: Aspect Minerals
Recycle Lagoon
Yancey County
WQ0008987/GW94038
( Angela Griffin: DEM SERG Review Engineer)
The Groundwater Section has reviewed the subject permit application. It should be
noted that our additional information request was not sent to the applicant until after the
ninety (90) day permitting deadline had expired. The package was first received by SERG on
February 2, 1994. The Groundwater Section received the package for review on March 1, 1994
and a request for additional information was sent to SERG on March 8, 1994. The additional
information letter to the applicant from SERG is dated May 24, 1994.
On May 24, 1994, I received a phone call from Pat Shillington of Engineering &
Environmental Science Company, the consulting firm for the applicant, and we discussed the
request. At that time he informed me that Aspect Mineral was rather upset at the late additional
information request as they were under pressure to start operations. These comments are
presented due to a cooperative Regional Groundwater staff who rearranged their schedule in
order to expedite these comments.
After an on-site visit by the Regional Office, it was discovered that the nearby residence's
water supply (a natural spring) is located in a different drainage divide and the recycle lagoon
should not influence that supply. This fact plus the amount of land owned by the applicant, in all
other directions, negate the need for monitoring wells. We recommend issuance of the permit
with the following conditions:
1. Any groundwater quality monitoring, as deemed necessary by the Division, shall be
provided.
Pt"�s 4" ,
k
JUN - 61994
UU
K._

The COMPLIANCE BOUNDARY for the disposal system is specified by
regulations in 15A NCAC 2L, Groundwater Classifications and Standards. The
Compliance Boundary for disposal systems constructed after December 31, 1983 is
established at either (1) 250 feet from the waste disposal area, or (2) 50 feet within
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).
3. In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around
the disposal systems 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.
cc: Don Link'
Colleen Sullins
Central Files
Permit Files
baw/94038.doc
U— 6 1994.,_9

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DATE:
EXPOSED GROUND OBSERVATIONS 01181194
Ui JUN`
South Toe River Plast
fL, p es { 4
Ydncy County, NC.

GROUNDWATER SECTION
ASHEVILLE REGIONAL OFFICE
May 27. 1994
MEMORANDUM:
To: Brian Wagner
Through: Don Link
From: Ka.v Dechant
Subject.: Permit Review
Aspect Minerals. Inc.
WQ0008987 GW94038
Yancey County
I have reviewed the subject permit application and visited the site on
May 26. 1994 and make the following comments:
1). The spring serving the private residence on the adjacent property
east of the Aspect Minerals plant is located in a different
drainage divide. therefore it would be unlikely to receive any
impact from activities occurring at Aspect Minerals.
2). The pond is located upgradient from the plant. Aspect Minerals
owns and controls all of the property between the pond and the
South Toe River.
3). It is questionable as to the existence of a water table above
bedrock on this site. Groundwater monitoring of the bedrock
aquifer may not be representative for assessing activities
occurring on site, depending on the source of the recharge for the
water bearing fracture.
I recommend that the permit_ be issued with the standard clause that any ;
groundwater monitoring, as deemed necessary by the Department, shall be
provided.

DMSRON OF ENVHRONMENTAL MANAGEMENT
Groundwater Section
MEMORANDUM
Fr j
Date:
MAR 1 11994 k
To:
Review Engineer harre! rs Rsre� Seen
Permits & Engineering Unit sKYb,9ej�e
From:
Groundwater Section
Subject:
Request for Additional Information
WQ000 / GW
County
The Groundwater Section has conducted a preliminary review of the subject application
and request that the following items, as indicated in the list of additional information items
dated July 15, 1990 to be included in the request for additional information to the applicant:
Item 1 Item 7 Item 13 Item 18
Item 2 Item 8 Item 14 Item 19
p
Item 3 Item 9 Item 15 Item. 20
Item 4 Item 10 Item 16 Item 21
u
Item 5 Item I 1 Item 17 Itern 23
4.11 Ile Item 6 Item 12
Other Items (See attachment)
For Item 22 fill in blanks: ,
For. -Items -,15 -:.and 21 --list_ parameters:
� f
1 F
_ if you have any questions, please advise.
NOTE: See Reverse For Additional Information Items
= Regional Groundwater Supervisor
Copy - Water Quality Section Yellow Copy Groundwater Section Pink Copy - Regional Office

GROUNDWATER SECTION
ASHEVILLE REGIONAL OFFICE
May 27. 1994
To: Brian Wagner
Through: Don Link
From: Kay Dechantt�
Subject: Permit Review
Aspect Minerals, Inc.
WQ0008987 GW94038
Yancey County
I have reviewed the subject permit application and visited the site on
Mav 26. 1994 and make the following comments:
1.). The spring serving the private residence on the adjacent property
east of the Aspect Minerals plant is located in a different
drainage divide, therefore it would be unlikely to receive anv_
impact from activities occurring at Aspect Minerals.
2). The pond is located upgradient from the plant. Aspect Minerals
owns and controls all of the property between the pond and the
South Toe River.
3). It. is questionable as to the existence of a water table above
bedrock on this site. Groundwater monitoring of the bedrock
aquifer may not be representative for assessing activities
occurring on site, depending on the source of the recharge for the
water bearing fracture.
I recommend that the permit be issued with the standard clause that anv
groundwater monitoring, as deemed necessary by the Department, shall be
provided.

GROUNDWATER SECTION
DIVISION OF ENVIRONMENTAL MANAGEMENT GW #1 c
RECORD OF WASTE DISPOSAL PERMIT APPLICATION REVIEW
REVIEW BY q ZN�� DATE _�5 2 FIELD INVESTIGATION? ( Y/N )
FACILITY NAME _, sD� cf` /%%il,Pr� sic , COUNTY— VI-71,hccfc,
LOCATION D>� v� D��1��/� 1k'�r�^ �i1lPysc�c4ji !4/,TZ /It
TYPE OF DISPOSAL SYSTEM (LAGOON, ETC.)
DESCRIPTION OF FACILITY �Y7,� %W) ail,
DESIGN CAP. (GPD)---�"5�` /cxyc/p�
r Y L
SIZE OF IMPOUNDMENT (FT. S9) 9 2% 060 p- & /OR JSIZE OF APPLICATION AREA
WASTE SOURCE : F] MUN. SLUDGE MUN. W. WATER: O PRIMARY [SECONDARY E] TERTIARY
F1IND. SLUDGE ND, W. WATER OTHERS
DISTANCE FROM WASTE SOURCE TO NEAREST: STREAM _,Qy FT., WELL FT,
FOR WELL: TYPE OF USE , DEPTH , PUMP RATE ( EST. )
WHAT DESIGN CONDITIONS WILL REDUCE / It CREASE CHANCE' Of GW /C/UNTeAOIN IATIDN
✓/I
A` /51
/.J
WHAT NATURAL SITE CONDITIONS WIL�`REDUdj INCItASE CHANCE OF GW CONTAMINATION
TO: BEDROCK n --&O FT.. SEASONAL HIGH W. T. FT.. ANNUAL W. T. FLUX : 2 FT.
SURFICIAL AQUIFER BEDROCK/ ARTESIANA6IUIFE
GEN. L.ITHOLOGY �n l nA s S�/sfi /�iicA a
MEASURED E] MEASURED
HYD. COND. k4 y1 FT./DAY ESTIMATED ��� FT./DAY ESTIMATED
THICKNESS uIlk FT.
NO. OF MONITOR WELLS: PROPOSED: UP 0 DOWN 0 t EXISTING UP DOWN
FROM WORKSHEET: SITE NUMERICAL DESCRIPTION = ./L - _q - _a -7f 14 4 S .,,-
Leo�r'apj 3y S+pl+ T 1 2 3 4 5 6 6A 68
SITE GRADE (HYDROGEOL.) _ SITUATION GRADE
PROPOSED SAMPLING SCHEDULE & PARAMETER(S):
REMARKS/REC
GW -48 Revised 8187
i

WASTE DISPOSAL PERMIT APPLICATION REVIEW 1
2
3 A
8 -
sorptlon for the
4A
waste disposal sBe.
facility
(2) A Row - Rock > 100
Gradient .Valle
r -.aunty ;
Gradient
Gradient Gradient
'W:
(Stop 3)
gradlent and away 6om almost
.evlewer : - d Oyu
ler than grec4er
greater
bate
Flow direction all water flat
2 percent
Determine the distance Point volue
0 1 2 3 4 5 6 7 a
9'
on ground between con- Distance in
Iomiratlonsource and
2000+ 300909 75-149 35-49 10-19
150-299 50-74 20-34
0-9
meters
water supply (w11I or Distance in
1000-20W
62M+ 1001- 3100 251 - 500 101-160 31-60
on closer
dream. bet
3100 - 6200 501- 1000 161-250 61- 100
0-30
NOW K water table 1n permeable bedrock pt. value -6: In poorly permeable bedrock
than 1000
M ml✓ but
pt. Valle � 4
water
Stec 2 Point value
0 1 2 3 4 5-- 6 7 S
9
Esfknatethe depth Meters
60+ 3060 2¢29 12-29 8-11 5-7 3-4 15.25 6-1
0
to the water table Feet
200+ 91-200 61-90 3660 26-35 16-25 9-15 3-a 0-2
0
below base of con -
M.,hx , On source
more than 5 % of
the year.
Me 3
Estimate water
table gradient
from contomin-
atlon Me
DRKSNEET
Distance *Pta-
(slop
1)
Depth
W.I.
Pt. Value
(Step 2)
PC" s r. 0 1
2
3 A
8 -
sorptlon for the
4A
waste disposal sBe.
6A
(2) A Row - Rock > 100
Gradient .Valle
Water table Gradient Gradient
Gradient
Gradient Gradient
Gradient
(Stop 3)
gradlent and away 6om almost
ler than
ler than grec4er
greater
1
Flow direction all water flat
2 percent
2 percent turf 2
than 2
Q
supplies that
toward
towaed percent
Percent
rek:lwely
on closer
water .
water toward
toward
4G
than 1000
M ml✓ but
supply water
water
;
meters
not the
and Is the supply
supply
2C
IE
anticipated
anticipated but not
and Is the
5G
6F
direction of
direction of the antF
anticipated
9N
60-74
flow
flow clpaied
direction
IF
4C
4E
direction
of flow
7D
74
8G
Of flow
90
A6 - 59
Stag 4
'mate of
OA
rmeabllMy-
2A
sorptlon for the
4A
waste disposal sBe.
6A
(2) A Row - Rock > 100
`
feet bebw
f—►
land
/1
solace
t
i
1`
11
1
(3)l cokxnn - bedrock
f
Poorly w
permeable
LL
I
Q
i
U
(4) N column - bedrock -Q
V
rek:lwely
1C
Of very
permeable
E - Distance In Step 1 based on separation from
contaminant plume rather than P044 source
Clay wRh
no more Sand wBh
than 50% 15-30%
Clean
Sand with gravel or
love than Clean fine coarse
19 -K 111W sand sand
More than 30
O
OA
ea
2A
4A
6A
6 = fairly confident
OA
ConNderx e
9A
More than 95
6A
t
i
1`
11
1
Ii
f
II
I
II
i
it
M • Fluid mounding under the highly ■rely
25-29
08
1C
ID
E - Distance In Step 1 based on separation from
contaminant plume rather than P044 source
3E
4G
5F
6E
7F
SE
9G
9M
75-94
2o-24
OC
2C
IE
30
4D
5E
5G
6F
7G
9F
vN
9N
60-74
15-19
OD
38
IF
4C
4E
6C
5N
7D
74
8G
91
90
A6 - 59
10-14
OE
4B
2D
58
4F
60
SI
7E
71
9D
9J
9P
26-45
3-9
18
68
2E
78
SC
7C
5J
8D
7J
9E
9K
90
10-27
lets than 3
15
8B
3C
BC
I 5D90
bK
9C
7K
9F
9R
. �°°s 111pt11
8edroek at land iulr6cei I
U,11 91
Note: If Bedrock al land surfacs. use 10 (pia appropriate letter)
eg°
(Step 4)
ea
Degree of confidence In accuracy of values A = very confident
6 = fairly confident
ConNderx e
C -wNh low confidence
(Step 5)
6A
PointSt*p
of concemwffh regard 10 cortammIrxxt source N : W i nem by wet
Point
of Concern
S - spring / dream
8. perimeter of compliance
(Ste�p^6N
.glen A,"lond Oudtfler (Circle Only One)
D - Cone of depresslon of nearby pumping well hos,
M • Fluid mounding under the highly ■rely
or will skety. Influence contaminant flowQualifierP
. Site horn poor percolation potential (Nalue at 3 or lea In Step A)
(Step 68)
E - Distance In Step 1 based on separation from
contaminant plume rather than P044 source
a . Wade source in groundwater recharge area
F . Waste source In groundwater discharge area,
t. Water table In very highly fractured Or cavenous rock
I" mhknol gmundwoler contamination al depth / dlstamce
Y SNe underlain by 1 or more artedan aquifers
v - Area rxxlerkAn by coverous limestone

-' WASTE bISPOSAL PERMIT APPLICATION REVIEW WORKSHEET (CONT.)
22122
Oft Num/errical description
-41—
Told Step 1 S*p 2
Step S Step 4 step 6
Shap 6A Stop 68
(Acid Steps T - 4 (Om# letters ) )
Slfe Grade Bated on ttydrogeobpic Parameters
Mai
Hatard Potential Matrix IdenOW (HP4)
(Choose One) D
G i
B
A
E H +
C F
HPMI
>lten 9
(1) Numerical Site De11on (hStep 7 )
Told Perm/Sorp.
ifMem
(2) PAR VALUE (Stage J)
, D
SITUATION RATING: (1) - (2)
(table below)
SITUATION GRADE
no still maalaams
pee table below)
wool SITUATION GRADE
e mo co toms
(–
Gee table below)
SITUATION RATING TABLE
To be used for Step p (Noturat) and Step 10 (Modlhed) (Step 10)
SITUATION RATING PROBABILITY OF
( Combined Value) CONTAMINATION SITUATION
DEGREE OF ACCEPTABILITY GRADE
S a las Improboble
aooePbble jr,
-7 to d ? Probd�fy acceptable ot 6
,31o+3 --*x* unaxwoublisC
� 410+1
b +1 Probably �urxxxapp p
+8 or mote Very Probable Ainast certain b be F
unacceptable
The ProboIsN of contom°minallon from situations having values between t 7 and - 7 Is difficult to categorize
sollsfactorly. Ttwetore, this range of values represented by grades B and C. It designed only by a question mark
ACCeptdnce Of refection of oo stle for Thi intended purpose is a responsbNMy of the particubr fegulofory agenx y
and may depend on special Tequlremenh of k» agency or on
engineering of a site ( Stags+ A feasibility and execution of approved

sr`SGvt4
State of North Carolina
Department of Environment, Health, and Natural Resources
Division of Environmental Management
Non -Discharge Permit Application
(THIS FORM MAYBE PHOTOCOPIED FOR USE AS AN ORIGINAL)
RECYCLE FACILITIES
I. GENERAL INFORMATION:
1. Applicant (corporation, individual, or other;) Aspect _Mi.11(21--11 Tnc.
2. Print Owners or,; Signing Official's Name and Title (the person who is legally
responsible for the facility and its compliance): _ it. Gree Wood,_, Pr,)duct i.on
Suix.r_i r,t ei.id(,--a
3. Mailing Address: 1'.01. --Box 277
City:ruCe i.r,c State: Zip: -2 8 7 7 7 _
Telephone No.: 7(i!�' C 88-25 72
4. Project Name (subdivision, facility, or establishrnen-t-name - should be consistent with
project name on plans/specs., letters of flow acceptance, Operational Agreements, etc.):
;;ouLh 'Loe Riv..r. 1' 1.ant'
S. Application Date: 02/01/94 6. Fee'Submitted: $ 400.00
7. County where project is located: Yancey county
8. Latitude: 35052' 56" ; Longitude 132011' 20" of recycle facility location
II. PERMIT INFORMATION:
1. Permit No. (willbe completed by DEM): �� _T_—
2. Specify whether project is: new; renewal*; modification.
*If renewal, complete only sections I, II, ` III, & applicant signature
(on pg.6). Submit only pgs. 1, 2, 6' (original and 3 copies of each). Engineer
signature not required for renewal.
3. If this application is being submitted as a -result of a'renewal or modification to an
existing permit, list the existing permit number, 141A and issue date ,''/A
4. Specify whether the applicant is public or x private.
FORM: RFAC 4/91 Page 1 of 7

RECYCLE FACILITIES
PAGE 2 (4/91)
HL INFORMATION ON WASTEWATER:
I Nature of Wastewater: % Domestic; % Commercial;
100 % Industrial; %Other waste (specify):
2. Please provide a one or two word description specifying the origin of the wastewater,'
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
The water is derived by washinii ore Ito se }ara{ a
3. Volume of recycle water generated by this project: _ 960 , 480 gallons per day
4. Explanation of how recycle water volume was determined: based or, paste
use of tlaL., e�:asti.ii facility
S. Brief project description: wager is used':to separate Mica and Sand' from c1,'ty
particles. :°iC-c 1'Ci)ort by 1''1'1S' & L;ay'. L' (let:o: lod discript inTI.
IV DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of tanks, pumping facilities, high water alarms, filters,.
ponds, lagoons, etc.: '11"he, recirculation sysLem will consist of one; 472,060
gallon pond with a rete bora time of 11 -Tars a 20ft diameter Enviroc.lear
Thickener, and a vacuum drum filter with a cloth surface area of 1900
"square feet. See report by Engineerini; Science
for additional information.
2. Name of closest downslope surface waters: South 'toe River
3. Classification of closest downslope surface waters: c—trou7" (as established
by the Environmental Management Commission &,specified on page 4 of this
application).
4. if a power failure at the facility could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent such impact, as
required in 15A NCAC 2H.0200: � power f a ilure would -not caul d • s cu r�
iLo surface water. 'riicr water, from Lh )27-ic Qan be 1; a .; , by ry� 11(,
valves at the pl.ant.
5. The facilities must conform to the following buffers (and all other applicable buffers).
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100 feet between a surface sand filter and any residence under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) 50 feet between the recycle facilities and property lines;
2of7

RECYCLE FACILITIES
PAGE 3 (4/91)
6. If any of the buffers specified in no. 5 above are not being met, please explain how the
proposed buffers will provide equal or better protection of the Waters of the State with
no increased potential for nuisance conditions: NIA
7. Are any components of the recycle facility located within the 100 -year flood plain?
yes; x no If yes, briefly describe the protective measures being taken to protect
against flooding.'
THIS APPLICATION PACKAGE WILL NOT BE ACCEPTED BY THE
DIVISION OF ENVIRONMENTAL MANAGEMENT UNLESS ALL OF'!
THE APPLICABLE ITEMS ARE INCLUDED WITH THE SUBMITTAL
Required Items
a. One original and three copies of the completed and appropriately executed application form.
b. The appropriate permit processing fee, in accordance with 15A NCAC 2H .0205(c)(5).
c. Five sets of detailed plans and specifications signed and sealed by a North Carolina
Professional Engineer. The plans must include a general location map, a site map which
indicates where any borings or 'hand auger samples were taken, along with buffers,
structures, and property lines. Each sheet of the plans and the first page of the specifications
must be signed and sealed.
d. For industrial wastewater, a complete chemical analysis of the typical wastewater
must be provided. The analysis may include, but shall not be limited to, Total Organic
Carbon, BOD, COD, Chlorides,Phosphorus, Nitrates, Phenol, TotalTrihalomethanes,,'
TCLP analysis,' Total' Halogenated Compounds, Total Coliforms, and Total Dissolved
Solids.
e. If lagoons are a part of the facilities and the recycle water is industrial, provide a
hydrogeologic description of the subsurface to a depth of 20 feet or bedrock, whichever is
less. The number of borings shall be sufficient to define the following for the area
underlying each major soil type at the site: significant changes in lithology, the vertical
permeability of the unsaturated zone, the hydraulic conductivity of the saturated zone, and
the depth of the mean seasonal high water table.
f. Five copies of all reports, evaluations, agreements, supporting calculations, etc., must be
submitted as a part of the specifications which are signed and sealed by"a North Carolina
Professional Engineer. Although certain portions of this required submittal must be
developed by other professionals, inclusion of these materialsunder the signature and seal
of a North Carolina Professional Engineer signifies that he has reviewed this material and
has judged it to be consistent with his proposed design
g. Five copies of the existing permit if a renewal or a modification.
3of7

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ell
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✓'''�"�� �<<I. l� /}�, /; )t1 ✓ 'r Approxi Location of Disoharge'
)VN� fonds For Zee Existing'Disolrarge�.
it N N 0000434
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( ltd 0nsh�eh`) 1��i . I i r
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(� � � . � r• .[i1 � lhQ(J l •r
SCALA i' 200©
/j tl (r,r C ill/r�
DATE:
US'cS `MI�'AVILLE
a
Romer or., Can of/ay/sa
QUADRANGLE MAP
South Toe River Plant a �
Yaa: c County, NC.
' .
CIS

RECYCLE FACILITIES
PAGE 4 (4/91)
TO: REGIONAL WATER QUALITY SUPERVISOR
Please provide me with the classification of the surface waters identified in number 5
below and on the attached map segment:
Name of surface waters: Solitttl Toe River
Classification (as established by the Environmental Management Commission): C=�i2oT
Proposed Classification, if applicable:
Signature of regional office personnel: Date: 1 fes'
INSTRUCTIONS TO ENGINEER
In order to determine whether provisions for dual or standby power may be required for the
subject facility, the classification of the closest downslope surface waters (the surface waters that
any overflow from the facility would flow toward) must be determined. You are required to
submit this form, with items 1 through 10 completed, to the appropriate Division of Environmental`
Management Regional Water Quality Supervisor (see attached listing). At a minimum, you must
include an 8.5" by 11" copy of the portion of a 7.5 minute USGS Topographic Map which shows
the subject surface waters. You must identify the location of the facility and the closest downslope
surface waters (waters for which you are requesting the classification) on the submitted map copy.
The application may not be submitted until this form is completed and included with the submittal.
1, Applicant (corporation, individual, or Other): Asl2ect
2. Name and Complete Address of Engineering Firm: I'w ineeriws & Eavironnzer�ta1
Science G,ompany, 3008 Anderson Dr, Suite 102
City: Raleig State: NC Zip: 27609
Telephone No. (91.9)-781-7798
3. Project Name: South J?oe Raver Plant
4. Storage Facility Volume: 472,060 gallons
5. Name of closest downslope surface waters: south 'roe River
6. County(s) where project and surface waters are located:.-
7. Map name and date: s(Ys iii t,;a�T 1 1 S2 �c9r�.7n1 n M a _278
8. North Carolina Professional Engineer's Registration No. 15472
9. Print Name of Engineer T Patrick s, '
10. Seal and Signature (specify date):
° ®FEss/49
J
54
.09 GINE
4 of 7 iT�7� , SH1��- °�''

DIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL OFFICES (4/91)
Asheville Regional WQ Super.
Washington Regional WQ Super.
Raleigh Regional WQ Super.
59 Woodfin Place
P 0 Box 1507
3800 Barrett Dr., Suite 101
Asheville, NC 28802
Washington, NC 27889
Raleigh, NC 27609
704/251-6208
919/946-6481
919/'733-2314
Avery Macon
Beaufort Jones
Chatham Nash
Buncombe Madison
Berge Lenoir
Durham Northampton
Burke McDowell
Camden Martin
Edgecombe Orange
Caldwell Mitchell
Chowan Pamlico
Franklin Person
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay Rutherford
Currituck Perquimans
Halifax Wake
Graham Swain
Dace Pitt
Johnston Warren
Haywood Transylvania
Gates Tyrell
Lee Wilson
Henderson Yancy
Greene Washington
Jackson
Hertford Wayne
Hyde
Fayetteville Regional WQ Super. >
Mooresville Regional WQ Super,
Wilmington Region. WQ Super.
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845
919/486-1541
704/663-1699
919/395-3900
Anson Moore
Alexander Mecklenburg
Brunswick New Hanover
Bladen Robeson
-us Rowan
Carteret Onslow
Cumberland Richmond
Catawba Stanly
Columbus Pender
Harnett Sampson
Gaston Union
Duplin
Hoke Scotland
lredell Cleveland
Montgomery
Lincoln
i
Winston-Salem Regional WQ Super.
8025 North Point Boulevard, Suite 100
Winston-Salem, NC 27106
919/761-2351
Alamance ' Rockingham
Alleghany Randolph
Aske Stokes
Caswell Sung
Davidson Watauga
Davie Wilkes
Forsyth Yadkin
Guilford
5of7

RECYCLE FACIL=S
PAGE 6 (4/91)
Name and Complete Address of Engineering Firm: 'Engineering & Environmental Science
Company, 300£ Anderson Dr.,Suite 102
City: Raleigh State: T;c Zip: 27609
Telephone No. (919)-781-7798
Professional Engineer's Certification:
I, 1.I'atrick Shillin ton , attest that this application for solit,li ,00,. _
River Plant has been reviewed by me and is accurate
and complete to the best of my knowledge. I further attest that to the best of my knowledge the
proposed design has been prepared in accordance with the applicable regulations, Although certain
portions of this submittal package may have been developed by other professionals, inclusion of
these materials under my signature and seal signifies that I have reviewed this material and have
judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Registration No. :15472
Print Naive of Engineer `-'' • Patrick Shillingtonr
dl�N
Seal and Signature (specify date):' �FESS,
sIMtd
i` A
°�irT�,G'K
Applicant's Certification: ���+euuniu�u►ua
Gre woody , attest that this application for
South Floe River. Plant'
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand
that if all required parts of this application are not completed and that if all required supporting
information and attachments are not included, this application package will be returned as
incomplete.
Signature Date02/01/94
...
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL SUPPORTING
INFORMATIONAND MATERIALS,SHOULD BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA 27626-0535
TELEPHONE NUMBER: 919/733-5083
6of7

RECYCLE FACILITIES
PAGE 7 (4/91)
PERMIT APPLICATION
PROCESSING FEES
(effective
October 1, 1990)
CATEGORY
NEW APPLICATIONS/
RENEWALS WIn30UT'
MODIFICATTONS
MODIFICATIONS
> 1,000,000 GPD
Industrial
$400
$300
Domestic/Cooling Water
$400
$300
10,001 - 1,000,000 GPD
Industrial
$400
$250 "
Domestic/Cooling Water
$400
$250
1,001 -`10,000 GPD
Industrial
$400
$200
Domestic/Cooling Water
$400
$200
< or = 1,000 GPD and
Single Family Dwelling
$240
$120
Sludge < or ='300 Acres
$400
$250
Sludge > 300 Acres
$400
$250
Sewer Extensions
(nondelegated)
$400
0
Sewer Extensions
(delegated)
$200
0
Closed -Loop Recycle
or Evaporative
$400
$200
NOTE: The Fees for Soil Remediation
Projects are the
same as for Sludges.
Under the Sewer Extension Fee, "delegated to municipalities" applies
only to those governmental
jurisdictions that
review authority, as granted by the Division
have specific delegation
of Environmental
Management.
7of7

4orth Carolina
Ament of Environment,
dith and Natural Resources ,
Jvision of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Greg Woody, Production Superintendent
Aspect Minerals, Incorporated
Post Office Box 277
Spruce Pine, North Carolina 28777
AT4
MOM
ED F=
May 24, 1994
Subject: Application No. WQ0008987
Additional Information Request
Aspect Minerals, Incorporated
South Toe River Plant
Yancey County
Dear Mr. Woody:
The Division of Environmental Management's Permits and Engineering Unit and Groundwater
Section have completed a preliminary engineering review of the subject application.
The groundwater section needs the following items before the review can be completed:
1) A site-specific map, with topographic contours (contour interval should not exceed 10
feet or 25 percent of total site relief, whichever is less), showing the property
boundary, all facility -related structures within the property boundary, and the location
of all wells, springs, lakes, ponds, or other surface drainage features within 500 feet of
the perimeter of the lagoon. Wells should be labeled as to their primary usage (drinking
water, process water, monitoring, etc.). The map should indicate, by note, that all
wells and other features within 500 feet of the disposal system are shown.
2) Proposed location and construction details of a groundwater monitoring well network
as specified in Rule .0205(d) of the Regulations (15 NCAC 2H. 0200).
Refer to the subject permit application number when providing the requested information. Please
submit four copies of all requested information to my attention at the address below.
Also, please note that failure to provide this additional information on or before June 24, 1994 will subject
your application to being returned as incomplete, in accordance with 15A NCAC 2H.0208.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity. Affirmative Action Employer 50% recycled/ 1:0% post -consumer paper

at No. WQ0008987
Aay 24, 1994
If you have any questions regarding the information requested by the Groundwater Section, please
call Mr. Brian Wagner at 919/733-5083. If your questions concern other aspects of the permitting
process, please call me at 919/ 733-5083.
Sincerely,
y
Angela Y. Griffin
Environmental Engineer
State Engineering Review Group
cc: Asheville Regional Office, Water Quality Section
Asheville Regional Office, Groundwater Section
Permit File WQ0008987
Mr. Brian Wagner, Groundwater Section, Central Office
Mr. T. Patrick Shillington, Engineering & Environmental Science Company

r
43�y
6
DIVISICK OF MVIRMMNIAL MANAGE F Rr ���
C�&�R&TE R SE MCN MA — 7
TO: Lin/C ZAay Beelo" l
DATE: ouch
FE M: Jack Fl l00%t--.
S[JB=: Application for RENEWAL/ANIENIDM M of Permit No.
NEV PEST
Facility Name:.e IS
County: c ey
Type Of Project: /"pCvc% 42 On-, /YIin:s�G .Q+Lip1.i
Central Office Contact:
Applicable Permit Numbers: WQ oC)a X9877 Gw 9V,0,5,?
DEH AC
EPA
The Groundwater Section has received a copy of the above referenced
permit` application. A copy of the application package is attached
The Groundwater Section has received a copy of the above referenced
permit application, which has been sent to the regional office water
quality supervisor. If a oopy has not been sent to the regional
office please let me know.
The Groundwater Section has received the subject Division of
Environmental Health project for review. A copy of the application
has been forwarded to , Regional Soil
Specialist. Please coordinate your review with the regional soil
specialist.
Please review the application materials for completeness and submit
any request for additional information to the central office contact on
or before — --Zn c*,, ek /,5" . A copy of the formal request for
additional information will be forwarded to you.
If you do not require any additional information to complete your review,
please provide your final comments by - /YI�c/ .?S"
If you have any questions, please let me know as soon as possible.

G2�
ENGINEERING & ENVIRONMENTAL SCIENCE COMPANY
3008 ANDERSON DRIVE, SUITE 102
RALEIGH, NC 27609
[phone]
February 3, 1994
Michael R. Parker
Water Quality Section
Asheville Regional Office
59 Woodfin Place
As i. —L -Le, NC 28801
Re: Plans and Specifications Addendum
Non -Discharge Permit (Recirculation System)
South Toe River Plant
Yancey County, North Carolina
Dear Mr. Parker:
On Sheet No. 2 of 2, for the POND AND CONTAINMENT PAD LINER -CROSS
SECTION, the liner coefficient of permeability should read
COMPACTED LINER WITH 1X10-7 cm/s. COEF. OF PERMEABILITY.
Thank you for your time on February 1, 1994, to discuss this
project with you.
Sincerely,
T. Patrick Shill; Eµ
President' "
CAR
ry.m
FESS/�
7e SEAL '-
15472 15472 'yy
u W N.,
p � V
�1
9 FEB
9

ENGINEERING & ENVIRONMENTAL SCIENCE COMPANY
3008 ANDERSON DRIVE, SUITE 102
RALEIGH, NC 27609
[phone]
January 31, 1994
Mr. Greg Woody
Aspect Minerals, Inc.
P.O. Box 277
Spruce Pine, NC 28777
RE: Non -Discharge Permit (Recirculation System)
South Toe River Plant
Yancey County, North Carolina
Dear Mr. Woody:
Engineering & Environmental Science Company has completed the
evaluation of the Recirculation System for the South Toe River
Plant. This report contains a discussion of the system, waste
water characteristics, subsurface conditions and other pertinent
information. Submitted with this report are the "Plans and
Specifications". Following is brief discussion of the project.
GENERAL DISCUSSION
A recirculation system is proposed at the South Toe River Facility.
This facility is located in Yancy County immediately north of Hwy
19 (see Figure No. 1 in Attachment A). This facility will process
ore mined for mica and sand.
This facility was formally known as Deneen Mica Company and the
existing structures will be used for the processing of mica and
sand. When the facility was operated by Deneen Mica Company,
processing was conducted under a NPDES Permit. Water was pumped
from the South Toe River to a pond upslope of the facility. The
water then would drain by gravity to the mica processing facility.
The washwater would be pumped to a series of ponds that are located
on the opposite side of the South Toe River. As much a 1 MGD of
water could be discharged back to the river (see Figure No. 1 in
Attachment A).
Instead of operation of the plant with the existing NPDES permit,
a non -discharge (Recirculation Permit) is desired. This water will
be recirculated back to the upslope pond. However, the wash water
will be cleaned of fine colloidal clay prior to discharge back into
the pond. An Enviroclear thickener and _vacuum drum filter are
proposed to remove the colloidal clay sediments from the water.
Since some water will coat the mica and sand or be trapped in the
clay sediments, makeup water will be derived by pumping from the
South Toe River.

Page 2
Non -Discharge Permit
(Recirculation System)
South Toe River Plant
Yancey County, North Carolina
All of the existing plant facility equipment, including the various
process water lines and _pumps will be used with the proposed
recirculation system. However, some modifications of the facility
will be required and will include:
1. Plugging the overflow pipe at the upslope pond. The overflow
pipe presently discharges to the South Toe River.
2. Construction of ditches around the upslope pond to prevent
upslope surface water runoff into the pond. Upslope stormwater
runoff into the pond could cause overtopping of the pond
embankment
3. Placement of Class A Erosion Control Stone at the water inlet
to the pond
4. Verification, _through falling head permeability tests on
undisturbed soil samples, that at least 1 ft. of the pond's
surficial soils have a coefficient of permeability of at least
1X10-7 cm/sec.
5. Installation of a pump and pipe line to the clay thickening
devices. The clay thickening devices will consist of and
Enviroclear Thickener and a vacuum drum filter.
6. Construction of a containment pad for temporary deposition of
the clay. The containment pad will also have a soil liner 1 ft.
thick having a coefficient of permeability of at least 1X10-7
cm/sec.
7. Construction of a storm drain that leads from the containment
pad to the upslope pond. The clay thickening devices also will be
connected to the storm drain for discharge of the water from these
devices to the pond.
RECIRCULATION SYSTEM MATERIAL BALANCE
It is estimated, based on past experience with areas excavated
nearby, that approximately 40 percent of the material will consist
of clay. At maximum production 600 lbs. of ore can be processed
per min. and 240 lbs. of clay will be contained in the water. For
continuous process with three (3) shifts, 432 tons of ore can be
processed with 172.8 tons of clay (dry) produced.
The clay washwater (clay at 4 to 5 percent solids) will be pumped
through a 6 -inch approximately 420 ft. long Schedule 80 pipeline to
an Enviroclear Thickener. Prior to entering the thickener,
62S

Page 3
Non-Discharge Permit
(Recirculation System)
South Toe River Plant
Yancey County, North Carolina
Nalco 8873 Flocculant will be added at a rate of 0.3 pounds per ton
of clay or at approximately 0.12 lbs. of flocculant per minute or
51.84 lbs. of flocculant per day (3 shifts).
The clay is brought to approximately 20 percent solid and then
pumped to a vacuum drum filter where the clay is increased to 60
percent solids. The clay is then temporarily stored in a
containment.area inwhich direct contact with precipitation drains
to a surface drain. The surface drain connects to the pond by a 1
ft. diameter concrete pipe. The clay will be appropriately
disposed in accordance with DEM and Solid Waste Management
Regulations.
Recirculation water will be lost due to water coating the mica and
sand particles and also from the water left in the clay. Based on
water balance calculations (see Attachment B) approximately 24.5
gallons/mina or 35,280 gallons per day (3 shifts) will need to be
made up by pumping from the river.
WASHWATER CHARACTERISTICS
In addition to utilizing Nalco 8873 Flocculant, Nalco 8852
Coagulant and Nalco 3D4147. A mine Flotation Aid will be used
during the watersortingof the mica, sand and clay (see Attachment
C for Material Safety Data Sheets). Based on past operation of
this facility, and other nearby facilities, the. water will have
BOD, COD and TOC of less than 10 mg/1 due to the small quantities
of material used. The Total Solids in the water after treatment
and discharge into the pond will be no more than100mg/1. The
Nalco produces will general adhere to the clay particles and will
be removed with the clay.
SUBSURFACE CONDITIONS
Figure No. 3 in Attachment D shows the generalbedrockmaterials in
the vicinity of the facility. Bedrock materials generally consist
of layers and bands of Hornblene gneiss and schist and mica gneiss
and schist. A dike runs through the site in a northeast to
southwest direction (see Figure 3 in Attachment D).
To further evaluate the subsurface conditions, on January 20, 1994,
the subsurface conditions were observed by a-Geotechnical Engineer.
Since 20 ft. to 40 ft. steep cuts were observed east of the pond
and below the pond, no soil boring were conducted.

South Toe River Plant
Yancey County, North Carolina
In general, the exposed soils predominantly consisted of a
micaceous silty sandy CLAY (CL). However, at a few locations as
noted on Figure No. 4 in Attachment D, micaceous silty SAND (SM)
zones and hard rock were exposed. Where the rock was exposed,
moisture seepage was noted. Seepage was not observed at other
locations:
Based on the site observations, it appears that ground water will
be at least 4 ft. below the existing pond and the containment pad.
Any water infiltrating these areas would travel in a South -Western
direction and eventually daylight where the rock is exposed at
lower ground levels. It is estimated that the CLAY has a
coefficient of permeability near 1 x 10-6 cm./sec. The SAND zones
are estimated to have a coefficient of permeability ranging from
1 x 10-4 cm. /sec. to 1 x 10-.5 cm. /sec
SURFACE WATER RUNOFF
Surface water runoff from the plant area will eventually drain.to
the South Toe River. However, direct precipitation on the pond and
containment area will be contained within the recirculation system.
Based on ,review of information at the Yancey County Government
offices, the plant is outside of the 100 -year flood plain limits.
SYSTEM EVALUATION
The evaluation of the system includes those areas of the existing
plant that require modifications. More than likely there will be
other plant modifications, since this plant has not been in
operation for nearly two (2) years and several existing plant
components may not be `repaired. As these modifications become
apparent, as -built drawings and designevaluations will be
provided. Following is a brief discussion of these evaluations
with any needed design calculation provided in the Attachments.
Pond
The pond will serve as a constant supply of water to the plant. On
January 20, 1994, the spot evaluations of the pond were taken with
a level, and distances were conducted with a tape. Based on these
measurements, the pond has an average depth of 7.5 ft. and a volume
of approximately 472,060 gallons. Minor pond modifications will
include stabilization of the water inlet area of the pond and
plugging the overflow pipe that discharges directly to South Toe
62

Page 5
Non -Discharge Permit
(Recirculation System)
South Toe River Plant
Yancey County, North Carolina
River. If the pond does not have adequate low permeable soils, a
new soil clay liner system also will need to be constructed for the
pond. In-place testing can be conducted to verify soil
permeability adequacy. At least 1 ft. of the pond's surf icial soil
should have a coefficient of permeability of the 1 x 10-7 CM. /Sec.
or slower.
Approximately five (5) acres of upslope land presently drain to the
pond.To ensure a non -discharge recirculation system, perimeter
ditches will be constructed to pass at least the 50 -year rain event
around the pond. The west ditch will be a grassed trapezoidal
channel while the east ditch will be v -shaped -and lined with Class
A Erosion Control Stone. Attachment E contains the ditch design
calculations.
Recirculation Pump and Pipe Line
A new pump and approximately 420 lineal feet of new pipe line will
be required to take the process water from the plant to the clay
thickener, system. The pipe will consist of a 6 -inch diameter
Schedule 80 PVC.
At a flow rate of 700 gpm and an elevation head of 85 ft., the
total dynamic system head will be 99.0 ft. Attachment F contains
the system head calculations.
Clay Thickener System
The clay thickener system will consist of an Enviroclear Thickener
and a vacuum drum filter. In evaluation of the effectiveness of
this system, the laboratory report prepared by Mr. Gary L. Nelson
and dated February 24, 1987 was used. The area used for these
evaluations will be the same source as at the South Toe River
Plant.
The laboratory tests indicated scale -up rates of 2.5 to 3.5
gpm/ft.2 for the Enviroclear thickener. At a flow rate of 700 gpm,
the diameter of the thickener will need to be at least 20 ft.
Addition of 0.3 lbs. of floculant per one (1) ton of dry clay soil
will be required.
The vacuum drum filter was based on the Buchner funnel test
performed by Mr. Nelson. At a vacuum of 20 to 25 inches of
mercury, submergence of 30%, and a clay load rate of 240 lbs./min.,
the surface area of the drum will need to be at least 1,100 ft.2.
It' is estimated that the clay solid will be 60% after treatment.
The calculations are contained in Attachment G. Attachment G also
contains a general schematic of the Enviroclear system.
62s

Page 6
Non -Discharge Permit
(Recirculation System)
South Toe River Plant
Yancey County, North Carolina
Containment Area
The clay thickener system and temporary storage of the clay will be
within`a 50 ft. by 100 ft. pad having a 1 ft. soil liner with a
coefficient of permeability of at least 1 x 10-7 cm./sec. Perimeter
berms will be constructed around the containment system to divert
upslope runoff around the system, and to collect direct
precipitation that will drain through a collection system back to
the pond.
CLOSURE
We appreciate serving you on this project. Please contact us, if
you have any questions about these evaluations.
Sincerely,
CART
T. Patrick SIIAllie on, P.E. �� s
President SEAL �.
15472
°
TPS/ds
Attachment A: Site & Vicinity DrawingsCK
Attachment B: Water Balance Calculations
Attachment C: Material Data Safety Sheets
Attachment D: Subsurface Conditions
Attachment E: Pond Diversion Ditch Evaluations
Attachment F: System Head Calculations
Attachment G: Clay Thickener System Evaluation

REFERENCES
American Water Work Association, Inc., Water Quality and
Treatment, McGraw-Hill Book Company, 1971.
Wastewater Treatment Plant Design, WPCF Manual of Practice No. 8,
ASCE Manual on Engineering, Practice No. 36, 1977.
EPA/625/1-87/014, Design Manuals Dewatering Municipal Wastewater
Sludges, Sept., 1971.
W Wesley Eckenfelder, Jr., Industrial Water Pollution Control,
2nd Ed., McGraw-Hill Book Company, 1989.
Brater and King, Handbook of Hydraulics, 6th Ed., McGraw-Hill
Book Company, 1976
Erosion and Sediment Control Planning and Design Manual, NCDNR,
recent addition.
John M. Parker, _III, Geology and Structure of Part of the Spruce
Pine District, North Carolina, Geological.Survey, U.S. Department
of the Interior, Bulletin No. 65, 1952.
G2S

l
Wr
1 deo
i 1 t r �l i t�I Al -
'ti.. 1 �4 a. lj't, ',� I � I � � �� � � � �'` � � � � �`Z� "� i�t , q
{i
� � 14 i
i \, i r
l �p It��ta � � y / �� i �j ')J
41
%
r)rl� �1' '�Op:� Il �1� ii �r',�, r J,� �i,,
, �'°•`n �� � -''��,.�„"" /�.•� r s � � ,l it ���� �� y �- ,--s�r / 1 .
y1 r r i 4
{c,�i�4.�/� 1� pry �1
y
t V '
..�;I\
lk' 1 i i Approx. Locaiio? Of Pond
i. V
1 ><.
i l r
PlarLt Area,;',,,,
7 ni
v
n�
� � r{IN.t� iMm I _ �I 1 � �/ i � � •,,'^ • 1 " \� �� �' � � .r/u Nt dal �tiii, �° /
tt//
�.< ' � /11 J r ! ✓ 'T 'r r Approx. ' Locat on o f Discharge'
Ponds For The Existing Dtischarge,]:)
) i1��i �'•, o NCOOOO434
� it N
� � � r � � .. � 1
,
l l
G� i 3
f aci
� SCALS' 1' .2f?0!1
!!� �, � ,, aI � I Cern .�a'�ue �i.cic,k r _-�!g.— __••--c__-, (gf i�
{ 4•' 'St C i� !f �i i`� t')II �/ / i� /�\�1y \�u ��`... "',+ �YW,
Mfie
' ' USCS MICA I LL E DAz :
QUADRANGLE MAC
IX
t t /in , ..1 ►,��
�� Q'uth Toe River Flarf.i
✓ f } 1 Ycxn.cy County, NC.
G2�

MATERIAL SAFETY DATA SHEET
IPRODUCTNALCO 8873 FLOCCULANT

A
SECTION 5 HEALTH- EFFECTSINFORMATION ( CONTINUED
EYE CONTACT: 'Can cause moderate irritation.'
SKIN CONTACT: Can cause minimal irritation.
SYMPTOMS OF EXPOSURE: A review of available data does not identify any
symptoms from exposure not previously mentioned, or identified in
Section 6 or 14
AGGRAVATION OF EXISTING CONDITIONS: A review of available data does
not identify any worsening. of existing conditions not previously
mentioned, or identified in Section 6 or'14.
SECTION 6 TOXICOLOGY INFORMATION
ACUTE TOXICITY STUDIES: Acute toxicity studies have been conducted
on this product. The results are shown below'
ACUTE ORAL TOXICITY (ALBINO RATS): LDa,'= Greater than 5,000 mg/kg
COMMENTS: No significant'gross pathologic changes were noted at the
time of sacrifice.
PRIMARY SKIN IRRITATION TEST ('ALBINO. RABBITS):
SKIN IRRITATION INDEX DRAIZE RATINGi 1.33/8.0 Slightly irritating
COMMENTS: `Slight redness and swelling was noted four to five hours after
application. The swelling subsided after 24 hours. The redness remained
for 14'days in three of the six animals. The application site appeared'
dried and `cracked after 14 days.
PRIMARY EYE IRRITATION TEST (ALBINO RABBITS):
EYE IRRITATION INDEX DRAIZE RATING: 26.5/110:0 Moderately irritating
COMMENTS: Slight focal corneal opacity and irritation of the iris'
and conjunctiva was noted in all six animals one hour after contact.
The effects cleared in three of six animals the fourth day after .11
contact and persisted up to seven days in the other three animals..
SECTION 7 PHYSICAL AND CHEMICAL PROPERTIES
COLOR: Cream FORM: 'Liquid ODOR: Slight hydrocarbon
DENSITY: 8.7 lbs/gal'.
SOLUBILITY IN WATER: Dispersible
-VISCOSITY: 400 cps @ 75 Degrees F ASTM D-2983
POUR POINT: -36 Degrees F ASTM D-97
FLASH POINT: Greater than 200 Degrees F (PMCC) ASTM D-93
PAGE 2 OF 8

MATERIAL SAFETY ®ATA ' S
BEET

MATERIAL SAFETY DATA SHEEN"
PRODUCT
e4i NALCO NALCO 8852 COAGULANT
N /� � LC
Emergency Telephone Number
Medical [phone] (24 hours) (800) FWALERT
SECTION 1 PRODUCT IDENTIFICATION
TRADE NAME: NALCO 8852 COAGULANT
DESCRIPTION: An aqueous solution of a polyquaternary amine
NFPA 704M/HMIS RATING: 0/0 HEALTH 1/1 FLAMMABILITY 0/0 REACTIVITY 0 OTHER`
O=Insignificant 11=Slight 2=Moderate 3=High 4=Extreme`
SECTION 2 HAZARDOUS INGREDIENTS
Our hazard evaluation of the ingredient(s) under OSHA's Hazard Communication
Rule,[ 29 CFR 1910.1200 has found none of the ingredient(s) hazardous.
SECTION 3 PRECAUTIONARY LABEL INFORMATION
CAUTION: May cause irritation to skin and eyes. 'Avoid contact with
skin,eyes and clothing. Do not take internally.
Empty containers may contain residual product. Do not reuse container
unless properly reconditioned.
SECTION' 4 FIRST AID INFORMATION
EYES: Flush with water for 15 minutes. Call a`physi.cian.
SKIN: Flush with water for 15 minutes.
INGESTION: Do not induce vomiting. Give water. Call a physician.
INHALATIONS Remove to fresh air. Treat symptoms. Call a physician.
NOTE TO PHYSICIAN: Based on the individual reactions of the patient, the
physician's judgment should be used to control symptoms` and clinical condition.
CAUTION: If unconscious,;_ having trouble breathing or in convulsions,
do not induce vomiting or give water.
SECTION 5 HEALTH EFFECTS INFORMATION
PRIMARY ROUTE(S) OF EXPOSURE: Eye, Skin
EYE CONTACT: Non -irritating.
SKIN CONTACT: Can cause mild, short -lasting irritation.
SYMPTOMS OF EXPOSURE: A review of available data does not identify any
symptoms from exposure not previously mentioned.
AGGRAVATION OF EXISTING CONDITIONS: A review of available data does
not identify any worsening of existing conditions.
PAGE 1 OF 8
NALCO CHEMICAL. COMPANY �^?^t+:_' N,^,t I C1 (_.f PJT"E FS � NAPERVILLE, ILLINOIS 60563-1 1 9F3
AREA 108-305-1000

MATERIAL SAFETY( DATA SHEET
PRODUCT
e4j pp����
NALCO 8852 COAGULANT
NALCO
Emergency Telephone Number
Medical [phone] (24 hours) (800) I-M•ALERT
SECTION 6 TOXICOLOGY INFORMATION
ACUTE TOXICITYSTUDIES: Acute toxicity studies have been conducted on.;
this product. The 'results are shown below.
ACUTE ORAL TOXICITY (ALBINO RATS): LDS, = 4,699 mg/kg
95% Confidence Limit = 3,`772 5,854 mg/kg
ACUTE DERMAL TOXICITY (ALBINO RABBITS): LD,,= Greater than 2,000 mg/kg
PRIMARY SKIN IRRITATION TEST (ALBINO RABBITS):
SKIN IRRITATION INDEX DRAIZE'RATING:
0.84/8.0 Mildly Irritating
PRIMARY EYE IRRITATION TEST (ALBINO RABBITS)
EYE IRRITATION INDEX DRAIZE RATING:
1.0/110.0 Practically Non -Irritating
.SECTION 7 PHYSICAL <AND 'CHEMICAL PROPERTIES
COLOR: Clear light yellow FORM: Liquid ODOR: None
DENSITY: 9.1 lbs/gal.
SOLUBILITY IN WATER:; Completely
SPECIFIC GRAVITY: 1`.09 @ 60 Degrees F ASTM D-1298
pH (NEAT)' 4.5 ASTM E-70
FREEZE POINT: 14 Degrees F ASTM D-1177
FLASH POINT: Greater than 200 Degrees F (PMCC) -ASTM D-93
NOTE: These physical properties are typical values for this product.
SECTION 8 FIRE AND EXPLOSION INFORMATION
FLASH POINT: Greater than 200 Degrees F'(PMCC) ASTM D=93
'EXTINGUISHING MEDIA: This product would not be expected to burn unless
all the water is boiled away. The remaining organics may be
ignitable. Use water to cool containers exposed to fire.
UNUSUAL FIRE AND EXPLOSION HAZARD: May evolve NOx under fire conditions.
SECTION 9 REACTIVITY INFORMATION
INCOMPATIBILITY': Avoid alkaline materials (eg. ammonia and its solutions
carbonates, sodium hydroxide (caustic), potassium hydroxide, calcium hydroxide
(lime), cyanides, sulfides, hypochlorites, chlorites) which can generate heat
PAGE 2 OF 8
NALCO CHEMICAL MICAL COMIPANY ONE NAI -CO CENTER s NAPERVILLE, ILLINOIS 60580-119B

MATERIAL SAFETY DATA SHEET
Emergency Telephone Number
Medical [phone] (24 hours) (800) I-M•ALEI _T
SECTION 9 REACTIVITY INFORMATION ( CONTINUED )
with splattering or boiling and the release of toxic fumes.
THERMAL DECOMPOSITION PRODUCTS: In the event of combustion CO, CO„ NOx may
be formed. Do not breathe smoke or fumes. Wear suitable protective equipment.
SECTION 10 PERSONAL PROTECTION EQUIPMENT
RESPIRATORY PROTECTION: Respiratory protection is not normally needed since
the volatility and toxicity are low. If significant vapors, mists or aerosols
are generated, wear a NIOSH approved or equivalent respirator.
For large spills, entry into large tanks, vessels or enclosed small spaces
with inadequate ventilation, a pressure -demand, self-contained breathing
apparatus is recommended
VENTILATION: General ventilation is recommended.
PROTECTIVE EQUIPMENT: Use impermeable gloves and chemical splash goggles when
attachingfeeding equipment, doing maintenance or handling product. Examples of
impermeable gloves available on the market are neoprene, nitrile, PVC, natural
'rubber, viton and butyl ,(compatibility studies have not been performed).
The availability of an eye wash fountain and safety shower is recommended.
If clothing is contaminated, remove clothing and thoroughly wash the
affected area. Launder contaminated clothing before reuse.
SECTION 11 SPILL AND DISPOSAL INFORMATION
IN CASE OF TRANSPORTATION ACCIDENTS, CALL THE FOLLOWING 24-HOUR
TELEPHONE NUMBER (708-920.-1510)
SPILL CONTROL AND RECOVERY:
Small liquid spills: Contain with absorbent material, such as clay, soil or
any commercially available absorbent. Shovel reclaimed liquid and absorbent
into recovery or 'salvage drums for disposal. Refer to CERCLA in Section 14.'
-Large liquid spills: Dike to prevent further movement and reclaim into
recovery Ior salvage, drums or tank truck for disposal. Refer to CERCLA
in Section 14..
This product is toxic to fish. It should not be directly discharged
into lakes, ponds, streams, waterways or public water supplies.
PAGE 3 OF 8
NALCO CHEMICAL COMPANY ONE NALCO CENTER ®n NAPERVIL.:LE, ILLiI�IC�i;� hO��3 a- i 1 �H
AREA 708-005-1000

MATERIAL TY DATA SHEET
PRODUCT
NALCO 8852 COAGULANT
Lc
Emergency, Telephone Number
-Medical [phone] (244 hours) (800) i -M -ALERT
SECTION 11 SPILL AND DISPOSAL INFORMATION ( CONTINUED
DISPOSAL: If this product becomes a waste, it does not meet the criteria of
a hazardous waste as defined under the Resource Conservation and Recovery Act
(RCRA) 40 CFR 261, since it does not have the characteristics of Subpart C,
nor is it listed under Subpart D.
As a non -hazardous liquid waste, it should be solidified with stabilizing
agent's (such as sand, fly, ash,or cement) so that no free liquid remains
before disposal to an industrial waste landfill. A non -hazardous liquid
waste can also be incinerated in accordance with local, state and federal
regulation's.
SECTION 12 ENVIRONMENTAL INFORMATION
BIOCHEMICAL OXYGEN DEMAND (5 -day BOD): 700 mg/L
CHEMICAL OXYGEN DEMAND (COD) 88,940 mg/L
TOTAL ORGANIC CARBON (TOC): 62,440'mg/L
AQUATIC DATA:
96 hour static acute LC,, to Bluegill Sunfish-= 0.90 mg/L
96 hour no observed' effect concentration is 0.56 mg/L based on no mortality
or abnormal effects
96 hour static acute LC,, to Rainbow Trout = 0.47 mg/L
96 hour no observed effect concentration is 0.18 mg/L based on no mortality
or abnormal effects:
96 hour static acute LCs, to Sheepshead Minnow = Greater than 1000 mg/L
96 hour no observed effect concentration' is 100 mg/L based on no mortality
or abnormal effects.
96 hour static acute LC50 to Fathead Minnow =`0.9 mg/L
96 hour no observed' effect concentration is 0.6 mg/L based on no observed
abnormal behavior.
TOXICITY RATING: Extremely toxic
PAGE 4 OF 8
NALCO CHEMICAL COMPANY ONE NALCO CENTER NAPERVII. LE, ILLINOIS 60563-119B
AREA 708-305-1000

MATERIAL AFETTA SHEET
PRODUCT
NALCO 8852 COAGULANT
f4
LC
Emergency Telephone Number
Medical [phone] (24 hours) (800) [-M-ALERT
SECTION '12 ENVIRONMENTAL INFORMATION ( CONTINUED,)
48 hour static acute LC,,, to Daphnia magna - '97 mg/L
48 hour no observed effect concentration is less than 40 mg/L based on ,no
observed abnormal behavior.
TOXICITY RATING: Moderately toxic
If released into the environment, see CERCLA in Section 14.
SECTION 13 TRANSPORTATION INFORMATION
DOT PROPER SHIPPING NAME/HAZARD CODE - PRODUCT IS NOT REGULATED
DURING TRANSPORTATION
SECTION ''14 REGULATORY INFORMATION
The following regulationsapply to this product.
FEDERAL REGULATIONS:
OSHA'S HAZARD COMMUNICATION RULE, 29 CFR 1910.1200:
Based on our hazard evaluation, this product is not hazardous.
CERCLA, 40 CFR 117, 302:
Notification of spills of this product is not required.
SARA/SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT OF 1986
(TITLE III) -'SECTIONS 302, 311,-312 AND 313:
SECTION 302 —EXTREMELY HAZARDOUS SUBSTANCES (40 CFR 355) :
This product does not contain ingredients listed in Appendix A and B as an
Extremely Hazardous Substance.
SECTIONS 311 and 312 - MATERIAL SAFETY DATA SHEET REQUIREMENTS (40 CFR 370):
Our hazard evaluation has found that this product is not hazardous under
29 CFR 1910.1200.
SECTION 313 - LIST OF TOXIC CHEMICALS (40 CFR 372)
This; product does not contain ingredients on the List of Toxic Chemicals.
TOXIC SUBSTANCES CONTROL ACT (TSCA);
The chemical ingredients in this product are on .the 8(b) Inventory List
(40 CFR 710).
PAGE 5 OF 8
NALCO CHF=MICAL_ COMPANY [."SNE: NALCO CEN NAPERVILLE:, ILILINUIS'!=`05E-33-1'1'98

MATERIAL SAFETY DATA SHEET
PRODUCT
NALCO 8852 COAGULANT
NALCO
Emergency Telephone Number
Medical [phone] (24 hours) (800) I-M-ALERT
SECTION 14 REGULATORY INFORMATION ( CONTINUED )
FOOD AND DRUG ADMINISTRATIONS '(FDA)'Federal Food, Drug and Cosmetic Act:
When use situations necessitate compliance with FDA regulations, this product
is.acceptable under 21 CFR 176.170 components of paper and paperboard in
`contact with aqueous and fatty foods, and under 21 CFR 176.180 components of
paper and paperboard in contact with dry food.
U. S. EPA OFFICE OF DRINKING WATER -`ADDITIVES EVALUATION BRANCH:
The`USEPA has approved this product for use as a coagulation aid in
the treatment of potable water. The maximum recommendedproduct'
dosage limit is 50 ppm.
RESOURCE CONSERVATION AND RECOVERY ACT (RCRA), 40 CFR 261 SUBPART C & D:
Consult Section 11 for RCRA classification.
FEDERAL WATER POLLUTION CONTROL ACT', CLEAN WATER ACT, 40 CFR 401.15
(formerly 'Sec. 307), 40 CFR 116 (formerly Sec. 311):
None of the ingredients are specifically listed.
CLEAN AIR ACT, .'Sec. 111 (40 CFR 60), Sec. 112 (40 CFR 61, 1990 Amendments):'
This 'product does not contain ingredients covered by the Clean Air Act'.
STATE REGULATIONS:
CALIFORNIA PROPOSITION 65:
This product does not contain any chemicals which require warning under
California Proposition 65.
MICHIGAN 'CRITICAL `MATERIALS:
This; product does not contain ingredients listed on the Michigan Critical
Materials Register.
STATE RIGHT TO KNOW' 'LAWS
The 'following ingredient(s) are disclosed for compliance with State Right To
Know Laws:
Polyquaternary amine Trade secret
Sodium chloride 7647-14-5'
Water 7732.-18-5
SECTION 15 ADDITIONAL INFORMATION
None'
PAGE 6 OF 8
NALCO CHEMICAL COMPANY ONE NALCO CENTER s NAPERVILLE, ILLINOIS 60563-1198

MATERIAL SAFETY DATA SHEET
PRODUC1"
NALCO 8852 COAGULANT
LC
Emergency Telephone Number
Medical (800)'462-5378 (24 hours) (800) I -M -ALERT
SECTION 16 USER'S RESPONSIBILITX
This product material safety data sheet provides health and safety
information, The product is to be used in applications consistent with
our product literature. Individuals handling this product should be
informed of the recommended safety precautions and should have access
to this information. < For any other uses, exposures should be evaluated
so that appropriate handling practices and training programs can be
"established to ensure safe workplace operations. Please consult your
local sales representative for any further information.
SECTION 17 BIBLIOGRAPHY
ANNUAL REPORT ON CARCINOGENS, U.S; Department of Health and Human Services,
Public Health Service, PB`33-135855,-1983.
CASARETT AND DOULL'S TOXICOLOGY, THE BASIC SCIENCE OF POISONS, Doull, J.,
Klaassen, C. D., and Admur, M. 0.,,eds.,,Macmillian Publishing` Company, Inc.,
N. Y. 2nd edition, 1980.
CHEMICAL HAZARDS OF THE WORKPLACE, Proctor, N. H., and Hughes, J. P., eds.,
J. P. Lipincott Company, N.Y., 1981.
DANGEROUS PROPERTIES OF INDUSTRIAL MATERIALS, Sax, N. Irving, ed.;' Van
Nostrand Reinhold Company, N.Y., 6th edition, 1984.
IARC MONOGRAPHS ON THE EVALUATION OF THE CARCINOGENIC RISK OF CHEMICALS
TO MAN, Geneva: World Health Organization, International Agency for
Research on Cancer, 1972-1977.
PATTY'S INDUSTRIAL HYGIENE AND TOXICOLOGY, Clayton, G. D., Clayton, F. E.,'
eds., John Wiley and Sons, N. Y. 3rd edition, Vol. 2 A -C, 1981.
REGISTRY OF TOXIC EFFECTS ON CHEMICAL SUBSTANCES, U.S. Department of
Health and Human Services, Public Health Service, Center for Disease
Control, National Institute for Occupational Safety and Health, 1983
supplement of 1981-1982 ,edition, Vol. 1-3, 08,,1984.
Title 29 Code of Federal Regulations Part 1910, Subpart Z, Toxic and
Hazardous Substances, Occupational Safety and Health Administration (OSHA).
THRESHOLD LIMIT VALUES FOR CHEMICAL' SUBSTANCES AND PHYSICAL AGENTS IN THE
WORKROOM ENVIRONMENT WITH INTENDED CHANGES, American Conference of
Governmental Industrial Hygienists, OH.`
PAGE 7 OF 8
NALCO ICF!€FFMICAL. COMPANY ONE ('.IAL.(30 CENTER N,4PERVILLE, (LI-INC'jiS SCJ563-119B
A R I:: n. 70FI-30 -1 0 C:'

NALGO' Cmemim&i I r*#"IkAdog%mks v

NALCO

NALGOCINIMbiICAL COMPAPJV 1lh:is` h1.^.i r^n r.irrr

NA1.:Go C:HrMMI CAL "O-OMPANt V i-)N

11 $`1 70376 320i4 NALCO CHEMICAL C�7]OU3
MATERIAL SAFETY DATA SKEET
PRODUCT
P4
N A L�.: NALM 3DA147 MINERAL FLOTATION
Emergency 'telephone Number
Medical (708), 920.1 Sy o (24 hours)
SECTION 14 REGULATORY INFORMATION ( CONTINUED -)
Thi$ prcduot does not contain ingredients lister on the Michigan
Critical Materials Register.
STATE RR't= TQ FNc)w LAws:
The followwinci smites identify the ingredient (s) shown below as hazardous:.
Massachusetts, Pennsylvania Diet]-hyl.et-)e glycol
Regulated in those states using the TLV for ethylene glycol as a
Criteria for listing.
INrE�MTTONAL RUWLATTONS:
This is -a WHMIS controllEd prCdUCt under The House of COITMns of Canada Bill
C-70. The product contains the following substance(s), from the Ingredient
Disclosure List or hes been evaluated based on its toxicological properties,
to contain the fallowing hAzard0us ingx ed..ient (s)
ChOn.icaI Name CAS# % Concentration Rango
tthylene glycol 107-21-1. 40-70
Diethylene glycol 111-46-6 5-10
SECTION 15 ADDITIONAL INFORMATION
None
SECTIO.i 16 USER'S RESPONSIBILITY
'Phis product material safety data sheat provides health and safety -
information. The Product is; to .be used 1n applications r onsistent with
aur prciduct literature. Individuals handling this product should be
ityform d of the re=miended safety precautions and should have acmes
to this information. For any other uses, &Vosures should be evaluated
so that appraprie-Ate handling practices and training programs can be
established to ensure safe workplace operations. Please consult your
local sales representative for any further information.
SECTION 17 "BIBLIOGRAPHY _
ANNUAL REMRT oN CARCINoGENs U.S. Department of Health and Human Services,
Public Health Service, PB 33-1358551 1983,
cASAREIT A D4ULL- S TOXICx)LOGX, THE BASIC SCTENOZ OF POISONS, Doull, J.
Klaassen, C. D-, and Admut M. Q. , eds. , Macmil]..i.an Publishing Company, Inc, r
PAGE 7 OF 8
NAL-430 CHEMICAL 'cr3mP"Afi!Y 0r,-JE Ntai r'rr'rF-nrr��.�-

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NOTE: SOIL EXPOSED AT ALL AREAS CONSISTEY
OF SILTY SANDY. CLAY UNLESS OTHERWISE NOTED.
1 TREE LINE
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WARE HOUSE \
- ' • _ PLANT \\ -
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/ CONTROL
SHED /0 OFFICE
EXPOSED GROUND OBSERVATIONS DATE:
01/81/94
South Toe River Plant „w�,a
Yancy County, NC.

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DOCUMENT CODE: 55 DOCUMENT DATE: 02/24/87
HUBER LABORATORY LABORATORY
REPORT NO. 2169 REPORTING WORK: Pilot Plant
PROJECT NO. CL -3 (41) WORK BY: Gary L. Nelson
NOTEBOOK REF. NO. 422 pg. 28, -REQUESTED BY Gary L. Nelson
43-44
COPIES: SKW WFA ACK JSW
JJF JC BB DD
TITLE:
Mica Project Clay Process Verification and Optimization
Background and Scope:
The proposed mica plant ;to be constructed at Ring's Moun-
tain, North Carolina, will require a dewatering process for han-
dling the clay fraction by-product. The primary equipment
required for the ,process will include a high capacity thickener
and a filter for solids concentration.
It was necessary for the clay thickening and filtration
processes be evaluated in the pilot plant for equipment and proc-
ess verification, optimization, and scale -up. A 3.5 inch diam-
eter Enviroclear high capacity thickener wasprovidedby Mr.
Archie Brumfield of.M. S. French Company,' Inc., Palmetto, Flo-
rida, to evaluate the thickening process. A laboratory Buchner
funnel was used to evaluate the filtration process'.
Summary:
Utilizing a 3.5 inch diameter Enviroclear high capacity
thickener and Nalco 8873 polymer to set le a representative clay
slurry, scale -up rates of 2.5`-3.5 gpm/ft were achieved. Using
the assumed plant production rates, a`high capacity thickener di-
ameter of -35 feet would be required with a polymer dosage re-
quirement of 0.3 pounds per ton. The project allows for a 60
foot diameter thickener and a polymer dosage requirement of 0.33
pounds per ton.
A filtration rate of 58.9 lb/hr/ft2 was calculated from
data using a 12.5 CM diameter Buchner funnel and 1.0;cfm,,filter
cloth. Based 2on the assumed plant production rates, approxi-
mately 564 ft of filt?tion area would be required. The project
allows for over 600_ft of area.

Procedure and Results:
Two 55 -gallon drums ofclay were received from North Caro-
lina --one from KMG Minerals located in King's Mountain and one
from Deneen Mica Company located near Micaville. The Deneen-Mica:
sample contained slurry produced from the tolling of ore from J.
M. Huber`s King's Mountain, reserves and represented clay; benefi-
ciated from shallow, excavations (less than ,40 feet of depth).
The KMG Minerals sample contained slurry produced from theirown
ore mined from depths probably exceeding 40 feet.
The 3.5 inch diameter Enviroclear high capacity thickener
was set-up, demonstrated, and then left with the pilot plant for
a two week period by Mr. Brumfield to allow for extensive trials.
A schematic of the Enviroclear unit is shown in Figure I. Peris-
taltic pumps were used for motoring all streams. Nalco 8873 po-
lymer was used in solutions of 0.05-0.1%.as a flocculant settling
aid.
A series of trials were performed using each clay slurry.
Each trial` consisted of selecting a desired slurry feed .rate, op-
timizing the polymer dosage rate to achieve a stable floc, and
achieving a consistent bed level in the thickener by pumping the
underflow at a steady; rate. Once this was accomplished, all per-
tinent flow rates were recorded and samples taken to determine
solids content. Results from the various trail are shown in Ta-
ble I. The value pertinent to scale -up, gp5/ft was computed
based on the correlation that one gpm/ft is equal .to each 250
ml/min of feed rate. The results indicated a throughput range of
gpm/ft2could be used for scale -up. From this value,
based on projected `clay `production, a required thickener size of
35 feet is diameter was calculated.
The polymer dosage requirements was calculated at 0.3
pounds per ton of clay based on average data from the trials'.
Calculations to support these results are shown in Appendix I.
Filtration requirements for the project were determined by
filtering clay underflow from the thickener thru a 12.5 CM'diam-
eter Buchner funnel using 10 cfm filter cloth. Several trials
were conducted on both clay slurries adjusting process; variables
to ;optimize the rate. The results from the trials are shown in
Table II. Trials 1--8 were .used to determine the optimum feed
slurry batch quantity of 200 ml. Trials 9-14 were ,used to deter-
mine the ,optimum filtration time of 120 seconds. Trials 15-20
were used to determine the average; cake solids for each clay.
The fina results were used to calculate a`filtration rate of q5
lb/hr/ft requiring a' filtration area of approximately 563.6 ft
The calculations are shown in Appendix II.'
Gary L. Nelson
GLN:dh

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APPENDIX I
Thickener Calculations
Thickener Size Requirements:
Project Peak Clay Tonnage = 92900,TPY
= 15.5 TPH (6000 Hr/Yr)
Assume 2000 GPM SJ�urry Feed Rate '*
Assume 2.5 GPM/FtThickener Feed Rate
2000 GPM.
= soa Ft
2.5 GPM/Ft2
A = n r2
800 Ft nr
r 15.96 Ft 16 Ft
d = 32 Ft
:35 Ft Diameter Thickener is Acceptable
* Conservative value (rate is high) since .15.5 TPH at an
average % 5 solids (0.431 lb/gal) would equal 1`200 GPM.
Polymer Dosage Requirements:
Assume 15.5 TPH Feed Rate at 5% Solids (1200 GPM)
Assume Polymer Dosage at 7.5 PPM ;(Nalco 8873 = 8.6 lb/gal)
7.5 PPM = 0.009 GPM
0.009 GPM x 60 min/hr x 8.6 lb/gal =.4.644 lb/hr
4.644 lb/hr
= 0.3 lb/ton Polymer Requirement
15.5 ton/hr'

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