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HomeMy WebLinkAboutNC0047384_Pretreatment_IUP_Hallstar_Renewal_20240509 CITY OF GREENSBORO WATER RESOURCES DEPARTMENT INDUSTRIAL WASTE SECTION SIGNIFICANT INDUSTRIAL USER WASTEWATER DISCHARGE PERMIT SIU PERMIT NUMBER P0025 HALLSTAR GREENSBORO LLC IS AUTHORIZED TO DISCHARGE WASTEWATER FROM A FACILITY LOCATED AT 520 BROOME ROAD GREENSBORO, NORTH CAROLINA into the City of Greensboro Sanitary Sewer System to the T.Z. OSBORNE Water Reclamation Facility [NPDES PERMIT NUMBER NCO047384] in accordance with the limitations and conditions set forth in this permit. This permit shall become effective SEPTEMBER 1, 2023 This permit and the authorization to discharge shall expire at midnight on AUGUST 31, 2028 or upon permit reissuance, whichever comes first. Amy Var' ski Date Pretreatment Coordinator Page 2, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 INDUSTRY OFFICIAL RESPONSIBLE FOR PERMIT COMPLIANCE This signatory official shall be responsible for permit compliance, including monitoring, report submittals, accidental discharge notification, and permit renewal. Although certain of these activities may be delegated to other individuals, the Signatory Official is ultimately responsible for compliance with all permit conditions, limits, activities and terms. I am aware of my responsibilities as Signatory Official and I am aware of the terms and conditions set forth in this wastewater discharge permit and the City of Greensboro Sewer Use and Pretreatment Ordinance. Signatory Official NAME (PLEASE PRINT) Signatory Official TITLE (PLEASE PRINT) Signatory Official Signature Date: CHANGE OF SIGNATORY OFFICIAL If there is a change of the Signatory Official for this facility, the City of Greensboro shall be notified of such change within thirty (30) days. A new page 2, "INDUSTRY OFFICIAL RESPONSIBLE FOR PERMIT COMPLIANCE" shall be submitted to the Industrial Waste Section with the name, title and signature of the new official. September 1,2023 Permit Renewal Page 3, SIU Permit 4P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 SECTION I - PERMIT MODIFICATION HISTORY DATE MODIFIED REASON & DESCRIPTION OF MODIFICATION OR ACTION September 1, 1998 PERMIT RENEWAL Permit Modification January 7, 2000 Flow Limit decrease from six month average of 50,000 to 25,000 gallons based on flow date received form sampling and industry submitted data PERMIT RENEWAL September 1, 2003 Increased flow limit to 35,000 gallons per day[daily maximum]due to discharge of stormwater from tank farm area. Increased daily maximum flow limit from 35,000 gpd to 50,00 gpd. December 1, 2004 Additional flow is needed for new business. The sampling location for the OCPSF sample has been changed from the manhole to the sampler in the Sample House. PERMIT RENEWAL Page 4, Section II.A -added wastestream being discharged, change Pipe 01 does include domestic; 2) Page 5 & 6, Section III-flow changed from daily maximum of 50,000 to monthly average 45,000; 3) Page 6- September 1, 2008 monitoring frequency changed from 416 months to 216 months); 5) Page 7, Section IV.A3 - included flow readings submittal date; 6) A.5 - added new contact; 5) Page 8, Section IV.A -deleted last paragraph requiring dates for compliance with installation offlow measuring equipment; 7) IV.B. Self-Monitoring Report Submittal-added requirement for when no discharge by Permittee October 1, 2008 Modify sample location for OCPSF compliance sampling. Section IL C. modified to incorporate new location. Page 5 and 6, Section III-Changed minimum sampling requirement for City to 1/year. 2) Page 7, Section IV.A.4-changed effluent meter July 1, 2011 calibration requirement from once per six-month period to once a calendar year; 3) Page 7, Section IV.A.5. and 6. -deleted names from permit and included the position titles only; 4) Page 8, Section IV.B. -Report Submittal date changed from 20th to I5th Permit transferred to Lanxess Corporation. New owner confirmed that all October 12, 2011 products and processes will remain unchanged throughout duration of this permit. Changed expiration date based on Lanxess Corporation request. Finalized name change to Lanxess Corporation. Increased flow to 65,000 July 1, 2012 gpd monthly average from 45,000 gpd to permit increased production from 7-days per week operations. Allocations increased proportionately. No domestic at Pipe 01. PERMIT RENEWAL September 1, 2013 Section III- City monitoring frequency set to 116 months; - Section IV. Added Special Condition D (Slug/Spill Control Plan)per DWQ guidance; Added Special Condition E (Surrogate Process Control Sampling). September 1, 2023 Permit Renewal Page 3A, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective October 13, 2022 DATE MODIFIED REASON&DESCRIPTION OF MODIFICATION OR ACTION PERMIT RENEWAL Modified flow limit from 65,000 to 80,000 monthly average; Modified September 1, 2018 composite sampling technique and location language; Special Conditions changes: Modified Flow Language;Added Flow Measurement Calibration/ Verification Section. PERMIT MODIFICATION(Due to NCDEQ Comments) October 1, 2020 Modified flow limit/OCPSF mass limits-Based on Five Year Long-Term Average Calculation: Sampling Language Clarified PERMIT MODIFICATION March 9, 2022 Modified flow limit/OCPSF mass limits based on updated review of facility's average flow data. PERMIT MODIFICATION October 13, 2022 Modified to reflect purchase of company and name change from Lanxess to Hallstar Industrial Solutions Company October 27, 2022 PERMIT MODIFICATION Modified to correct SIU name to Hallstar Greensboro LLC September 1, 2023 PERMIT RENEWAL September 1, 2023 Permit Renewal Page 4, SIU Permit 4P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 SECTION II - GENERAL INFORMATION A. Description of Discharge Pipe 01 —Process Wastewater from production process waters [Two reaction types; 1.Esterification where an alcohol is reacted with an organic acid or anhydride and 2. Sulfoamidation where an aliphatic amine is reacted with an aromatic sulfonylchloride]. Facility/equipment wash down and industrial storm water. Pipe 01 does not include domestic or non-regulated wastewater wastestreams. B. Authorization Statement 1. The permittee is hereby authorized to discharge wastewater in accordance with the effluent limitations, monitoring requirements, and all other conditions set forth in this Industrial User Pretreatment Permit (IUP) into the sewer collection system and wastewater treatment facility of the City of Greensboro 2. The permittee is hereby authorized to continue operation of and discharge wastewater from the following treatment or pretreatment facilities. These facilities must correspond to the treatment units listed on both the application and inspection forms. Flow Equalization (non-aerated) Neutralization, pH adjustment Spill Protection 3. If requested by the City of Greensboro and given Authorization to Construct (A to C) from the City of Greensboro, the permittee is hereby authorized to construct and operate additional pretreatment units as needed to meet final effluent limitations. C. Monitoring Location Grab samples: Sampling tap on Wastewater Holding Tank C6 located in tank farm C at the backside of the property shall be used for all OCPSF and Local Pollutant Allocation Sampling Composite samples: Taken from automatic sampler located in sampling house in front of Tank C6 D. Composite Sampling Technique 1. Compliance samples for EPA Method 624.1 OCPSF regulated parameters shall be grab samples taken from Wastewater Holding Tank C6. 2. Compliance samples for EPA Method 625.1 OCPSF regulated parameters including Lead and Zinc flow proportional composite samples shall be collected from the automatic sampler. 3. The automatic sampler shall be used to collect flow proportional composite samples for compliance with Local Pollutant Allocation parameters and for surcharges. September 1, 2023 Permit Renewal Page 5, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 SECTION III-EFFLUENT LIMITS AND MONITORING REQUIREMENTS Effluent Limits and Monitoring Requirements for Pipe 01 THIS FACILITY IS REGULATED BY FEDERAL CATEGORICAL PRETREATMENT STANDARDS FOR ORGANIC CHEMICALS, PLASTICS AND SYNTHETIC FIBERS [40 CFR PART 414.1101 EFFLUENT LIMITATIONS MONITORING FREQUENCY EFFLUENT Daily Monthly Sample CITY OF CHARACTERISTICS PERMITTEE Maximum Average Type GREENSBORO Flow (gallons per day) 80,000 # DAILY H standard units 5.0— 12.0 Grab 1/6 months Chemical Oxygen Demand Immediately report all m /1 ^ values >10,000 mg/1 C 1/month^ EFFLUENT LIMITATIONS MONITORING FREQUENCY EFFLUENT Daily 6 Month Sample CITY OF CHARACTERISTICS Maximum Average Type PERMITTEE GREENSBORO BOD++ m /1 M C 1/6 months Suspended Solids++ m /1 M C 1/6 months Cadmium T m /1) M C 1/6 months Chromium T) m /1) M C 1/6 months Copper T m /1 M C 1/6 months Lead T) m /1 * C *Seepage 5A 1/6 months Nickel T m /1 M C 1/6 months Zinc T m /l)* C *See a e 5A 1/6 months Silver T m /1 M C 1/6 months Cyanide Total m /1 * Grab *See page 5A 1/6 months ALL METALS ARE TO BE ANAL YZED AS TOTAL[TJ ^ See Special Conditions: SURROGATE PROCESS CONTROL SAMPLING # The Greensboro Industrial Waste Section does not consider Flow to be a pollutant and flow data is not considered to be a report. ++ALL BOD CONCENTRATIONS OVER 200 mg/I AND ALL TOTAL SUSPENDED SOLIDS CONCENTRATIONS OVER 200 mg/1 ARE SUBJECT TO AN INDUSTRIAL WASTE SURCHARGE C - Composite Sample [See Section II Part D for permit-specific definition] G - Grab Sample M- Monitoring Only [See Local Pollutant Allocation Document to determine if an Allocation has been issued for this parameter] September 1, 2023 Permit Renewal OCPSF PERMIT LIMITS PAGE 5A, SIU Permit P025 (40 CFR Part 414) HALLSTAR GREENSBORO LLC Effective: September 1, 2023 SIU Process Flow Limit(MGD)= 0.080 EFFLUENT LIMITS MONITORING FREQUENCY EPA DAILY MAXIMUM MONTHLY AVERAGE SAMPLE CITY OF Method POLLUTANT (pounds) (pounds) TYPE PERMITTEE GREENSBORO 1 624 Methylene chlori b 0.1134 0.0240 Grab 116 months 1/year 2 624 1,1 Dichloroethylene 0.0400 0.0147 Grab 1/6 months 1/year 3 624 1,1 Dichloroethane 0.0394 0.0147 Grab 1/6 months 1/year 4 624 Chloroform 0.2168 0.0741 Grab 1/6 months 1/year 5 624 Carbon tetrachloride 0.2535 0.0947 Grab 1/6 months 1/year 6 624 1,2 Dichloropropane 0.5298 0.1308 Grab 1/6 months 1/year 7 624 Trichloroethylene 0.0460 0.0173 Grab 1/6 months 1/year 8 624 1,1,2 Trichloroethane 0.0847 0.0214 Grab 1/6 months 1/year 9 624 Tetrachloroethylene 0.1094 0.0347 Grab 1/6 months 1/year 10 624 Chlorobenzene 0.2535 0.0947 Grab 1/6 months 1/year 11 624 1,2 trans Dichloroethylene 0.0440 0.0167 Grab 1/6 months 1/year 12 624 1,2 Dichloroethane 0.3830 0.1201 Grab 1/6 months 1/year 13 624 1,1,1 Trichloroethane 0.0394 0.0147 Grab 1/6 months 1/year 14 624 1,3 Dichloropropylene 0.5298 0.1308 Grab 1/6 months 1/year 15 624 Benzene 0.0894 0.0380 Grab 116 months 1/year 16 624 Toluene 0.0494 0.0187 Grab 1/6 months 1/year 17 624 Ethylbenzene 0.2535 0.0947 Grab 1/6 months 1/year 18 624 Methyl chloride 0.1968 0.0734 Grab 1/6 months 1/year 19 624 Vinyl chloride 0.1148 0.0647 Grab 1/6 months 1/year 20 624 Chloroethane 0.1968 0.0734 Grab 1/6 months 1/year 21 625 4,6 Dinitro-o-cresol 0.1848 0.0520 Composite 1/6 months 1/year 22 625 2-Nitrophenol 0.1541 0.0434 Composite 1/6 months 1/year 23 625 4-Nitrophenol 0.3843 0.1081 Composite 1/6 months 1/year 24 625 Acenaphthene 0.0314 0.0127 Composite 1/6 months 1/year 25 625 Anthracene 0.0314 0.0127 Composite 1/6 months 1/year 26 625 Bis(2-ethyl hexyl)phthalate 0.1721 0.0634 Composite 116 months 1/year 27 625 1,2 Dichlorobenzene 0.5298 0.1308 Composite 1/6 months 1/year 28 625 1,3-Dichlorobenzene 0.2535 0.0947 Composite 1/6 months 1/year 29 625 1,4-Dichlorobenzene 0.2535 0.0947 Composite 1/6 months 1/year 30 625 Diethyl phthalate 0.0754 0.0307 Composite 116 months 1/year 31 625 Dimethyl phthalate 0.0314 0.0127 Composite 1/6 months 1/year 32 625 Di-n-butyl phthalate 0.0287 0.0133 Composite 1/6 months 1/year 33 625 Fluoranthene 0.0360 0.0147 Composite 116 months 1/year 34 625 01. Fluorene 0.0314 0.0127 Composite 1/6 months 1/year 35 625 Hexachlorobenzene 0.5298 0.1308 Composite 1/6 months 1/year 36 625 Hexachlorobutadiene 0.2535 0.0947 Composite 1/6 months 1/year 37 625 Hexachloroethane 0.5298 0.1308 Composite 1/6 months 1/year 38 625 Naphthalene 0.0314 0.0127 Composite 1/6 months 1/year 39 625 Nitrobenzene 4.2714 1.4925 Composite 116 months 1/year 40 625 Phenanthrene 0.0314 0.0127 Composite 1/6 months 1/year 41 625 Pyrene 0.0320 0.0133 Composite 1/6 months 1/year 42 625 1,2,4 Trichlorobenzene 0.5298 0.1308 Composite 1/6 months 1/year 43 Total Lead 0.4604 0.2135 Composite 1/6 months 1/year 44 Total Zinc 1.7414 0.7006 Composite 116 months 1/year 45 Total Cyanide 0.05 mg/I Grab 1/6 months 1/year All sampling must occur during normal operational periods and must be representative of a production day. Compositing of grab samples for EPA Method 624 parameters is allowed,but must be performed by a laboratory certified by the State of North Carolina. A "Grab Composite"sample shall consist of a minimum of four grab samples. Samples for lead,zinc and the EPA Method 625 parameters shall be composited using an automatic sampler. Page 6, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 SECTION IV - SPECIAL PERMIT CONDITIONS A. FLOW MEASUREMENT Compliance with the flow limit in this permit shall be documented in the following manner: 1. The Permittee shall provide and maintain a refrigerated composite sampler and primary flow measurement device for flow proportional sampling and flow measurement of the permittee's process wastewater discharge. 2. The effluent process flow meter readings shall be recorded daily and the daily effluent flow calculated in gallons per day. Flow measurement records shall be submitted to the City of Greensboro Industrial Waste Section monthly. Data is to be submitted by the 15th of each month for the previous month's flow measurements. 3. The permittee shall maintain permanent flow records and maintenance and calibration records on-site for a minimum of three years. These records shall be available to the City of Greensboro Industrial Waste Section during inspections or upon request. 4. Immediate notification, within 24 hours of becoming aware of the problem, shall be provided to the Pretreatment Coordinator [336-433-7227] or Pretreatment Compliance Specialist [336- 373-3285] by phone or e-mail for any periods in which the effluent meter is inoperable with the exception of periods for maintenance/calibration. This notification shall include the cause of the malfunction/failure, anticipated repair time and/or plan of action to allow the permittee to comply with the requirement to record the flow meter readings daily. 5. Malfunction/failure of effluent flow meters that are used for sewer billing purposes shall also be immediately reported, within 24 hours of becoming aware of the problem, to the Water Resources Customer Service Division by phone---Assistant Manager [336-373-4108] or Manager [336-373-2639]. Failure to do so will result in the Industrial Waste Section and the Water Resources Customer Service Division reverting back to the incoming water meter to determine compliance and billing. 6. The wastewater meter must have a non-resettable totalizer that reads in cubic feet or gallons. There shall be no by-pass capability of the wastewater metering devices and monitoring point(s). 7. If the wastewater meter is being used for billing or compliance, it must have permanent flow records (i.e. strip chart recordings) that include at minimum the following basic information: date, time, totalizer reading (with units), interval flow volume(with units), maximum flow rate (with units), and primary measuring device type. Any interruption in such records with the exception of periods for maintenance/calibration are a violation of this permit and may result in a civil penalty each day the interruption is allowed to continue. September 1, 2023 Permit Renewal Page 7, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 8. The wastewater meter shall have a back-up power source (battery or generator) to ensure uninterrupted measurement of the discharge flow in the event of a power failure unless loss of power automatically prevents any discharge from the facility. The back-up source shall provide power to the wastewater meter's sensor and permanent flow records for a minimum of 12 hours. B. PERMITTEE SAMPLING AND MONITORING REPORT SUBMITTAL DATES Permittee Sampling for the pollutant limitations in Section III (Effluent Limits and Monitoring Requirements) of this permit shall be conducted in the following manner: 1. Samples for the January 1-June 30 Reporting Period shall ALL be taken during the months of January, February and/or March. The compliance report shall be submitted on or before APRIL 15 of each year. 2. If there are no discharges during months designated for sampling, the April 15 compliance report shall be submitted with the notation "NO DISCHARGE/NO SAMPLING". If there is a discharge after March and prior to June 30, self-monitoring is still required to meet the permit monitoring requirements and that data shall be submitted with the corresponding monthly flow data. 3. Samples for the July 1-December 31 Reporting Period shall ALL be taken during the months of July, August and/or September. The compliance report shall be submitted on or before OCTOBER 15 of each year. 4. If there are no discharges during months designated for sampling, the October 15 compliance report shall be submitted with the notation"NO DISCHARGE/NO SAMPLING". If there is a discharge after September and prior to December 31, self- monitoring is still required to meet the permit monitoring requirements and that data shall be submitted with the corresponding monthly flow data. If there are no discharges during an entire semi-annual reporting period, a letter must be submitted to the Industrial Waste Section by July 15 or January 15 stating there was no discharge and no sampling for that period. This letter must be signed and certified by the signatory official. September 1, 2023 Permit Renewal Page 8, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 C. SIGNATORY REQUIREMENTS FOR INDUSTRIAL USER REPORTS All self-monitoring and re-sampling data submitted for compliance to the City of Greensboro shall include the certification statement below and shall be signed by the person on-site at the facility who is authorized to represent the company in an official capacity concerning matters that involve the City of Greensboro Industrial Waste Section("Signatory Official"). I certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fine and imprisonment for knowing violations. [40 CFR Part 403.6] D. SLUG/SPILL CONTROL PLAN The permittee shall provide protection from accidental and slug discharges of prohibited materials and other substances regulated by this permit, which have a reasonable potential to cause Interference or Pass Through, or in any other way violate the POTW's regulations, local limits or Permit conditions. The permittee shall notify the Industrial Waste Section immediately of any changes at its facility affecting potential for a Slug Discharge. The permittee shall submit a new or updated slug/spill control plan for approval when so directed in writing by the City of Greensboro Industrial Waste Section. The plan shall contain, at a minimum the following elements: ■ Description of discharge practices, including non-routine batch discharges; ■ Description of stored chemicals; ■ Procedures for immediately notifying the POTW of slug discharges that would cause a violation of 40 CFR Part 403.5(b) [EPA Specific Prohibitions included in Greensboro SUO Article II, Section 1. B.], with procedures for follow up written notification within 5 days; ■ If necessary, procedures to prevent adverse impact from accidental spills, including inspection and maintenance of storage areas, handling and transfer of materials, loading and unloading operations, control of plant site run-off, worker training, building of containment structures or equipment, measures for containing toxic organic pollutants (including solvents) and/or measures and equipment for emergency response. Any current slug/spill control plan developed by the permittee and approved by the City of Greensboro is hereby incorporated as a condition of this Significant Industrial User Permit. September 1, 2023 Permit Renewal Page 9, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 E. SURROGATE PROCESS CONTROL SAMPLING Chemical Oxygen Demand (COD) sampling shall be performed at least monthly for process control and POTW loading estimations. COD analyses may be performed in-house or by a commercial laboratory. If more than one COD analysis is performed in a calendar month, only the highest COD value need be reported. The six monthly process control COD values shall be submitted to the Industrial Waste Section by July 15 (for January through June) and by January 15 (for July through December). All COD analyses shall be made available during inspections and upon request by the IWS. Any COD value greater than 10,000 mg/1 shall be immediately reported(within 24 hours of becoming aware of the result) to the City of Greensboro Industrial Waste Section. The notification shall be made by telephone or email to the Pretreatment Coordinator, the Pretreatment Compliance Specialist and/or the Laboratory and Industrial Waste Section Supervisor. F. FLOW METER CALIBRATION/VERIFICATION Flow meters used for flow monitoring under this permit shall be calibrated in accordance with manufacturer's recommendation by an independent contractor or a Greensboro Industrial Waste Section approved in-house technician. Calibration documentation shall be maintained for a minimum of three (3) years and made available upon request and during on-site inspections. 1. Industries with a highly-accurate (<0.5% variance) flow meter, such as a magnetic or ultrasonic (doppler and transit) meter, must have the meter calibrated/verified once every five years. 2. Industries with effluent wastewater meters that are used for City of Greensboro sewer billing purposes, must calibrate the meters annually. Permanent records in the form of electronic data trend sheets, strip or circular chart recordings that have back-up and fail-safe capabilities are also required to be maintained. 3. Any industry may conduct meter calibration more frequently than required in this permit. The following flow meters/systems have no calibration requirements: 4. Industries with custom built Memtek0 pretreatment systems have a permanently calibrated flow measurement system (as long as the plumbing remains intact and the viscosity of the liquid does not change) and no calibration is required. 5. Industries with a non-discharge closed-loop system are not required to have any meter on the system calibrated. 6. Industries that record daily flow from a City of Greensboro owned, maintained, and calibrated incoming potable water meter are not required to have the meters calibrated. 7. The Industrial Waste Section does not require deduct meters to be calibrated. Industries with an electronic data base with power back-up do not need to maintain redundant paper recorders. September 1, 2023 Permit Renewal Page 10, SIU Permit#P025 HALLSTAR GREENSBORO LLC Effective September 1, 2023 G. DETECTION LIMITS AND MATRIX INTERFERENCES Proof of efforts to resolve effluent sample detection limits reported higher than permit limits issued herein [due to matrix interference] shall consist of the information included in"Chapter 1- Checklist of Laboratory Data Required to Support a Claim that the Permittee was Unable to Measure Pollutants Due to Matrix Problems" of EPA Guidance on Evaluation, Resolution and Documentation of Analytical Problems Associated vvith Compliance Monitoring [EPA Publication 821-13-93-001 June 1993]. All costs associated with the proof of matrix interferences, included any third party review of the analytical data and supporting documentation, shall be the responsibility of the permittee. This shall also include the costs for any additional procedures, analyses or data review of samples collected by the City of Greensboro to determine compliance with the permit limits issued herein. September 1, 2023 Permit Renewal