NCS000332_Staff Report_20190716

NC Division of Energy, Mineral and Land Resources
Review for Permit Renewal — NCS000332
Hexion Inc
Morganton, NC
Facility Activities and Processes:
• SIC Code: 2821— Plastics Materials, Synthetic Resins, and Nonlocalizable Elastomers. The site has one
outfall that discharges to Gunpowder Creek, a class WS-IV stream in the Catawba River Basin.
• The facility primarily makes Melamine laminating resin (Melamine Formaldehyde) which is used in the
paper industry and for flooring and cabinets. The facility also manufactures resins for paints, textiles, and
the automotive industry and catalysts and lubes.
• The facility specializes in urea formaldehyde resins, used mainly for non-structural bonding applications in
the wood products industry, are a cost-effective and proven performer. Melamine formaldehyde is used
extensively in decorative laminates installed in thousands of products from countertops to laminate
flooring. You'll also find them used as modifiers in other materials, such as textiles, tires, paper, fertilizers,
glass, and metals.
Monitoring Information:
• The facility has been monitoring for COD, Ammonia, Formaldehyde, pH, and oil and grease associated
with onsite vehicle maintenance.
• There are missing paper files for multiple monitoring events between 2009 and 2018. One monitoring
event occurred in September 2018, one occurred in May 2016, one occurred in November 2016, one
occurred in October 2015, one occurred in March 2014, and one occurred in November 2014.
• An exceedance of formaldehyde measured at 0.590 mg/I (benchmark: 0.5mg/1) occurred in September
2018. Hexion responded with a Tier I event. An exceedance of COD measured at 166 mg/I (benchmark
120 mg/1) in May 2016. Hexion responded with a Tier I event. An exceedance of COD measured at 253
mg/I (benchmark: 120 mg/1) in November 2016. Hexion responded with Tier II corrective actions. An
exceedance of formaldehyde measured at 0.786mg/l (benchmark: 0.5 mg/1) occurred in October 2015. An
exceedance of COD measured at 572 mg/I (benchmark: 120 mg/1) occurred in March 2014. It was noted
that there had been a release of material from the facility die to an overflow of the water recovery tank
on December 12, 2014. Most of the overflow material was contained in the building, but 75-gallons or
0.25 Ibs of formaldehyde escaped. Corrective and preventative actions were completed by May of 2015.
• Several inspections have occurred at the facility and are detailed in BIMS.
Surface Water Information:
• Little Silver Creek is not listed as an impaired water.
• There are no TMDL's for this section of Gunpowder Creek.
Discussions with the Facility:
Discussions began via email on 4/25/2019. Jeffrey McDaniel, the site/permit contact, is working on
providing a monitoring data spread sheet.
Regional Office Information:
• Draft to Isaiah Reed on 4/30/2019 by email.