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HomeMy WebLinkAboutNCS000107_Renewal Application_20220317SW Individual Permit Coverage Renewal Stormwater Planning Program 1612 Mail Service Center Raleigh, NC 27699-1612 LANXESS Energizing Chemistry RECEIVED MAR 17 2927_ DENR•LANO QUALITY 3TORMWATER PERMITTING Subject: Lanxess Corporation NPDES Stormwater Permit Renewal Application Permit Number NCS000107 Dear Brianna , Please find enclosed the application for renewal of NPDES Stormwater Permit NCS000107 for its stormwater discharge. The permit expires July 31, 2022. Attached are one copiy of the NPDES Stormwater Permit renewal application and supplemental information. We appreciate the opportunity to submit this renewal application and hope that it meets your approval. We are available to meet with you at your convenience to provide clarification on the renewal application. Please contact me at 336-378-0965 extension 115 or 336-709-0046 if you have any questions or need additional information. Yours.sincerely, 4 LaSon 00_ Mc7 Millian , Plant Manager March 11, 2022 LANXESS Corporation LaBAROn O. McMillian 520 Broome Road Greensboro, NC 27406 Phone 336-378.0965 Fax 336-272-4312 LaBarron.McMillian@lanxess.com w .us.lanxessxom INTERNAL RECEIVED EPA Identification Number NPDES Permit Number Facility ame5/19 MAft0%7 20409�004 NCDO61795696 NCS000107 Lanxese Corporation ....... Form U.S. Environmental Protection Agency TnRAAWATER 1 :.EPA Application for NPDES Permit to Discharge Was Atg3ttrt NPDES GENERAL INFORMATION SECTION• • r 1.1 Applicants Not Required to Submit Form 1 1.1.1 Is the facility a new or existing publicly owned 1.1.2 Is the facility a new or existing treatment works treatment works? treating domestic sewage? If yes, STOP. Do NOT complete Ej No If yes, STOP. Do NOT No Farm 1. Complete Farm 2A. complete Form 1. Complete Farm 2S. 1.2 Applicants Required to Submit Form 1 1.2.1 Is the facility a concentrated animal feeding 1.2.2 Is the facility an existing manufacturing, € operation or a concentrated aquatic animal commercial, mining, or silvicultural facility that is rl production facility? currently discharging process wastewater? oYes 4 Complete Farm 1 ❑✓ No Yes 4 Complete Form 0 No z and Form 2B. 1 and Form 2C, 1.2.3 Is the facility a new manufacturing, commercial, 1.2.4 Is the facility a new or existing manufacturing, m mining, or silvicultural facility that has not yet commercial, mining, or silvicultural facility that commenced to discharge? discharges only nonprocess wastewater? Yes 4 Complete Form 1 ❑� No ❑ Yes 4 Complete Form 0 No N and Form 2D. 1 and Form 2E. 1.2.5 Is the facility a new or existing facility whose 2 discharge is composed entirely of stormwater a associated with industrial activity or whose discharge is composed of both stormwater and non-stormwater? Yes 4 Complete Form 1 No and Form 2F unless exempted by 40 CFR 122.26(b)(14)(x) or SECTION ADDRESS, AND LOCATIONr 2.1 Facility Name Lanxess Corporation `0 2.2 EPA Identification Number u 0 NCD061795696 a 2.3 Facility Contact N v Name (first and last) Title Phone number La Barron O. McMillian Plant Manager (336) 378-0965 a Email address labarron.mcmillian@lanxess.com 2.4 Facility Mailing Address E Street or P.O. box z 520 Broome Road City or town State ZIP code Greensboro North Carolina 27406 EPA Form 3510-1 (revised 3-19) Page 1 EPA Identification Number NPDES Permit Number Facility Name Form Approved 03/05/19 NCD061795696 NCS000107 Lanxess Corporation OMB No. 2040-0004 2.5 FacilEty Location Street, route number, or other specific identifier - o = 20 Broome Road y c o County name County code (if known) z Guilford, a a4 Y K City or town State ZIP code =' Z. .; Greensboro North Carolina 27406 SECTION•D 40 CFR -� 3.1 'S C�Gode(s� � I�esc�ip�tcn�iL v 3.2 NAiCS Cade(s) Desc#ption'(ophoal) ` 325199 All other basic organic manufacturing ' " 1 325998 All other miscellanous chemical product and preparation manufacturing 4.1 ,Name oQ a afor~ A377 Lanxess Corporation o 4.2 Is the name you listed in Item 4.1 also the owner? o ✓❑ Yes ❑ No .'. 4.3 0 erator;$tatus ❑Public —federal Elublic—state ❑ Other public (specify) O ❑✓ Private ❑ Other (specify) 4.4 _ .PhoeeNiumbe�:of Operator (336) 378-0965 4.5 0 rator.:Address . Street or P.O. Box 520 Broome Road c .0 _ City or town State ZIP code o 'o Greensboro North Carolina 27406 Email address of operator labarron.mcmillian@lanxess.com SECTION =a 5.1 Is the facility located on Indian Land? A c, c ❑ Yes ❑✓ No EPA Form 3510-1(revised 3-19) Page 2 EPA Idenfificagon Number NPDES Permit Number Facility Name Form Approved 03/05/19 NCD061795696 NCS000107 Lanxess Corporation OMB No. 2040-0004 SECTION-s ,i CFR • r 6.1 `xistilii "Eit�n" eriaPelrlmiscie " i-: - - g. ... c a�fh'aPPY and pIn:arYl�e :die crrsponngermt nuea ® NPDES (discharges to surface m RCRA (hazardous wastes) ❑ UIC (underground injection of a I water) fluids) -2 NCS000107 NCD061795696 "W i ❑ PSD (air emissions) ❑ Nonattainment program (CAA) ❑ NESHAPs (CAA) 'Ss3 r ❑ Ocean dumping (MPRSA) ❑ Dredge or fill (CWA Section 404) ❑ Other (specify) k SECTION A• 40 7.1 Have you attached a topographic map containing all required information to this application? (See instructions for specific requirements.) ✓❑ Yes ❑ No ❑ CAFO—Not Applicable (See requirements in Form 2B.) SECTIONOF 4t CFR s 8.1 Describe the nature of your business. The Greensboro, North Carolina location operates as a production site for the Polymer Additives Business Unit. " Lanxess Corporation site is dedicated to producing Flame Retardants, phthalate -free plasticizers for polymer processing and other specialty products SECTION• COOLING WATER INTAKE STRUCTURES (40 CFR • 9.1 Does your facility use cooling water? ❑ Yes ❑ No + SKIP to Item 10.1. 3 9.2 Identify the source of cooling water. (Note that facilities that use a cooling water intake structure as described at o, 40 CFR 125, Subparts I and J may have additional application requirements at 40 CFR 122.21(r). Consult with your -$x- NPDES permitting authority to determine what specific information needs to be submitted and when. p 9 tY p ) The source of the cooling water from the City of Greensboro SECTION 10. VARIANCE 10.1 REQUESTS (40 CFR 122.21(f)(10)) Do you intend to request or renew one or more of the variances authorized at 40 CFR 122.21(m)? (Check all that T apply. Consult with your NPDES permitting authority to determine what information needs to be submitted and when.) ❑ Fundamentally different factors (CWA ❑ Water quality related effluent limitations (CWA Section Section 301(n)) 302(b)(2)) ❑ Non -conventional pollutants (CWA ❑ Thermal discharges (CWA Section 316(a)) Section 301(c) and (g)) Not applicable EPA Form 3510-1(revised 3-19) Page 3 STORMWATER SAMPLE ANALYTICAL RESULTS Sampling Date 2/1/2017 Location Out Flow 1 • (reported 5.9 • (Calculated value) 0.0059 • , • 35 7 2 2/1/2017 Out Flow 2 2.5 0.0025 20 7 2 9/12/2017 Out Flow 1 6.8 0.0068 28 7 3 9/12/2017 Out Flow 2 1.9 0.0019 25 7.5 3 5/1/2018 Out Flow 1 3.9 0.0039 35 6.5 3 5/1/2018 Out Flow 2 21.9 0.0219 33 6.9 3 12/14/2018 Out Flow 1 4.6 0.0046 143 6.7 3 12/14/2018 Out Flow 2 70.5 0.0705 182 6.6 3 3/25/2019 Out Flow 1 8.1 0.0081 28.9 6.4 2 3/25/2019 Out Flow 2 27.8 0.0278 113 6.5 2 10/20/2019 Out Flow 1 17.7 0.0177 62.5 6.2 2 10/20/2019 Out Flow 2 8 0.008 ND 6.5 2 1/24/2020 Out Flow 1 6.6 0.0066 56 6.3 0.25 1/24/2020 Out Flow 2 3.8 0.0038 ND 6 0.25 10/28/2020 Out Flow 1 6.3 0.0063 58.5 6.3 2 10/28/2020 Out Flow 2 1.9 0.0019 201 6.4 2 3/19/2021 Out Flow 1 6.2 0.0062 58.6 6.4 1 3/19/2021 Out Flow 2 1.9 0.0019 30.6 6.8 1 12/18/2021 Out Flow 1 15.1 0.0151 49.3 7 1.5 F- 12/18/2021 Out Flow 2 6.3 0.0063 35 7 1.5 [P►��X.1IT,14 EPA Identification Number NPDES Permit Number Facility Name Form Approved 03/05/19 NCD061795696 NCS000107 Lanxess Corporation OMB No. 2040-0004 SECTION 11. CHECKLIST e CERTIFICATION STATEMENT. I • • 11.1 In Column 1 below, mark the sections of Form 1 that you have completed and are submitting with your application. For each section, specify in Column 2 any attachments that you are enclosing to alert the permitting authority. Note that not all applicants are required to provide attachments. [� Section 1: Activities Requiring an NPDES Permit ❑ wl attachments Section 2: Name, Mailing Address, and Location ❑ w/ attachments [� Section 3: SIC Codes ❑ wl attachments [� Section 4: Operator Information ❑ w/ attachments Section 5: Indian Land ❑ w/ attachments [� Section 6: Existing Environmental Permits ❑ w/ attachments E : Section 7: Map w/ topographic pograp ❑ wl additional attachments ❑ ma Section 8: Nature of Business Elwl attachments 0 0 Aa Pr Section 9: Cooling Water Intake Structures ❑ wl attachments [� Section 10: Variance Requests ❑ w/ attachments c Section 11: Checklist and Certification Statement ❑ wl attachments of 11.2 Certification Statement 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. l am aware that there are significant penalties for submitting false information, including the possibility of fine and imprisonment for knowing violations. Name (print or type first and last name) Official title LaBarron O. McMillian Plant Manager Signature Date signed PFA EPA Form 3510-1 (revised 3-19) Page 4 STORMWATER DISCHARGE OUTFALL MONITORING REPORTS Date of Inspection Location Color Odor Clarity Floating Solids Suspended Solids Foam Oil Sheen Erosion 9/12/2017 Out Flow 1 Clear None 1 2 2 No No No 9/12/2017 Out Flow 2 Clear None 1 1 2 No No No 5/1/2018 Out Flow 1 Clear None 1 1 3 No No No 5/1/2018 Out Flow 2 Clear None 1 1 2 No No No 12/14/2018 Out Flow 1 Clear None 1 1 2 No No No 12/14/2018 Out Flow 2 Clear None 1 1 2 No No No 3/25/2019 Out Flow 1 Clear None 1 1 3 No No No 3/25/2019 Out Flow 2 Clear None 1 1 2 No No No 10/20/2019 Out Flow 1 Clear None 1 1 1 No No No 10/20/2019 Out Flow 2 Clear None 1 1 1 No No No 1/24/2020 Out Flow 1 Clear None 1 1 1 No No No 1/24/2020 Out Flow 2 Clear None 1 1 1 No No No 10/28/2020 Out Flow 1 Clear None 1 2 2 No No No 10/28/2020 Out Flow 2 Clear None 1 2 3 No No No 3/19/2021 Out Flow 1 Clear None 1 1 1 No No No 3/19/2021 Out Flow 2 Clear None 1 1 1 No No No 12/18/2021 Out Flow 1 Clear None 1 1 1 No No No 12/18/2021 Out Flow 2 Clear None 1 1 1 No No No INTERNAL STORMWATER POLLUTION PREVENTION PLAN DEVELOPMENT AND IMPLEMENTATION CERTIFICATION North Carolina Division of Energy, Mineral, and Land Resources — Stormwater Program Facility Name: LANXESS CORPORATION Permit Number: NCS000107 Location Address: 520 BROOME ROAD GREENSBORO, NC 27406 County: GUILFORD COUNTY "I certify, under penalty of law, that the Stormwater Pollution Prevention Plan (SPPP) document and all attachments were developed and implemented under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information required by the SPPP. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information gathered is, to the best of my knowledge and belief, true, accurate and complete." And "I certify that the SPPP has been developed, signed and retained at the named facility location, and the SPPP has been fully implemented at this facility location in accordance with the terms and conditions of the stormwater discharge permit." And "I am aware that there are significant penalties for falsifying information, including the possibility of fines and imprisonment for knowing violations." Sign (according to permit signatory requirements) and return this Certification. DO NOT SEND STORMWATER POLLUTION PREVENTION PLAN WITH THIS CERTIFICATION. Signature LABARRON O. MCMILLIAN Date Z d Z t- PLANT MANAGER Print or type name of person signing above Title SPPP Certification 10/13 SUPPLEMENTAL INFORMATION REQUIRED FOR RENEWAL OF INDIVIDUAL NPDES STORMWATER PERMIT Two copies of each of the following shall accompany this submittal in order for the application to be considered complete: Nz (Do not submit the site Stormwater Pollution Prevention Plan) 1. A current Site Map from the Stormwater Pollution Prevention Plan. The location of industrial activities (including storage of materials, disposal areas, process areas and loading and unloading areas), drainage structures, drainage areas for each outfall, building locations and impervious surfaces should be clearly noted. 2. A summary of Analytical Monitoring results during the term of the existing permit (if your permit required analytical sampling). Do not submit individual lab reports. The summary can consist of a table including such items as outfall number, parameters sampled, lab results, date sampled, and storm event data. 3. k 4. A summary of the Visual Monitoring results. Do not submit individual monitoring reports. The summary can consist of a table including such items as outfall number, parameters surveyed, observations, and date monitoring conducted. A summary of the Best Management Practices utilized at the permitted facility. Summary should consist of a short narrative description of each BMP's in place at the facility. If the implementation of any BMP's is planned, please include information on these BMP's. 5. A short narrative describing any significant changes in industrial activities at the permitted facility. Significant changes could include the addition or deletion of work processes, changes in material handling practices, changes in material storage practices, and/or changes in the raw materials used by the facility. 6. Certification of the development and implementation of a Stormwater Pollution Prevention Plan for the permitted facility (Sign and return attached form). If the final year analytical monitoring of the existing permit term has not been completed prior to filing the renewal submittal, then the last years monitoring results should be submitted within 30 days of receipt of the laboratory reports. (i.e. do not withhold renewal submittal waiting on lab results) T1' r z , q ' , Outfalls from the facility flow generally to the east and discharge through wooded property South Buffalo Creek (Stream Index 16-11-14-2a), part of the Cape Fear River drainage basin. South Buffalo Creek is considered impaired (according to the NC 303(d) list of impaired waters) for which a Total Maximum Daily Loads (TMDLs) have been established for Cyanide, Fluoride and Selenium (approved 09/16/97). FIGURE F-2 SITE MAP MAP SCALE: 1 INCH = 200 FEET (approximate) LANXESS Corporation MAP SOURCE: Greensboro, North Carolina Guilford County GIS: http://gis.guilfordcountync.aoy/guilfordis/ April 2020 SECTION NO.4 SUPPLEMENTAL INFORMATION BEST MANAGEMENT PRACTICES LANXESS Corporation is committed to preventing pollution at the source, and as such, has implemented numerous best management practices (BMPs) and at -source storm -water pollution prevention controls to reduce the quantity of pollutants in the Storm -water runoff. The structural controls (e.g., containment, dike, curb, and/ or roof) and management practices employed at the individual significant materials at LANXESS are, listed in Table 2 in the Supplemental Information Section No. 1. The site -wide BMPs that are, utilized by LANXESS are; described in this section and include: ➢ Good Housekeeping, ➢ Inspections/Preventative Maintenance Programs, ➢ Outside Material Storage/Tanks/Secondary Containment, ➢ Material Handling, ➢ Spill Prevention and Response, ➢ Sewer and Outfall Identification, and ➢ Employee Training. Good Housekeeping LANXESS Corporation maintains a clean and orderly facility through implementation of a variety of programs, practices and procedures, including: • Regular pickup and disposal of garbage and debris • Routine inspection for leaks Proper material container storage practices • Identification and labeling of all chemical substances • Disposal of old equipment and used chemicals These housekeeping practices help to reduce waste and pollutant generation as well as the potential for spills and leaks. Inspection/Preventative Maintenance Program The preventive maintenance program at LANXESS ensures that the Storm -water control facilities are clean and operating effectively. The program consists of visual inspection, cleaning, and repair activities. Inspections are, conducted at the Storm -water controls and the significant materials identified on the Site Map and Table 2 in the Supplemental Information Section No.1. At a minimum, these inspections are, conducted semi-annually. Upon completion of the inspection, any cleaning and repair activities, if needed are, documented. Completion of the inspections, cleaning, and repairs are tracked electronically. LANXESS Corporation-MES Storm -water INTERNAL 4 '.__�t Specific inspection areas include: ■ Material handling and storage areas ■ Secondary containment areas ■ Storm -water outfalls ■ Catch basins and trench drains ■ Roofs and covers ■ Potential spills and areas of possible contamination Outside Material Storaae/Tanks/Secondary Containment LANXESS Corporation practices and activities related to outside material storage areas and aboveground tanks are in place to prevent or minimize contact of significant materials with storm -water. Many material storage areas are covered and /or have containment curbing or grading. Aboveground tanks; are in compliance with federal and state laws for containment, integrity testing, overflow protection, and protective guards. Storm - water retained by the curbing or dikes is, visually inspected for contaminants prior to release. BMPs currently in use: ■ Provide secondary containment for liquid storage ■ Provide containment curbing, dikes, and /or grading ■ Cover materials to eliminate exposure to Storm -water ■ Store materials on pallets or racks ■ Visually inspect Storm -water retained by curbing/dikes/containment prior to release ■ Move storage areas inside if possible Material Handling Material loading and unloading is, typically conducted in areas designed to reduce potential contact with Storm - water. Loading areas for bulk chemical transfers are either: (1) contained to allow visual inspection of Storm - water prior to release, or (2) are, graded to direct Storm -water to the process drain system for treatment prior to discharge. The Storm -water is contained during transfer operations by secondary containment, curbing, grading, trays, and /or drain covers. Further, manual valves in the closed position have, been installed in selected storm drains. Direct pipeline transfers are in place for several materials and waste streams. This method of material transfer greatly reduces the potential of Storm -water contamination. There are detailed written guidelines on loading and unloading procedures in the Spill Prevention Control and Countermeasures Plan. Spill Prevention and Response LANXESS Corporation has written procedures on spill prevention and response. These procedures describe the protocol of responding to a spill and the individuals at the site that are to be, contacted. The procedures are included in the facility Spill Prevention Control and Countermeasures Plan and in the Radiological Contingency and Emergency Plan. Site staff are; trained on spill prevention and response. LANXESS Corporation-NMES Storm -water INTERNAL EmAloyee Training The Employee Education and Training Program is, designed to familiarize key employees with the intent and components of the Storm -water Pollution Prevention Plan. Training is, provided for employees involved in operations with the potential to affect Storm -water. Topics included in the training session include: ■ General Storm -water awareness ■ How to use the Storm -water Pollution Prevention Plan ■ Chemical spill response procedures ■ Preventative maintenance ■ Inspection Procedures ■ Materials management practices ■ Good housekeeping measures Sewer and Outfall Identification There are three separate drainage collection systems at the facility: process wastewater, sanitary wastewater, and Storm -water. Sewer manhole covers and catch basins have been color -coded to distinguish between these systems. In addition, as described previously, placards are, posted at all storm -water outfalls. This ensures consistent location evaluation during visual monitoring, outfall inspections, and non -storm -water discharge assessments. (Specialist, 2018) LANXESS Corporation-MMES Storm -water INTERNAL LaNXESS Energizing Chemistry SITE MAP for Storm Water Prevention Plan Permit NCS000107 Expires 6/31/2022 Lanxess Corporation 520 Broome Road Greensboro, NC 27406 Attached is a site map of the Lanxess Corporation showing the following: 1. Industrial Buildings 2. Drainage Areas for each outfall 3. Activities occurring for each outfall 4. Concrete Impervious Areas. 5. Storm water outfall #1 near the shipping dock 6. Storm water outfall #2 gate valves between E & C tank farms. Raw materials used in manufacturing include various alchols, organic anhydrides, sulfonyl chlorides, inorganic alkaline material, and organic solvents. Finished products include esters, sulfonamides, polymers, and other specialty chemical compounds. During the past five years time frame, there have been no significant spills or leaks of pollutants that have come in contact with the storm water discharges. INTERNAL Lanxess Corporation 520 Broome Road Greensboro, NC 27406 LANXESS Energizing Chemistry Best Management Practices for Storm Water Prevention Plan Permit NCS000107 Expires 6/31/2022 Stormwater Management Overview At the Lanxess Greensboro facility, all loadinglunloading areas are covered. The areas behind inside production area LP-2 are primarily for drum and tote filling on both liquid and molten materials. Filled drums are stored in warehouse by shipping dock. Cast molten material is stored on racks and shelves prior to being ground to meet customer specifications. Cast material solidifies quickly while filling and casting in LP1 or LP2 diked production areas, to prevent spilling to environment. Drum recycling takes place on contained concrete pad behind LP2. Drum recycling consists of weak caustic rinse of emptied drums on concrete pad by automated filling equipment. Caustic is pumped into and out of drum. Concrete pad contains all spill to the sump, for collection to C6 pretreatment. C6 pretreatment is discharged to City of Greensboro POTW. All outside tanks are diked, in the event of a spill or leak. Storm water from these dikes is pumped to collection in C6, prior to discharge to City of Greensboro POTW. Facility has equipment for recovery in the event of a spill or leak. No spills from the diked tank farms should ever be released to stormwater drainage system. Additionally the manufacturing areas designated on the map (UP-1, UP-2, LP-1, and LP-2, Flammable Storage Warehouse, Finished Product Storage, Centrifuge Building, hot room storage, and Pilot Plot) are all designed to contain accidental spills or leaks to roadways and storm water discharge. Spill Prevention and Response Management Overview The identified potential pollutant sources at Lanxess Greensboro are: 1. Failed or broken valves, transfer lines, or hoses used during loading and INTERNAL LANXESS Energizing Chemistry unloading operations. 2. Accidental release of materials, from the reactors, such as rupture discs, pressure relief valves activation, or in the event of attached broken valves or lines. 3. Accidental spills of materials while transporting containers between production and warehouse areas, including flammable storage building, and the hot room storage buildings. Daily management walk-arounds are conducted to assess status of tanks and production equipment. Work orders for needed improvements are recorded in computer system to be repaired. Employee Training The Employee Education and Training Program is, designed to familiarize key employees with the intent and components of the Storm -water Pollution Prevention Plan. Training is, provided for employees involved in operations with the potential to affect Storm -water. Topics included in the training session include: ■ General Storm -water awareness • How to use the Storm -water Pollution Prevention Plan ■ Chemical spill response procedures ■ Preventative maintenance ■ Inspection Procedures ■ Materials management practices ■ Good housekeeping measures INTERNAL