HomeMy WebLinkAboutIndustrial Wastewater Discharge Permit Renewal - Pioneer Metal Finisher LLC5
City of South Bend
Department of Public Works
Industrial Pretreatment Program
Significant Industrial User – Permit No. 160445-88012
In accordance with all the terms of Chapter 17 of the City of South Bend’s Municipal Code, and with any
applicable provisions of federal or state law and regulations, permission is hereby granted to:
Pioneer Metal Finishing, LLC
2424 Foundation Drive
South Bend IN 46628
for the contribution of wastewater into the City of South Bend Publicly Owned Treatment Works.
This permit is granted in accordance with the application filed on 11 July, 2022.
Effective on: 8 October, 2022
Expires on the: 7 October, 2027
Any violation of the terms and conditions of this permit shall be deemed a violation of the City of South
Bend Municipal Code and will subject the permittee to the sanctions set out in section 17-11 through 17-
13 of the Municipal Code.
The permittee shall file an application for a renewal permit, a minimum of 90 days prior to the expiration
date.
Approved By:
September 13, 2022
Pioneer Metal Finishing, LLC Industrial Wastewater Discharge Permit
page 7 of 44
Facility Description
Pioneer Metal Finishing is classified as a Categorical Industrial User (CIU) as defined in the South Bend
Municipal Code. Specifically, Pioneer Metal Finishing is classified as a metal finisher covered by 40 CFR
433.17 (PSNS) due to both the anodizing operation and the electroless nickel plating operation. Pioneer is a
job shop. Raw materials and process additives used in these processes include customer supplied parts, sulfuric
acid, nitric acid, hydrochloric acid, caustic soda, nickel acetate, PTFE, organic dyes, alodine, alkaline soaps,
and electroless nickel solution.
PART I – EFFLUENT LIMITATION
A. Sample Port and Collection Location
1. Sample Site #323 B is located inside the main facility after the indoor final weir tank on the
west wall of the wastewater treatment room. Wastewater flows through the weir tank for
flow measurement prior to discharge. Grab samples are collected from the flow out of the
weir tank, and 24-hour composite samples are collected from the discharge pipe after the
weir tank.
2. The location of Sample Site Outfall # 323 A is an outdoor manhole on the west side of the
building and south of the outside door to the production area. Effluent Limitations are in
effect for Outfall # 323 A and wil be sampled if the Control Authority deems it necessary.
3. Any discharge of water or waste having a pH lower than 6.0 S.U. or a pH higher than 11.0
S.U. is prohibited. In addition, the permittee’s wastewater discharge shall not exceed the
following effluent limitations:
Effluent limitations for Sample Site Outfall # 323 A & # 323 B:
Parameter Daily Maximum Limit (mg/L)Monthly Average Limit (mg/L)
Arsenic 1.0 0.3
Cadmium Report*Report*
Chromium 2.7 1.68
Copper 3.3 1.2
Cyanide 1.18 0.64
Lead 0.68 0.42
Mercury 0.00019 -na-
Nickel 3.9 1.2
Oil & Grease 300 -na-
Oil & Grease, TPH 100 -na-
Silver Report* Report*
TTO 2.1 -na-
Zinc 2.57 1.46
Pioneer Metal Finishing, LLC Industrial Wastewater Discharge Permit
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*Note: In accordance with the City of South Bend’s “What You Need Is What You Get” allocation method,
local Daily Maximum and Monthly Average limits have only been developed for those pollutants that have
been observed at or above certain concentrations in each Significant Industrial User’s wastewater discharge. If
“Report” appears on the table, it has been determined that an allocation of this pollutant is not necessary. The
permittee shall compare any monitoring data for these pollutants with the screening table in Part I (3) below. If
pollutant concentrations above the screening levels are observed, a local Daily Maximum and/or Monthly
Average limit may be developed for that pollutant.
Please be aware that Federal Categorical Limits are still in effect, as required by 40 CFR 433.17. For
pollutants that do not have local limits in the table above, the permittee is still required to comply with any
applicable categorical
Parameter Daily Maximum (mg/L) Monthly Average Limit (mg/L)
Cadmium 0.11 0.07
Silver 0.42 0.23
a. Daily Maximum Limit means the maximum allowable discharge limit of a pollutant
during a calendar day or any 24-hour period that represents a calendar day. Where
Daily Maximum Limits are expressed in units of mass, the daily discharge is the total
mass discharged over the course of the day. Where Daily Maximum Limits are
expressed in terms of a concentration, the daily discharge is the arithmetic average
measurement of the pollutant concentration derived from all measurements taken that
day. In the case of samples collected by the grab method, the daily maximum shall
be applied as an Instantaneous Maximum Allowable Discharge Limit or as an
Instantaneous Minimum Allowable Discharge Limit as follows:
i. Instantaneous Maximum Allowable Discharge Limit – shall mean the
maximum concentration or loading of a pollutant allowed to be discharged at
any time, determined from analysis of any discrete or composite sample
collected, independent of the industrial flow rate and the duration of the
sampling event.
ii.Instantaneous Minimum Allowable Discharge Limit – shall mean the minimum
concentration of a pollutant allowed to be discharged at any time, determined
from analysis of any discrete or composite sample collected, independent of the
industrial flow rate and the duration of the sampling event. The lower pH limit
is applied as an Instantaneous Minimum Allowable Discharge Limit.
b. Monthly Average Limit means the maximum allowable average of daily discharges
over a calendar month, calculated as the sum of the concentrations of all daily
discharges measured during a calendar month divided by the number of daily
discharges measured that month.
Pioneer Metal Finishing, LLC Industrial Wastewater Discharge Permit
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4. Discharge Screening Level Limitations have been established to evaluate the need for a
limitation for pollutants that are not listed in the Effluent Limitation section of the permit. If a
permittee has no limit for a particular pollutant, but observes, through monitoring and analysis,
a concentration of that pollutant greater than the listed Discharge Screening Level concentration
found in the table below, the permittee shall notify the Control Authority. This notification shall
be made in writing within five days of observing the pollutant concentration.
Parameter Daily Maximum Screening Level (mg/L)
Arsenic (mg/L) 0.2
Cadmium (mg/L) 0.1
Chromium (mg/L) 2.0
Copper (mg/L) 0.3
Lead (mg/L) 0.3
Nickel (mg/L) 0.3
Silver (mg/L) 0.2
Zinc (mg/L) 0.3
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PERMIT BRIEFING MEMO
1. Facility Description
Pioneer Metal Finishing (Pioneer) is a job shop and operates on one shift, 10-12 hours per
day, on a seven day per week period. Pioneer engages metal finishing activities including
anodizing and electroless nickel plating of customer supplied parts, as well as
masking/painting, and chem film. Chemicals utilized in Pioneer’s processes include
various dyes, seals, sulfuric acid, nitric acid, hydrochloric acid, caustic soda, nickel
acetate, PTFE, Alodine, alkaline soaps, and electroless nickel solution.
2. Discharge description:
Discharge to Sample Site # 323 (A&B) is metal finishing process water combined with
boiler blowdown and non-contact cooling water. Boiler blowdown discharge is minimal
at 5 gallons per day. Non-Contact Cooling water amounts change seasonally. Pioneer
uses RO treated water in process lines and channels the RO backwash to a process rinse
tank.
Metal finishing wastewater originates at each of the rinse tanks which are situated
between process tanks. Since Pioneer is a job shop, volume of discharge can vary
significantly.
From January 1, 2021 to May 31, 2022
Wastestream Average gpd Max gpd
Non-Contact Cooling Water 303 1,500
Total Flow 18,827 78, 357
3. Sample Site Description
Sample Site # 323 B is located inside the main facility after the indoor final weir tank on
the west wall of the wastewater treatment room. Wastewater goes through the weir tank
for flow measurement prior to discharge. Grab samples are collected from the flow out of
the weir tank, and 24-hour composite samples are collected from the final discharge pipe
after the weir tank.
Pioneer requested to move the monitoring point indoors in the letter dated September 12,
2020. Pioneer commissioned “Bob Frame Plumbing” to camera the line between the
Sample Site Outfall # 323 A and #323 B and certify that there were no inlets between the
monitoring points.
The location of Sample Site Outfall # 323 A is an outdoor manhole on the west side of
the building and south of the outside door to the production area. The Control Authority
requires Pioneer to maintain this sample site including the flowmeter cable for
unannounced monitoring if the Control Authority deems it necessary. The Control
Authority reserves the right to re-institute the Sample Site Outfall #323 A as Pioneer’s
only sampling location if deemed appropriate.
4
4. Wastewater Treatment
Wastewater treatment consists of metal precipitation with coagulation and flocculation
for nickel baring wastestreams. The remaining wastewater is treated via pH adjustment
only.
Pioneer generates hazardous, nonhazardous and special wastes and these are shipped off
site for disposal. These wastes include: electroless nickel solution, PTFE, sand blasting
media, nitric acid, alkaline etch, electroless nickel stripping solution, spent chemical
baths, dyes and MEK. Pioneer is a large quantity hazardous waste generator.
5. Classification
Pioneer is classified as a Categorical Industrial User (CIU) as defined in the South Bend
Municipal Code. Specifically, Pioneer is classified as a metal finisher covered by 40 CFR
433.17 (PSNS) due to the anodizing and electroless nickel plating operations. Pioneer is
categorized as an B industry per the City’s Industrial Pretreatment Program. All CIU’s
with process discharge are defined as Category B at a minimum.
6. Calculation of Limits
Wastewater discharged at Outfall 323 A & B is subject to the Metal Finishing Categorial
Standard at 40 CFR 433.17. The more stringent of Chapter 17 of the City South Bend
Municipal Code limits (local limits) or the limits provided in 40 CFR 433.17 with a
combined wastestream formula modification have been applied.
The combined wastestream formula for Pioneer is based on wastewater flow averages
from January 1, 2021 to May 31, 2022. The average dilution wastewater from this
timeframe was 303 gpd, and average total wastewater flow at Outfall #323 (A&B) was
18, 827 gpd, amounting to a 1.61% dilution factor. The combined wastestream formula
has been calculated in accordance with 40 CFR 403.6 (e) and applied to end of process,
local limits were applied at end of pipe.
7. Monitoring Frequency
Monitoring frequencies are based on South Bend’s US EPA approved industrial
pretreatment program monitoring plan.
8. Industrial Operator Certification Requirement
Operator Certification Requirement: C
Industrial operator certification requirements are based on the criteria listed in Indiana
Administrative Code, Title 327, 5-22-5.
Permit Drafted by:
City of South Bend
Industrial Pretreatment Group
August 10, 2022
August 29, 2022
Board of Public Works
City of South Bend
1316 County City Building
227 West Jefferson Boulevard
South Bend IN 46601
RE: Renewal of Industrial Wastewater Discharge Permit
Dear Board Members:
The Division of Environmental Services recommends approving the renewal of the Industrial
Discharge Permit for Pioneer Metal Finishing, LLC at the September 13, 2022, Board of Public
Works Meeting.
Pioneer Metal Finishing LLC is a metal finisher under categorical standards 40 CFR 433.17.
Pioneer Metal Finishing LLC requirements were reviewed for necessary changes to ensure the
industrial permit remains legally substantiated. After review of requirements and historical data,
some pollutant limitations were adjusted.
The following changes have been made to Pioneer Metal Finishing LLC permit:
• Non-Contact Cooling Water is considered a dilution to Metal Finishing Waters, Effluent
Limitations revised per 40 CFR 403.6(e) Combined Wastestream Formula.
If you should have any questions, please do not hesitate to contact me (574) 235-5798 or at
sshane@southbendin.gov. Please let me know if I need to attend the Board Meeting to present
this permit.
Sincerely,
Serena Lozano-Shane
Pretreatment Manager
City of South Bend
Division of Environmental Services, Department of Utilities
(574) 235-5798
sshane@southbendin.gov
Enclosure(s)
- Industrial Discharge Permit Board of Public Works Signature Page, Part I- Effluent Limitation,
-Agenda Request Form, Permit Briefing Memo
CITY OF SOUTH BEND JAMES MUELLER, MAYOR
DEPARTMENT OF PUBLIC WORKS
ERIC HORVATH, DIRECTOR
BOARD OF PUBLIC WORKS
AGENDA ITEM REVIEW REQUEST FORM
Date 8/29/2022
Name Serena Lozano-Shane Department UTILITIES
BPW Date 9/13/2022 Phone Extension 5798
Review and Approval Required Prior to Submittal to Board Diversity Compliance
and Inclusion Officer Officer Name BPW Attorney Attorney Name
Dept. Attorney Attorney Name
Purchasing
Check the Appropriate Item Type – Required for All Submissions
Professional Services Agreement Contract Proposal
Open Market Contract Amendment/Addendum Special Purchase, QPA
Bid Opening Bid Award Req. to Advertise Title Sheet
Quote Opening Quote Award Reject Bids/Quotes
Proposal Opening C/O & PCA No. PCA
Chg. Order, No. Traffic Control Resolution
x Other: Pioneer Metal Finisher, LLC Industrial Discharge Permit Renewal
Required Information
Company or Vendor Name
New Vendor Yes If Yes, Approved by Purchasing
No
MBE/WBE Contractor MBE
WBE Completed E-Verify Form Attached Yes
No
Project Name
Project Number
Funding Source
Account No.
Amount
Terms of Contract
Purpose/Description _______________________________________________________________
_______________________________________________________________
___________________________________________________
For Change Orders Only
Amount of
Increase
Decrease
$
($ )
Previous Amount $
Current Percent of Change:
Increase
Decrease
%
( %)
New Amount $
Total Percent of Change:
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%
( %)
Time Extension Amount:
New Completion Date: