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Home My WebLink AboutIndustrial Wastewater Discharge Permit Renewal - Unifrax 1 LLCCity of South Bend Department of Public Works Industrial Pretreatment Program Significant Industrial User – Permit No. 218071-92046 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: Unifrax 1 LLC 54401 Smilax Road New Carlisle IN 46552 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 January, 2023. Effective on: 14 April, 2023 Expires on the: 13 April, 2028 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: March 14, 2023 Unifrax 1 LLC Industrial Wastewater Discharge Permit page 3 of 36 PART II - MONITORING REQUIRMENTS A. Monitoring Frequency 1. The following parameters shall be monitored at the frequency and with the sampling type stated below. All measurements, tests, and analyses of the characteristics of water and wastes to which reference is made in this permit shall be conducted using the methods and procedures approved in 40 CFR 136 and amendments thereto, unless otherwise specified in an applicable Categorical Pretreatment Standard. The following parameters shall be monitored at Sample Site Outfall # 5-1 with the methods and at the frequency stated below: Parameter Sampling Frequency Sampling Type Flow, total (gpd) Daily Continuously Flow Monthly (gal) Monthly Continuously BOD5 (mg/l) Monthly Composite pH (SU) Monthly Grab Total Suspended Solids (mg/l) Monthly Composite Phosphorus (mg/l) Semiannual Composite Ammonia, nitrogen (mg/l) Semiannual Composite Arsenic (mg/L) Semiannual Composite Cadmium (mg/L) Semiannual Composite Chromium (mg/L) Semiannual Composite Copper (mg/L) Semiannual Composite Lead (mg/L) Semiannual Composite Mercury (mg/L) Semiannual Grab Nickel (mg/l) Semiannual Composite Oil and grease (mg/l) Semiannual Grab Oil and Grease TPH (mg/l) Semiannual Grab Silver (mg/L) Semiannual Composite Zinc (mg/L) Semiannual Composite See Flow Measurement Requirements referenced in Part III - Reporting Requirements. PERMIT BRIEFING MEMO 1. Facility Description Unifrax 1 LLC engages in the production of high temperature ceramic fiber insulation and value- added products. The ceramic fiber is produced from raw materials such as alumina, sand, zircon, and kaolin. At this facility, insulation is manufactured in bulk, needled into blanket form, or is processed into coatings/mixes. Unifrax operates 24 hours a day, 7 days a week. Unifrax currently employs 165 people. There is no seasonal variation in production. It has been determined that Unifrax does not fit into category 40 CFR 414: organic chemicals, plastics, and synthetic fibers. 2. Discharge Description This permit oversees, but not limited to, wastewater discharged at Sample Site 5-1. Discharge from Sample Site 5-1 includes domestic wastewater and process wastewater from the fabrication department which includes SiFab Line addition. The wastewater leaves the facility, is channeled through Sample Site 5-1, and is measured via Parshall Flume and ultrasonic flow meter prior to discharge into the City of South Bend Sewer System. Unifrax has identified copper and zinc as known to be present in their wastewater. Unifrax suspects that all toxic organic compounds are absent. From 2018-2022, Unifrax’s wastewater flows were as follows: Average daily flow was: 30,444 gpd. Maximum daily flow was: 204,000 gpd SiFab Line is estimated to add 4,000 to 10,000 gpd Note that precipitation is diverted to a storm pond and is not discharged to the City of South Bend’s POTW. Wastewater from furnace trough is also discharged to the storm pond. 3. Sample Site Description Sample monitoring is conducted at Sample Site 5-1, which is located in a sample shed south of the facility. Inside the sampling shed is a manhole with a light plastic cover that has a handle to lift it out of the opening. The wastewater is metered with a three (3) inch parshall flume and ultrasonic flow meter. The flow meter output is in the shed and is equiped such that flow proportioned sampling may be conducted. 4. Wastewater Treatment Unifrax employs the use of grit removal, filtration, and a settling tank to pretreat its wastewater. 5. Classification Unifrax 1 LLC is classified as a Significant Industrial User (SIU). Unifrax Corporation is further categorized as a C industry per the City’s Industrial Pretreatment Program Monitoring Plan in which all industries that discharge process wastewater between >25,000 gpd <50,000 gpd are Category C industries. 6. Calculation of Limits Discharge limits are applied from the South Bend Municipal Code without modification. 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: A-SO 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 March 6, 2023 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 Unifrax 1 LLC at the March 14, 2023, Board of Public Works Meeting. Unifrax 1 LLC engages in the production of high temperature ceramic fiber insulation. Unifrax 1 LLC requirements were reviewed for necessary changes to ensure the industrial permit remains legally substantiated. After review of requirements and historical data, the following changes have been made. • BOD5 sampling frequency has been changed from Quarterly to a Monthly requirement. • Total Suspended Solids sampling frequency has been changed from Quarterly to a Monthly Requirement. • pH sampling frequency has been changed from a Quarterly to a Monthly requirement. If you should have any questions, please do not hesitate to contact me (574) 235-5798 or at sshane@southbendin.gov. 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) Agenda Request form- Industrial Discharge Permit Board of Public Works Signature Page, Part II- Monitoring Requirements, 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 3/6/2023 Name Serena Lozano-Shane Department UTILITIES BPW Date 3/14/2023 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: Unifrax 1 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: Increase Decrease % ( %) Time Extension Amount: New Completion Date: