2025 Intro to Foundry Environmental Compliance

Bryant Esch, Waupaca Foundry Inc.

• Overview of metalcasting issues for the environmental manager
• Potential environmental impacts of metalcasting processes
• Overview of major laws and regulations affecting foundries
• Overview of environmental management systems
• Environmental, Social and Governance (ESG)
• Online information reference resources

Bryant Esch, Waupaca Foundry Inc.

Curtis Veit, Waupaca Foundry Inc.

• Waste management laws
• Waste management regulations
• Identification and classification foundry wastes
• Testing/point of generation/baghouse dusts
• Waste generator requirements
  • Storage, accumulation and labeling
  • Containers, emergency response, planning and training
  • Waste minimization and shipment
• Management of Other Wastes
  • Oily wastes, empty containers, aerosol cans, contaminated wipes/rags universal waste
  • Other non-hazardous foundry process wastes
• Recordkeeping and reporting

Craig Schmeisser, Mad River Strategies

Jeet Radia, McWane, Inc.

Kathy Moore, Keramida, Inc.

• The Clean Air Act
• Review of basic terms and concepts
• Basic emission estimation techniques
• Air permitting
  • Construction permits, operating permits
  • Major Source/Minor sources, PSD/NSR avoidance concepts

• NESHAPs - Applicable MACT and GACT requirements review
• Stack testing basics - What you need to know
• Air dispersion modeling basics
• Air pollution control systems commonly used in foundries
• Neighborhood issues commonly encountered by foundries
• Road to success: Air Professionals Top 10

Wesley Fleming, Keramida, Inc.

Curtis Veit, Waupaca Foundry Inc.

Greg Kramer, American Foundry Society

• Regulatory background and the Clean Water Act
  • Water quality standards
  • Technology-based categorical standards
  • Production-based effluent limits
  • Water usage
• Permit Overview
  • Direct discharge NPDES permitting (individual and general)
  • Indirect discharge POTW permitting
• TMDL Regulations
  • Basis for development
  • Impact on permits
• Monitoring and reporting
• Common compliance pitfalls
• Other Issues

Greg Kramer, American Foundry Society

Curtis Veit, Waupaca Foundry Inc

Wesley Fleming, Keramida Inc.

• Introduction to the EPA Stormwater Management Program
  • Applicability and relationship to state permits
  • Stormwater Pollution Prevention Plan (SWPPP) development (introduction to AFS template)
  • Non-numeric technology-based effluent limits
  • Benchmark monitoring
  • Visual evaluations
  • Routing and comprehensive inspections
  • Corrective actions and the iterative process
• State permit variability
• Metalcasting-specific opportunities and challenges 
• Overview of common administrative management practices
• Overview of available structural controls
• Common compliance pitfalls

6A. Major Regulations for Metalcasters

Jeff Hannapel, The Policy Group

• Laws and regulations affecting foundries:
  • CERCLA (aka Superfund), SARA, EPCRA, TSCA, FIFRA (all w/EPA) and HMTA (w/DOT)
• Asbestos
• Polychlorinated biphenyls (PCB)
• Pesticides and radiation
• Testing
• PFA's

6B. Spill Prevention, Control and Countermeasure (SPCC) Plans

Mack Overton, Keramida, Inc.

• Who is subject to SPCC rules? What are the requirements?
• What to do when you are subject to SPCC?
• Common complicance issues

6C. Beneficial Reuse and Recycling

Mike Lenahan, Badger Mining Corp.

6D. Management Issues

Mack Overton, Keramida, Inc.

Mike Lenahan, Badger Mining Corp.

• Recordkeeping and reporting
• Training requirements
• Regulatory Inspections (EPA, state, local) - Do's and Dont's
• Community relations