ZANESVILLE, OH — Casting Solutions, LLC, a Zanesville-based gray iron casting operation, has been cited for multiple air and water pollution violations following recent inspections by the Ohio Environmental Protection Agency (Ohio EPA). The violations, detailed in two separate notices sent to James Dingey, Environmental Engineer for Casting Solutions, LLC, require the company to submit compliance plans within 30 days.
An Ohio EPA follow-up site visit on May 20, 2025, focused on air pollution control compliance, revealing several infractions related to the facility's gray iron cupola (P905) and sand and bond unloading silos (P911).
According to the Ohio EPA's Notice of Violation concerning air permits, the facility was found to be in violation of:
- Visible Emissions: On May 20, 2025, Method 9 readings of fugitive emissions from the P905 Gray Iron Cupola documented a 74.58% opacity over a three-minute average, significantly exceeding the 20% limitation. The Ohio EPA was informed that the company had been aware of this ongoing issue for the previous four weeks.
- Cupola Charging Door: The facility failed to ensure the cupola charging door remained closed when not in use, as required by its permit. Ohio EPA observed malfunctions, and company personnel indicated that repairs were deferred until the end of a shift.
- Scrubber Monitoring Equipment: Casting Solutions, LLC failed to install, operate, and maintain equipment for continuous monitoring of the scrubber liquid pH during the operation of the P905 emissions unit. The company had notified Ohio EPA in October 2025 (sic) that it was awaiting quotes for a new probe, but no operable equipment was in use during the May 20 inspection.
- Sand Storage Silo Venting: Emissions from the upriver sand storage silo (P911) were not properly vented to the fabric filter bin, with observed fugitive emissions from a flange missing connecting bolts.
The Ohio EPA has requested that Casting Solutions, LLC submit a compliance plan within 30 days for each of these air quality violations, outlining how the facility will promptly address these issues.
In a separate letter dated April 1, 2025, following a March 26, 2025, compliance evaluation inspection of the facility's National Pollutant Discharge Elimination System (NPDES) permit, the Ohio EPA's Division of Surface Water (DSW) also detailed findings related to wastewater treatment and discharge.
The NPDES inspection report noted that Casting Solutions, LLC is subject to federal regulations for gray iron foundry operations. The facility's process wastewaters from various scrubbers and hydrostatic testing are routed to an equalization tank, which also receives stormwater, before being treated and discharged intermittently at Outfall 005.
While the inspection found no discharge at Outfall 005 during the visit, non-contact cooling waters were discharging at Outfalls 001, 002, and 004, and the sanitary treatment plant was discharging at Outfall 003.
The DSW inspection report also highlighted:
- Permit Limit Exceedances: A summary of reported data from November 2023 through February 2025 showed two permit effluent limit violations for "Phenolic 4AAP, Total" at Outfall 005 in February 2025. The report suggests that cold weather may reduce the effectiveness of biological treatment for phenolics.
- Future Permit Adjustments: The renewal NPDES permit will include updated calculations for annual loading limits, with significant changes expected. While allowances for Roberts and Schneible scrubbers will be reduced, the allowance for the Cupola scrubber is expected to triple due to its multi-device configuration. Stormwater allowances for copper, lead, and zinc may also be added.
- Dechlorination Recommendation: The Ohio EPA recommended that Casting Solutions, LLC explore the use of sodium bisulfite for dechlorination when using city water to supplement or replace cooling water, as city water's free chlorine content can exceed aquatic life water quality criteria.
- Sanitary Treatment Plant Elimination: The sanitary treatment plant is planned for elimination, possibly as early as 2026, once a connection to the extended sanitary collection system along Licking Road is made.
The Ohio EPA has emphasized that failure to comply with environmental laws and regulations may result in administrative or civil penalties. The agency has requested documentation of steps taken to return to compliance, including written correspondence, updated policies, and photographs, as appropriate, within 30 days of receiving the violation notices.
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