HomeMy WebLinkAboutDAQ-2024-005100ND
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UTAH DEPARTMENT OF
ENVIRONMENTAL QUALITY
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February 13,2024
Mr. Bryce Bird, Director
State of Utah, Division of Air Quality
150 North 1950 West
PO Box 144820
salt Lake ciry, ut 847L4-4820
RE: Investigation for Breakdown Report filed fanuary 31, 2024: No Deviation
Dear Mr. Bird:
In accordance with the Title V Permit number 4900017004, provision I.S.Z.c., McWane Ductile -
Utah (MDU) is submining the following deviation report regarding a breakdown report filed with
DAQ on fanuary 3L,2024, included as Attachment 1. Based on investigation and data analysis, a
deviation of permit conditions did not occur, only a permit excursion occurred.
Title V Permit provision ll.B.2.a requires less than 0.80 pounds CO emissions per ton of iron melted.
Excess CO emissions is a permit deviation. Per Title V Permit provision II.8.2.a.1(b), temperature in
the C0 thermal oxidizer is used as an indicator to provide assurance of compliance with the C0
emission limit. An excursion is defined as a 3-hour average temperature of less than 1,500oF as
measured by the installed thermocouples. Combustor monitoring data was used to determine the
CO emission rate at 50oF intervals. This data was provided to the agency as part of the Title V
Permit renewal in May 2010. The indicator temperature permit condition was established at
1,500oF but the data showed CO emission rates remained below 0.8 pounds CO per ton of iron
melted down to 1,350oF.
CO thermal oxidizer temperature excursions trigger an inspection and review of the CO oxidizer
performance by confirming the validity of the data and identifying any CO oxidizer operating
deficiencies. Corrective actions on any identified issues are then implemented. Excursions are
included in the semiannual Title V Deviations report required in provision I.S.2.a. Additionally, an
excursion triggers a review of CO emissions during the excursion period. MDU preemptively files a
breakdown report within Z4-hours of any temperature excursion below 1,400oF, since data
confirmation and investigation take longer than Z4-hours. On lanuary 3L,2024, MDU identified a
temperature excursion of 1,35ZoF during operations on fanuary 30,2024, and per procedure filed a
breakdown report.
There are two thermocouples measuring temperature in the thermal oxidizer. The primary
thermocouple in its data validation indicated from 7:10 am -10:09 am an excursion of 1,35ZoF on
fanuary 30,2024. The other thermocouple indicated t,396oF during the same period. A review of
the CO thermal oxidizer equipment, thermocouples, and the data did not identify any deficiencies.
The thermocouples met the quality assurance and quality control standards as per
II.8.2.a.1(bX3XB), agreement of the indicated combustor thermocouple temperatures.
Temperature data graphs for both thermocouples are included in Attachment 2.
B-2-10794
InvesUgatlon for Breakdown Report filed January 31,2024: No Devladon
,.*:::BX['l':'r13i
Page 2 of 2
An excursion investigation was expanded to the entire cupola system to determine a potential cause
of the temperature drop. No specific deficienry was identified, but current investigation is focusing
on the cupola charging system. The theory is during the excursion period, excess ambient air was
being drawn into the charge opening of the cupola exhaust system. The colder surface air would
dilute the temperature inside the CO thermal oxidizer. MDU is currently continuing to investigate
potential root cause(s) of the temperature excursion and will implement corrective actions as
appropriate. As a preventative action, MDU has improved the CO thermal oxidizer temperature
data display for cupola operators to enable more rapid response to changing temperatures inside
the thermal oxidizer. The display now shows the current temperature, a 1-hr temperature average,
and a 3-hr temperature average.
Please contact our Environmental Manager, Christy Seiger-Webster, with any questions at
christy.webster@mcwaneductile.com, or at 801-62 3 -4224.
In accordance with Operating Permit provision I.K and UAC R307-415-5d, and based on the
information and belief formed after reasonable inquiry I certify that the statements and
information in this report are true, accurate, and complete.
Vice President and General Manager
Attachments
Cc: File
Respecttully,
H r norr,.or
Attachment {
lndustry Breakdown Report
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Cornpany Name
Mcwrm Drctlc t t|h
Address
2550 S hduslrlal Pa&way
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Provo
County
utah
Person Reportlng BreetdoM
chnsty salgcr-iYcbslar
Phone Numbet
401.t23-tut
Plail Faclllty Breakdown
Crrbon Monondc AfiGrburncr Lor Tcmpiltul
Type of Egulpment Malfunctlon
Q emse
@ contot
O ceM
ClGr. sl*ti6
Date ot Breakdown/Malfuncllon
01t30t2021
Tlme of Breakdown/Mslf unctlon
1 0:10 Em
Cauge of Ereakdown
Wss &r*d6.rnr'MaftrEtion Dtr to Proc€durl Ercr
O v".
@no
Duratlon ot Breekdown/Melfunctlofl (lf f\nown)
Und!r lnvcallgailon
Type ot Pollutam(s) Eelng Emined (lt Known)
Carbon Morcid. (CO)
Excess opaclty
Ov*
OHo
Quenw of Emlsstons Behg Emmed (lf Known)
Unkniln - wlllcrlculrtc brst rsthate
Level Prlor Breakdown
Lad of producllon/op.raion p.ior lo ttr brcakdM.
Nmrl Opcrdion
Levd Dudng Breakdown
Lsel of prodwtlon/oparallon .fts tr durlng Uakdom
Normal Opcratlon
UTAH DEPARTMENT OF
ENVIRONMENTAL QUALITY
FEB Z0 Z0Zl
DIVISION OF AIR QUALlTY
C1... !.1*tiff
Clsa. ralcclim
Produclion Level
lI level of productim/operation was not curtsiled o. reduced Efts/durhg breakdom
Approximal?ly 42 tons mollen metsl/hour
Problem and Acllon
Describe the nalure ofthe pEblem and the actlon being iaken to correcl the problem.
Title V Permit ll B.2 a deviation Emlssions greate|than the llmit were likely released CO
afterburner3-hrtemperoturewasbelowl500FduringlheTl0-1010pertodw{ha3-hr
average of 1 352F No operalional malfuncllons or syslem fautts occurred Stle dats shows
lemperatures below 1 400F resutt ln CO emissions greatlr than thc 0 8 h/ton iron melled.
Temperaiures belween 1 400F and 1 500F Ere a process €xcursron bul do not result ln an
emrssron deviatlon. Atemperature excursion of '1442F occutred on 1j29/2023 between 7-
10am lnvestigationlntoth€excursionhrdbegunwhenlhel,/30/2024datashow€nother
lemperature excursion Because the low temperatures are only occurflng during a bflef
period, lroubleshooting ls ongolng and requlres the system 10 be operational.
Source Class
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Addltlonal lnformatlon
Preliminary data from 1 /31/2024 shows no temperature ercursron dunng the 7-1 oEm penod
for today's operatlons We are conlinurng to monllor and rnvesllgatq
Ci6ar fo.m
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lndustry Breakdown Report
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Fugitive Dust Control Plan
Compliance Activity
gJmrnaries
Complaint Form
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