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HomeMy WebLinkAboutDAQ-2024-0046091 DAQC-CI109780001-23 Site ID 10978 (B1) MEMORANDUM TO: FILE – WEST SIDE GRADING INCORPORATED – Standard Pugmill Asphalt Batch Plant THROUGH: Chad Gilgen, Minor Source Compliance Section Manager FROM: Jared James, Environmental Scientist DATE: November 14, 2023 SUBJECT: FULL COMPLIANCE EVALUATION, Minor, Millard County INSPECTION DATE: July 12, 2023 SOURCE LOCATION: 1530 East Main Street Delta, UT 84624 DIRECTIONS: East side of town, on the south side of Main Street. SOURCE CONTACTS: Pam Smith, Owner smithjohnpam@frontiernet.net Merlin Enis, Plant Manager OPERATING STATUS: The asphalt plant is temporarily shut down, and had not operated in over a year. The source was operating an unapproved concrete batch plant. PROCESS DESCRIPTION: West Side Grading owns and operates a standard pugmill asphalt batch plant. The plant consists of a drum aggregate dryer, fueled by No. 2 burner oil, and a pugmill for mixing the hot aggregate with asphaltic cement. Exhaust gases and dust from the pugmill and dryer pas through a dry dust collector. Fines collected are routed back to the dryer. Exhaust gases then pass through a multiple stage wet collector before being emitted to the atmosphere. APPLICABLE REGULATIONS: Approval Order (AO) DAQE-AN109780002-22, dated August 4, 2022 SOURCE EVALUATION: Name of Permittee: Permitted Location: West Side Grading Incorporated - Standard Pugmill Asphalt Batch Plant P.O. Box 549 1530 East Main Street Delta, UT 84624 Delta, UT 84624 SIC Code: 2951: (Asphalt Paving Mixtures & Blocks) 0 0 2 Section I: GENERAL PROVISIONS I.1 All definitions, terms, abbreviations, and references used in this AO conform to those used in the UAC R307 and 40 CFR. Unless noted otherwise, references cited in these AO conditions refer to those rules. [R307-101] I.2 The limits set forth in this AO shall not be exceeded without prior approval. [R307-401] I.3 Modifications to the equipment or processes approved by this AO that could affect the emissions covered by this AO must be reviewed and approved. [R307-401-1] I.4 All records referenced in this AO or in other applicable rules, which are required to be kept by the owner/operator, shall be made available to the Director or Director's representative upon request, and the records shall include the two-year period prior to the date of the request. Unless otherwise specified in this AO or in other applicable state and federal rules, records shall be kept for a minimum of two (2) years. [R307-401-8] I.5 At all times, including periods of startup, shutdown, and malfunction, owners and operators shall, to the extent practicable, maintain and operate any equipment approved under this AO, including associated air pollution control equipment, in a manner consistent with good air pollution control practice for minimizing emissions. Determination of whether acceptable operating and maintenance procedures are being used will be based on information available to the Director which may include, but is not limited to, monitoring results, opacity observations, review of operating and maintenance procedures, and inspection of the source. All maintenance performed on equipment authorized by this AO shall be recorded. [R307-401-4] I.6 The owner/operator shall comply with UAC R307-107. General Requirements: Breakdowns. [R307-107] I.7 The owner/operator shall comply with UAC R307-150 Series. Emission Inventories. [R307-150] Status: Out of Compliance. The source had unapproved equipment on site. See condition II.A. Records were not current. No limits appear to have been exceeded. No reportable breakdowns have occurred. The source is not required to submit an emission inventory at this time. Section II: SPECIAL PROVISIONS II.A The approved installations shall consist of the following equipment: II.A.1 Standard Pugmill Asphalt Plant II.A.2 One (1) Pugmill Asphalt Plant Capacity: 125 tons/hr Control: Multi-stage Wet Scrubber Manufactured prior to 1969 II.A.3 One (1) Engine Generator Electrical Output: 500 kW Fuel: #2 Fuel Oil Manufactured prior to 1969 II.A.4 Miscellaneous Equipment Various Front-end Loaders, Haul Trucks Status: Out of Compliance. The source had an unapproved concrete batch plant in operation and a second concrete batch plant which had not yet been installed. The source is run solely on line power, the generator is no longer in use. 3 II.B Requirements and Limitations II.B.1.a The owner/operator shall keep a copy of this AO shall be posted on site. The AO shall be available to the employees who operate the air emission producing equipment. These employees shall receive proper instruction as to their responsibilities in operating the equipment according to all of the relevant conditions listed below. [R307-401-8] Status: Not Observed. This was not asked for at the time of inspection. However, the owner does have a copy of the AO in their possession which they referenced in conversation with the inspector. II.B.1.b The owner/operator shall not exceed the following opacity limits for the indicated emission units. A. All crushers - 15% opacity B. All screens - 10% opacity C. All conveyor transfer points - 10% opacity D. All diesel engines - 20% opacity E. Conveyor drop points - 20% opacity F: Haul road traffic - 20% opacity G. All other points - 20% opacity. [R307-401-8] II.B.1.b.1 Opacity observations of emissions from stationary sources shall be conducted according to 40 CFR 60, Appendix A, Method 9. [R307-401-8] II.B.1.b.2 Opacity observations of emissions from mobile sources and intermittent sources shall use procedures similar to Method 9, but the requirement for observations to be made at 15-second intervals over a six- minute period shall not apply. Any time interval with no visible emissions shall not be included. [R307-401-8] II.B.1.b.3 Opacity observations of emissions for traffic sources shall use procedures similar to Method 9, but the requirement for observations to be made at 15-second intervals over a six-minute period shall not apply. Six points, distributed along the length of the haul road, shall be chosen by the Director or Director's representative. An opacity reading shall be made at each point when a vehicle passes the selected points. Opacity readings shall be made not less than one-half the vehicle length behind the vehicle. The accumulated six readings shall be averaged for the compliance value. [R307-401-8] Status: In Compliance. All opacity observations during the inspection were within the allowed limits. II.B.1.c The owner/operator shall not produce more than the following: A. 30,000 tons of asphaltic concrete per rolling 12-month period B. 125 tons of asphaltic concrete per hour. [R307-401-8] II.B.1.c.1 The owner/operator shall: A. Determine production by plant weigh scale records B. Record production on a daily basis C. Use the production data to calculate a new rolling 12-month total by the 20th day of each month using data from the previous 12 months 4 D. Keep the production records for all periods the plant is in operation. [R307-401-8] Status: Not Observed. The asphalt plant had not operated in the last 12-months, so there were no production records. II.B.1.d The owner/operator shall not produce asphaltic concrete for more than 10 hours per day. [R307-401-8] II.B.1.d.1 Hours of operation shall be determined by supervisor monitoring and maintaining an operations log or an operations totalizer meter. [R307-401-8] Status: Not Applicable. The asphalt plant had not operated in the last 12-months. II.B.2 Asphalt Plant Exhaust Stack Requirements II.B.2.a Emissions to the atmosphere from the asphalt plant shall not exceed the following rates and concentrations: Pollutant lb/hr grain/dscf PM10 3.17 0.03 [R307-401-8] II.B.2.a.1 Compliance Demonstration To demonstrate compliance with the emission limitations above, the owner/operator shall perform stack testing on the emissions unit according to the stack testing conditions contained in this AO. [R307-401-8] II.B.2.a.2 Test Frequency The owner/operator shall conduct a stack test on the emission unit within five (5) years after the date of the most recent stack test of the emission unit. The Director may require the owner/operator to perform a stack test at any time. [R307-401-8] II.B.2.b The owner/operator shall conduct any stack testing required by this AO according to the following conditions. [R307-401-8] II.B.2.b.1 Notification At least 45 days prior to conducting a stack test, the owner/operator shall submit a source test protocol to the Director. The source test protocol shall include the items contained in R307-165- 3. If directed by the Director, the owner/operator shall attend a pretest conference. Testing & Test Conditions The owner/operator shall conduct testing according to the approved source test protocol and according to the test conditions contained in R307-165-4. Access The owner/operator shall provide Occupational Safety and Health Administration (OSHA)- or Mine Safety and Health Administration (MSHA)-approved access to the test location. Possible Rejection of Test Results The Director may reject stack testing results if the test did not follow the approved source test protocol or for a reason specified in R307-165-6. New Source Operation For a new source/emission point, the production rate during all compliance testing shall be no less than 90% of the production rate listed in this AO. Existing Source Operation For an existing source/emission point, the production rate during all compliance testing shall be no less than 90% of the maximum production achieved in the previous three (3) years. [R307-401-8] 5 II.B.2.c Test Methods When performing stack testing, the owner/operator shall use the appropriate EPA-approved test methods as acceptable to the Director. Acceptable test methods for pollutants are listed below. [R307-401-8] II.B.2.c.1 Standard Conditions A. Temperature - 68 degrees Fahrenheit (293 K) B. Pressure - 29.92 in Hg (101.3 kPa) C. Averaging Time - As specified in the applicable test method PM10 For stacks in which no liquid drops are present, the following methods shall be used: 40 CFR 60, Appendix A, Method 5; 40 CFR 51, Appendix M, Method 201; Method 201A; or other EPA- approved testing method as acceptable to the Director. For stacks in which liquid drops are present, methods to eliminate the liquid drops should be explored. If no reasonable method to eliminate the drops exists, then the following methods shall be used: 40 CFR 51, Appendix M, Method 202; 40 CFR 60, Appendix A, Method 5, 5a, 5d, 5e; or other EPA-approved testing method as acceptable to the Director. The back half condensibles shall also be tested using the method specified by the Director or Director's representative. All particulate captured shall be considered PM10. The back half condensibles shall not be used for compliance demonstration but shall be used for inventory purposes. Sample Location 40 CFR 60. Appendix A, Method 1 Volumetric Flow Rate 40 CFR 60, Appendix A, Method 2 Calculations To determine mass emission rates (lb/hr, etc.), the pollutant concentration as determined by the appropriate methods above shall be multiplied by the volumetric flow rate and any necessary conversion factors determined by the Director to give the results in the specified units of the emission limitation. [R307-401-8] Status: Out of Compliance. The source was unable to supply any stack test documentation. II.B.3 Scrubber Requirements II.B.3.a The owner/operator shall maintain the following operating parameters within the indicated ranges for the scrubber system: A. The pressure drop shall not be less than 15 inches of water gauge (minimum) for more than five minutes in any 60-minute period. B. The water pump pressure shall be no less than 50 psig for more than five minutes in any 60-minute period at any time during the aggregate dryer operation. Items A and B of this section shall be monitored with equipment located such that an inspector/operator can safely read the output anytime. The readings shall be accurate to within the following ranges: A. Venturi throat pressure drop: plus or minus 1 inch of water column B. Water pump pressure: plus or minus 1 psi The venturi throat pressure drop and water pump pressure shall be recorded once each day that the plant is in operation. [R307-401-8] 6 II.B.3.a.1 The owner/operator shall install, calibrate, maintain, and operate each monitoring device certified by the manufacturer for the continuous measurement of the scrubbing liquid flow rate to the venturi scrubber. The monitoring device must be certified by the manufacturer to be accurate within plus or minus 5% of the design scrubbing liquid flow rate and must be calibrated on an annual basis in accordance with manufacturer's instructions. The scrubbing liquid flow rate to the scrubber shall be recorded at the time of the compliance stack test and shall be maintained as the minimum flow rate during asphalt production. [R307-401-8] II.B.3.a.2 The owner/operator shall install, calibrate, maintain, and operate each monitoring device certified by the manufacturer for the continuous measurement of the change in pressure of the gas stream through the venturi scrubber. The monitoring device must be certified by the manufacturer to be accurate within plus or minus one (1) inch of water gauge pressure and must be calibrated on an annual basis in accordance with manufacturer's instructions. The pressure drop across the venturi shall be recorded at the time of the compliance stack test and shall be maintained as the minimum pressure during asphalt production. [R307-401-8] Status: Out of compliance. The asphalt plant has not operated in the last 12-months due to disrepair. Therefore, the scrubber has not been in operation. II.B.4 Roads and Fugitive Dust Requirement II.B.4.a The owner/operator shall use water application and/or chemical suppressants for all unpaved haul roads and wheeled-vehicle operational areas to maintain opacity limits listed in this AO. If chemical treatment is to be used, the plan must be approved by the Director. [R307-401-8] II.B.4.a.1 Records of chemical suppressant and water application shall be kept for all periods when the plant is in operation. The records shall include the following items: A. Date and time treatments were made B. Number of treatments made and quantity of water applied C. Rainfall amount received, if any, and the approximate amount. [R307-401-8] Status: Out of compliance. No records were provided at the time of inspection. The source had a water truck on site and opacity readings were within the allowed limit. II.B.4.b The owner/operator shall install water sprays or chemical dust suppression sprays on all conveyor transfer points on site to control emissions. Water sprays shall operate as necessary to prevent visible emissions from exceeding the opacity limits listed in this AO. [R307-401-8] Status: Not Observed. The asphalt plant had not operated in the last 12-months. II.B.4.c The owner/operator shall not exceed 0.3 miles of haul road. The owner/operator shall not exceed a speed limit of 20 miles per hour. [R307-401-8] Status: In Compliance. The haul road appeared to be within the set parameters and the speed was posted. II.B.4.d The owner/operator shall water all storage piles on site to prevent visible emissions from exceeding the opacity limits listed in this AO, as dry conditions warrant. [R307-401-8] Status: Not Observed. Opacity limits were within set limits. II.B.5 Fuel Requirements II.B.5.a The owner/operator shall use only #2 fuel oil as a primary fuel and natural gas as a backup fuel in the asphalt batch plant aggregate dryer. [R307-401-8] Status: Not Observed. The asphalt plant has not operated in the last 12-months. 7 II.B.5.b The owner/operator shall only combust fuel oil or diesel that has a maximum sulfur content of 0.5 percent by weight. [R307-401-8] II.B.5.b.1 The sulfur content shall be determined by ASTM Method D-4294-89 or approved equivalent. [R307-401-8] Status: Not Observed. The asphalt plant has not operated in the last 12-months. II.B.6 Construction Requirements II.B.6.a The owner/operator shall construct and maintain the settling ponds for the scrubbing liquor according to the following parameters: A. The residence time for settling shall be no less than 4 hours. This means that for a liquid flow rate of 150 gallons per minute (gpm), the pond should hold at least 36,000 gallons (approximately 200 cubic yards). B. In order to prevent short circuiting of the water flow through the pond, the pond shall be divided into three sections separated by two weirs. The third section can be the return sump. Baffles may also need to be installed to trap any oil floating on the surface of the pond which might foul the scrubber system. C. As a rule of thumb, the primary section of the pond should be at least six feet deep. The overall length of the pond should be at least two times the width. [R307-401-8] Status: Not Observed. The asphalt plant has not operated in the last 12-months. Section III: APPLICABLE FEDERAL REQUIREMENTS In addition to the requirements of this AO, all applicable provisions of the following federal programs have been found to apply to this installation. This AO in no way releases the owner or operator from any liability for compliance with all other applicable federal, state, and local regulations including UAC R307. MACT (Part 63), ZZZZ: National Emissions Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines. Status: Not Applicable. The source operates on line power, the generator is no longer used. AREA SOURCE RULES EVALUATION: The following Area Source Rules were evaluated during this inspection: R307-205. Fugitive Emissions. Fugitive Dust. Status: In compliance. Observed emissions were within set limits. 8 EMISSION INVENTORY: The emissions listed below are an estimate of the total potential emissions (PTE) from West Side Grading Incorporated - Standard Pugmill Asphalt Batch Plant on the Approval Order (AO) DAQE-AN109780002-22, dated August 4, 2022. PTE are supplied for supplemental purposes only. Criteria Pollutant PTE tons/yr CO2 Equivalent 8288.00 Carbon Monoxide 3.81 Nitrogen Oxides 13.34 Particulate Matter - PM10 3.17 Particulate Matter - PM2.5 3.17 Sulfur Dioxide 8.31 Volatile Organic Compounds 1.43 Hazardous Air Pollutant PTE lbs/yr Generic HAPs (CAS #GHAPS) 1100 PREVIOUS ENFORCEMENT ACTIONS: No enforcement actions within the past five years. COMPLIANCE STATUS & RECOMMENDATIONS: In regards to Approval Order (AO) DAQE-AN109780002-22, dated August 4, 2022: Out of compliance with condition I.3 for operating an unapproved concrete batch plant, condition II.B.2.a.2 for failing to stack test the asphalt plant exhaust stack, and II.B.4.a.1 for failing to maintain water records. This was the initial compliance inspection for this source. The initial AO was issued July 7, 1997 (DAQE-613-97). A Compliance Advisory was issued August 2, 2023 (DAQC-730-23). A Warning was issued October 27, 2023 (DAQC-1151-23). HPV STATUS: Not Applicable. RECOMMENDATION FOR NEXT INSPECTION: The source was in the process of selling the operating concrete batch plant and a second concrete batch plant that was on site but not installed. Verify that this sale was finalized and that the equipment is no longer on site. The source also needs to conduct a stack test of the asphalt plant exhaust stack within 180 days of startup when the asphalt plant comes back into repair. Verify that watering records are being kept. NSR RECOMMENDATIONS: Verify the equipment on site is consistent with the equipment list. ATTACHMENTS: Emails, CA Response. 195 North 1950 West • Salt Lake City, UT Mailing Address: P.O. Box 144820 • Salt Lake City, UT 84114-4820 Telephone (801) 536-4000 • Fax (801) 536-4099 • T.D.D. (801) 903-3978 www.deq.utah.gov Printed on 100% recycled paper State of Utah Department of Environmental Quality Kimberly D. Shelley Executive Director DIVISION OF AIR QUALITY Bryce C. Bird Director SPENCER J. COX Governor DEIDRE HENDERSON Lieutenant Governor DAQC-1151-23 Site ID 10978 (B1) Sent Via Certified Mail No. 70190700000208346085 Pam Smith West Side Grading Incorporated P.O. Box 549 Delta, Utah 84624 Dear Ms. Smith: Re: Warning Letter – West Side Grading Incorporated, Utah Administrative Code (UAC) R307-401, Approval Order (AO) DAQE-AN109780002-22, Millard County On July 12, 2023, the Utah Division of Air Quality (DAQ) conducted an inspection of West Side Grading Incorporated, located at 1500 East 100 South, Delta, Utah. The DAQ believes that West Side Grading Inc. was in violation of: 1. UAC R307-401-5. Notice of Intent and DAQE-AN109780002-22 condition I.3 for adding emission producing equipment (Concrete Batch Plant) without prior approval and without submitting a Notice of Intent. 2. DAQE-AN109780002-22 condition II.B.2.a.2 for failing to stack test the asphalt plant exhaust stack. Please be aware this letter is a warning and that future instances of noncompliance may be considered violations of UAC R307-401 and AO DAQE-AN109780002-22 and West Side Grading Inc. may be assessed penalties up to $10,000 per day if found to be in violation of Utah Air Quality Rules. If the sale of the two concrete batch plants is not finalized, a Notice of Intent must be submitted to the DAQ to add the equipment to West Side Gradings Inc.’s AO if they will continue to be used on-site. When the asphalt plant is brought back online, a stack test must be conducted within 180 days of start-up to be in compliance with condition II.B.2.a.2 of the AO. The DAQ retains its authority to take subsequent enforcement action if during the next inspection the DAQ finds the source is still not in compliance with R307-401-5. 1 , " / Û à Û Ù Û Ü DAQC-1151-23 Page 2 A response to this letter is not required. If you have any questions regarding this letter, please contact Chad Gilgen at 385-306-6500 or at cgilgen@utah.gov. Sincerely, Bryce C. Bird Director BCB:CG:rh cc: Central Utah Public Health Department 4 * - - $ . — / A D v A ? A B @ E w C C ˜