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HomeMy WebLinkAboutDAQ-2024-0079801 DAQC-CI124690001-24 Site ID 12469 (B1) MEMORANDUM TO: FILE – WESTERN EMULSIONS, INC. – Woods Cross Hot Asphalt Storage Terminal (Peak Asphalt) THROUGH: Chad Gilgen, Minor Source Compliance Section Manager FROM: Jared James, Environmental Scientist DATE: May 7, 2024 SUBJECT: FULL COMPLIANCE EVALUATION, Minor, Davis County INSPECTION DATE: April 17, 2024 SOURCE LOCATION: 991 West 1500 South Woods Cross, UT 84087 DIRECTIONS: Take the road that parallels the west side of the train tracks. Look for the Peak Asphalt sign. SOURCE CONTACTS: Mike Thorpe, Plant Manager 385-566-7751, mthorpe@idahoasphalt.com Matthew Church, Records Contact 208-821-7039, mchurch@idahoasphalt.com OPERATING STATUS: Operating normally. PROCESS DESCRIPTION: Asphalt blending and storage facility. Raw asphalt materials are shipped to the site by railcar. As the asphalt is needed, the railcars are heated and the material is piped to the storage tanks. Hot oil heaters are used to keep the asphalt material warm enough to flow to and from the storage tanks. Boilers are used to provide steam for heating the asphalt in the railcars. Materials are piped to different tanks for blending and adding additives such as rubber, polymers, and chemicals. The blended material is then piped to a truck terminal (rack) where it can be loaded into haul trucks for distribution. Natural gas is used as a fuel in the boilers and oil heaters. Tanks are all sealed fixed-roof tanks. Fugitive dust is controlled by the use of magnesium chloride (MgCl2). APPLICABLE REGULATIONS: Approval Order (AO) DAQE-AN124690012-14, dated August 4, 2014 NSPS (Part 60) Dc: Standards of Performance for Small Industrial-Commercial-Institutional Steam Generating Units. 0 0 2 SOURCE EVALUATION: Name of Permittee: Permitted Location: Western Emulsions, Inc. – Woods Cross Hot Asphalt Storage Terminal PO Box 50538 991 West 1500 South Idaho Falls, ID 83405 Woods Cross, UT 84087 SIC Code: 2951: (Asphalt Paving Mixtures & Blocks) 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. Inventories, Testing and Monitoring. [R307-150] Status: In Compliance. No limits appear to have been exceeded. No modifications have been made to equipment or processes. The source appeared to be adequately maintained. No breakdowns have occurred. A 2022 emission inventory was submitted to DAQ. 3 Section II: SPECIAL PROVISIONS II.A The approved installations shall consist of the following equipment: II.A.1 Asphalt and Emulsion Plant Ergon Asphalt and Emulsions, Incorporated II.A.2 Medium Cure Asphalt Tanks Six (6) Tanks Item numbers 1 through 6 Capacity: 12'x30' each Service: medium cure asphalt II.A.3 Asphalt Emulsion Tanks Nine (9) Tanks in total Item numbers 7 through 13, 15, and 16 Three (3) tanks Capacity: 11'x28' each One (1) tank Capacity: 11'x30' One(1) tank Capacity: 12'x28' One (1) tank Capacity: 12'x30' One (1) tank Capacity: 11'x16' Two (2) tanks Capacity: 12'x30' Service: asphalt emulsion II.A.4 Asphalt Cement Tanks Sixteen Tanks in total Item numbers 103 through 109, and 201, 202, 206 through 210, 211, and 212 Two (2) tanks Capacity: 67'x40' each Two (2) tanks Capacity: 16.5'x30' each Two (2) tanks Capacity: 50.7'x28' each 4 One (1) tank Capacity: 25.6'x30' One (1) tank Capacity: 22'x16' One (1) tank Capacity: 16.5'x28' Two (2) tanks Capacity: 36.6'x40' each Three (3) tanks Capacity: 25.7'x30' each Two (2) tanks Capacity: 10'x10' Service: asphalt cement II.A.5 Distillate Tanks Three (3) Tanks in total Item numbers 14, H2, and H3 One (1) tank Capacity: 12'x30' Two (2) tanks Capacity: 7.8'x27.4' each Service: distillate II.A.6 Extender Tanks Three (3) Tanks in total Item numbers H4, H5, and H8 Two (2) tanks Capacity: 12'x36' each One (1) tank Capacity: 8'x10' Service: extenders II.A.7 Miscellaneous Tanks Six (6) Tanks in total Item numbers C1, C2, 204, 204, H6, and HCL One (1) tank Capacity: 9'x15' Service: chemical 5 One (1) tank Capacity: 6'x19' Service: chemical One (1) tank Capacity: 7'x21' Service: anti-strip agent One (1) tank Capacity: 10'x14' Service: sulfur One (1) tank Capacity: 11'x28' Service: water One (1) tank Capacity: 6'x19' Service: HCl II.A.8 Asphalt Tanks Two (2) Asphalt Tanks Item number 301, 302 Capacity: 40'x95' each Service: asphalt II.A.9 Heaters Two (2) heaters Ratings: One (1) 14.5 MMBtu/hr One (1) 10 MMBtu/hr II.A.10 Boilers Two (2) Boilers Ratings: One (1) 16.5 MMBtu/hr One (1) 5.2 MMBtu/hr II.A.11 Truck Loading Racks II.A.12 Railcar Heating II.A.13 Overhead Loading Rack II.A.14 Furnace One (1) controlled pyrolysis cleaning furnace Rating: 0.325 MMBtu/hr II.A.15 Miscellaneous Equipment Small storage tanks Small generators Asphalt reclamation tanks Propane heating torches 6 Miscellaneous maintenance equipment Odor control devices (do not control emissions) Laboratory equipment Emulsion mills Polymer grinders Parts washers Maintenance equipment Status: In Compliance. The following were observed: II.A.2 - medium cure asphalt tanks are only used 1-2 times/year. II.A.3 - emulsion tanks are no longer used. The emulsion is made at the 1100 North 95 West plant. II.A.4 - asphalt cement tanks: 2 tanks 67'x40' each - 103 and 104 2 tanks 16.5'x30' each - 105 and 106 2 tanks 50.7'x28' each - 107 and 109 1 tank 25.6'x30' - not in use - no outer shell 1 tank 22'x16' - 201 1 tank 16.5'x28' - 202 2 tanks 36.6'x40' each - 206 and 207 3 tanks 25.7'x30' each - 208, 209, and 210 2 tanks 10'x10' - 211 and 212 - no longer on site II.A.5 - distillate tanks - horizontal - no longer used, but still on site. II.A.6 - extender tanks (extenders "soften" the asphalt so road retains shape after buckling): 2 tanks 12'x36' - H4 and H5 1 tank 8'x10' - H8 - not in use II.A.7 - miscellaneous tanks: 2 tanks 6'x19' - chemical - C1 and C2 – no longer used. 1 tank 7'x21' - 204 - empty, no longer used. 1 tank 10'x14' - sulfur - no longer used as they now use a dry bagged product. 1 tank 11'x'28' - water - no longer used 1 tank - 6'x9' - HCl - never used II.A.8 - asphalt tanks - 301 and 302 - not yet built, no current plans - 50,000 bbl each II.A.9 - heaters - smaller unit is no longer functional. II.A.10 - boilers - smaller unit no longer used, but the larger boiler is functional II.A.11 - truck loading racks - 4 (1 not used) II.A.12 - railcar heating - pipelines from the boiler II.A.13 - overhead loading rack. 7 II.A.14 - furnace - 350,000 Btu/hr oven - in building now used as storage II.A.15 - miscellaneous equipment: no generators on site; lid was closed on the parts washer. Also on site was a lime silo with baghouse that is no longer used. II.B Requirements and Limitations II.B.1 The Woods Cross asphalt terminal shall comply with the following conditions: II.B.1.a Visible emissions from any stationary point or fugitive emission source associated with the source or with the control facilities shall not exceed 10% opacity for the heaters, furnaces, and boilers, and 20% opacity for all other emission points except for periods of start-up, shut-down, or malfunction. Opacity observations of emissions from stationary sources shall be conducted in accordance with 40 CFR 60, Appendix A, Method 9. [R307-401-8] Status: In Compliance. No visible emissions were observed during the inspection. II.B.1.b The following throughput limit shall not be exceeded: 260,000,000 gallons of crude oil per rolling 12-month period A new 12-month total shall be calculated on a monthly basis by summing the monthly totals for the previous consecutive 12-months. Monthly calculations shall be made no later than 20 days after the end of each month. Records of throughput shall be kept for all periods when the plant is in operation. Throughput shall be determined by examination of company and/or customer billing records. The records of crude oil throughput shall be kept on a daily basis. [R307-401-8] Status: Not Applicable. This facility is used as an asphalt storage yard now, no mixing is currently being done onsite. Zero gallons of crude oil throughput for the current 12-month period. For informational purposes, the source supplied the total asphalt throughput as 43,883.84 tons for the 12-month period. See attached. II.B.1.c Visible fugitive dust emissions from haul-road traffic and mobile equipment in operational areas shall not exceed 20% opacity at any point. Visible emission determinations shall use procedures similar to Method 9. The normal requirement for observations to be made at 15-second intervals over a six-minute period, however, shall not apply. Visible emissions shall be measured at the densest point of the plume but at a point not less than 1/2 vehicle length behind the vehicle and not less than 1/2 the height of the vehicle. [R307-401-8] Status: In Compliance. No visible fugitive dust emissions were observed. Only one haul truck came through during the inspection. II.B.1.d All unpaved operational areas that are used by mobile equipment shall be water sprayed, and/or chemically treated to control fugitive dust. An application of water, or chemical treatment shall be used. Treatment shall be of sufficient frequency, intensity, and duration to maintain the surface material in a damp/moist condition unless it is below freezing. If chemical treatment is to be used, the plan must be approved by the Director. 8 Records of water, and/or chemical treatment shall be kept for all periods when the plant is in operation. The records shall include the following items: 1. Date Number of treatments made, dilution ratio, and quantity Rainfall received, if any, and approximate amount Time of day treatments were made Records of temperature if the temperature is below freezing. [R307-401-8] Status: In Compliance. The operation yard is almost entirely covered with crushed asphalt. Haul traffic is low. The source only has need to bring in a water truck once or twice a year. Records of watering are kept in a log in the office. II.B.1.e The paved in-plant haul road shall not exceed 0.40 miles in combined length, and the vehicle speed along the haul road shall not exceed 10 miles per hour. [R307-401-8] Status: In Compliance. The haul road appears to be within the set parameter. 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. NSPS (Part 60) Dc: Standards of Performance for Small Industrial-Commercial-Institutional Steam Generating Units Status: In Compliance. Notification of the date of construction and startup along with heat input capacity were submitted in the NOI and archived in the file of the previous owner. Only natural gas is used as fuel in the boiler. AREA SOURCE RULES EVALUATION: The following Area Source Rules were evaluated during this inspection: Stationary Sources [R307-210] Status: In Compliance. This condition is met by compliance with NSPS (Part 60) Dc. Solvent Cleaning [R307-304] Status: In Compliance. The source uses Safety Kleen Premium Solvent which has a vapor pressure of 0.2 mm Hg @ 20 C. Waste rags are kept in covered containers. 9 Nonattainment and Maintenance Areas for PM10 and PM2.5: Fugitive Emissions and Fugitive Dust [R307-309] Status: In Compliance. No visible emissions were observed during the inspection. The operations yard is almost completely covered with crushed asphalt. Ozone Nonattainment and Maintenance Areas: General Requirements [R307-325] Status: In Compliance. No spills, discarded, or open containers of asphalt or other VOC containing materials were observed during the inspection. Degreasing [R307-335] Status: In Compliance. The source has one parts washer, which is lidded with operation instructions posted on the inside of the lid. The lid was closed at the time of inspection. EMISSION INVENTORY: Listed before are the Actual Emissions Inventory provided from Western Emulsions, Inc.- Woods Cross Hot Asphalt Storage Terminal. A comparison of the estimated total potential emissions (PTE) on AO: DAQE-AN124690012-14, dated August 4, 2014 is provided. PTE are supplied for supplemental purposes only. Criteria Pollutant PTE tons/yr Actuals tons/yr CO2 Equivalent 1.00 Carbon Monoxide 17.46 1.685 Nitrogen Oxides 19.98 2.006 Particulate Matter - PM10 4.75 0.194 Particulate Matter - PM2.5 4.75 0.157 Sulfur Oxides 0.13 0.012 Volatile Organic Compounds 45.93 0.739 Hazardous Air Pollutant PTE lbs/yr Actuals lbs/yr Formaldehyde (CAS #50000) 208 Generic HAPs (CAS #GHAPS) 342 Hexane (CAS #110543) 790 Xylenes (Isomers And Mixture) (CAS #1330207) 146 10 PREVIOUS ENFORCEMENT ACTIONS: No enforcement actions within the past five years. COMPLIANCE STATUS & RECOMMENDATIONS: In regards to Approval Order (AO) DAQE-AN124690012-14, dated August 4, 2014: the source should be considered in compliance. The facility appeared to be adequately maintained and operated properly. Records were made available for review during the inspection and after by email. HPV STATUS: Not Applicable. RECOMMENDATION FOR NEXT INSPECTION: Inspect as normal. Steel toes, hard hat, safety glasses, and long sleeves are required to walk the facility. NSR RECOMMENDATIONS: Update process and equipment list if any modifications are made. ATTACHMENTS: VEO Form, Email, Throughput Record. Shipping Report Material shiped between April 01, 2023 and March 31, 2024 WXN1 - Woods Cross North Asphalt & FG Tons Shipped AC - Asphalt Cement PG58-28 36,687.92 PG64-22 5,227.73 Total AC Shipped 41,915.65 Blended AC - Blended Asphalts Finished Goods 15-Pen 554.90 56 PEN 1,413.29 Total Blended AC Shipped 1,968.19 Intermediate - Inventoried Intermediates 30 Pen 908.66 Total Intermediate Shipped 908.66 WXN1 Product Summary 41,915.65AC 1,968.19Blended AC 908.66Intermediate 44,792.50 43,883.84 Total Shipped: Total Asphalt Throughput Page 1 Business Date:4/25/2024 9:40:39 AM4/25/2024Run Date: