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Home My WebLink AboutDAQ-2024-008546 1 DAQC-562-24 Site ID 10007 (B5) MEMORANDUM TO: FILE – HOLCIM USA INCORPORATED – Devils Slide THROUGH: Harold Burge, Major Source Compliance Section Manager FROM: Rob Leishman, Environmental Scientist DATE: June 6, 2024 SUBJECT: Holcim USA Incorporated (Holcim), Major, Title V, MACT, NSPS, Weber County, FRS # UT00000049002900001 INSPECTION TYPE: State Electronic Data Report (SEDR) Review REVIEW DATE: June 6, 2024 SOURCE LOCATION: Devils Slide/Weber County SOURCE CONTACT: Mark Miller – Director of Land and Environment – 972-221-4646 Javier Sosa – Plant Manager – 801-829-6821 APPLICABLE REGULATIONS: Title V Operating Permit PERMIT NUMBER: 2900001004 DATE OF PERMIT: November 18, 2021 Date of Last Revision: March 25, 2022 SOURCE INSPECTION EVALUATION: With the exception of sources that only monitor for opacity, quarterly report memoranda will only address the findings of the quarterly report. Approval Order and Title V permit conditions addressing continuous emission monitoring requirements will be addressed in Holcim’s relative accuracy performance specification test review memorandum. SOURCE REVIEW EVALUATION: First Quarter 2024 % Monitor Availability (MA) Performance Test Dates (N/A to Opacity) Summary of Excess Emissions During Point Source Operation Point Source Op. hrs. Channel MA CGA Lin RATA Point Source Channel Hrs. Limitation Kiln 1253 THC 97% 02/14/24 07/20/23 Kiln NOx 0.00 1817 Tons - 12 mo. ra 1 8 2 2 First Quarter 2024 % Monitor Availability (MA) Performance Test Dates (N/A to Opacity) Summary of Excess Emissions During Point Source Operation Point Source Op. hrs. Channel MA CGA Lin RATA Point Source Channel Hrs. Limitation Kiln 1253 HCl 98% 02/07/24 11/04/22 Kiln SO2 0.00 475 lb/hr - 24 hr. ra. Kiln 1253 O2 99% 02/13/24 07/20/23 Kiln SO2 0.00 457 Tons - 12 mo. ra Kiln 1253 NOx 98% 02/12/24 07/20/23 Kiln HCl 0.00 3 ppmd - 30- day ra. Kiln 1253 SO2 98% 02/12/24 07/20/23 Kiln THC 0.00 38.14 ppmw - 30-day ra. Kiln 1253 CO2 98% 02/12/24 07/20/23 Kiln Hg 0.00 55 lb/MMton clink - 30- day ra. Kiln 1253 Hg 97% 01/30/24 08/29/23 Excess Emission Report – Hourly Summary Point Source Channel Startup & Shutdown Control Equipment Problems Process Problems Other Known Causes Unknown Causes Emission Limit Kiln NOx 0 0 0 0 0 1817 Tons - 12 mo. ra Kiln SO2 0 0 0 0 0 475 lb/hr - 24 hr. ra. Kiln SO2 0 0 0 0 0 457 Tons - 12 mo. ra Kiln HCl 0 0 0 0 0 3 ppmd - 30-day ra. Kiln THC 0 0 0 0 0 38.14 ppmw - 30-day ra. Kiln Hg 0 0 0 0 0 55 lb/MMton clink - 30-day ra. CMS Performance Summary - Hourly Summary Point Source Channel Monitor Malfunction Non-monitor Malfunction QA Calibrations Other Known Causes Unknown Causes Kiln THC 32 2 7 0 0 Kiln HCl 4 9 6 0 0 Kiln O2 4 9 5 0 0 Kiln NOx 7 9 5 0 0 Kiln SO2 7 9 5 0 0 Kiln CO2 4 9 6 0 0 Kiln Hg 30 0 4 0 0 3 Pollutant Concentration Exceeded Span of CEM Monitor Outage During Point Source Operation Alternate Sampling CEM Modifications 0 Hours 173 Hours 0 Hours 0 Events SOURCE INSPECTION SUMMARY EVALUATION: Holcim is maintaining its COMS as required in R307-170 and 40 CFR 603. Cylinder gas audits were conducted as required. CURRENT RECOMMENDATIONS: Holcim failed to conduct a RATA for HCl in 4Q2023. That RATA was completed on May 2, 2024, and results will be due 60 days from the date of that test. Compliance action regarding the failure to conduct a RATA annually will be addressed in the review of that report. All other deviations appear to be a result of breakdown or process related problems that do not warrant issuing a violation. Periods of excess emissions that were recorded by the CMS in service on each point source during this reporting period are summarized in the SEDR and described in Pivot Table 400 “Excess Emissions Review.” Excessive monitor unavailability between March 19-25, 2022, was due to monitor malfunction and supply chain issues causing unavailability of parts. With the exception of the HCl RATA, Holcim was in compliance during this reporting period. No further enforcement actions should be taken. Holcim’s NSPS monitoring system meets the performance standards of 40 CFR 60, Appendix B Performance Specifications. HIGH PRIORITY VIOLATOR (HPV): No RECOMMENDATION FOR NEXT INSPECTION: Check DAS for daily zero and span drift. Check the QC program to ensure that monitor drift is being tracked and that the source can identify excessive drift. ATTACHMENTS: Excel spreadsheet review Holcim EER 1Q2024 Point Source Information Late Expired Cal. Gas Valid Cal. Gas Days Yes No 1 Type Code 100 (Company Information)Type Code Company Manager Company Name AIRS # Phone Number Environmental Contact 1 100 Javier Sosa Ortiz 02900001 801-829-2122 Mark Miller 1 100 0 0 0 0 1 Type Code 110 (Point Source Identification)Type Code Point Source Quarter 1 - 4 Year Point Source Operating Hrs. in Quarter 1 110 1 2024 1253 1 110 1 2024 1253 1 Type Code 200 (Monitor Identification)Type Code Point Source Channel Manufacturer Model No. Monitor SN Low Span High Span Installation Date Monitor Location 1 200 CO2 ABB ACF5000 3.368022.6 0 30 Nov. 16 Stack 1 200 HCl ABB ACF5000 3.368022.6 0 20 Nov. 16 Stack 1 200 Hg Tekran 3310Xi 3122 0 20 Nov. 16 Stack 1 200 NOx ABB ACF5000 3.368022.6 0 1000 Nov. 16 Stack 1 200 O2 ABB ACF5000 3.368022.6 0 25 Nov. 16 Stack 1 200 SO2 ABB ACF5000 3.368022.6 0 325 Nov. 16 Stack 1 200 THC ABB Multi FID 14 3.344762.1 0 60 Sep. 16 Stack 1 200 0 0 0 0 0 0 1/0/1900 0 1 Type Code310 (Excess Emissions) SUMMARY REPORT Type Code Channel Total Hours of Excess Emissions Excess Emissions - % of Total Operating Hours RC 701 Hours - start up/Shutdown RC 702 Hours- Control Equipment Problems RC 703 Hours - Process Problems RC 704, 706, 707 Hours -Other Known Causes RC 705 Hours - Unknown Causes Emission Limitation Emission Limitation Units Emission Limitation Averaging Period 1 TRUE 310 NOx 0 0.00% 0 0 0 0 0 1817 Tons 12 mo. ra 1 TRUE 310 SO2 0 0.00% 0 0 0 0 0 475 lb/hr 24 hr. ra. 1 TRUE 310 SO2 0 0.00% 0 0 0 0 0 457 Tons 12 mo. ra 1 TRUE 310 HCl 0 0.00% 0 0 0 0 0 3 ppmd 30 day ra. 1 TRUE 310 THC 0 0.00% 0 0 0 0 0 38.14 ppmw 30 day ra. 1 TRUE 310 Hg 0 0.00% 0 0 0 0 0 55 lb/MMton clink30 day ra. 1 310 0 0 0 0 0 0 0 0 0 1 Type Code 300 (CMS Performance Summary) Type Code Channel Point Source Operating Hours Downtime - % of Total Operating Hours Total CMS Downtime RC 721 Hours - Monitor Malfunction RC 722 Hours - Non-monitor Malfunction RC 723 Hours - QA Calibrations RC 724 Hours - Other Known Causes RC 725 Hours - Unknown Causes 1 TRUE 300 THC 1253 3.27% 41 32 2 7 0 0 1 TRUE 300 HCl 1253 1.52% 19 4 9 6 0 0 1 TRUE 300 O2 1253 1.44% 18 4 9 5 0 0 1 TRUE 300 NOx 1253 1.68% 21 7 9 5 0 0 1 TRUE 300 SO2 1253 1.68% 21 7 9 5 0 0 1 TRUE 300 CO2 1253 1.52% 19 4 9 6 0 0 1 TRUE 300 Hg 1253 2.71% 34 30 0 4 0 0 1 300 0 0 0 0 0 0 1 Type Code 250 (Performance Specification RATA Results) Type Code Channel Date of Most Current RATA Date of Preceding RATA Months Between RATA's Units of Measurement CEM Value Reference Method Value Relative accuracy Pass/ Fail 1 405 Days 250 Hg 08/29/23 07/20/22 13 ug/wscm 1.348 0.955 0.52% P 1 360 Days 250 HCl 11/04/22 11/09/21 11 ppm 4.11 3.97 4.93% P 1 365 Days 250 THC 07/20/23 07/20/22 12 ppmw 7.644 6.511 5.98% P 1 365 Days 250 NOx 07/20/23 07/20/22 12 ppmw 347.533 356.582 4.50% P 1 365 Days 250 O2 07/20/23 07/20/22 12 0 8.978 9.767 8.34% P 1 365 Days 250 SO2 07/20/23 07/20/22 12 lb/hr 0.011 0.891 0.19% P 1 365 Days 250 CO2 07/20/23 07/20/22 12 0 15.789 15.267 3.64% P 1 0 Days 250 0 01/00/00 01/00/00 0 0 0 0 0.00% 0 Point Source Point Source Point Source Kiln 0 Kiln 0 Kiln Kiln Kiln Kiln Kiln Kiln Kiln 0 Kiln Kiln Kiln Holcim US Inc. 0 Kiln Kiln Kiln Kiln Kiln Kiln Kiln 0 Kiln 0 Kiln Kiln Kiln Kiln Kiln Kiln Kiln Kiln Holcim EER 1Q2024 1 Type Code 260 (CGA Results)Type Code Channel Date Audit Point No. Cylinder ID Cylinder Expiration Date Type of Certification Units of Measurement CEM Value Cylinder Value Precision %Pass/ Fail Range - High or Low 1 Valid Cal. Gas 260 CO2 02/12/24 1 CC142824 11/30/29 EPA P1 % 7.59 7.48 1.47% P Low 1 Valid Cal. Gas 260 CO2 02/12/24 2 CC365043 01/29/32 EPA P1 % 16.86 16.5 2.18% P High 1 Valid Cal. Gas 260 HCl 02/07/24 1 CC517309 04/13/24 EPA P1 ppm 4.94 4.98 0.84% P Low 1 Valid Cal. Gas 260 HCl 02/07/24 2 CC515927 04/13/24 EPA P1 ppm 10.33 10.42 0.90% P High 1 Valid Cal. Gas 260 Hg 01/30/24 1 2537 Xi N/A NIST µg 4.73 4.97 4.93% P Low 1 Valid Cal. Gas 260 Hg 01/30/24 2 2537 Xi N/A NIST µg 10.48 10.72 2.26% P High 1 Valid Cal. Gas 260 NOx 02/12/24 2 CC365043 01/29/32 EPA P1 ppm 164.12 164.5 0.23% P High 1 Valid Cal. Gas 260 NOx 02/12/24 1 CC142824 11/30/29 EPA P1 ppm 246.78 252.4 2.23% P Low 1 Valid Cal. Gas 260 O2 02/13/24 1 ALM056085 09/04/27 EPA P1 % 4.87 5.07 3.94% P Low 1 Valid Cal. Gas 260 O2 02/13/24 2 EEB0082909 09/11/26 EPA P1 % 10.64 11.04 3.62% P High 1 Valid Cal. Gas 260 SO2 02/12/24 1 CC365043 01/29/32 EPA P1 ppm 76.3 82.89 7.95% P Low 1 Valid Cal. Gas 260 SO2 02/12/24 2 CC142824 11/30/29 EPA P1 ppm 168.54 179.8 6.28% P High 1 Valid Cal. Gas 260 THC 02/14/24 1 CC452508 01/24/31 EPA P1 ppm 15.62 15.04 3.86% P Low 1 Valid Cal. Gas 260 THC 02/14/24 2 CC127602 01/23/31 EPA P1 ppm 35.4 32.48 9.00% P High 1 260 0 01/00/00 0 0 01/00/00 0 0 0 0 0.00% 0 0 1 Type Code 270 (Linearity Test Results)Type Code Channel Date Audit Point No. Cylinder ID Cylinder Expiration Date Type of Certification Units of Measurement CEM Value Cylinder Value Precision %Pass/ Fail Range - High or Low 1 270 0 01/00/00 0 0 01/00/00 0 0 0 0 0.00% 0 0 1 Type Code 210 (Pollutant Concentration Exceeded Span of CEM) Type Code Channel Start Date Start Time End Date End Time Hours 1 0 0 0 1/0/00 0:00 1/0/00 0:00 1 1 None Reported 1 0 TC 220 Hours 173.00 TC 220 Hours 0.00 TC 230 Hours 0.00 Events 0.00 Hours 0.00 Events 0.00 0.00 1 173.00 TC 300 Hours 0.00 TRUE None Reported None Reported None Reported None Reported None Reported None Reported Point Source Point Source Point Source Yes Kiln Kiln Kiln Kiln Kiln Kiln Type Code 550 (Changes in Operation in Control Equipment When CEM Data Not Available) Type Code 500 (Boiler Operating Days w/o 18 Hours of Data) Type Code 450 (Data Excluded) Type Code 210 (Pollutant Concentration Exceeded Span of CEM) Type Code 220 (Monitor Outage During Point Source Operation) Type Code 230 (Manual Sample - Alternate Sampling During Monitor Outage) Type Code 240 (CEM Modifications) Type Code 530 (Excess Emissions During Emergency Conditions) Kiln Kiln Kiln Kiln Kiln Kiln Kiln Kiln 0 0 0 Holcim EER 1Q2024 Relative Accuracy Overview Point Source Channel Date of Most Current RATA Date of Preceding RATA Months Between RATA's Units Measured CEM Value Reference Method Value Relative Accuracy Pass/ Fail Kiln Hg 08/29/23 07/20/22 13 ug/wscm 1.348 0.96 0.52% P Kiln HCl 11/04/22 11/09/21 11 ppm 4.11 3.97 4.93% P Kiln THC 07/20/23 07/20/22 12 ppmw 7.644 6.51 5.98% P Kiln NOx 07/20/23 07/20/22 12 ppmw 347.533 356.58 4.50% P Kiln O2 07/20/23 07/20/22 12 8.978 9.77 8.34% P Kiln SO2 07/20/23 07/20/22 12 lb/hr 0.011 0.89 0.19% P Kiln CO2 07/20/23 07/20/22 12 15.789 15.27 3.64% P * NSPS CGA First 2024 Audit Gas Ranges Audit Gas Ranges AP1 Low AP2 Low AP1 High AP2 High Kiln CO2 2/12/24 30 7.48 5 to 8 Kiln CO2 2/12/24 30 16.5 10 to 14 Kiln HCl 2/7/24 20 4.98 10 to 12 Kiln HCl 2/7/24 20 10.42 16 to 24 Kiln Hg 1/30/24 20 4.97 4 to 6 Kiln Hg 1/30/24 20 10.72 10 to 12 Kiln NOx 2/12/24 1000 164.5 500 to 600 Kiln NOx 2/12/24 1000 252.4 200 to 300 Kiln O2 2/13/24 25 5.07 4 to 6 Kiln O2 2/13/24 25 11.04 8 to 12 Kiln SO2 2/12/24 325 82.89 65 to 97.5 Kiln SO2 2/12/24 325 179.8 162.5 to 195 Kiln THC 2/14/24 60 15.04 12 to 18 Kiln THC 2/14/24 60 32.48 30 to 36 Point Source Channel Audit Date Low Span Audit Gas Used High Span Audit Gas Used Holcim EER 1Q2024 Monitoring Information TC 210, 230, & 240 Type Code 210 (Pollutant Concentration Exceeded Span of CEM) - 500 (All) * Sum of Hours Column Labels Row Labels (blank) Grand Total (blank)0 0 Grand Total 0 0 * Type Code 230 (Manual Sample - Alternate Sampling During Monitor Outage) - 500 (All) * Sum of Hours Column Labels Row Labels (blank) Grand Total (blank)0 0 Grand Total 0 0 * Type Code 240 (CEM Modifications) - 100 (All) * Count of Channel Column Labels Row Labels (blank) Grand Total (blank) (blank) Grand Total Holcim EER 1Q2024 Type Code 220 (Monitor Outage During Point Source Operation) - 600 (All) * Sum of Hours Column Labels Row Labels 723 722 721 Grand Total Kiln NOx Daily Calibration 3 3 Malfunction Data Collection Equipment 9 9 Preventative Maintenance 2 2 Failed Calibration 7 7 SO2 Daily Calibration 2 2 Malfunction Data Collection Equipment 9 9 Preventative Maintenance 2 2 Failed Calibration 7 7 Cyliner Gas Audit 1 1 O2 Daily Calibration 3 3 Malfunction Data Collection Equipment 9 9 Failed Calibration 4 4 Cyliner Gas Audit 2 2 CO2 Daily Calibration 3 3 Malfunction Data Collection Equipment 9 9 Preventative Maintenance 2 2 Failed Calibration 4 4 Cyliner Gas Audit 1 1 HCl Daily Calibration 4 4 Malfunction Data Collection Equipment 9 9 Preventative Maintenance 2 2 Failed Calibration 4 4 THC Daily Calibration 6 6 Malfunction Data Collection Equipment 2 2 Failed Calibration 12 12 Cyliner Gas Audit 1 1 Monitor Anomoly / Malfunction 20 20 Hg Daily Calibration 4 4 Monitor Anomoly / Malfunction 30 30 Grand Total 38 47 88 173 Holcim EER 1Q2024 SO2 * SO2 Type Code 410 (SO2) - 6000 (All) SO2 * SO2 Count of Magnitude of Emissions Column Labels SO2 Row Labels Grand Total SO2 Grand Total NOx * NOx Type Code 420 (NOx) - 6000 (All) NOx * NOx Count of Magnitude of Emissions Column Labels NOx Row Labels Grand Total NOx Grand Total CO * CO Type Code 440 (CO) - 6000 (All) CO * CO Count of Magnitude of Emissions Column Labels CO Row Labels Grand Total CO Grand Total VOC/THC * VOC/THC Type Code 460 (VOC/THC) - 6000 (All) VOC/THC * VOC/THC Count of Magnitude of Emissions Column Labels VOC/THC Row Labels Grand Total VOC/THC Grand Total O2 * O2 Type Code 470 (TRS as O2) - 6000 (All) O2 * O2 Count of Magnitude of Emissions Column Labels O2 Row Labels Grand Total O2 Grand Total Hg * Hg Type Code 480 (Hg Mercury) - 6000 (All) Hg * Hg Count of Magnitude of Emissions Column Labels Hg Row Labels Grand Total Hg Grand Total HCl * HCl Type Code 401 HCl - 6000 (All) HCl * HCl Count of Magnitude of Emissions Column Labels HCl Row Labels Grand Total HCl Grand Total Holcim EER 1Q2024 Type Code 500 Before February 28, 2005 (Boiler Operating Days w/o 18 Hours of Data) After February 28, 2005 (90% Operating Hours For each 30 BOD) - 500 (All) * Count of Channel Column Labels Row Labels Grand Total Grand Total * Type Code 510 (F-factor, Equations & Conversion Factors) - 500 (All) Count of F-factor Column Labels Row Labels Grand Total Grand Total * Type Code 520 (Minimum Data Not Obtained <22/30 BODs) - 500 (All) Count of Channel Column Labels Row Labels Grand Total Grand Total * Type Code 530 (Excess Emissions During Emergency Conditions) - 500 (All) Count of Date Column Labels Row Labels Grand Total Grand Total * Type Code 540 (Fuel Pre-treatment Credit SO2) - 500 (All) Count of Date Column Labels Row Labels Grand Total Grand Total * TypeCode 550 (Changes in Operation in Control Equipment When CEM Data Not Available) - 500 (All) Column Labels Row Labels Grand Total Grand Total