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HomeMy WebLinkAboutDAQ-2024-011091m\E.-,3!/. Dcen P. Andenon Vice Prcsidcnt Salt Lakc City Rcfincry Tesoro Refining & luly 25,2024 Bryce Bird, Director Attr: Jeremy Marsigli Utah Division of Air Quality 195 North 1950 West P.O. Box 144820 salt Lake ciry, utah 84114-4820 A subsidiary of Marathon Patrol6um Corporation 474 W 900 N urAH Dl:n^ R-trt, nrf6P*e Citv' Ur 84103 ENVIRONMENTAL OUALITV JUL I; 2.?,?4 Marketing Gompany LLC Hmo Demcnv tlan/ dc li wrcl 40 CFR 63 Subpart A and IIUU Compliance Report - 1H2024 Approval Order: DAQE-ANI 0335007tf 8 Tesoro Refining & Marketing Company,LLc Salt Lake City Refinery Please find enclosed the periodic report for Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery covering the time period from January L,2024 through June 30, 2024. T\is report includes the periodic report in accordance with 40 CFR 63.1575, Table 43 - Subpart UUU Requirements for Reports, Table 44 Applicability of I\IESHAPS General Frovisions to Subpart UUU, and applicable sections of 40 CFR 63.10. If you have any questions conceming the content of this report, please contact Brian Mitchell (801) 606-2165. Sincerely,iltu Dean P. Anderson Vice President Tesoro Refining & Marketing Company LLC B-2-10335 cc:USEPA Region VIII MC ENF-AT 1595 Wynkoop Street Denver CO 80202-1129 Vnurl SEMIANNUAL COMPLIANCE REPORT 40 CFR 63 Subpart UUU (REFTNERY MACT rr) Reporting Period: January 1,2024 - June 30,2024 Tesoro Refining & Marketing Gompany, LLG Salt Lake City Refinery 474rflest 900 North Salt Lake City, Utah 84103 @'tj'm I Hq*d De li\,rt "ed I DIVISION OF AIR OUALITY Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery Table of Contents l. GENERAL REPORTTNG REQUTREMENTS- 40 CFR 63.1s7s(C) .........................4 2. FCCU PERIODTC REPORTTNG REQUTREMENTS - 40 CFR 63.rs7s@) AND (E)-..-............4 3. REFORMER PERTODIC REPORT REQUIREMENTS - 40 CFR 63.1575(D) AND (E)..............6 4. SRU PERTODIC REPORT REQUTREMENTS - 40 CFR 63.r575(D) AND (E).............................7 s. coNTRoL EQUTPMENT BYPASS ROUTE PERTODIC REPORT REQITIREMENTS - 40 cFR 63.1s7s(D) AND (E) 6. PERIODIC REPORT PERFORMANCE TEST REPORTING REQTJIREMENTS4O CFR 63.1s7s(F).......................... 9 7. TNFORTVTATION SUBMTTTED rN OTHER REGUT.ATORY REPORTS-4o CFR 63.1575(G) .. 9 8. RESERVED - 40 CFR 63.1s7s(H)... ..........10 9. MULTTPLE FCCUS VENTING TO A STNGLE WGS - 40 CFR 63.1575(r)&(0........................10 IO. ELECTRONIC SIJBMITTAL OF PERFORMANCE TEST AI\[D CEMS PERFORMANCE EVALUATION DATA - 40 CFR 63.1575(K).. .......................10 TABLE I FCCU CATALYST REGENERATOR DEVIATIONS FOR COKE BI]RN coMpLIANCE LIMrT... .............11 TABLE 2 FCCU CATALYST R.EGENERATOR EMISSION MONITORING DOWI\TIME FOR COKE BURN CPMS.......... .......................11 TABLE 3 FCCU CATALYST REGENERATOR DEVIATIONS FOR CO LIMIT.....................I2 TABLE 4 FCCU CATALYST REGENERATORDEVIATIONS FOR TOTAL POWER LIMIT l3 TABLE 5 FCCU CATALYST REGENERATOR ENIISSIONS MONITORING DOWI\TIME FOR TOTAL POWER CPMS TABLE 6 FCCU CATALYST REGENERATOR DEVIATIONS FOR SECOI\DARY CT]RRENT LIMIT TABLE 7 FCCU CATALYST REGENERATOR E1VtrSSIONS MONITORING DOWNTIME FOR SECOIIDARY CTJRRENT CPMS... ........I4 TABLE 8 FCCU CATALYST REGENERATOR DEVIATIONS FOR TOTAL DIFFERENTIAL PRESSURE LIMrT.......... .............15 TABLE 9 FCCU CATALYST REGENERATOR EIVtrSSIONS MONITORING DOWNTIME FOR TOTAL DIFFERENTIAL PRESSTJRE CPMS ............15 TABLE IO FCCU CATALYST REGENERATOR DEVHTIONS FOR LIQTIID-TO-GAS RATIOLIMIT 16 TABLE 11 FCCU CATALYST REGENERATOR EMISSIONS MONITORING DOWIITIME FOR LIQIIID-TO-GAS RATIO CPMS.......... ........................16 TABLE 12 UFU CATALYST REGENERATOR DEVIATIONS FOR FLARE PILOT PRESENCE 17 TABLE 13 UFU CATALYST REGENERATOR E1VtrSSIONS MONITORING DOWNTIME FOR FLARE CPMS t7 TABLE 14 UFU CATALYST REGENERATOR DEVIATIONS FOR HCL LIMIT......................1E TABLE 15 UFU CATALYST REGENERATOR EMISSIONS MONITORING DOWI\iTIME FOR HCL CONCENTRATION........... .............1E 13 t4 Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery TABLE 16 UT'U CATALYST REGENERATOR DEVIATIONS FOR REGENERATOR TEMPERATURE LIMIT 19 TABLE 17 UT'U CATALYST REGENERATOR EIVflSSIONS MONITORING DOWNTIME FOR TEMPERATURE CPMS.......... ................19 TABLE 18 SRU DEVIATIONS FOR TEMPERATURE LIIIyIIT 20 TABLE 19 SRU EMISSIONS MONITORING TEMPERATI]RE DOWI\ITIME FOR TEMPERATURE CPMS 20 TABLE 20 SRU DEVIATIONS FOR OXYGEN LIMIT... .....................21 TABLE 2I FCCU CATALYST REGENERATOR BYPASS ROUTE DEVIATIONS...................22 TAB,LE22 FCCU CATALYST REGENERATOR BYPASS ROUTE MONITORING DOWNTIME FOR TEMPERATI]RE & POSITIOI\,ER CPMS 22 TABLE 23 UT'U CATALYST REGENERATOR V.15 BYPASS DEYIATIONS............................23 TABLE 24 UT'U V.15 BYPASS CAR SEAL CHANGES.. ......................23 TABLE 25 UFU CATALYST REGENERATOR FLAR.E BYPASS ROUTE DEVIATIONS........24 TABLE 26 SOUTH FLARE BYPASS ROUTE EMISSIONS MONITORING DOWI{TIME FOR POSITIONER CPMS ...................24 Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery 1. General Reporting Requirements- 40 CFR 63.1575(c) The cover page of this report contains the company name, address, and reporting period for this report. [$ 63.1575(cX1)] ln cases where there were no deviations from emission limitations or there were no deviations from the requirements for work practice standards, a statement is included in the corresponding table. Instances where continuous monitoring systems were inoperative, inactive, malfunctioning, out-of-control, repaired, or adjusted are noted in the corresponding tables. [$63. I 575(c)(a)]. 2. FCCU Periodic Reporting Requirements - 40 CFR 63.1575(d) and (e) The Fluid Catalytic Cracking Unit (FCCU) catalyst regenerator at Tesoro's Salt Lake City Refinery is subject to New Source Performance Standards (NSPS) and complies with NSPS Subpart Ja to meet Subpart UUU continuous compliance demonskation requirements as specified in Subpart UUU Table 6, Item 2 and Table 10, Item l. Tesoro determined that the modernization of the Carbon Monoxide (CO) Boiler at the Salt Lake City Refinery conducted in 2013 triggered 40 CFR Part 60 Subpart Ja for CO emissions. Startup of the CO Boiler began on May 26,2013. For purposes of MACT 40 CFR 63.1565(a), Tesoro complies with NSPS Subpart Ja. The reporting of deviations in Table 3 is based on the NSPS Subpart Ja limit. Tesoro reports compliance with the NSPS Subpart Ja limit in the quarterly State Electronic Data Report (SEDR) pursuant to Utah Air Quality Rules 307-170 and in compliance with $63.1575(G). Tesoro complies with the FCCU PM limit, testing, monitoring and recordkeeping requirements of 40 CFR Part 60, Subpart Ja - Federal Standards of Pedormancefor Petroleum Refineries for Which Construction, Reconstruction, or Modification Commenced After May 14, 2007 (NSPS Ja). $63.1564(a)(l) requires that each FCCU subject to $60.102a(bxl), must meet the emission limitations for NSPS units. This testing is conducted to meet the FCCU PM testing requirement of $60.104a(a) and confirms compliance with the 1.0 gram (g) PM per kilogram (kg) coke bum-off limit for reconstructed or modified FCCUs from $60.102a(bXlXi). Note that the presented units of glkg align with those represented in the technical corrections to NSPS Ja as part of the Refinery Sector Rule. Method 5B Emissions Performance Tests were conducted in the first half of 2023 and Tesoro demonstrated compliance with testing results of 1.0 kg PM/IvIg coke burn-off. $60.102a(c)(lXii) requires that the daily average exhaust coke burn-off rate does not exceed the level established during the most recent performance test. The daily average exhaust coke burn-off rate limit established include:20,647 lbs./hr. set on Apnl24,2023. Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery The reporting of deviations in Tables I and,2 are based on compliance with the applicable coke burn-off rate. $60.105a(a) requires that each FCCU subject to a PM emission limit under 960.102a(b)(l) be compliant with the use of a continuous monitoring system (CMS) to verifu continuous compliance with the limits. $63.1572(c) contains additional, more stringent requirements for the continuous parametric monitoring system (CPMS) used to demonstrate compliance with the operating limits. Tesoro operates a FCCU that is controlled by an Electostatic Precipitator (ESP) and as such is required by $60.105a(b)(i) and $63. $6a@)Q) to monitor the total power input and secondary current from the ESP using a CPMS. A Wet Gas Scrubber (WGS) is installed downsheam of the ESP; therefore, Tesoro is also required by $60.1O5a(b)(ii) to monitor and record the hourly average pressure drop, liquid feed rate, and exhaust gas flow rate using CPMS. Tesoro is required to operate and maintain the CPMSs in accordance with 63.1572(c). $60.102a(c)(l)(i) requires FCCUs conholled by an ESP to maintain the 3-hour rolling average total power and secondary ctrrent above the level established during the most recent performance test. $60.102a(c)(2xi-ii) requires FCCUs contolled by a WGS to maintain the 3-hour rolling average pressure drop and liquid+o-gas ratio above the level established during the most recent performance test.. Upon result confirmation on April 24,2023, the following limits were established:o 0 kW Total Power to the ESPo 0 Amps Secondary Current to the ESPo 4.9 in HzO for WGS pressure drop across the tower o 62.9 gaU MSCF for WGS liquid-to-gas ratio, all applicable on a 3-hr rolling average. Tesoro is continuously monitoring these parameters using CPMSs to confirm compliance with the PM limit. The reporting of deviations in Tables 4 through 11 is based on these parametric limits. Per 40 CFR 63.1575(eX12), this report should also include "the date of last certification of audit for the continuous opacity monitoring system or continuous emissions monitoring system." This information is addressed in Section 7 (MACT Subpart UUU Periodic Report Requirements; Information Submitted in Other Regulatory Reports) of this report. Tesoro utilizes the WGS to comply with opacity requirements and does not operate a continuous opacity monitoring system. Tesoro's deviation and monitoring report information for this source is located in the periodic report tables identified in the matrix listed below. These tables are located at the end of this document. Refinery MACT II - Periodic Report Tesoro Refrning & Marketing Company, LLC, Salt Lake City Refinery Emission Limitation Deviations Report Table # Continuous Compliance I)emonstration Monitoring Renort Table # 20,647 lb/hr FCCU catalyst regenerator coke burn rate for metallic HAPs Table I Continuously monitor FCCU catalyst regenerator coke bum rate for metallic HAPs Table 2 500 ppm ofCO on a dry l-hour average basis for organic HAPs Table 3 CO emissions from the CO boiler on the FCCU catalyst regenerator, measured at the WGS. See Section 7 0 kW Total Power to ESP for 3-hour rolling averase basis Table 4 Continuously monitor the total power to the ESP usins a CPMS. Table 5 0 Amps Secondary Current from ESP for 3-hour rolling average basis Table 6 Continuously monitor the secondary current from the ESP using a CPMS. Table 7 4.9 inches H2O Total Pressure Drop at WGS for 3-hour rollins averase basis Table 8 Continuously monitor the total differential pressure across the WGS column usins a CPMS. Table 9 62.9 gal MSCF Total Liquidto-Gas Ratio at WGS for 3-hour rolline averase basis Table l0 Continuously monitor WGS exhaust air flow rate and total liquid to the column usine CPMS. Table I I Reformer Periodic Report Requirements - 40 CFR 63.1575(d) and (e) The Ultraformer Unitr (UFU) catalyst reformer at Tesoro's Salt Lake City Refinery uses a flare to confiol organic IIAP emissions and a fxed bed adsorber to control inorganic HAP emissions. Tesoro's continuous compliance demonstration requirements for the UFU are specified in Subpart UUU Table 21, Option 1 and Table 28, Option 4. Tesoro's deviation and monitoring information for this source is located in the periodic report tables identified in the matrix listed below. These tables are located at the end of this document. Emission Limitation and Ooeratins Limit Deviations Report Table # Continuous Compliance Demonstration Monitoring Report Table # Flare pilot light must be present at all times and flare must be operatins at all times Table 12 Tesoro monitors for the presence of a flame at the pilot light using an optical sensor (ultraviolet). Table 13 that emissions may be vented to it Fixed bed adsorber HCI concentration <9ppm Table 14 The concentration of HCI in the adsorber is tested manually using colorimetric tubes. Measurements are taken once per week or during each regeneration cycle whichever is less freouent. Table 15 Fixed Bed Adsorber daily average temperature < 238oF Table 16 Continuously monitor the fixed bed adsorber operating temperature usins a CPMS. Table 17 Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery I T"be Catalytic Reforming Unit defined in MACT UUU 63.1579 is what Tesoro Salt Lake City refers to as the Ultraformer Unit. 4. SRU Periodic Report Requirements - 40 CFR 63.1575(d) and (e) The Sulfur Recovery Unit (SRU) at Tesoro's Salt Lake City Refinery has an incinerator for control of reduced sulfur HAPs. Tesoro's continuous compliance demonstration requirements for the SRU are specified in Subpart UUU Table 35, ltem 3, Option 2. Tesoro uses CPMS to monitor incinerator temperature and oxygen content for its compliance demonstration in accordance with 63.1572(c). During periods of startup or shutdown, Tesoro complies with 63. 1 5 68(a)(a)(i). Tesoro's deviation and monitoring report information for this source is located in the periodic report tables identified in the matrix listed below. These tables are located at the end of this document. Operating Limits Deviations Report Table # Continuous Compliance Demonstration Monitoring Report Table # SRU lncinerator daily average temperature > 1075"F Table 18 Continuously monitor the SRU Incinerator operating temperature usins a CPMS. Table 19 SRU Incinerator daily average oxygen (Oz) concentration > l.sYo Table 20 Continuously monitor the SRU Incinerator oxygen (Oz) concentration using a CPMS. See Section 7 Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery 5. Control Equipment Bypass Route Periodic Report Requirements - 40 CFR 63.1575(d) and (e) Tesoro's Salt Lake City Refinery has tlree control equipment bypass routes. One bypass route is located at the FCCU and trvo are located at the UFU. Tesoro continuously monitors the FCCU blpass with two temperature indicators in the bypass seal tank (Tll20246.pv and Tll20245.pv) and two nozzle position tags (H 1 00445.OP and H 1 00 446.OP). Tesoro's continuous compliance demonstration requirements for the FCCU blpass route are specified in Subpart UUU Table 39, Option 1. The first bypass route at the Ultraformer Unit catalyst regeneration system bypasses the V-15 HCI fixed bed adsorption system. Tesoro inspects the car-seal system installed on the bypass valve to ensure it remains closed. Tesoro's continuous compliance demonstration requirements for the UFU bypass route are specified in Subpart UUU Table 39, Option 2. The UFU catalyst reformer system also has a bypass of the flare when venting non- contaminated inert purge gas to atrnosphere through bypass valve HC-61. Tesoro operates continuous electronic valve position monitors (HC032062.PV and HC032061.PV) on the bypass valve to make sure the valves are not opened to atmosphere, except to vent inert gas. Tesoro's continuous compliance demonstration requirements for this bypass route are specified in Subpart LIfU, Table 39, Option 1. Tesoro's deviation and monitoring report information for these soruces is located in the periodic report tables identified in the matrix listed below. These tables are located at the end of this document. Emission Limitation Deviations Report Table # Continuous Compliance Demonstration Monitoring Report Table # FCCU Control Equipment Bypasses Table 2l Continuously monitor the temperature &nozzle positions in the bwass seal tank Table22 UFU HCI Adsorber Bvoasses Table23 lnspect the lock or car seal once oer month Table24 UFU South Flare Bvoasses Table 25 Continuously monitor the bypass valve position Table26 6. Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery Periodic Report Performance Test Reporting Requirements-40 CFR 63. I 575(f) A Method 5 Emissions Performance Test was performed to establish a new daily average exhaust coke burn-off rate limit in the first half of 2023 and compliance with the operational parametric limits established during this test are detailed in this report. Information Submitted in Other Regulatory Reports-40 CFR 63.1575(9) Pursuant to 40 CFR 63.1575(9) reports required by other regulations may be submitted in place of or as part of the compliance report if they contain the required information. Tesoro submits a quarterly State Electronic Data Report (SEDR) pursuant to Utah Air Quality Rules 307-170. The SEDR will take the place of the following MACT Subpart UUU reporting requirements : 63. I 575(dX3) Information on the number, duration, and cause for monitor downtime incidents (including un-lmown cause, if applicable, other than downt:me associated with zero and span and other daily calibration checks). 63. I 575(e)(2) The date and time that each continuous opaciry monitoring system or continuous emission monitoring system was inoperative, except for zero (low-level) and high-level checks. 63. I 575(e) (3) The date and time that each continuous opacity monitoring system or continuous emission monitoring system was out-of-control, including the information in $63.8(c)(8). 63.1575(e) (7) A summary of the total duration of downtime for the continuous opacity monitoring system or continuous emission monitoring system during the reporting period (recorded in minutes for opacity and hours for gases and in the averaging time specified in the regulation for other types of standards), and the total duration of dowutime for the continuous opacity monitoring system or continuous emission monitoring system as a percent of the total source operating time during that reporting period. 63.1575(e) (8) A breakdown ofthe total duration ofdowntimc for the continuous opacity monitoring system or continuous emission monitoring system during the reporting period into periods that are due to monitoring equipment malfunctions, non-monitoring equipment malfi,rnctions, quality assurance/quality control calibrations, other known causes, and other unlcrown causes. 63.1575(e) (l l) The monitoring equipment manufacturer(s) and model number(s). 63.1575(e) (12) The date ofthe latest certification or audit for the continuous opacity monitoring system or continuous emission monitoring system. The above information will be reported in the SEDR for the following Subpart UUU affected soruces and monitoring equipment: Affected Source CEMs/CPMS HAP Monitored 7. FCCU ESPAI/GS SRU CEMs CPMS Organic HAP (CO/O, Reduced Sultur HAP (Oz) Refinery MACT II - Periodic Report Tesoro Refining & Marketing Company, LLC, Salt Lake City Refinery Tesoro submits a semi-ulnnrnl MACT CC periodic report pursuant to 40 CFR 63.655(e)(1 1)(i) - (iv). (i) Records as specified in paragraph (iX9XD of this section for each l5-minurc block during which there was at least one minute when regulated material is routed to a flare and no pilot flame is present. (ii) Visible emission records as specified in paragraph (i)(gXiD(C) of this section for each period of 2 consecutive hours during which visible emissions exceeded a total of 5 minutes. (iii) The l5-minute block periods for which the applicable operating limits specified in $ 63.670(d) through (f) are not met. lndicate the date and time for the period, the nct heating valuc operating parameter(s) determined following the methods in $ 63.670(k) through (n) as applicable. (iv) For flaring events meeting the criteria in $ 63.670(o)(3): (A) The start and stop time and date of the flaring event. (B) The length of time for which emissions were visible from the flare during the event. (C) The periods of time that the flare tip velocity exceeds the maximum flare tip velocity determined using the methods in $ 63.670(dX2) and the maximum lS-minute block average flare tip velocity recorded during the event. @) Results of the root cause and corrective actions analysis completed during the reporting period, including the corrective actions implemented during the reporting period and, if applicable, the implonentation schedulc for planned corrective actions to be implernented subsequent to the reporting period. 8. Reserved - 40 CFR 63.1575(h) ln accordance with 63.1575(h), this requirement is reserved. This section serves as a placeholder to align with the regulation and is intentionally blank. Multiple FCCUs Venting to a Single WGS - 40 CFR 63.1s7s(i)&CI) Not Applicable. Tesoro's Salt Lake City refinery does not operate multiple fluid catalytic cracking units vented to a single wet scrubber (WGS). Therefore, these requirements are not applicable. 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