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Home My WebLink AboutDAQ-2025-002273 1 DAQC-404-25 Site ID 10008 (B5) MEMORANDUM TO: FILE – NUCOR STEEL THROUGH: Harold Burge, Major Source Compliance Section Manager FROM: Rob Leishman, Environmental Scientist DATE: April 28, 2025 SUBJECT: Nucor Bar Mill Group – Plymouth Division, NSPS, Title V, Box Elder County, FRS # UT00000049000300002 INSPECTION TYPE: State Electronic Data Report (SEDR) Review REVIEW DATE: April 28, 2025 SOURCE LOCATION: Plymouth/Box Elder County SOURCE CONTACT: Kyndal Bair 435-458-2496 APPLICABLE REGULATIONS: Title V Operating Permit Permit Number: 300002004 Date of Permit: May 23, 2022 Date of Last Revision: September 12, 2024 SOURCE REVIEW EVALUATION: 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 Nucor Steel’s relative accuracy performance specification test review memorandum. SEDR Review: First Quarter 2025 % 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 Baghouse Stack 1888 CO 100% 02/14/25 09/06/24 Baghouse Stack CO 0.00 1200 lbs/hr - 1 hr average 1 8 2 2 First Quarter 2025 % 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 Baghouse Stack 1888 NOx 100% 02/14/25 09/06/24 Baghouse Stack CO 0.00 682.93 lb/hr - 8 hr average Baghouse Stack 1888 SO2 100% 02/14/25 09/06/24 Baghouse Stack CO 0.00 2800 tons/yr - rolling 12- month total Baghouse Stack NOx 0.00 245 tons/yr - rolling 12- month total Baghouse Stack NOx 0.00 59.5 lb/hr - calendar-day average (State Only) Baghouse Stack SO2 0.00 93.98 lb/hr - 3 hr rolling average Baghouse Stack SO2 0.00 89 lb/hr - 24 hr average Baghouse Stack SO2 0.00 245 tons/yr - rolling 12- month total Excess Emission Report - Hourly Summary Point Source Channel Startup & Shutdown Control Equipment Problems Process Problems Other Known Causes Unknown Causes Emission Limit Baghouse Stack CO 0 0 0 0 0 1200 lbs/hr - 1 hr average Baghouse Stack CO 0 0 0 0 0 682.93 lb/hr - 8 hr average Baghouse Stack CO 0 0 0 0 0 2800 tons/yr - rolling 12- month total Baghouse Stack NOx 0 0 0 0 0 245 tons/yr - rolling 12- month total Baghouse Stack NOx 0 0 0 0 0 59.5 lb/hr - calendar-day average (State Only) Baghouse Stack SO2 0 0 0 0 0 93.98 lb/hr - 3 hr rolling average Baghouse Stack SO2 0 0 0 0 0 89 lb/hr - 24 hr average Baghouse Stack SO2 0 0 0 0 0 245 tons/yr - rolling 12- month total 3 CMS Performance Summary - Hourly Summary Point Source Channel Monitor Malfunction Non-monitor Malfunction QA Calibrations Other Known Causes Unknown Causes Baghouse Stack CO 0 0 0 0 0 Baghouse Stack NOx 0 0 0 0 0 Baghouse Stack SO2 0 0 0 0 0 Pollutant Concentration Exceeded Span of CEM Monitor Outage During Point Source Operation Alternate Sampling CEM Modifications 0 Hours 0 Hours 0 Hours 0 Events SOURCE INSPECTION SUMMARY EVALUATION: Nucor Steel maintains its CEMS as required in R307-170 and 40 CFR 60.13. CURRENT RECOMMENDATIONS: All deviations appear to be a result of breakdown or process related problems that do not warrant issuing a violation. Nucor Steel was in compliance during this reporting period. No further enforcement actions should be taken. Nucor Steel’s NSPS monitoring system meets the performance standards of 40 CFR 60, Appendix B Performance Specifications. Duplicate monitoring systems and offset calibration times have resulted in monitor unavailability at or near zero hours. 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: Spreadsheet Review. Nucor Steel EER 1Q2025 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 Adam Zewe 00300002 435-458-2415 Doug Jones 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 2025 1888 1 110 0 0 0 1 110 0 0 0 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 CO Ecochem MC3 512 0 1000 3/20/2013 STACK 1 200 NOx Ecochem MC3 512 0 250 3/20/2013 STACK 1 200 SO2 Ecochem MC3 512 0 50 3/20/2013 STACK 1 200 CO Thermo Scientific 48iQ-CAN 1181830035 0 1000 12/14/2018 STACK 1 200 NOx Thermo Scientific 42iQLS-ACBNA 1181830033 0 250 12/14/2018 STACK 1 200 SO2 Thermo Scientific 43iQ-CAN 1181830034 0 50 12/14/2018 STACK 1 200 0 0 0 0 0 0 1/0/1900 0 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 CO 0 0.00% 0 0 0 0 0 1200 lbs/hr 1 hr average 1 TRUE 310 CO 0 0.00% 0 0 0 0 0 682.93 lb/hr 8 hr average 1 TRUE 310 CO 0 0.00% 0 0 0 0 0 2800 tons/yr rolling 12 month total 1 TRUE 310 NOx 0 0.00% 0 0 0 0 0 245 tons/yr rolling 12 month total 1 TRUE 310 NOx 0 0.00% 0 0 0 0 0 59.5 lb/hr calendar-day average (State Only) 1 TRUE 310 SO2 0 0.00% 0 0 0 0 0 93.98 lb/hr 3 hr rolling average 1 TRUE 310 SO2 0 0.00% 0 0 0 0 0 89 lb/hr 24 hr average 1 TRUE 310 SO2 0 0.00% 0 0 0 0 0 245 tons/yr rolling 12 month total 1 310 0 0 0 0 0 0 0 0 0 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 CO 1888 0.00% 0 0 0 0 0 0 1 TRUE 300 NOx 1888 0.00% 0 0 0 0 0 0 1 TRUE 300 SO2 1888 0.00% 0 0 0 0 0 0 1 300 0 0 0 0 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 1 396 Days 250 CO 09/06/24 08/07/23 13 lbs/hr 208.5 211.3 77.00% Pass 1 396 Days 250 NOx 09/06/24 08/07/23 13 lbs/hr 40.9 40.1 754.00% Pass 1 396 Days 250 SO2 09/06/24 08/07/23 13 lbs/hr 43.9 43.8 724.00% Pass 1 396 Days 250 CO 09/06/24 08/07/23 13 lbs/hr 231.1 211.3 208.00% Pass 1 396 Days 250 NOx 09/06/24 08/07/23 13 lbs/hr 35.8 35.2 540.00% Pass 1 396 Days 250 SO2 09/06/24 08/07/23 13 lbs/hr 44.3 44.3 795.00% Pass 1 0 Days 250 0 01/00/00 01/00/00 0 0 0 0 0.00% 0 1 0 Days 250 0 01/00/00 01/00/00 0 0 0 0 0.00% 0 Point Source Point Source Point Source Baghouse Stack 0 0 0 0 Baghouse Stack Baghouse Stack Baghouse Stack 0 0 Baghouse Stack Baghouse Stack Baghouse Stack Nucor Steel 0 Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack 0 0 Baghouse Stack Baghouse Stack Baghouse Stack 0 0 Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Nucor Steel EER 1Q2025 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 CO 02/14/25 1 EB0142277 02/08/27 P1 ppm 243.1 249 590.00% pass low 1 Valid Cal. Gas 260 CO 02/14/25 2 EB0085547 05/17/26 P1 ppm 544.567 544.3 26.70% pass high 1 Valid Cal. Gas 260 NOx 02/14/25 1 EB0142277 02/08/27 P1 ppm 64.7 63.8 90.00% pass low 1 Valid Cal. Gas 260 NOx 02/14/25 2 EB0085547 05/17/26 P1 ppm 140.467 136.5 396.70% pass high 1 Valid Cal. Gas 260 SO2 02/14/25 1 EB0142277 02/08/27 P1 ppm 13.5 12.7 80.00% pass low 1 Valid Cal. Gas 260 SO2 02/14/25 2 EB0085547 05/17/26 P1 ppm 26.933 27.8 86.70% pass high 1 Valid Cal. Gas 260 CO 02/14/25 1 EB0142277 02/08/27 P1 ppm 241.467 249 753.30% pass low 1 Valid Cal. Gas 260 CO 02/14/25 2 EB0085547 05/17/26 P1 ppm 531.733 544.3 1256.70% pass high 1 Valid Cal. Gas 260 NOx 02/14/25 1 EB0142277 02/08/27 P1 ppm 65.633 63.8 183.30% pass low 1 Valid Cal. Gas 260 NOx 02/14/25 2 EB0085547 05/17/26 P1 ppm 138.5 136.5 200.00% pass high 1 Valid Cal. Gas 260 SO2 02/14/25 1 EB0142277 02/08/27 P1 ppm 12.8 12.7 10.00% pass low 1 Valid Cal. Gas 260 SO2 02/14/25 2 EB0085547 05/17/26 P1 ppm 25.167 27.8 263.30% pass high 1 260 0 01/00/00 0 0 01/00/00 0 0 0 0 0.00% 0 0 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 1 270 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 0 210 0 1/0/00 0:00 1/0/00 0:00 1 1 None Reported 1 0 TC 220 Hours 0.00 TC 220 Hours 0.00 TC 230 Hours 0.00 Events 0.00 Hours 0.00 Events 0.00 0.00 1 0.00 TC 300 Hours 0.00 TRUE None Reported None Reported None Reported None Reported None Reported None Reported Point Source Point Source Point Source None Reported Baghouse Stack Baghouse Stack Baghouse Stack 0 Baghouse Stack Baghouse Stack 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) Baghouse Stack Baghouse Stack 0 Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack Baghouse Stack 0 0 0 Nucor Steel EER 1Q2025 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 Baghouse Stack CO 09/06/24 08/07/23 13 lbs/hr 208.5 211.30 77.00% Pass Baghouse Stack NOx 09/06/24 08/07/23 13 lbs/hr 40.9 40.10 754.00% Pass Baghouse Stack SO2 09/06/24 08/07/23 13 lbs/hr 43.9 43.80 724.00% Pass Baghouse Stack CO 09/06/24 08/07/23 13 lbs/hr 231.1 211.30 208.00% Pass Baghouse Stack NOx 09/06/24 08/07/23 13 lbs/hr 35.8 35.20 540.00% Pass Baghouse Stack SO2 09/06/24 08/07/23 13 lbs/hr 44.3 44.30 795.00% Pass * NSPS CGA First 2025 Audit Gas Ranges Audit Gas Ranges AP1 Low AP2 Low AP1 High AP2 High Baghouse Stack CO 2/14/25 1000 249 200 to 300 Baghouse Stack CO 2/14/25 1000 544.3 500 to 600 Baghouse Stack NOx 2/14/25 250 63.8 50 to 75 Baghouse Stack NOx 2/14/25 250 136.5 125 to 150 Baghouse Stack SO2 2/14/25 50 12.7 10 to 15 Baghouse Stack SO2 2/14/25 50 27.8 25 to 30 Baghouse Stack CO 2/14/25 1000 249 200 to 300 Baghouse Stack CO 2/14/25 1000 544.3 500 to 600 Baghouse Stack NOx 2/14/25 250 63.8 50 to 75 Baghouse Stack NOx 2/14/25 250 136.5 125 to 150 Baghouse Stack SO2 2/14/25 50 12.7 10 to 15 Baghouse Stack SO2 2/14/25 50 27.8 25 to 30 Point Source Channel Audit Date Low Span Audit Gas Used High Span Audit Gas Used Nucor Steel EER 1Q2025 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 Nucor Steel EER 1Q2025 Type Code 220 (Monitor Outage During Point Source Operation) - 600 (All) * Sum of Hours Column Labels Row Labels (blank) Grand Total (blank) (blank) 0 0 Grand Total 0 0 Nucor Steel EER 1Q2025 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 NOx d * NOx d Type Code 421 (Daily NOx Emissions) - 500 (All) NOx d * NOx d Count of Reason Code Column Labels NOx d Row Labels Grand Total NOx d 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 Nucor Steel EER 1Q2025 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