Region 5 Enforcement Approach

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Region 5 Enforcement Approach

George CzerniakJune 13, 2007

NACAA Enforcement and

Compliance Workshop

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TARGETED INVESTIGATIONS

• Don’t Try for Broad Coverage• Don’t Affirm Compliance• High Likelihood of Violation Where

Correction Will Result in Significant Emission Reduction

• Focus on Company, Sector, Rule

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CASE DISTRIBUTION

Referrals to DOJ in FY 2000

SIP/FIP39%

AIR TOXICS (HAPS)

10%

PSD/NSR33%

NSPS10%

CFC6%

TITLE V2%

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CASE DISTRIBUTION

Referrals to DOJ in FY 2003

SIP/FIP6%AIR TOXICS

(HAPS)2%

PSD/NSR7%

CFC83%

TITLE V2%

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CASE DISTRIBUTION

Referrals to DOJ in FY 2006

SIP/FIP24%

AIR TOXICS (HAPS)

20%

PSD/NSR6%

NSPS7%

FESOP1%

CFC13%

TITLE V29%

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ENVIRONMENTAL BENEFIT FROM FY 2006 CAA SETTLEMENTS

• Primary Environmental Benefit– Emission Reductions (142,942,912 lbs/yr)

• 98,828,033 lbs/yr Sulfur Dioxide• 13,628,951 lbs/yr Nitrogen Oxides• 10,468,625 lbs/yr Volatile Organic Compounds• 9,574,790 lbs/yr Carbon Monoxide• 6,946,758 lbs/yr Carbon Dioxide• 2,326,870 lbs/yr PM10 /Particulate Matter• 1,158,218 lbs/yr Hazardous Air Pollutants• 8,588 lbs/yr Chlorofluorocarbons• 2,079 lbs/yr Lead

– Federal Penalties Assessed - $4,512,447

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PORTION OF ENVIRONMENTAL BENEFIT IN SUPPLEMENTAL ENVIRONMENTAL PROJECTS

– SEP Emission Reductions (11,667,767 lbs/yr)• 6,946,758 lbs/yr Carbon Dioxide• 4,071,210 lbs/yr Carbon Monoxide• 240,033 lbs/yr Sulfur Dioxide• 233,398 lbs/yr Hazardous Air Pollutants• 130,748 lbs/yr PM10 /Particulate Matter• 26,951 lbs/yr Nitrogen Oxides• 15,425 lbs/yr Volatile Organic Compounds• 2,079 lbs/yr Lead• 1,165 lbs/yr Chlorofluorocarbons

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TARGETING APPROACH

Theory of Violation

Develop Expertise

Work Through Company, Sector, Rule

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TARGETING EXAMPLES

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ACID PRODUCTION

THEORY:NSR

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ACID PRODUCTION PLANT DIAGRAM

DryingTower

Sulfur Burner

Air Blower

Converter

AbsorbingTower

Replaced 1986

Replaced 1994Demister

Oleum Tower

Economizer

PumpTankReplaced 1992 Pump

Tank

StackReplaced 1992

WasteHeatBoiler

WasteHeatBoiler

Steam Turbine

Air

PumpTank

CEM

Replaced 1992

95%-99%H2SO4

Oleum

Sulfur

93% Acid

Replaced 1996

Replaced 1993

Replaced 1989

Replaced 1989

Control Room

Replaced 1992

Sulfur Controler

Replaced 1992

Waste WaterDischargeReplaced 1992

Water WellsReplaced 1989

AbsorbingTowerCooler

Replaced 1986

Replaced 1985Replaced 1989

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ACID PRODUCTION

• Remedy– Sulfuric Acid Plants

• Wet Gas Scrubber• Double Contact Double Absorption System

Capable of Meeting an Emissions Limit of 1.5 lbs/ton

• Mist Elimination System Capable of Meeting Sulfuric Acid Mist Emission Rates of 0.15 lbs/ton or less

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ACID PRODUCTION

• Remedy (cont.)– Nitric Acid Plants

• Selective Catalytic Reduction (SCR)• Non-Selective Catalytic Reduction (NSCR), and/or• Extended Absorption System• Capable of Meeting NOx Emission Limits in the

Range of 0.3 to 0.6 lbs/ton

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ACID PRODUCTION

• Potential Environmental Results– 120,000 TPY of SO2

– 30,000 TPY of NOx• Current Status

– Two (2) Settlements• 6 Sulfuric Acid Plants• 1 Nitric Acid Plant

– Reductions:• 19,000 TPY SO2

• 200 TPY NOx• Sulfuric Acid Mist Reductions

– Settlement discussions continue with others

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PETROLEUM COKE

THEORY:NSR

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PETROLEUM COKE

• Affected Sectors– Cement– Iron and Steel– Coal Fired Boilers– Calcining

• Remedy – SO2 (Scrubbers) – NOx (SCR and SNCR) Controls

• Potential National Environmental Results– 160,000 TPY SO2 and NOx Reductions

• Current Status– One Global Negotiation in Progress, One On-going

Case, Two Investigations

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FLARING

THEORY:LESS SCRUTINY

FOCUS ON OPACITY

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FLARING

• Proper Operation– Pilot flame must be present– Sufficiently low exit velocity– Smokeless operation

• Steam or air commensurate with organics– Heat Content > (300 BTU/scf)

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FLARING

• Regulations – MACT

• General provisions 63.11(b)• Polymers & Resins, HON, Pharmaceuticals,

Refineries, etc.– NSPS

• General Provisions 60.18(b)• SOCMI, Polymers, Refineries, etc.

– SIP• State VOC reduction requirements• State permit requirements (e.g. 300 BTU)

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FLARING

• Violations– Heat Content lower than 300 BTU/scf

(63.11(b), 60.18(b))– Failure to use good air pollution control

practices by steam addition in excess of design parameters (63.6(e), 60.11(d))

• Specified by API and Flare Manufacturer• Typically near 1 lb steam/1 lb gas

– Destruction Efficiency Specified in SIP (95%)

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FLARING

• Remedy– Heat Content (BTU/scf) Instrument– Steam Addition Control Valve– Natural Gas Addition Control Valve– PLC So Heat Content Dictates Steam and

Natural Gas Addition Rates• Potential Environmental Benefits

– Increase In Destruction Efficiency at the Flare– Less VOC and HAPs Emissions

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FLARING

• Current Status– Batch Chemical Plant in SW Ohio

• 300 BTU/scf and oversteaming violations• NOV issued• > 560 TPY excess emissions

– Batch Chemical Plant in NW Ohio• 300 BTU/scf and oversteaming violations• NOV issued • ~ 12 TPY excess emissions

– Batch Chemical Plant in SE Ohio• $675,000 instrument upgrade for two flares in response to an

information request • < 5 TPY excess emissions

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CEM

THEORY:WRONG PERCEPTIONS

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Region 5 Percent Non-Exempt Excess Emissions (%) 2004-2005, SO2

Utilities

63892%

81%

30%

10%

91%

275%

30%

20%

51%3

0%

No Exceedances

0.01 - 0.19%

0.2 - 0.39%

0.4 - 0.59%

0.6 - 0.79%

0.8 - 0.99%

1 - 1.99%

2 - 2.99%

3 - 4.99%

>= 5%

CEM

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Region 5 Percent Non-Exempt Excess Emissions (%) 2004-2005, Opacity

Utilities

45130%

56638%

15811%

1369%

332%

705%

272%

262%

121% 3

0% No Exceedances

0.01 - 0.19%

0.2 - 0.39%

0.4 - 0.59%

0.6 - 0.79%

0.8 - 0.99%

1 - 1.99%

2 - 2.99%

3 - 4.99%

>= 5%

CEM

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Region 5 Percent Non-Exempt Excess Emissions (%) 2004-2005, SO2

Non-Utilities

44589%

112%

61%

61%

61%

71%

20%

31%

133%

31%

No Exceedances

0.01 - 0.19%

0.2 - 0.39%

0.4 - 0.59%

0.6 - 0.79%

0.8 - 0.99%

1 - 1.99%

2 - 2.99%

3 - 4.99%

>= 5%

CEM

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Region 5 Percent Non-Exempt Excess Emissions (%) 2004-2005, Opacity

Non-Utilities

54130%

1347%

563%

221%

92451%

261%58

3%

271%

241% 30

2% No Exceedances

0.01 - 0.19%

0.2 - 0.39%

0.4 - 0.59%

0.6 - 0.79%

0.8 - 0.99%

1 - 1.99%

2 - 2.99%

3 - 4.99%

>= 5%

CEM

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CEM

• Remedy– Continuous compliance– Fixing causes of excess emissions/CEMS downtime so

they don't happen again– Injunctive relief (redesigned/new control technology to

replace old/underdesigned controls)– SEPS

• Current Status– Seven Notices/Findings of Violation– ~ 100 Facilities Being Reviewed

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QUESTIONS