United States of America v. Maynard Steel Casting Company

Filing 11

CONSENT DECREE signed by Magistrate Judge William E Duffin on 5/30/2017. Within 30 days after the Effective Date of this Consent Decree, Defendant shall pay the first of 5 consecutive monthly sums of $5,000 each, as a civil penalty, together wit h interest accruing from the date on which this Consent Decree is lodged with the Court, at the rate specified in 28 USC § 1961 as of the date of lodging. The parties shall bear their own costs, including attorneys' fees, except that the Uni ted States shall be entitled to collect the costs (including attorneys' fees) incurred in any action necessary to collect any portion of the civil penalty or any stipulated penalties due but not paid by Defendant. The Court shall retain jurisdic tion over this case until termination of this Consent Decree. This Consent Decree shall constitute a final judgment of the Court. See Consent Decree for additional details. (Attachments: # 1 Appendix A - EAF Fume Collection System Study, # 2 Ap pendix B - Maynard Steel Casting Company Operation & Maintenance Plan and Malfunction Prevention & Abatement Plan, # 3 Appendix C - Electric Arc Furnace - Outdoor Fugitive Emissions Opacity Monitoring Protocol, # 4 Appendix D - Maynard Steel Documents Used for Civil Penalty Ability-to-Pay Analysis, # 5 Appendix E - Diagram of RCRA Containment Structure) (cc: all counsel)(lz)

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Consent Decree in United States of America v. Maynard Steel Casting Co. (E.D. Wis.) Appendix A EAF Fume Collection System Study Consent Decree in United States of America v. Maynard Steel Casting Co. (E.D. Wis.) Appendix A EAF Fume Collection System Study 1.0 Purpose The purpose of this Fume Collection System (FCS) study (the Study) is to generate sufficient data to evaluate the capacity of the FCS on each of Maynard’s electric arc furnaces (EAF) to capture and control the maximum emissions of particulate matter (PM) that could reasonably be generated during a single heat. Maynard Steel Casting Company (Maynard Steel) will be conducting this Study in accordance with the terms of a Consent Decree between the United States and Maynard Steel. 1.1 Metal Melting and Oxygen Lancing Emissions During the initial stages of a heat, the electrical arcing that takes place between the electrodes and the scrap metal heats the air inside the furnace. The heated air creates buoyant forces beneath the furnace cover, which causes hot air containing particulate matter to escape the furnace through the annular spaces between the electrodes and the furnace cover. The volume of hot exhaust during the initial stages of a heat depends on the duration and magnitude of electrical arcing, which varies heat to heat. Later in the heat, oxygen lancing is typically employed to melt down bridging of scrap and to assist in drawing all of the scrap into the molten bath. The compressed oxygen used during oxygen lancing substantially expands as oxygen forcefully contacts hot metal scrap and the furnace walls, which increases both the air temperature inside the furnace and the thermal-driven exhaust rate through the annular openings in the furnace cover. Again, the volume of exhaust gases, and the mass and concentration of particulate matter, among other pollutants, depends on the duration and intensity of the oxygen pressure, which varies from heat to heat. Once the scrap has become molten, the metal bath is typically refined. This entails employing oxygen lancing at a pressure higher than is used during the melt down activity discussed above. This high pressure oxygen lancing (i.e., refining) creates a boiling effect and promotes chemical reactions within the molten metal. This condition typically creates the highest buildup rate of thermal energy in the furnace air environment throughout the entire heat and, consequently, is expected to result in the highest instantaneous exhaust rate (i.e., volume of air per unit of time) from the furnace. Because the duration of oxygen lancing during refining varies from heat to heat, the instantaneous exhaust rate of gases and also the PM mass and concentration in the gases also varies from heat to heat. A-1 Each of the side-draft hoods on EAF Nos. 5, 6, and 7 function similar to one another. Because of its own thermal buoyancy, the furnace exhaust with entrained emissions rises within the furnace up through the annular spaces between the electrodes and the furnace cover. There, continuous suction created by a fan draws the furnace exhaust into the ventilation system using a side-draft hood. Suction is maintained during furnace tiling via a telescoping duct. A strong suction is needed to turn the thermally rising air from vertical to horizontal and to direct the plume into the local exhaust ventilation system. The air leaving the furnace is replaced primarily by air drawn in through the open slag door and pour spout. Because the ventilation system is operated at a single fan speed setting, exhaust must be continuously applied throughout the entire heat at the minimum airflow rate that is capable of effectively capturing the maximum emissions generated during the refining phase. The FCS associated with EAF No. 4 utilizes direct draw above the melting surface of the furnace at the annular spaces between the three melting electrodes and the roof on EAF No. 4 (the delta section), and routes emissions to a baghouse. There is currently no telescoping duct associated with the EAF No. 4, and EAF No.4 is currently not in operation. Maynard will repair the existing FCS prior to restarting EAF 4 operations as provided under the Consent Decree. Within one year of exceeding 12-heats on EAF No. 4 in a rolling 12-month period, Maynard will install a telescoping duct similar to those in place at EAF Nos. 5, 6 and 7 and will conduct this Study at EAF No. 4. 1.2 Ventilation Control and Monitoring of Melting Emissions Each of the exhaust systems, except as otherwise noted above for EAF No. 4, is essentially a single source system - i.e., there is only one exhaust hood, one trunk duct (with articulation to assure continuous attachment to the capture hood during furnace tilting), one air filtering chamber (baghouse), one suction fan, and one discharge stack. Maynard’s exhaust fans are not constant airflow rate devices; rather the fans’ airflow rates reduce as the need for suction draw (i.e., fan static pressure) increases. Thus, exhaust rate and fan static pressure are inversely related. These suction fans operate at a single speed setting, drawing airflow at a static pressure that is dictated by both the configuration (and the extent to which the ducts are maintained in proper repair and cleanliness) of the ventilation system and the total differential pressure across the filters (baghouse). This Study will evaluate the system configuration’s effect on static pressure. The filter total differential pressure increases as collected material builds up on the filter media surfaces. Without adequately removing collected particulate matter from the filters (as by filter shaking), the filter total differential pressure will eventually build up such that the exhaust rate diminishes until emissions are no longer adequately captured by the local exhaust hood. A-2 In accordance with Maynard’s Operation & Maintenance / Malfunction Prevention & Abatement Plan (O&M Plan) (Consent Decree Appendix B), prior to commencing a heat, each baghouse will be cleaned to a starting filter total differential pressure that will be established by this Study for each baghouse. When necessary, this cleaning is accomplished by mechanically shaking the filter bags so that the collected particulate matter drops into a hopper. This type of bag cleaning will be performed offline. Cleaning is terminated at a target starting filter total differential pressure that will be set to assure sufficient filter thickness for efficient filtration (i.e., to achieve sufficient filter “cake”). The O&M Plan also requires that Maynard perform a second type of filter cleaning, terms on-line modular cleaning, to prevent rapid rise of filter total differential pressure during a heat. The filtering system for each furnace is constructed as a series of modules. In a filter cleaning sequence repeated continuously throughout the melting shift, each of the modules is sequentially dampered off-line and shaken to remove collected particulate matter, while the balance of the modules continue to operate with the fan on. The total differential pressure across the baghouse will increase during the melting shift as a cumulative effect of the emissions loading from the various heats. Such an increase in the total differential pressure will reduce the exhaust airflow rate at the local exhaust hood. To ensure adequate suction is continuously applied to the exhaust hood throughout the melting shift, the hood static pressure will be continuously measured. The hood static pressure serves as a surrogate indicator for the exhaust rate measurement. Hood static pressure has a direct, although non-linear, relationship to exhaust rate. Hood static pressure represents the suction level that the fan exerts in the ductwork at the transition from the capture hood (i.e., side-draft hood) to the ductwork system. Hood static pressure is created by two suction levels that are needed to create airflow into the hood: 1) the suction energy to accelerate room air to duct velocity; and 2) the suction energy to overcome the turbulence losses of air as it enters the hood and proceeds into the duct transition. Although the relationship of hood static pressure to hood exhaust rate is non-linear, it is direct and can be accurately calibrated as a surrogate for measuring hood exhaust flow rate. Maynard Steel will use monitoring instruments to continuously monitor the hood static pressure and the baghouse filter total differential pressure. Maynard Steel will employ preventative maintenance of the entire ventilation system to assure proper filtration performance of each baghouse per the O&M Plan. 2.0 Basis for EAF FCS Assessment This section of the Study identifies the specific measures that Maynard will implement to evaluate the capacity of its emissions capture system. This Study is targeted to assess each EAF’s local capture system. This local capture system extends from the collection hood at the furnace and corresponding duct to the exhaust stack of each baghouse. A-3 There are two critical components to this assessment: 1) maintaining adequate draw to capture the maximum emission rate from an EAF throughout a heat; and 2) effectively controlling the captured emissions to limit emissions released to the atmosphere. This Study is a performance-based assessment targeted to determine if the capture system (as defined above) has sufficient capacity to capture the emissions during the melting and refining phases. For this Study, there are three principal elements for determining capacity in the collection systems: 1. Minimum Required Draw and the Low-Low Set Point: The minimum required draw is the point at which EAF emissions begin to escape capture by the exhaust hood. Such challenges to the system are associated with increases in the volumetric rate of air emanating through the annular spaces around the electrodes that occur during oxygen lancing, as discussed in Section 1.1 of this Study. When oxygen is introduced, there is an increase in the volume of gas (due to the injection of oxygen) within an EAF that also increases the temperature of the atmosphere within the EAF above that which is associated with standard melting. The increase in temperature has an associated increase in thermal energy in the furnace air environment that, when combined with the added volume of oxygen, results in the highest instantaneous exhaust rate (i.e., volume of air per unit of time) from the furnace. Coincidentally, the maximum emission rate is expected to correspond to that which is experienced during oxygen lancing. The rate of oxygen introduction is highest when refining, which is typically performed at a higher pressure (100 pounds per square inch [PSI]) than at other times that oxygen lancing is performed (e.g., to assist in the melt down of metal bridging within a furnace). Consequently, the Low-Low Set Point corresponds to the minimum draw needed to effectively capture emissions while refining. Maintaining a minimum draw that corresponds to the Low-Low Set Point effectively provides capture for the lower emission rates that are expected throughout a heat outside of refining. Maynard shall determine the minimum required draw and the Low-Low Set Point based on hood static pressure measurements by decreasing the hood flow rate during one or more test heats and visually observing the hood static pressure at the point at which emissions begin to escape capture while refining at a minimum oxygen pressure of 100 pounds per square inch (PSI). Visual observation and video recordings will be used to document conditions that coincide with the Low-Low Set Point. Operation at or above this set point throughout an entire heat demonstrates that the system has the capacity to capture the maximum emissions. Visual and audible alarms will be programmed to sound on parametric monitoring panels serving each EAF baghouse to directly alert the operator, and e-mail alerts will be sent to key designated individuals alerting them that the Low-Low Set Point has been tripped so that appropriate actions can be implemented. A-4 2. Minimum Required Draw and the High-Low Set Point: As the heat progresses, the pressure drop across the baghouse tends to incrementally increase, which results in a corresponding decrease in hood static pressure. The operating span for the hood static pressure is the difference between the hood static pressure under optimal conditions (i.e., when the bags have been shaken to the extent practicable) prior to the start of a heat, minus the Low-Low Set Point that corresponds to the minimum hood static pressure required to maintain no visual emissions escaping capture from the start to the end of the test heats, as confirmed by both visual observation and video recordings. The High-Low Set Point is the hood static pressure at which the heat ends during normal operating conditions. A hood static pressure that drops below the High-Low Set Point will trigger an alarm. The difference between the High-Low and Low-Low Set Points may be considered a safety margin above minimum required draw as illustrated in Figure 1, below on page 5. 3. Minimal Initial Margin and the Low-High Set Point: Before emissions from the melting phase of a heat are generated, the FCS will be checked to ensure it has the capability to capture and collect all emissions generated during the heat. The hood static pressure before the heat should be high enough such that it does not drop below the High-Low Set Point during the heat. The pre-melt minimum target hood static pressure is the Low-High Set Point. The difference between the Low-High and High-Low Set Points is the “minimal initial margin,” as illustrated in Figure 1, below. 4. Maximum Emission Rate – Oxygen Lancing: Maynard shall maximize the oxygen lancing operating pressure and duration to the extent practicable during refining phase for all test heats, which should generate the maximum emission rate during that heat from that EAF. 5. Baghouse Performance - Effective Control of Captured Emissions: Prior to dampering the flow to determine the Low-Low Set Point for each FCS, Maynard shall do the following: 1) collect information to calculate the predicted fan performance for each FCS; 2) collect ventilation performance measurements (e.g., static pressure, airflow traverses, temperature and baghouse total differential pressure) to verify predicted fan performance; and then 3) compare the FCS’s predicted fan performance curve to that FCS’s actual fan performance. A-5 FIGURE 1. HOOD STATIC PRESSURE SET POINTS (IN-H2O) Low-High: Target for start of heat Initial Margin Adequate Margin 3.0 High-Low: Target end point of heat. ALARM Condition - Implement appropriate actions to ensure that hood static does not drop below Low-Low set point. Low-Low: No further melting except in accordance with O&M Plan. ALARM Condition - Implement appropriate actions to return hood static pressure above Low-Low set point. Protocol to Evaluate the EAF FCS The evaluation of the actual performance of each FCS during typical operations will be conducted in three phases: Phase 1 – Specification and Installation of Parametric Monitoring Systems Phase 2 – Evaluating Exhaust System Capability and Establishing Ventilation Performance Limits Phase 3 – Monitoring Ongoing Fume Control Performance During Production Melting Heats The following identifies the particulars for each of the three phases. Phase 1 – Specification and Installation of Continuous Parametric Monitoring Systems Maynard will develop and implement the following continuous parametric monitoring systems (CPMS) for the emissions capture system for both this Study and compliance A-6 with the Consent Decree: Parameter Hood Static Pressure Pressure Drop (by module) Total Pressure Drop Range Note 1 1 to 8 in-H2O (permitted) 1 to 8 in-H2O (permitted) Frequency of Measurement Method Continuously Pressure transducer Note 2 Magnehelic Gauge Continuously Diff. Pressure transducer Recorded Electronically Note 2 Electronically Notes 1. The low end of the range is planned to be es tablis hed for each EAF FCS by modulating the air flow and vis ually as s es s ing ca pture. 2. The pres s ure drop acros s each module will be us ed, as needed, for trouble-s hooting purpos es . During Phase 1 of this Study, these CPMS must be installed, calibrated, commissioned and operating continuously during a heat on each EAF before Phases 2.b and 3 can be undertaken at that EAF. The CPMS is required to implement specific phases of this Study to determine the exhaust system capability of each FCS and to establish performance limits for these ventilation systems. Preliminary specifications for these systems include (in part): Display panel and continuous data logging for each furnace will include: o Display of instantaneous hood static pressure and baghouse total differential pressure o Low-Low and High-Low visible and audible alarms for hood static pressure o High-High and Low-Low visible and audible alarms for total pressure drop across the baghouse. These Set Points indicate possible problems with the baghouse, including bag clogging, broken bags, etc. o Low-High and High-Low visible alarms for total pressure drop across the baghouse to allow operators to take appropriate actions before the pressure drop further approaches either the Low-Low or High-High Set Points Maynard Steel may elect to conduct additional parametric monitoring at various points along the FCS (elbows, duct expansions/reductions, etc.) to evaluate FCS performance during the course of this Study. These additional parametric monitors, however, are not intended to be permanent or be included as part of the CPMS requirements under the Consent Decree. Phase 2 – Confirming Exhaust System Capability and Establishing Ventilation Performance Limits Phase 1 must be completed before Phase 2 can be initiated. Phase 2 is divided into two parts, Phase 2A and Phase 2B. Note that the canopy hood associated with EAF No. 4 shall not operate during Phase 2B for EAF Nos. 5 and 6. A-7 A. Confirming Exhaust System Capability – Cold Work Phase 2A is called Cold Work because it is work that will be completed when the EAFs are not in use and the bag houses are shaken in preparation for a melting shift using off-line shaking and with on-line shaking shut-off (as described in Section 1.2). In Phase 2A, Maynard shall complete the following: 1. If not currently available, obtain from the manufacturers fan curves for baghouse fans associated with each FCS. 2. Develop AutoCAD line drawing schematics of each FCS, showing the furnace capture hood, all of the ductwork sections, transitions and fittings, baghouse, fan, control damper and stack; and provide dimensional data by way of diameters, lengths, and fitting angles. 3. With each FCS in its starting mode (i.e., after completing at least one complete off-line shaking cycle), gather the following data: a. Flow Rates: Using standard pitot tubes compensated for temperature and Magnehelic gauges calibrated against manometers, air flow readings shall be obtained at each of the following locations: In the trunk duct on the roof In the downcomer duct between the baghouse and the fan In the stack b. Static Pressure: Using Magnehelic gauges calibrated against manometers, the static pressure readings shall be obtained at each of the following locations: Upstream and downstream of the: 1) duct separation on the furnace; 2) telescoping duct; and 3) baghouse at the points where filter total differential pressure will be monitored Fan inlet and outlet (fan outlet on both sides of the control damper) The starting mode is when the FCS is operating optimally. This means that the baghouse has been thoroughly shaken down and the entire system is otherwise clean and operational. 4. Compare the measured fan airflow rate and differential static pressure to that predicted by the fan curve. Where there is variance, identify the reasons for any variance. 5. Use the design parameters of the Industrial Ventilation Manual of Recommended Practice of the American Conference of Governmental Industrial Hygienists (ACGIH) to predict the pressure drops of the ductwork and fittings. Where there A-8 is variance between the measured and the predicted static pressures, identify the reasons for any variance. 6. After completing evaluations in the ventilation system starting mode in Steps 3-5 with the damper set in its normal position, damper back the fan to a minimum of ten (10) additional settings. At each of these ten (10) settings, measure fan static pressure and fan exhaust flow rate and temperature. Plot these actual points of operation on a fan performance graph to demonstrate that the relationship between flow rate and fan static pressure is always inverse, signifying that the fan performance in this zone is predictable. 7. Within 30 days of completing Phase 2A, prepare and submit to EPA a report detailing the findings and conclusions, together with supporting documentation, about Maynard’s ventilation system capacity. B. Establishing Ventilation Performance Limits – Hot Work Prior to conducting Phase 2B, first the hood static pressure and filter total differential pressure monitors described in Phase 1 must be installed, calibrated and commissioned, and operating continuously on EAF Nos. 5, 6 and 7 (Phase 1). Phase 2B will include data collection on a minimum of three (3) heats per EAF as described below. During Phase 2B, Maynard shall complete the following: 1. Maynard shall: (1) within 30 days of commencing test heats and no later than 30 days after completing a shift during which the test heats were performed, conduct bag leak testing using fluorescent dye, as set forth in either paragraph 9 of the “Periodic Inspection Guide – EAF Shaker Baghouse” contained in the O&M Plan, or a comparable procedure from an outside contractor; and (2) conduct a visual clean-side inspection of the baghouse associated with the EAF for which Phase 2B is being conducted no more than 48 hours before commencing and within 48 hours of the end of the shift in which the test heat(s) were completed. The cleanside inspection shall be conducted during daylight hours and consist of the following activities: a. Ensuring that the baghouse ventilation system is turned off. b. Observing the condition of the baghouse access door for faulty gaskets, warping and proper alignment. Air leakage into the clean air plenum from outdoors via improper seals around the access door has the potential to alter dust settling conditions inside the clean air plenum – if such conditions are encountered, then they must be corrected. c. Opening the access door to the baghouse. A-9 d. Without physically entering the baghouse, visually verifying that the floor of the clean air plenum is free of any readily visible dust layer. This may necessitate the use of supplemental artificial lighting to visibly assess the condition of the floor of the clean air plenum. e. Noting whether or not any dust is observed on the floor of the clean air plenum. If dust is observed, then investigate and correct the cause thereof (e.g., repair access door gaskets, etc.) consistent with the O&M Plan, and remove the dust from the floor of the clean air plenum in accordance with applicable requirements (e.g., confined space entry). f. Securely closing access to the baghouse. The results of these inspections shall be documented and provided to EPA as part of the Final FCS Report, described in Phase 3, item 5 below. 2. Begin a melting heat with the FCS in its starting mode as described in Phase 2A, item 3 above. Operate the FCS to collect and capture all PM emissions from the EAF for the duration of the heat, unless otherwise specifically noted. Leave the on-line shaking protocol (as described in Section 1.2) on, as usual, and the fan control damper in its normal position. The hood static pressure in the starting mode prior to powering on the EAF will be a candidate Low-High Set Point. 3. Record on a Microsoft Excel spreadsheet pertinent process information for this heat, including: 1) mass of total metal charged; 2) start time; 3) power on / off time; 4) oxygen lancing start / end time(s) and associated pressure settings; 5) refining – start / end time(s) and associated pressure settings; 6) tapping start time; 7) type of metal(s) charged; and 8) type and mass of each additive. 4. Visually observe and document emissions capture at the electrodes throughout the heat via video recording. Qualitatively confirm that emission capture at the inlet of the local exhaust hood is essentially complete throughout the heat. 5. From the continuously monitored data, establish the reduction in hood static pressure, and the rise in total filter differential pressure across the baghouse that occurred throughout the heat. 6. Repeat steps 2-5 on a second heat, except that during the high-pressure oxygen lancing phase of the heat (refining, specifically), reduce the hood flow rate via fan dampering to a flow rate such that capture of emissions during refining is substantially complete and visually marginal (e.g., capture may be less direct and small puffs may start to move away, only to be drawn back by the suction of the fan). The hood static pressure associated with that suction level will represent a candidate Low-Low Set Point below which melting and refining should not continue, or should continue only in accordance with procedures established in A-10 the O&M Plan, which are intended to raise hood static pressure and flow rate to sufficient levels to allow the heat to continue. 7. Complete the heat under normal conditions after Step 6. The hood static pressure at the completion of the heat will be a candidate High-Low Set Point. 8. During the course of completing evaluations in Steps 2-5, at a minimum, measure fan static pressure and fan exhaust flow rate and temperature at the following points during the furnace heat: a. at the start of the heat b. at the beginning and end of low pressure oxygen lancing (melting) c. at the beginning and end of high pressure oxygen lancing (refining) d. at the end of the heat 9. Evaluate the circumstances around any instances where hood static pressure fell below the High-Low, and/or the Low-Low Set Point, and detail the steps that were taken to remedy those conditions. 10. During the course of completing evaluations in Steps 6 and 7 in subsequent furnace test heats and in the following order, at a minimum, measure fan exhaust flow rate, fan static pressure and temperature at the following points: a. at the start of the heat b. at the beginning and end of low pressure oxygen lancing (melting) c. at the start of high pressure oxygen lancing (refining) d. after reducing the exhaust rate to the point that defines the Low-Low Set Point during refining e. as time allows given the relatively short duration of refining operations, following airflow adjustments to one or more airflow rates between points c and d, above f. at the end of the heat Phase 3 – Fume Capture Performance during Subsequent Production Melting Heats Phase 3 is intended to use the monitoring Set Points established in Phase 2B to assess capture performance during three (3) additional heats on each EAF. During Phase 3, Maynard will complete the following: 1. Begin a melting heat with each FCS in its starting mode as described in Phase 2A, item 3 above. Operate the FCS to collect and capture all PM emissions from the EAF for the duration of the heat, unless otherwise specifically noted. The hood static pressure in the starting mode shall be a candidate Low-High Set Point. 2. Using the parametric monitoring equipment (Phase 2B), monitor the hood static pressure and total filter differential pressure, and respond to any limit settings A-11 reached during the three (3) additional heats on each furnace by taking corrective steps as detailed in the O&M Plan. 3. Record pertinent process information for each heat on a Microsoft Excel spreadsheet (see Phase 2B, Step 2). 4. Use a single stationary video camera to record emissions capture where the electrodes penetrate the furnace cover, coordinated with the parametric monitoring of the hood static pressure, and total baghouse differential pressure. 5. Prepare a Final FCS Report detailing the steps taken and results of Phase 2B and Phase 3. Submit the Final FCS Report to EPA for review and approval within 60 days of completing Phase 3. Phase 4 – Performance Testing Phase 4 is the final phase of the Study. Maynard shall conduct stack performance tests on the baghouse associated with each operational EAF. These performance tests will be conducted in accordance with the requirements detailed in Section VI (Compliance Requirements) of the Consent Decree. 4.0 Modification of Study This Study may be modified as a non-material change by written agreement between Maynard Steel and the USEPA, as provided under Paragraph 129 of the Consent Decree. A-12

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