Document OzmKwjpwrmbbnpXMEb4eenkVj

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 SUBJECT: FROM: THRU: TO: CLEAN AIR ACT INSPECTION REPORT Graymont Western Lime Inc., Green Bay, Wisconsin Manojkumar P. Patel, Environmental Engineer AECAB (MI/WI) Sarah Marshall, Section Supervisor AECAB (MI/WI) File BASIC INFORMATION Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 EPA Inspector(s): 1. Manojkumar P. Patel, Environmental Engineer Other Attendees: 1. Edd Tadulan, Plant Manager, Graymont Western Lime, Inc. 2. Charles Clark, Health, Safety, and Environment, Graymont Western Lime, Inc. 3. David Kaiser, Production Supervisor, Graymont Western Lime, Inc. 4. Dan Ulman, Maintenance Supervisor, Graymont Western Lime, Inc. Contact Email Address: etadulan@graymont.com Purpose of Inspection: Determine compliance with the Clean Air Act and Wisconsin State Implementation Plan Facility Type: Hydrated lime manufacturer Regulations Central to Inspection: Title V Permit Regulations, New Source Performance Standards, and Wisconsin State Implementation Plans Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 Arrival Time: 10:00 AM Departure Time: 4:00 PM Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Small Business Resource Information Sheet not provided. Reason: Not a Small Business Provided CBI warning to facility The following information was obtained verbally from the facility personnel unless otherwise noted. Process Description: Graymont Western Lime, Inc. (Graymont) operates a lime manufacturing plant at 137 James Street, Green Bay, Wisconsin. Graymont receives limestone from two different quarries in Michigan. The limestone shipping season starts in April and it ends sometime in December. Graymont's lime products are mostly used in the pulp and paper industries, metallurgical industry, industrial chemical processes, construction, and water treatment facilities. The facility receives limestone from the Michigan quarries in self-unloading boats and stores it in piles on site. Dolomite and High calcium limestones are 2" by 1" in size at the facility. The screening area is enclosed and the upper deck screens limestone at 3" and the lower deck screens limestone at " size. The facility uses a hopper and a belt conveyor to transfer the limestone to the top of a preheater. In the preheater, hot gases from the lime kiln are used for preheating the limestone to 1,400 before entering the kiln. Graymont's vibrating feeders and rams feed the limestone into the two on-site kilns. The pre-heated limestone travels from the feed end to the burner end and is turned into the quick lime. The lime falls into a lime cooler, where ambient air is used to cool the lime. The lime is then conveyed to several large storage bins which load trucks, rail cars, and bulk bags for eventual shipment. Exhaust streams from the kilns (which initially pass through the preheater) are sent through two separate baghouses (Kiln #1 baghouse has three bays and each bay consists of 196 bags; Kiln #2 has four bays and each bay consists of 320 bags) prior to discharge to the atmosphere. Some of the pebble lime is used to produce hydrated lime. The exhaust steam from the hydrator is sent through a wet scrubber prior to discharge to the atmosphere. Both kilns are allowed to use either coal or natural gas. Coal is delivered by truck, dumped into a hopper and conveyed to a 70-ton capacity storage bin. The bin gravity feeds to a variable speed belt conveyor which loads into a pulverizer. Adjusting the silo bin opening Page 2 of 5 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 and belt speed regulate the coal feed. The pulverizer is Raymond Bowl type. Primary heated air feeds to the pulverizer and carries the powdered coal (of size less than 200 mesh) to the lime kiln through a circular pipe. The primary air/coal mixture is ignited from the heat in the lime kiln. Natural gas can be directed through the same pipe. Some of the lime produced at the plant is passed through a crusher and a hammer mill, where it is turned into fine powder of size less than 200 mesh. The crusher is equipped with a bag type collector for controlling emissions. The powdered quick lime is mixed with water in a pug mill to produce hydrated lime. The hydrator is equipped with a wet scrubber to control particulate emissions. Final dolomite lime has three different sizes - " plus, 5/8" to 1/8" wide, and 1/8" fine. High calcium lime has two sizes - 3/4" x 0 and " x 0. TOUR INFORMATION EPA Tour of the Facility: Yes Data Collected and Observations: EPA was led on a tour of the facility by the facility personnel. Eight percent (8%) excess air is required at the Kiln for the quality lime production. Lime Kiln temperature is approximately at 22000F. The refractories layered is approximately at 9 inches at the burner zone. Lime Kiln #1 has a capacity of 300 to 400 tons of stone per day, with a diameter of 10 ft and 150 feet of length. Lime Kiln #1 bag house has 3 bays and 196 bags per bay with the total of 588 bags. Each bag is 61/2 ft in diameter and 143" in height. Each bay has its own pulsing jet system in the baghouse. Last year (2022), 70 ft of refractories were replaced on the discharge end. Baghouse on Bay C was entirely replaced on November 3, 2022. Lime Kiln #2 has a capacity of 700 tons of stone per day, a diameter of 11 ft, and 170 feet in length. At the inlet of the baghouse, the pressure is reading at -11.6" H2O and at the outlet of the baghouse, the pressure is reading at -21.6" H2O, with a net pressure differential of 9.90" H2O. Graymont performed a capital project in or around 2020 and upgraded/modified the gearbox on Lime Kiln #1. Graymont spent more than $350,000 for the Lime Kiln Gearbox upgrades. The facility has total of 13 baghouses in the process. The glycol system is used for cooling of the main shaft bearings for both lime kilns. I observed lots of fine particulate of lime dust inside the Hydrating area. I was not able to locate the pressure differential readout on the Baghouse HD-200 located on the rooftop. The hydrated plant kept the door open and the fugitive particulate were observed in the area. D-36 Baghouse pressure readout was covered with heavy dust buildup and it was difficult to read pressure differential. The facility personnel cleaned the readout thoroughly and I was then able to read 5" of H2O on the D-36 Baghouse. Page 3 of 5 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 I observed the visible emissions on the stack at Baghouse HD-200. In the product handling area, I observed lime dust build up and the door was kept open. The Lime Kiln #2 baghouse inlet pressure reading was -11.6" of H2O and the outlet of the baghouse pressure reading was of -21.6" of H2O and the net pressure differential was 9.91" of H2O. The facility personnel stated that if the lime kiln loses the flame or the coal mill is down then the oxygen levels start increasing. Photos and/or Videos: were taken during the inspection. Field Measurements: were not taken during this inspection. RECORDS REVIEW - Baghouses bags replacement history CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: Latest Laboratory Analysis for Lime Stones; Baghouses on Lime Kiln #1 and Lime Kiln #2 Operational Manuals; Latest Monthly Coal Analysis; Copies of Stack test reports for all criteria pollutants; Need copies of quarterly preventive maintenance report for Baghouses D-32; Air Emissions excedence from Title V air permit. DIGITAL SIGNATURES Patel, Digitally signed by Patel, Manojkumar Date: 2023.10.02 Report Author: _M_a__n_o_jk_u_m__a_r__0_9:_35_:0_9 _-0_5'0_0'_____________ Section Supervisor: SARAH Digitally signed by SARAH MARSHALL Date: 2023.10.02 _M__A_R_S__H_A__L_L__0_9_:58_:4_5_-0_5'0_0_' _____________ Page 4 of 5 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 APPENDICES AND ATTACHMENTS 1. Appendix A: Digital Image Log Page 5 of 8 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Manojkumar P Patel 2. Archival Record Location: CAA Inspection Pics Image File Name Number Date and Time (incl. Latitude and Time zone and DST) Longitude 1 P8030246.JPG 2023:08:03 13:35:53 2 P8030247.JPG 2023:08:03 13:36:06 3 P8030248.JPG 2023:08:03 13:36:34 4 P8040249.JPG 2023:08:04 09:43:35 5 P8040250.JPG 2023:08:04 09:43:42 6 P8040251.JPG 2023:08:04 09:43:46 7 P8040252.JPG 2023:08:04 09:49:40 8 P8040253.JPG 2023:08:04 09:52:54 9 P8040254.JPG 2023:08:04 09:53:54 10 P8040255.JPG 2023:08:04 09:54:00 11 P8040256.JPG 2023:08:04 09:55:17 12 P8040257.JPG 2023:08:04 09:55:22 13 P8040258.JPG 2023:08:04 09:56:43 14 P8040259.JPG 2023:08:04 10:00:59 15 P8040260.JPG 2023:08:04 10:02:26 16 P8040261.JPG 2023:08:04 10:05:04 17 P8040262.JPG 2023:08:04 10:11:26 18 P8040263.JPG 2023:08:04 10:14:31 19 P8040264.JPG 2023:08:04 10:14:42 20 P8040265.JPG 2023:08:04 10:14:50 21 P8040266.JPG 2023:08:04 10:15:23 Description of Image Lime Kilns 1 and 2 Baghouses' sample Bag with Metal Cage (Left is for LK1, Right is for LK2) Baghouses' Bag's Closer View Metal Cage Opening for Pulse Jet (from the Top) Baghouse HD-100 Baghouse HD-100 Closer View Baghouse HD-100 Pressure Differential 4" of Water Column HD-200 Baghouse on the Rooftop(No Pressure Differential Readout) HD-200 Baghouse Control Box Fine Lime Dust Accumulated on the Floor Fine Dust Accumulated on the Floor (Duplicate) Dolomite Limestone Pile View High Calcium Limestone Pile View Hydrated Lime Plant Door Open - Fugitive Particles Observed Limestone Screening Area High Line is for LK1; Lower Line is for LK2 Baghouse D-36 Baghouse D-36 Pressure Differential Readout 5" Water Column D-37 Baghouse Baghouse D-37 Readout Baghouse D-37 Pressure Differential Readout D-37 Baghouse Manufacturer Information D 37 Manufacturer Model and Tag Page 6 of 8 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 22 P8040267.JPG 2023:08:04 10:20:52 23 P8040268.JPG 2023:08:04 10:24:44 24 P8040269.JPG 2023:08:04 10:24:48 25 P8040270.JPG 2023:08:04 10:24:58 26 P8040271.JPG 2023:08:04 10:34:25 27 P8040272.JPG 2023:08:04 10:34:39 28 P8040273.JPG 2023:08:04 10:39:12 29 P8040274.JPG 2023:08:04 10:39:19 30 P8040275.JPG 2023:08:04 10:39:24 31 P8040276.JPG 2023:08:04 10:58:02 32 P8040277.JPG 2023:08:04 10:58:16 33 P8040278.JPG 2023:08:04 11:01:59 34 P8040279.JPG 2023:08:04 11:02:13 35 P8040280.JPG 2023:08:04 11:02:16 36 P8040281.JPG 2023:08:04 11:03:45 HD 200 Stack (Hydrating Process) Visible Emissions D-31 Baghouse D-31 Baghouse Closer View D-31 Baghouse Pressure Differential 5" of Water Column D-32 Baghouse D-32 Baghouse Closer View D-32 Product Handling Dust Built up on the door and Door is wide open D-32 Door Open Closer View of Lime Dust Build Up at D-32 Coal Mill #1 Coal Prep Area Coal Mill 2 (Coal Prep Area) Coal for Lime Kiln 2 Coal Line 2 (Fed into Coal Mill #2) Coal Line 2 (Closer View) Coal Dust from Coal Mill #2 to ID Fan Inlet 37 P8040282.JPG 2023:08:04 11:04:02 Coal Dust from ID fan blown into Lime Kiln 2 38 P8040283.JPG 2023:08:04 11:04:21 39 P8040284.JPG 2023:08:04 11:04:23 40 P8040285.JPG 2023:08:04 11:06:22 41 P8040286.JPG 2023:08:04 11:11:54 42 P8040287.JPG 2023:08:04 11:12:21 43 P8040288.JPG 2023:08:04 11:25:40 44 P8040289.JPG 2023:08:04 11:26:59 45 P8040290.JPG 2023:08:04 11:27:44 Discharge End (aka Burner End) Lime Kiln 2 Discharge End (Duplicate Pic) Lime Kiln 2 Coal Line and Natural gas Line Lime Kiln 2 Control Room Display Lime Kiln 2 Baghouse Process Operating Display Lime Kiln 2 Preheater Operating Display Lime Kiln 1 Operating Display Lime Kiln 1 Baghouse Operating Display 46 P8040291.JPG 2023:08:04 11:28:15 47 P8040292.JPG 2023:08:04 11:30:30 48 P8040293.JPG 2023:08:04 11:32:50 49 P8040294.JPG 2023:08:04 11:36:48 Lime Kiln 1 Cooler Operating Display D-131 Baghouse D-31 Pressure Differential Readout Glycol System for Lime Kilns Gear Drive (for cooling) Page 7 of 8 Facility Name: Graymont Western Lime, Inc. Facility Location: 137 James Street, Green Bay, Wisconsin 54303 Date of Inspection: August 3 and 4, 2023 50 P8040295.JPG 2023:08:04 11:37:10 51 P8040296.JPG 2023:08:04 11:40:27 52 P8040297.JPG 2023:08:04 11:41:58 53 P8040298.JPG 2023:08:04 11:45:09 54 P8040299.JPG 2023:08:04 11:50:58 55 P8040300.JPG 2023:08:04 11:51:26 56 P8040301.JPG 2023:08:04 11:52:29 57 P8040302.JPG 2023:08:04 11:52:50 58 P8040303.JPG 2023:08:04 11:54:27 Pressure Differential Readout Glycol System for Gear Cooling Coal Mill #2 Rejects D-231 Baghouse D -231 Baghouse D-231 Baghouse Pressure Differential Readout Pressure Readout (<90 PSI) at D-231 Baghouse Pressure readout Lime Kiln 2 from the Upper Deck View 59 P8040304.JPG 2023:08:04 11:54:59 60 P8040305.JPG 2023:08:04 12:02:47 61 P8040306.JPG 2023:08:04 12:03:08 62 P8040307.JPG 2023:08:04 12:03:28 63 P8040308.JPG 2023:08:04 12:04:16 64 P8040309.JPG 2023:08:04 12:08:02 65 P8040310.JPG 2023:08:04 12:08:27 66 P8040311.JPG 2023:08:04 12:09:03 67 P8040312.JPG 2023:08:04 12:09:06 68 P8040313.JPG 2023:08:04 12:10:12 69 P8040314.JPG 2023:08:04 12:10:17 70 P8040315.JPG 2023:08:04 12:11:21 71 P8040316.JPG 2023:08:04 12:11:23 72 P8040317.JPG 2023:08:04 12:12:29 73 P8040318.JPG 2023:08:04 12:12:30 74 P8040319.JPG 2023:08:04 12:13:47 75 P8040320.JPG 2023:08:04 12:18:59 76 P8040321.JPG 2023:08:04 12:19:00 77 P8040322.JPG 2023:08:04 12:19:15 78 P8040323.JPG 2023:08:04 12:19:25 Lime Kiln 1 View from the Upper Deck Baghouse Bay A for Lime Kiln 1 Baghouse Bay B for Lime Kiln 1 Baghouse Bay C for Lime Kiln 1 Lime Kiln 1 Stack LK1 Baghouse Sideview Lime Kiln 1 Preheater Building Preheater Building (Duplicate) Preheater Building (Duplicate) Truck Loadout Silos with Baghouse on the Top Baghouse on the Soils Lime Kiln 2 Preheater Lime Kiln 2 Baghouse Lime Kiln 2 Baghouse Inlet Lime Kiln 2 Baghouse Raws Information D 289 Baghouse D 289 Display D 289 Display (Duplicate) D 289 Pressure Differential Readout Page 8 of 8