Document dQk1NVeJKdkLvmZ8B570jJ2x6
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5
77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604
SUBJECT:
FROM: THRU: TO:
CLEAN AIR ACT INSPECTION REPORT Gateway Energy & Coke Company, LLC c/o SunCoke Energy, Granite City, Illinois
Carlo Demma, Physical Scientist (Env.) AECAB (MN/OH)
Brian Dickens, Section Supervisor AECAB (MN/OH)
File
BASIC INFORMATION
Facility Name: SunCoke Energy - Granite City Operations
Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: September 7, 2023
EPA Inspector(s): 1. Carlo Demma, Physical Scientist (Env.) 2. Valeria, Apolinario, Environmental Engineer
Other Attendees: 1. Brandon Whitman, Corporate HES Manager, SunCoke Energy 2. Ralph Kremer, General Manager, SunCoke Energy 3. Edward Glass, Operations Manager, SunCoke Energy 4. Chris Taylor, Operations Area Owner, SunCoke Energy 5. Brandon Koch, Heat Recovery Area Lead, SunCoke Energy
Contact Email Address: Brandon Whitman - BEWHITMAN@SUNCOKE.COM
Purpose of Inspection: EPA conducted this inspection to determine compliance with the air pollution requirements of the Illinois State Implementation Plan (IL SIP), and SunCoke Company's Construction Permit No: 06070020 relating to charging fugitive emissions and coke oven door regulations.
Facility Name: SunCoke Energy Granite City Operations Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: September 7, 2023
Facility Type: Stationary heat recovery coal carbonization facility.
Regulations Central to Inspection: The facility is subject to SunCoke Company's Construction Permit No: 06070020 and 40 CFR 63.303(d)(1), which states, the owner or operator shall not discharge or cause to be discharged to the atmosphere from charging operations any fugitive emissions that exhibit an opacity greater than 20 percent. Pursuant to the Illinois SIP at 35 IAC 212.443(d)(1), and SunCoke Company's Construction Permit No: 06070020, no person shall cause or allow visible emissions from more than 10 percent of all coke oven doors at any time.
Arrival Time: 8:00 AM Departure Time: 9:30 AM
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 Brandon Whitman and Ralph Kremer unless otherwise noted:
Process Description: SunCoke - Granite City (SunCoke) operates 120 ovens arranged in three 40-oven batteries at this site, labeled A, B, and C Battery. Coal is placed inside the one hundred twenty (120) nonrecovery coke ovens, and is then heated by recirculating combusted gas, but can also be supplemented by natural gas. The combusted flue gas is directed through heat recovery steam generators (HRSGs) where the residual heat is extracted, and steam is produced. The batteries are referred to as "non-recovery" and are operated under constant negative pressure, with emissions controlled by one lime spray dryer desulfurization unit (FGD) and one baghouse that removes entrained ash. Carbon is injected into the gas stream upstream of the spray dryer absorber to remove mercury. All waste gas emissions exhaust through one main stack, and occasionally through some of the seven bypass vent stacks distributed over the three batteries. One HRSG typically serves 20 ovens when gas sharing is not available. After coal carbonization is complete, the finished coke is pushed from the oven, quenched with water, screened to remove very fine material and delivered to the customer.
Staff Interview: SunCoke is preparing for a full FGD maintenance outage scheduled for October 3, 2023. SunCoke's West Extractor (Coke Side) has a baghouse filter attached to it,
Page 2 of 5
Facility Name: SunCoke Energy Granite City Operations Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: September 7, 2023
whereas the East Extractor does not. SunCoke only runs the East Extractor the minimum extent possible to ensure that it still operates correctly in the event of a malfunction or equipment failure of the West Extractor. The East Extractor typically operates once per week. SunCoke has begun filling the port hole openings on each oven and has also prioritized the missing Kaowool insulation, and door damages identified in EPA's May 16, 2023 inspection report.
TOUR INFORMATION
EPA Tour of the Facility: Yes
Photos and/or Videos: were taken during the inspection. EPA photographed a degraded door on Oven 92. The upper left corner of the jam of the door was fully melted (Photo 1). EPA did not notate any visible emissions associated with the damaged door. EPA's second inspector recorded video of all coal charging runs (Attachment A).
Field Measurements: were taken during this inspection. EPA performed Alternative Method - 082 (DCOT) on the Pusher Charger Machine (PCM) baghouse stack and its associated fugitive emissions while charging.
Data Collected and Observations: EPA's primary goal was to witness the push and resultant charge of five ovens at the B and C Batteries. On-site opacity observations were conducted in accordance with EPA Alternative Method 082 on the PCM stack and its associated fugitive emissions at the Facility during the morning of September 7, 2023.
SunCoke charged 5 ovens while EPA was on-site. Visible emissions were analyzed in accordance with EPA Alternative Method 082. Each production run took about 8-minutes to complete; EPA analyzed the highest opacity in a 6-minute interval during each run. The results of each 6-minute observation run are indicated below:
1. 16% opacity on a six-minute average for run #1 on B Battery, Oven 80 (Attachment B). Start: 8:22 AM Stop: 8:30 AM Coal charge: 42.5 tons
2. 9% opacity on a six-minute average for run #2 on C Battery, Oven 88 (Attachment C). Start: 8:33 AM Stop: 8:40 AM Coal charge: 45.0 tons
3. 20% opacity on a six-minute average for run #3 on C Battery, Oven 96 (Attachment D). Start: 8:40 AM Stop: 8:48 AM Coal charge: 44.5 tons
4. 18% opacity on a six-minute average for run #4 on C Battery, Oven 104 (Attachment E). Start: 8:50 AM Stop: 9:00 AM Coal charge: 43.5 tons
5. 9% opacity on a six-minute average for run #5 on C Battery, Oven 120 (Attachment F). Start: 9:03 AM
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Facility Name: SunCoke Energy Granite City Operations Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: September 7, 2023
Stop: 9:11 AM Coal charge: 42.5 tons
All Visible Emission Observation Reports are included in Attachments B to F.
CLOSING CONFERENCE
Provided U.S. EPA point of contact to the facility.
Concerns: After the C-Battery was pushed and ovens 96 and 104 were charged, the SunCoke PCM operator struggled to latch the door back onto the Battery. This resulted in extra minutes of excess emissions to escape from the battery. EPA notified SunCoke personnel of these concerns while on-site.
DIGITAL SIGNATURES
CARLO
Digitally signed by CARLO DEMMA
Date: 2023.10.20
Report Author: D__E_M__M__A______1_3:3_3_:14_-_05_'0_0'_____________
Section Supervisor:
DAVID
Digitally signed by DAVID SUTLIN
Date: 2023.10.20
_S_U__T_L_I_N______1_5_:00_:3_7_-0_5'0_0_' _____________ (Acting)
Page 4 of 5
Facility Name: SunCoke Energy Granite City Operations Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: September 7, 2023 APPENDICES AND ATTACHMENTS 1. Attachment A. Digital Image and Digital Video Log 2. Attachment B. Visible Emission Observation Report 3. Attachment C. Visible Emission Observation Report 4. Attachment D. Visible Emission Observation Report 5. Attachment E. Visible Emission Observation Report 6. Attachment F. Visible Emission Observation Report
Page 5 of 6
Facility Name: SunCoke Energy Granite City Operations Facility Location: 2585 Edwardsville Road, Granite City IL 62040
Date of Inspection: May 16, 2023
ATTACHMENT A: DIGITAL IMAGE AND DIGITAL VIDEO LOG
1. Inspector Name: Carlo Demma
2. Archival Record Location: Region 5 Electronic Records center
Number File Name
IMG_1004 1
Date and Time (incl. Time zone and DST) 9/7/2023 8:32AM
Description of Image Oven 96 partially melted door.
MVI_0350
9/7/2023
Run #1 on B Battery, Oven 80
2
N/A
3
MVI_0351
9/7/2023
Run #2 on C Battery, Oven 88
N/A
MVI_0352
9/7/2023
Run #3 on C Battery, Oven 96
4
N/A
MVI_0353
9/7/2023
Run #4 on C Battery, Oven 104
5
N/A
6
MVI_0354
9/7/2023
Run #4 on C Battery, Oven 104 (Extended)
N/A
7
MVI_0355
9/7/2023
Run #5 on C Battery, Oven 120
N/A
Page 6 of 6
Attachment B
VISIBLE EMISSION OBSERVATION FORM Form Number
Method Used
Alternative Method -082
Equipment Owner Start
n/a
Facility Name
SunCoke Energy Granite City Operations
EO Street Address
2585 Edwardsville Road,
EO City
EO Region
Granite City
US-IL
EO Zip
62040
Process
Coal Manufacturing
Control Equipment
Baghouse
Unit
B-Battery
Operating Mode
Push
Operating Mode
Operating
Describe Emission Point
N/A
Height of Emiss. Pt
Start 25
End Same
Distance to Emiss. Pt
Start 127.57 End Same
Height of Emiss. Pt. Rel. to Observer
Start 20
End Same
Direction to Emiss. Pt (Degrees)
Start 281.11 End Same
Vertical Angle to Obs, Pt.
Direction to Obs. Pt
Start 7.93
End Same
Start 279.7
End Same
Distance and Direction to Observation Point from Emission Point
Start 3.15 / 180.52
End Same
Describe Emissions
Start Fugitive Emission Color
End Same Water Droplet Plume
Start Black
End Same
Attached: ( ) Detached: ( ) N/A: ( X )
Describe Plume Backgroud
Start blue sky
End Same
Background Color
Sky Conditions
Start Blue
End Same
Start Broken End Same
Wind Speed
Wind Direction
Start 5
End Same
Start 45
End Same
Ambient Temp.
Wet Bulb Temp.
RH Percent
Start 83 End Same Start 61 End Same Start 63 End Same
Longitude
090.07.51.916.W
Latitude
38.41.47.121.N
Notes
Declination
Continued on VEO Form Number
Observation Date
9/7/2023
Time Zone
CDT
1
10 0
5
2
10 5
5
3
15 15 10
4
10 15 15
5
15 15 15
6
20 20 20
7
55 10 25
8
5
0
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Observers Name (Print)
Carlo Demma
Observers Signature
Carlo Demma
Organization
USEPA Region 5
Certified By
Carlo Demma
Page
of
Start Time
08:22:03
End Time
08:29:18
Comments
10
10
0
Avg Opacity = 16%
5
5
75
5
Date
9/7/2023
Date
10/13/2023
DOCS II Web Version 1.1 - SunCoke_PCM_fugitives_80 - 9/7/2023
Attachment C VISIBLE EMISSION OBSERVATION FORM
Form Number
Method Used
Alternative Method -082
Equipment Owner Start
n/a
Facility Name
SunCoke Energy Granite City Operations
EO Street Address
2585 Edwardsville Road,
EO City
EO Region
Granite City
US-IL
EO Zip
62040
Process
Coal Manufacturing
Control Equipment
Baghouse
Unit
C-Battery
Operating Mode
Push
Operating Mode
Operating
Describe Emission Point
N/A
Height of Emiss. Pt
Start 25
End Same
Distance to Emiss. Pt
Start 179.3
End Same
Height of Emiss. Pt. Rel. to Observer
Start 20
End Same
Direction to Emiss. Pt (Degrees)
Start 293.07 End Same
Vertical Angle to Obs, Pt.
Direction to Obs. Pt
Start 5.68
End Same
Start 293.23 End Same
Distance and Direction to Observation Point from Emission Point
Start 3.15 / 241.63
End Same
Describe Emissions
Start Fugitive Emission Color
End Same Water Droplet Plume
Start Black
End Same
Attached: ( ) Detached: ( ) N/A: ( X )
Describe Plume Backgroud
Start blue sky
End Same
Background Color
Sky Conditions
Start Blue
End Same
Start Scattered End Same
Wind Speed
Wind Direction
Start 5
End Same
Start 45
End Same
Ambient Temp.
Wet Bulb Temp.
RH Percent
Start 83 End Same Start 61 End Same Start 63 End Same
Longitude
090.07.49.483.W
Latitude
38.41.47.408.N
Notes
Declination
Continued on VEO Form Number
Observation Date
9/7/2023
Time Zone
CDT
1
5
0
5
2
5
15 0
3
10 15 0
4
10 10 5
5
0
10 5
6
5
10 10
7
5
0
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Observers Name (Print)
Carlo Demma
Observers Signature
Carlo Demma
Organization
USEPA Region 5
Certified By
Carlo Demma
Page
of
Start Time
08:33:24
End Time
08:39:54
Comments 5 15 15 Avg Opacity = 9% 0 50 5
Date
9/7/2023
Date
10/13/2023
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Attachment D VISIBLE EMISSION OBSERVATION FORM
Form Number
Method Used
Alternative Method -082
Equipment Owner Start
n/a
Facility Name
SunCoke Energy Granite City Operations
EO Street Address
2585 Edwardsville Road,
EO City
EO Region
Granite City
US-IL
EO Zip
62040
Process
Coal Manufacturing
Control Equipment
Baghouse
Unit
C-Battery
Operating Mode
Push
Operating Mode
Operating
Describe Emission Point
N/A
Height of Emiss. Pt
Start 25
End Same
Distance to Emiss. Pt
Start 195.93 End Same
Height of Emiss. Pt. Rel. to Observer
Start 20
End Same
Direction to Emiss. Pt (Degrees)
Start 300.96 End Same
Vertical Angle to Obs, Pt.
Direction to Obs. Pt
Start 5.2
End Same
Start 299.86 End Same
Distance and Direction to Observation Point from Emission Point
Start 6.83 / 206.17
End Same
Describe Emissions
Start Fugitive Emission Color
End Same Water Droplet Plume
Start Black
End Same
Attached: ( ) Detached: ( ) N/A: ( X )
Describe Plume Backgroud
Start blue
End Same
Background Color
Sky Conditions
Start Blue
End Same
Start Broken End Same
Wind Speed
Wind Direction
Start 5
End Same
Start 45
End Same
Ambient Temp.
Wet Bulb Temp.
RH Percent
Start 83 End Same Start 61 End Same Start 63 End Same
Longitude
090.07.47.087.W
Latitude
38.41.48.458.N
Notes
Declination
Continued on VEO Form Number
Observation Date
9/7/2023
Time Zone
CDT
1
0
0
0
2
10 0
10
3
70 60 10
4
0
0
20
5
15 15 30
6
15 10 45
7
10 10 0
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Observers Name (Print)
Carlo Demma
Observers Signature
Carlo Demma
Organization
USEPA Region 5
Certified By
Carlo Demma
Page
of
Start Time
08:40:24
End Time
08:48:00
Comments 0 10 10 Avg Opacity = 20% 20 45 65 10
Date
9/7/2023
Date
10/13/2023
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Attachment E VISIBLE EMISSION OBSERVATION FORM
Form Number
Method Used
Alternative Method -082
Equipment Owner Start
n/a
Facility Name
SunCoke Energy Granite City Operations
EO Street Address
2585 Edwardsville Road,
EO City
EO Region
Granite City
US-IL
EO Zip
62040
Process
Coal Manufacturing
Control Equipment
N/A
Unit
C-Battery
Operating Mode
Push
Operating Mode
N/A
Describe Emission Point
N/A
Height of Emiss. Pt
Start 25
End Same
Distance to Emiss. Pt
Start 207.3
End Same
Height of Emiss. Pt. Rel. to Observer
Start 20
End Same
Direction to Emiss. Pt (Degrees)
Start 286.7
End Same
Vertical Angle to Obs, Pt.
Direction to Obs. Pt
Start 4.92
End Same
Start 286.7
End Same
Distance and Direction to Observation Point from Emission Point
Start /
End Same
Describe Emissions
Start Fugitive Emission Color
End Same Water Droplet Plume
Start Black
End Same
Attached: ( ) Detached: ( ) N/A: ( X )
Describe Plume Backgroud
Start blue sky
End Same
Background Color
Sky Conditions
Start Blue
End Same
Start Scattered End Same
Wind Speed
Wind Direction
Start 5
End Same
Start 45
End Same
Ambient Temp.
Wet Bulb Temp.
RH Percent
Start 83 End Same Start 61 End Same Start 63 End Same
Longitude
090.07.45.928.W
Latitude
38.41.49.196.N
Notes
Declination
Continued on VEO Form Number
Observation Date
9/7/2023
Time Zone
CDT
1
5
0
0
2
10 10 30
3
10 10 5
4
5
5
5
5
5
10 10
6
10 45 15
7
20 20 5
8
10 15 45
9
75 15 10
10 0
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Observers Name (Print)
Carlo Demma
Observers Signature
Carlo Demma
Organization
USEPA Region 5
Certified By
Carlo Demma
Page
of
Start Time
08:49:51
End Time
09:00:01
Comments
0
5
0
Avg Opacity = 18%
5
5
15
10
75
5
Date
9/7/2023
Date
10/13/2023
DOCS II Web Version 1.1 - SunCoke_PCM_fugitives_104 - 9/7/2023
Attachment F VISIBLE EMISSION OBSERVATION FORM
Form Number
Method Used
Alternative Method -082
Equipment Owner Start
n/a
Facility Name
SunCoke Energy Granite City Operations
EO Street Address
2585 Edwardsville Road,
EO City
EO Region
Granite City
US-IL
EO Zip
62040
Process
Coal Manufacturing
Control Equipment
Baghouse
Unit
C-Battery
Operating Mode
Push
Operating Mode
Operating
Describe Emission Point
N/A
Height of Emiss. Pt
Start 25
End Same
Distance to Emiss. Pt
Start 265.99 End Same
Height of Emiss. Pt. Rel. to Observer
Start 20
End Same
Direction to Emiss. Pt (Degrees)
Start 273.02 End Same
Vertical Angle to Obs, Pt.
Direction to Obs. Pt
Start 3.84
End Same
Start 271.67 End Same
Distance and Direction to Observation Point from Emission Point
Start 8.64 / 157.19
End Same
Describe Emissions
Start Fugitive Emission Color
End Same Water Droplet Plume
Start Black
End Same
Attached: ( ) Detached: ( ) N/A: ( X )
Describe Plume Backgroud
Start blue sky
End Same
Background Color
Sky Conditions
Start Blue
End Same
Start Clear
End Same
Wind Speed
Wind Direction
Start 5
End Same
Start 45
End Same
Ambient Temp.
Wet Bulb Temp.
RH Percent
Start 83 End Same Start 61 End Same Start 63 End Same
Longitude
090.07.42.550.W
Latitude
38.41.51.228.N
Notes
Declination
Continued on VEO Form Number
Observation Date
9/7/2023
Time Zone
CDT
1
0
5
15
2
0
5
0
3
15 5
0
4
15 10 10
5
0
0
10
6
5
10 10
7
15 35 25
8
5
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Observers Name (Print)
Carlo Demma
Observers Signature
Carlo Demma
Organization
USEPA Region 5
Certified By
Carlo Demma
Page
of
Start Time
09:01:31
End Time
09:10:00
Comments
15
10
5
Avg Opacity = 9%
0
5
10
10
Date
9/7/2023
Date
10/13/2023
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