EPA v. ALLIANCE CASTING - ACO

Case summary

Alliance Castings owns and operates a steel foundry in Alliance, Ohio. The foundry is subject to the NESHAP for Iron and Steel Foundries as well as a Permit-to-Install and a Title V Permit. In a March 24, 2015 Notice and Finding of Violation, EPA alleged that Alliance Castings had violated several applicable requirements from each of these, including: 1. NESHAP for Iron and Steel Foundries a. Failure to install a properly sized baghouse to control EAF emissions during tapping and charging (the canopy baghouse); b. Failure to conduct opacity observations of foundry operations concurrently with the particulate matter performance test; c. Poor operation and maintenance of the baghouse; d. Failure to have a complete Operation and Maintenance Plan; e. Late installation of a bag leak detection system on the canopy baghouse; and f. Failure of the bag leak detection system to detect broken bags. 2. Title V Permit a. Significant deviations from the baghouse pressure drop limits. 3. Permit-to-Install 15-01570 a. Failed PM10 performance test for EUs (emission unit) P040, P041, P042, P043, and P044; b. Failure to achieve 99.9% control of PM emissions for EUs P040, P041, P042, P043, and P044; c. Failed VOC performance test for EUs P047, P048 and P049; d. Failure to achieve 99.9% control of VOC emissions for EUs P047, P048 and P049; and e. Significant deviations from the baghouse pressure drop limits. 4. Permit-to-Install P0116125, issued September 4, 2014 a. Incomplete permit application which resulted in a failure to obtain an adequate synthetic minor VOC limit, in violation of the Ohio State Implementation Plan. Alliance has already resolved many of these violation through permitting changes and corrections. The facility is currently idle, so most of the requirements are going to be put into a permit so that they will be required once the facility is restarted. The ACO requires Alliance to modify its O&M plan, conduct the required stack testing, conduct Method 9 readings, replace the baghouse hopper auger to prevent buildup and spills of baghouse dust, implement improvements to its baghouse inspections, and keep adequate records of baghouse inspections and corrective actions taken.

Defendants (1)

• ALLIANCE CASTINGNamed in complaintNamed in settlement

Facilities (1)

• ALLIANCE CASTING CO. LLC

  1001 E BROADWAY ST, ALLIANCE, OH, 446012602

  Registry ID: 110000390238

Statutes cited

• CAA 110 — Implementation Plan for National Primary and Secondary Ambient Air Quality Standards
• CAA 112D — MACT Standards

Enforcement conclusions (1)

• ALLIANCE CASTINGentered 2018-08-17

  Primary law: CAA

Timeline (2 milestones)

• 2018-08-17Final Order Issued
• 2018-08-20Enforcement Action Data Entered