APPENDIX D PETROLEUM REFINERY CONSENT DECREE EMISSION REDUCTION ASSESSMENT FOR OZONE AND REGIONAL HAZE SIPS 2013-013-SIP-NR Adoption February 26, 2014 Petroleum Refinery Consent Decree Emission Reduction Assessment for Ozone and Regional Haze SIPs Work Order No. 582-07-84005-01 Prepared for: Texas Commission on Environmental Quality Austin, Texas Prepared by: ENVIRON International Corporation Steven H. Ramsey, P.E., BCEE Christopher J. Colville, EIT, EPI Alessandra R. Carreon Shagun Bhat, Ph.D. November 2007 Project No. 06-17477A 10333 Richmond Avenue, Suite 910, Houston TX 77042 Tel: 713.470.6546 CONTENTS Page LIST OF TABLES......................................................................................................................... iii LIST OF FIGURES ....................................................................................................................... iv LIST OF ATTACHMENTS ............................................................................................................v ACCRONYMS .............................................................................................................................. vi 1. INTRODUCTION ......................................................................................................................1 1.1 Purpose.............................................................................................................................1 1.2 Background Information..................................................................................................1 1.3 EPA Petroleum Refinery Enforcement Initiative ............................................................1 2. REFINERY CONSENT DECREE REQUIREMENTS AND EMISSION CHANGES............7 2.1 BP.....................................................................................................................................8 2.2 Chalmette Refining........................................................................................................16 2.3 CITGO ...........................................................................................................................23 2.4 Conoco / ConocoPhillips ...............................................................................................34 2.5 ExxonMobil ...................................................................................................................50 2.6 Giant Industries (Western Refining)..............................................................................62 2.7 Koch Industries (Flint Hills Resources).........................................................................66 2.8 Lion Oil Company .........................................................................................................73 2.9 Marathon Petroleum Company LLC .............................................................................78 2.10 Navajo Refining Company, L.L.C. (Holly Corporation)...............................................88 2.11 Shell Joint Ventures: Motiva and Deer Park Refining ..................................................94 2.12 Sunoco, Inc..................................................................................................................106 2.13 Total Petrochemicals U.S.A.........................................................................................111 2.14 Valero...........................................................................................................................117 3. NON-REFINERY CONSENT DECREE REQUIREMENTS AND EMISSION CHANGES130 3.1 Equistar Chemicals ......................................................................................................130 3.2 Rhodia..........................................................................................................................132 4. ADDITIONAL CONSIDERATIONS ....................................................................................135 4.1 Flexible Permits ...........................................................................................................135 Petroleum Refinery Consent Decree Assessment -i- E N V I R O N TCEQ Work Order 582-07-84005-01 4.2 Emissions Trading.......................................................................................................135 4.3 MECT Cap...................................................................................................................136 4.4 Overly Conservative Emission Estimates....................................................................136 4.4 NSPS Subpart Ja ..........................................................................................................137 5. RECOMMENDATIONS........................................................................................................139 5.1 Data Acquisition..........................................................................................................139 5.2 Inventory Reconciliation..............................................................................................140 Petroleum Refinery Consent Decree Assessment -ii- E N V I R O N TCEQ Work Order 582-07-84005-01 LIST OF TABLES Page Table 1-1 Summary of Consent Decree Status....................................................................................... 3 Table 2.1-1 BP Texas City Refinery FCCU Emissions........................................................................... 11 Table 2.1-2 BP Texas City Refinery FCCU Emissions Used in Revised Modeling Inventory .............. 12 Table 2.1-3 BP Texas City Refinery Heater and Boiler Emissions......................................................... 13 Table 2.2-1 Chalmette Refining FCCU Emissions.................................................................................. 20 Table 2.3-1 CITGO FCCU NOX Emissions ............................................................................................ 29 Table 2.3-2 CITGO FCCU SO2 Emissions ............................................................................................. 29 Table 2.3-3 CITGO FCCU PM Emissions.............................................................................................. 29 Table 2.3-4 CITGO Heater and Boiler NOX Emission............................................................................ 30 Table 2.4-1 ConocoPhillips FCCU Emissions ........................................................................................ 43 Table 2.4-2 ConocoPhillips Alliance Refinery Heater and Boiler Emissions......................................... 43 Table 2.4-3 ConocoPhillips Borger Refinery Heater and Boiler Emissions ........................................... 44 Table 2.4-4 ConocoPhillips Lake Charles Refinery Heater and Boiler Emissions ................................. 44 Table 2.4-5 ConocoPhillips Ponca City Refinery Heater and Boiler Emissions..................................... 45 Table 2.4-6 ConocoPhillips Sweeny Refinery Heater and Boiler Emissions.......................................... 46 Table 2.4-7 ConocoPhillips SRP 2006 Actual Emissions....................................................................... 47 Table 2.5-1 ExxonMobil Baton Rouge Refinery Actual NOX Emissions............................................... 55 Table 2.5-2 ExxonMobil Baytown Refinery FCCU Emissions .............................................................. 56 Table 2.5-3 ExxonMobil Beaumont Refinery FCCU Emissions ............................................................ 57 Table 2.5-4 ExxonMobil Beaumont Refinery Combustion Unit Emissions ........................................... 58 Table 2.5-5 ExxonMobil Beaumont Refinery SRU Emissions............................................................... 60 Table 2.5-6 ExxonMobil Beaumont Refinery Flare Emissions............................................................... 60 Table 2.6-1 Giant FCCU Emissions........................................................................................................ 65 Table 2.7-1 Flint Hills Resources FCCU Emissions ............................................................................... 69 Table 2.7-2 Flint Hills Resources Heater and Boiler Emissions ............................................................. 70 Table 2.8-1 Lion Oil FCCU Emissions ................................................................................................... 76 Table 2.9-1 Marathon Petroleum Company FCCU Emissions................................................................ 83 Petroleum Refinery Consent Decree Assessment -iii- E N V I R O N TCEQ Work Order 582-07-84005-01 Table 2.9-2 Marathon Petroleum Company Garyville Refinery Heater and Boiler Emissions............... 84 Table 2.9-3 Marathon Petroleum Company Texas City Refinery Heater and Boiler Emissions ............ 84 Table 2.10-1 Navajo Refining FCCU Emissions ...................................................................................... 91 Table 2.10-2 Navajo Refining Heater and Boiler Emissions .................................................................... 92 Table 2.11-1 Motiva / Deer Park Refining FCCU Emissions ................................................................... 99 Table 2.11-2 Deer Park Refining Heater and Boiler Emissions.............................................................. 100 Table 2.11-3 Motiva Convent Refinery Heater and Boiler Emissions.................................................... 101 Table 2.11-4 Motiva Norco Refinery Heater and Boiler Emissions.......................................................