Stack Test Data

Johnson Controls is required to test its processes for air pollutant emissions. The test results are used to determine if the facility is in compliance with the emission limitations in its air permit. A facility may use its own stack testing group or hire a third party contractor to conduct the stack tests. In preparation for testing, facilities must prepare a Stack Test Protocol. It is the responsibility of DHEC to approve or disapprove the Stack Test Protocol. Like all facilities, Johnson Controls is required to notify DHEC at least 15 days before the test to give us the opportunity to observe the test. Once the stack tests are conducted, the facility must send a report of the results to DHEC for review. If the results are validated, DHEC will issue a letter approving the stack test. The links below will provide future information about the stack tests.

Notifications and Special Requests

Prior to testing sources are required to notify the Department of the exact testing date(s). Sometimes unusual circumstances arise that require special consideration. Documents relating to these topics will appear in this section.

• August 15, 2012 Extension Request for Testing Unit ID 03 – PP Storage and Extrusion
• August 29, 2012 Approval of August 15, 2012 Extension Request

Stack Test Protocol

A protocol is sent to DHEC for review and approval prior to the stack test. The protocol provides the details of how the test will be conducted. It includes the process and pollutants to be tested, the stack test method to be used and the facility's operating conditions during the test. This protocol must be sent to DHEC at least 45 days before the test date.

• No. 1, No. 2, and No. 3 Furnaces, Melter, Refining Combustion, and Refining Process CEMS RATA Testing - Conducted June 16-24, 2020
• Notification of Stack Testing - Clarios, LLC - Permit No. 1040-0129-CA, CB, CC and CD
• CX Scrubber, CX FEU Vent, Melter, Furnaces, Foundry Ventilation, Refining, & Slag Warehouse Emissions Testing - Conducted December 10-18, 2018 - REDACTED Summary
• CX Scrubber, Melter, Foundry Ventilation, & Slag Warehouse PM & Lead Test Plan Revision 1 - November 20, 2018
• CX FEU Vents PM, Lead, and Sulfuric Acid Mist Test Plan - January 9, 2017
• CX Scrubber PM, Lead, and Sulfuric Acid Mist Test Plan - August 17, 2016
• Slag Warehouse Temporary Baghouse PM and Lead Test Plan - July 17, 2015
• Annual CEMS RATA Test Plan - February 2015
• Furnaces 1 - 3, Refining Ventilation, Refining Combustion, and Refining Process Test Plan - December 2014
• CX Scrubber, Melter Foundry Ventilation, and Slag Warehouse MACT and Permit Required Stack Test Plan - October 2014 (revised November 2014)
• Unit ID's 01, 10, and 14 Stack Test and Unit ID's 06, 07, 08, 09, 11A, and 11B RATA Plan - February 2014
• Furnace No. 3 Initial MACT and Permit Test Plan - Revision 2 - May 17, 2013
• Johnson Controls Facility - Relative Accuracy Test Audit Test Plan Submitted November 21, 2012
• Johnson Controls Facility - Facility Source Test Plan Revision 1 - October 15, 2012

Letter Approving Stack Test Protocol

DHEC's approval of the stack test protocol describing any final information and/or reminders.

• December 12, 2012 Test Plan Approval Letter

Stack Test Results

After the stack test has been conducted, the facility is required to send a detailed stack test report to DHEC within 30 days of the stack test (or as otherwise approved by DHEC).

Letter Approving Stack Test

Once the stack test data is reviewed, DHEC will issue a final summary report. If DHEC approves the results, the summary report will contain the test results and any relevant operational parameters to be included in the operating permit. Otherwise, it would include the justification for the rejection of the tests and requirements for retesting.

• Furnace Nos. 1, 2, & 3, Refining Process, Refining FEU Vent, Refining Combustion, CX Scrubber, CX FEU Vent, Melter, Foundry Ventilation and Slag Warehouse Emissions Testing - Conducted December 7-14, 2020 - REDACTED Summary
• Furnace Nos. 1, 2, & 3, Refining Process, Refining FEU Vent, Refining Combustion, CX Scrubber, CX FEU Vent, Melter, Foundry Ventilation and Slag Warehouse Emissions Testing - Conducted December 9-14, 2019 - REDACTED Summary
• Furnaces 1, 2, 3, Melter, Refining Combustion, and Refining CEMS RATAs Conducted March 19-26, 2019
• Furnaces 1, 2, 3, Melter, and Refining CEMS RATAs Conducted March 20-28, 2018
• CX Plant, Furnaces, Refining, Foundry Ventilation, and Slag Warehouse Emissions Testing Conducted November 27 - December 13, 2017
• Furnaces 1, 2, 3, Melter, and Refining CEMS RATAs Conducted February 21 - March 1, 2017
• CX Plant FEU Vents Emissions Testing Conducted March 21-22, 2017
• Furnaces 1, 2, 3, Refining, and Slag Warehouse Emissions Testing Conducted January 10-19, 2017
• Foundry Ventilation and Melter & Charge Prep Emissions Testing Conducted December 6, 2016
• CX Plant PM, Lead, and Sulfuric Acid Testing Conducted October 4-5, 2016
• Furnaces 1, 2, 3, Melter, and Refining CEMS RATAs Conducted March 1-3, 2016 and March 22-24, 2016
• Refining and Slag Warehouse Lead and PM Testing Conducted February 10-12, 2016
• Furnaces 1, 2, &3, PM and Lead Testing Conducted January 19-22 and February 9-10, 2016
• Foundry Ventilation and Melter Lead Testing Conducted December 2-4, 2015
• CX Plant Lead Emissions Testing Conducted October 8, 2015
• Furnaces 1, 2, 3, Melter, and Refining CEMS RATAs Conducted March 10-18, 2015
• Furnaces 1, 2, 3, and Refining Emissions Testing Conducted January 13-22, 2015
• Melter and Charge Prep PM, Lead, Mercury, SO2 Emissions Testing Conducted January 6-7, 2015
• CX Plant, Foundry Ventilation, and Slag Warehouse PM, Lead, and Sulfuric Acid Emissions Testing Conducted December 9-11, 2014
• Furnaces 1, 2, 3, Melter, and Refining CEMS RATAs Conducted March 18-27, 2014
• CX Plant, Foundry Ventilation, and Slag Warehouse Multi-Metals Testing Conducted March 18-26, 2014
• Furnace 3 (ID 09) Emissions Testing — Conducted June 4-6, 2013
• Furnaces 1 & 2 (ID 07 & 08), Foundry Ventilation (ID 10), Refining Kettles (ID 11A), Refining Kettles and Casting Baghouse (ID 11B), Refining Ventilation (ID 12), and Slag Warehouse (ID 14) Emissions Testing – Conducted February 4-12, 2013 – Revision 1
• No. 3 Smelter Furnace CEMS Initial Certification Testing and Kettle Process and Hornito Melter Alternative RATA Testing - Conducted May 21, 2013 - Revision 1
• No. 1 and No. 2 Smelter Furnaces, Hornito Melter, Kettle Combustion, and Kettle Process CEMS Initial Certification Testing - Conducted January 16-18, 22-23, and 31, 2013 - Revision 1
• Charge Preparation and Melter Emissions Testing - Conducted January 12-13, 2013 - Revision 1

Contacts

Bureau of Air Quality

Brenna Lindler
Permit Writer
(803) 898-0457

Connie Turner
Air Laboratories Director
(803) 896-0903

Bureau Of Land & Waste Management