Holcim's air-quality violations highlighted

By KAYLEY MENDENHALL Chronicle Staff Writer

Holcim, the cement manufacturer near Trident, has had more "upset" hours and mechanical malfunctions in the past year than in previous years.

An upset occurs any time the smoke coming out of the stack is more than 20 percent opaque, said John Raudsep, the Montana Department of Environmental Quality compliance inspector who watches Holcim. Holcim's air-quality permit requires the smoke be less than 20 percent opaque.

From January through Nov. 15 of this year, Holcim had about 440 upset hours, according to DEQ reports.

For the same time period the year before, Holcim experienced only about 120 upset hours.

"We are very concerned that these malfunctions are impacting air quality in the Gallatin Valley," said Jennifer Swearingen, a member of Montanans Against Toxic Burning, which is calling attention to Holcim's environmental record.

But Nicole Prokop, Holcim's environmental manager, said this year has only been bad for upsets because the 94-year-old plant has had extreme maintenance problems -- not because the cement-making process is flawed.

The plant was built in 1908, although much of the equipment has been replaced over the years, she said. This past year several large pieces of machinery failed and required replacement or repair.

"I don't know if it's bad luck or wear or fatigue," she said.

Opaque smoke means the emissions contain more visible air contaminants than allowed by Montana air quality laws.

"When it comes out the stack and it is completely clear, that is zero opacity," Raudsep said, adding that entirely black smoke would be 100 percent opaque.

Opacity levels increase when machinery breaks down and an unstable condition is created in the cement kiln.

The opacity levels are of particular concern to MATB, which formed in 2000 to fight Holcim's application to add whole tires to its mix of fuel for the cement kiln.

Swearingen said if Holcim is already having problems with upsets, adding to the pollution by using tires for fuel is a bad idea.

The tire-burning application has been returned to Holcim numerous times by the DEQ requesting clarification and additional information.

DEQ received information from Holcim on Nov. 15 and is still reviewing the application for completeness, said Dave Klemp, air permitting supervisor.

Meanwhile, Raudsep has not fined Holcim for the upsets because he believes the company is working to fix its problems.

"My evaluation this year has shown the routine items they had last year ... they have done a lot of work to correct those and I have seen a drop in those," Raudsep said.

"The ones this year are major equipment-type things. I don't anticipate those reoccurring again."

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