Facility Information

Site Background

In May 2014, Shell Chemical Appalachia LLC (Shell) submitted initial applications to DEP necessary to construct a petrochemicals complex in Potter Township, Beaver County. Shell has renamed the facility Shell Polymers Monaca Site. The facility includes several ethane cracking furnaces and polyethylene units that use ethane (a natural gas product) to produce polyethylene (a common type of plastic), and three gas powered electricity generating turbines. This first-of-its-kind facility in Pennsylvania required several complex environmental reviews, approvals, and permits from DEP for new construction, remediation of contamination from previous industrial activities on the property, and operation.

The facility has been constructed and began polyethylene production processes in fall 2022. Under Permitting/Approvals, the Title V Operating Permit section includes a recently submitted Title V Operating Permit Application that is currently under review.

Permitting/Approvals

Accordion ‭[1]‬

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As part of the construction of petrochemical complex, Shell remediated the contaminated former Horsehead Corporation zinc smelter property under the Pennsylvania’s Land Recycling (Act 2) program. Shell submitted and DEP has approved a remedial investigation report, risk assessment, cleanup plan, and final report under the Act 2 program. Pursuant to the Cleanup Plan, Shell has covered most of the site with clean fill and has installed a synthetic cap over previous disposal areas on the property to prevent contact with any contaminated soils. Shell has collected all potentially contaminated storm water during construction and treated it prior to discharge under its NPDES permit. Groundwater use at the site will be restricted under an environmental covenant following completion of Act 2.

DEP approved the final report demonstrating attainment of site-specific and statewide health standards for cleanup of historic contamination in soil and groundwater. Clean up standards were achieved through remediation of soils and groundwater with institutional and engineering controls including a groundwater use restriction and pathway elimination for direct contact of contaminated soils. A post remediation care plan and soil management plan were included and approved with the final report. An environmental covenant is required for the site to ensure compliance with achieved remediation under the site-specific standard.

For more information on the Act 2 process, visit DEP's Land Recycling Program page.

On November 17, 2023, Shell submitted a final report.

Act 2 Final Report – November 17, 2023 (PDF)

On February 6, 2024, DEP issued a technical deficiency letter.

Technical Deficiency Letter – February 6, 2024 (PDF)

As part of the construction of petrochemical complex, Shell is remediating the contaminated former Horsehead Corporation zinc smelter property under the Pennsylvania’s Land Recycling (Act 2) program. Shell has submitted and DEP has approved a remedial investigation report, risk assessment, and cleanup plan under the Act 2 program. Shell is currently completing groundwater attainment monitoring and then will submit a final report. Pursuant to the Cleanup Plan, Shell has covered most of the site with clean fill and has installed a synthetic cap over previous disposal areas on the property to prevent contact with any contaminated soils. Shell has collected all potentially contaminated storm water during construction and treated it prior to discharge under its NPDES permit. Groundwater use at the site will be restricted under an environmental covenant following completion of Act 2.

For more information on the Act 2 process, visit DEP's Land Recycling Program page.

On November 17, 2023, Shell submitted a final report.