AQ_F_1800341_20160129_PRMT_Permit

ti. PAT MCCRORY
Governor
t.
DONALD R.VAN DER VAART
µ Secretary
Air Quality SHEILA C.HOLMAN
ENVIRONMENTAL QUALITY
Director
January 29,2016
Mr. Matt Daniels
Plant Manager
GKN Sinter Metals - Conover
407 Thornburg Drive SE
Conover,NC 28613
Subject: Air Permit No. 06135R12
GKN Sinter Metals - Conover
Conover, Catawba County,North Carolina
Permit Class: Small
Facility ID# 1800341
Dear Mr. Daniels:
In accordance with your completed application received January 13, 2016, we are
forwarding herewith Permit No. 06135R12 to GKN Sinter Metals - Conover, Conover, Catawba
County, North Carolina for the construction and operation of air emissions sources or air cleaning
devices and appurtenances. Additionally, any emissions activities determined from your air permit
application as meeting the exemption requirements contained in 15A NCAC 2Q .0102 have been
listed for information purposes as an "ATTACHMENT" to the enclosed air permit. Please note the
records retention requirements are contained in General Condition 2 of the General Conditions and
Limitations.
If any parts,requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request a formal adjudicatory hearing within 30 days following receipt of this
permit, identifying the specific issues to be contested. Such a request will stay the effectiveness of
the entire permit. This hearing request must be in the form of a written petition, conforming to G.S.
150B-23 of the North Carolina General Statutes, and filed with the Office of Administrative
Hearings, 6714 Mail Service Center, Raleigh,NC 27699-6714. The form for requesting a formal
adjudicatory hearing may be obtained upon request from the Office of Administrative Hearings.
Unless a request for a hearing is made pursuant to G.S. 15013-23,this air permit shall be final and
binding.
You may request modification of your air permit through informal means pursuant to G.S.
150B-22. This request must be submitted in writing to the Director and must identify the specific
provisions or issues for which the modification is sought. Please note that the permit will become
final and binding regardless of a request for informal modification unless a request for a hearing is
also made under G.S. 150B-23.
State of North Carolina I Environmental Quality I Air Quality
Mooresville Regional Office 1 610 East Center Avenue,Suite 301 1 Mooresville,NC 28115
704 663 1699 T 1 704 663 7579 F

Matt Daniels
January 29, 2016
Page 2
Unless exempted by a condition of this permit or the regulations, construction of new
air pollution sources or air cleaning devices, or modifications to the sources or air cleaning
devices described in this permit must be covered under a permit issued by the.Division of Air
Quality prior to construction.Failure to.do so is a violation of G.S. 143-215.108 and may
subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143-
215.114B.
This permit shall be effective from January 29, 2016 until December 31, 2016, is
nontransferable to future owners and operators, and shall be subject to the conditions and limitations
as specified therein.
Changes have been made to the permit stipulations. The Permittee is responsible for
carefully reading the entire permit and evaluating the requirements of each permit
stipulation. The Permittee shall comply with all terms, conditions, requirements,limitations
and restrictions set forth in this permit. Noncompliance with any permit condition is grounds
for enforcement action, for permit termination, revocation and reissuance, or modification, or
for denial of a permit renewal application. Should you have any questions concerning this matter,
please contact Jim Hafner at 704-235-2217.
Sincerely,
Ronald E. Slack, Regional Supervisor
Division of Air Quality,NC DEQ
JAH
Enclosures
c: Mooresville Regional Office
G:\AQ\SHARED\WPDATA\COUNTIES\CATAWBA\00341\R12_PERMIT.DOCX

NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF AIR QUALITY
AIR PERMIT NO. 06135R12
Issue Date: January 29, 2016 Effective Date: January 29,2016
Expiration Date: December 31, 2016 Replaces Permit: 06135RI I
To construct and operate air emission source(s) and/or air cleaning device(s),and for the
discharge of the associated air contaminants into the atmosphere in accordance with the provisions
of Article 21B of Chapter 143, General Statutes of North Carolina(NCGS) as amended, and other
applicable Laws, Rules and Regulations,
GKN Sinter Metals - Conover
407 Thornburg Drive SE
Conover, Catawba County,North Carolina
Permit Class: Small
Facility ID# 1800341
(the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air
cleaning devices and appurtenances described below:
Emission Emission Source Control Control System
Source ID Description System ID Description
Powder Metal Presses
CI,C10,C2,C3,C4, two(2)powder metal CD-DC2 cartridge-type filter(3,000
C7,C8,C9 presses(ID Nos.C1 and C2, square feet of filter area)
83 pounds per hour
maximum process rate,
each)
three(3)powder metal
presses(ID Nos.C7,C9,
and C10, 132 pounds per
hour maximum process rate,
each)
two(2)powder metal
presses(ID Nos.C3 and C4,
41.5 pounds per hour
maximum process rate,
each)
one(1)powder metal press
(ID No. C8,212 pounds per
hour maximum process rate)

Permit No. 06135R12
Page 2
Emission Emission Source Control Control System
Source ID Description System ID Description
C11 powder metal press(800 CD-DC3 bagfilter(1,300 square feet
pounds per hour maximum of filter area)
process rate)
Sintering Furnaces
ES-212 electric aluminum powdered 101 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-213 electric aluminum powdered 102 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-214 electric aluminum powdered 103 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-215 electric aluminum powdered 104 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-216 electric aluminum powdered 105 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-217 electric aluminum powdered 106 natural gas-fired stack
metal sintering furnace(300 burner(0.53 million Btu per
pounds per hour maximum hour maximum heat input)
process rate)
ES-218 electric aluminum powdered 107 natural gas-fired stack
metal sintering furnace(300 burner(0.795 million Btu
pounds per hour maximum per hour maximum heat
process rate) input)
in accordance with the completed application 1800341.16A received January 13, 2016 including
any plans, specifications,previous applications, and other supporting data, all of which are filed
with the Department of Environmental Quality, Division of Air Quality(DAQ) and are incorporated
as part of this permit.
This permit is subject to the following specified conditions and limitations including any
TESTING, REPORTING, OR MONITORING REQUIREMENTS:
A. SPECIFIC CONDITIONS AND LIMITATIONS
1. Any air emission sources or control devices authorized to construct and operate above must
be operated and maintained in accordance with the provisions contained herein. The
Permittee shall comply with applicable Environmental Management Commission

Permit No. 06135R12
Page 3
Permittee shall comply with applicable Environmental Management Commission
Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter
2D .0202, 2D .0515, 2D .0516, 2D .0521, 2D .0535, 2D .0540,2D .0611 and 2Q .0711.
2. PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT -The Permittee,
at least 90 days prior to the expiration date of this permit,shall request permit renewal by
letter in accordance with 15A NCAC 2Q .0304(d) and(f). Pursuant to 15A NCAC 2Q
.0203(i),no permit application fee is required for renewal of an existing air permit(without
a modification request). The renewal request(with AA application form) should be
submitted to the Regional Supervisor, DAQ. Also, at least 90 days prior to the expiration
date of this permit,the Permittee shall submit the air pollution emission inventory report
(with Certification Sheet) in accordance with 15A NCAC 2D .0202,pursuant to N.C.
General Statute 143 215.65. The report shall be submitted to the Regional Supervisor, DAQ
and shall document air pollutants emitted for the 2015 calendar year.
3. PARTICULATE CONTROL REQUIREMENT- As required by 15A NCAC 2D .0515
"Particulates from Miscellaneous Industrial Processes," particulate matter emissions from
the emission sources shall not exceed allowable emission rates. The allowable emission rates
are, as defined in 15A NCAC 2D .0515, a function of the process weight rate and shall be
determined by the following equation(s), where P is the process throughput rate in tons per
hour(tons/hr) and E is the allowable emission rate in pounds per hour(lbs/hr).
E=4.10 * (P) 0.67 for P <=30 tons/hr, or
E= 55 * (P) o.ii _ 40 for P>30 tons/hr
4. SULFUR DIOXIDE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0516
"Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the
combustion sources shall not exceed 2.3 pounds per million Btu heat input.
5. VISIBLE EMISSIONS CONTROL REQUIREMENT-As required by 15A NCAC 2D
.0521 "Control of Visible Emissions," visible emissions from the emission sources,
manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged
over a six-minute period, except that six-minute periods averaging not more than 87 percent
opacity may occur not more than once in any hour nor more than four times in any 24-hour
period. However, sources which must comply with 15A NCAC 2D .0524 "New Source
Performance Standards" or .1110 "National Emission Standards for Hazardous Air
Pollutants" must comply with applicable visible emissions requirements contained therein.
6. NOTIFICATION REQUIREMENT As required by 15A NCAC 2D .0535,the Permittee of
a source of excess emissions that last for more than four hours and that results from a
malfunction, a breakdown of process or control equipment or any other abnormal
conditions, shall:
a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time
of the Division's next business day of becoming aware of the occurrence and
describe:
i. the name and location of the facility,

Permit No. 06135R12
Page 4
ii. the nature and cause of the malfunction or breakdown, .
iii. the time when the malfunction or breakdown is first observed,
iv. the expected duration,and
V. an estimated rate of emissions.
b. Notify the Director or his designee immediately when the corrective measures have
been accomplished.
This reporting requirement does not allow the operation of the facility in excess of
Environmental Management Commission Regulations.
7. FUGITIVE DUST CONTROL REQUIREMENT - As required by 15A NCAC 2D .0540
"Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow
fugitive dust emissions to cause or contribute to substantive complaints or excess visible
emissions beyond the property boundary. If substantive complaints are received or excessive
fugitive dust emissions from the facility are observed beyond the property boundaries for six -
minutes in any one hour(using Reference Method 22 in 40 CFR,Appendix A),the owner or
operator may be required to submit a fugitive dust plan as described in 2D .0540(f).
"Fugitive dust emissions" means particulate matter that does not pass through a process
stack or vent and that is generated within plant property boundaries from activities such as:
unloading and loading areas,process areas stockpiles, stock pile working,plant parking lots,
and plant roads (including access roads and haul roads).
8. FABRIC FILTER REQUIREMENTS including cartridge filters,baghouses, and other dry
filter particulate collection devices -As required by 15A NCAC 2D .0611,particulate matter
emissions shall be controlled as described in the permitted equipment list.
a. Inspection and Maintenance Requirements - The inspection,maintenance and record
keeping requirements shall become effective February 27, 2016 for bagfilter(ID No.
CD-DC3). To comply with the provisions of this permit and ensure that emissions do
not exceed the regulatory'limits,the Permittee shall perform, at a minimum, an
annual (for each 12 month period following the initial inspection) internal inspection
of each particulate collection device system. In addition, the Permittee shall perform
periodic inspections and maintenance as recommended by the equipment
manufacturer.
b. Recordkeeping Requirements - The results of all inspections and any variance from
manufacturer's recommendations or from those given in this permit(when
applicable) shall be investigated with corrections made and dates of actions recorded
in a logbook: Records of all maintenance activities shall be recorded in the logbook.
The logbook (in written or electronic format) shall be kept on-site and made
available to DAQ personnel upon request.
9. STACK BURNER REQUIREMENTS -As required by 15A NCAC 2D .0611, particulate
matter emissions shall be controlled as described in the permitted equipment list.

Permit No. 06135R12
Page 5
a. Inspection and Maintenance Requirements - The inspection,maintenance and record
keeping requirements shall become effective February 28, 2016 for stack burner(ID
No. 107). To comply with the provisions of this permit and ensure that emissions do
not exceed the regulatory limits,the Permittee shall perform, at a minimum, an
annual (for each 12 month period following the initial inspection) internal inspection
of each particulate collection device system. In addition,the Permittee shall perform
periodic inspections and maintenance as recommended by the equipment
manufacturer.
b. Recordkeeping Requirements - The results of all inspections and any variance from
the manufacturer's recommendations or from those given in this permit(when
applicable) shall be investigated with corrections made and dates of actions recorded
in a logbook. Records of all maintenance activities shall be recorded in the logbook.
The logbook (in written or electronic format) shall be kept on-site and made
available to DAQ personnel upon request.
10. TOXIC AIR POLLUTANT EMISSIONS LIMITATION REQUIREMENT - Pursuant to
15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," for each of the below listed
toxic air pollutants (TAPs),the Permittee has made a demonstration that facility-wide actual
emissions, where one or more emission release points are obstructed or non-vertically
oriented, do not exceed the Toxic Permit Emission Rates(TPERs) listed in 15A NCAC 2Q
.0711(a). The facility shall be operated and maintained in such a manner that emissions of
any listed TAPs from the facility, including fugitive emissions,will not exceed TPERs listed
in 15A NCAC 2Q .0711(a).
a. A permit to emit any of the below listed TAPs shall be required for this facility if
actual emissions from all sources will become greater than the corresponding
TPERs.
b. PRIOR to exceeding any of these listed TPERs,the Permittee shall be responsible
for obtaining a permit to emit TAPs and for demonstrating compliance with the
requirements of 15A NCAC 2D .1100 "Control of Toxic Air Pollutants".
c. In accordance with the approved application,the Permittee shall maintain records of
operational information demonstrating that the TAP emissions do not exceed the
TPERs as listed below:
Carcinogens Chronic Acute Systemic Acute
Pollutant (lb/yr) Toxicants Toxicants Irritants
(lb/day) (lb/hr) (lb/hr)
Acetaldehyde (75-07-0) .M.._�. __. � ._. _ _.._6_g.__._._.__
Acrolein '107-02-8)
Ammonia(as NH3) (7664-41-7) �� +��--- — ^� 0.68 _
Benzene (71-43-2) T 1 ���� l: _771

Permit No. 06135R12
Page 6
Carcinogens Chronic Acute Systemic Acute.
Pollutant (lb/yr) Toxicants Toxicants Irritants
(lb/day) (lb/hr) (lb/hr)
Benzo(a)pyrene (Component of
83329/POMTV& 56553/7PAH) 2.2
(50-32-8)
Formaldehyde (50-00-0) �� �� _ 0.04
Toluene (108-88-3) 98 1:4�
B. GENERAL CONDITIONS AND LIMITATIONS
1. In accordance with G.S. 143-215.108(c)(1), TWO COPIES OF ALL DOCUMENTS,
REPORTS, TEST DATA, MONITORING DATA,NOTIFICATIONS, REQUESTS FOR
RENEWAL, AND ANY OTHER INFORMATION REQUIRED BY THIS PERMIT shall
be submitted to the:
Regional Supervisor
North Carolina Division of Air Quality
Mooresville Regional Office
610 East Center Avenue, Suite 301
Mooresville,NC 28115
704-663-1699
For identification purposes, each submittal should include the facility name as listed on the
permit,the facility identification number, and the permit number.
2. RECORDS RETENTION REQUIREMENT - In accordance with 15A NCAC 2D .0605,
any records required by the conditions of this permit shall be kept on site and made available
to DAQ personnel for inspection upon request. These records shall be maintained in a form
suitable and readily available for expeditious inspection and review. These records must be
kept on site for a minimum of 2 years,unless another time period is otherwise specified.
3. ANNUAL FEE PAYMENT- Pursuant to 15A NCAC 2Q .0203(a),the Permittee shall pay
the annual permit fee within 30 days of being billed by the DAQ. Failure to pay the fee in a
timely manner will cause the DAQ to initiate action to revoke the permit.
4. EQUIPMENT RELOCATION - In accordance with 15A NCAC 2Q .0301,a new air permit
shall be obtained by the Permittee prior to establishing, building,erecting, using, or
operating the emission sources or air cleaning equipment at a site or location not specified in
this permit.
5. REPORTING REQUIREMENT- In accordance with 15A NCAC 2Q .0309, any of the
following that would result in previously unpermitted,new,or increased emissions must be
reported to the Regional Supervisor, DAQ:

Permit No. 06135R12
Page 7
a. changes in the information submitted in the application regarding facility emissions;
b. changes that modify equipment or processes of existing permitted facilities; or
c. changes in the quantity or quality of materials processed.
If appropriate,modifications to the permit may then be made by the DAQ to reflect any,
necessary changes in the permit conditions. In no case are any new or increased emissions
allowed that will cause a violation of the emission limitations specified herein.
6. In accordance with 15A NCAC 2Q .0309,this permit is subject to revocation or
modification by the DAQ upon a determination that information contained in the application
or presented in the support thereof is incorrect, conditions under which this permit was
granted have changed, or violations of conditions contained in this permit have occurred. In
accordance with G.S. 143-215.108(c)(1),the facility shall be properly operated and
maintained at all times in a manner that will effect an overall reduction in air pollution.
Unless otherwise specified by this permit,no emission source may be operated without the
concurrent operation of its associated air cleaning device(s) and appurtenances.
7. In accordance with G.S. 143-215.108(c)(1),this permit is nontransferable by the Permittee.
Future owners and operators must obtain a new air permit from the DAQ.
8. In accordance with G.S. 143-215.108(c)(1), this issuance of this permit in no way absolves
the Permittee of liability for any potential civil penalties which may be assessed for
violations of State law which have occurred prior to the effective date of this permit.
9. In accordance with G.S. 143-215.108(c)(1), this permit does not relieve the Permittee of the
responsibility of complying with all applicable requirements of any Federal, State, or Local
water quality or land quality control authority.
10. In accordance with 15A NCAC 2D .0605,reports on the operation and maintenance of the
facility shall be submitted by the Permittee to the Regional Supervisor, DAQ at such
intervals and in such form and detail as may be required by the DAQ. Information required
in such reports may include,but is not limited to,process weight rates,firing rates,hours of
operation, and preventive maintenance schedules.
11. A violation of any term or condition of this permit shall subject the Permittee to enforcement
pursuant to G.S. 143-215.114A, 143-215.11413, and 143-215.114C, including assessment of
civil and/or criminal penalties.
12. Pursuant to North Carolina General Statute 143-215.3(a)(2),no person shall refuse entry or
access to any authorized representative of the DAQ who requests entry or access for
purposes of inspection, and who presents appropriate credentials,nor shall any person
obstruct,hamper, or interfere with any such representative while in the process of carrying
out his official duties. Refusal of entry or access may constitute grounds for permit
revocation and assessment of civil penalties.
13. In accordance with G.S. 143-215.108(c)(1), this permit does not relieve the Permittee of the
responsibility of complying with any applicable Federal, State, or Local requirements

Permit No. 06135R12
Page 8
governing the handling, disposal, or incineration of hazardous,solid, or medical wastes,
including the Resource Conservation and Recovery Act(RCRA) administered by the
Division of Waste Management.
14. PERMIT RETENTION REQUIREMENT- In accordance with 15A NCAC 2Q .0110,the
Permittee shall retain a current copy of the air permit at the site. The Permittee must make
available to personnel of the DAQ,upon request,the current copy of the air permit for the
site.
15. CLEAN AIR ACT SECTION 112(r)REQUIREMENTS -Pursuant to 15A NCAC 2D .2100
"Risk Management Program," if the Permittee is required to develop and register a risk
management plan pursuant to Section 112(r) of the Federal Clean Air Act,then the
Permittee is required to register this plan with the USEPA in accordance with 40 CFR Part
68.
16. PREVENTION OF ACCIDENTAL RELEASES - GENERAL DUTY -Pursuant to Title I
Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants -Prevention of
Accidental Releases -Purpose and General Duty," although a risk management plan may not
be required, if the Permittee produces, processes, handles, or stores any amount of a listed
hazardous substance, the Permittee has a general duty to take such steps as are necessary to
prevent the accidental release of such substance and to minimize the consequences of any
release. This condition is federally-enforceable only.
17. GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS - If emissions
testing is required by this permit, or the DAQ, or if the Permittee submits emissions testing
to the DAQ in support of a permit application or to demonstrate compliance,the Permittee
shall perform such testing in accordance with 15A NCAC 2D .2600 and follow all DAQ
procedures including protocol approval,regional notification, report submittal, and test
results approval.
Permit issued this the 29th of January, 2016.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
hon E. Slack
Regional Supervisor
By Authority of the Environmental Management Commission
Air Permit No. 06135R12

ATTACHMENT to Permit No. 06135R12, January 29, 2016
Insignificant/Exempt Activities
Source Exemption Source of Source of Title V
Regulation TAPs? Pollutants?
.0102
I1 - lube oil dip tank (QIF No No
I-05 -powder metal press used 2Q .0102 No Yes
exclusively for R&D (c)(1)(C)(iv)
12 -natural gas-fired heat treating unit(2.0 2Q 0102
million BTU per hour maximum heat Yes Yes
input rate) (c)(2)(E)(i)
1. Because an activity is exempted from being required to have a permit or permit modification
does not mean that the activity is exempted from an applicable requirement or that the owner
or operator of the source is exempted from demonstrating compliance with any applicable
requirement.
2. When applicable, emissions from stationary source activities identified above shall be
included in determining compliance with the permit requirements for toxic air pollutants
under 15A NCAC 2D .1100 "Control of Toxic Air Pollutants" or 2Q .0711 "Emission Rates
Requiring a Permit."
3. Sample permit conditions showing the regulatory requirements for exempt sources subject to
NESHAP,NSPS, and NCAC rules may be found here: http://www.ncair.org/permits/insig/