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HomeMy WebLinkAboutAQ_F_1800365_20150519_PRMT_Permit ARA NCDENR North Carolina Department of Environment and Natural Resources Pat McCrory Donald R. van der Vaart Governor Secretary May 19, 2015 Mr. Reuben Cannon, Plant Manager Corning Optical Communications, LLC -HMTC PO Box 489 Hickory,NC 28603 Subject: Air Permit No. 06409R18 Corning Optical Communications, LLC - HMTC Hickory, Catawba County,North Carolina Permit Class: Small Facility ID# 1800365 Dear Mr. Cannon: In accordance with your completed application received April 23,2015,.we are forwarding herewith Permit No. 06409RI8 to Corning Optical Communications, LLC - HMTC, Hickory, 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. 150B-23,this air permit shall be final and binding. You may request modification of your air permit through informal means pursuant to G.S. 15013-22. 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. Mooresville Regional Office-Division of Air Quality 610 East Center Avenue,Suite 301,Mooresville,North Carolina 28115 Phone:704-663-1699/FAX:704-663-7579 Internet:www.ncdenr.gov An Equal Opportunity 1 Affirmative Action Employer-Made in part by recycled paper Reuben Cannon May 19, 2015 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 May 19, 2015 until March 31, 2018, 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 Bob Caudle at 704-663-1699. Sincerely, Ronald E. Slack, Regional Supervisor Division of Air Quality,NCDENR JCR Enclosures c: Mooresville Regional Office G:\AQ\SHARED\WPDATA\COUNTIES\CATAWBA\00365\R18_PERMIT.DOCX NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 06409R18 Issue Date: May 19, 2015 Effective Date: May 19, 2015 Expiration Date: March 31, 2018 Replaces Permit: 06409R17 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 21 B of Chapter 143, General Statutes of North Carolina(NCGS) as amended, and other applicable Laws, Rules and Regulations, Corning Optical Communications, LLC - HMTC 1164 23rd Street SE Hickory, Catawba County,North Carolina Permit Class: Small Facility ID# 1800365 (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 L Description System ID Description_ P101,P102,P103,P104, painting process 1 consisting P 105,P 106,P 107,P 108, of seventy two(72)painting P 109,P 110,PI 11,P 112, lines(ID Nos.P 101 through P113,P114,P115,P116, P172) P 117,PI 18,PI 19,P 120, P121,P122,P123,P124, P125,P126,P127,P128, P129,P130,P131,P132, P133,P134,P135,P136, N/A N/A' P137,P138,P139,P140, P141,P142,P143,P144, P 145,P 146,P 147,P 148, ' P149,P150,P151,P152, P153,P154,P155,P156, P 157,P 158,P 159,P 160, P161,P162,P163,P164, P 165,P 166,P 167,P 168, P169,P170,P171,P172 P301,P302,P303,P304, painting process 3 consisting P305,P306,P307,P308, of eighteen(18)painting P309,P310,P311,P312, lines(ID Nos. P301 through N/A N/A P313,P314,P315,P316, P318) P317,P318 Permit No. 06409R18 Page 2 Emission _ Emission Source Control Control System Source ID -- Description...-___.-_... .._. _. ......System ID _....__.....__I ...__.---.....__Description ._....._._-- P0322,P0323,P0324, painting process 4 consisting P0325,P0326,P0327, of twenty(20)painting lines P0328,P0329,P0330, (ID Nos.P0322 through P0331,P0332,P0333, P0341) N/A N/A IP1334,PI335,PO336, P0337,P0338,P0339, P0340,P0341 P701,P702,P703,P704, painting process 7 consisting P705,P706,P707,P708, of thirty two(32)painting P709,P710,P711,P712, lines(ID Nos.P701 through P713,P714,P715,P716, P732) N/A N/A P717,P718,P719,P720, P721,P722,P723,P724, P725,P726,P727,P728, P729,P730,P731,P732 C101,C102,C103,C104, cleaning process 1 consisting C105 of five(5)cleaning lines(ID N/A N/A -] Nos.C 101 through C 105) C601,C602,C603 cleaning process 2 consisting of three(3)cleaning lines (ID Nos.C601 through N/A N/A C603) C301,C302,C303,C304 cleaning process 3 consisting of four(4)cleaning lines(ID N/A N/A Nos.C301 through C304) C401,C402,C403,C404, cleaning process 4 consisting C405,C406 of six(6)cleaning lines(ID N/A N/A Nos.C401 through C406) E101,E102,E103,E104, extrusion process 1 E105,E106,E107,E108, consisting often(10) N/A N/A E109,E110 extrusion lines(ID Nos. E101 through El 10) E201,E202,E203,E204, extrusion process 2 E205,E206,E207,E208, consisting of forty(40) E209,E210,E211,E212, extrusion lines(ID Nos. E213,E214,E215,E216, E201 through E240) E217,E218,E219,E220, N/A N/A E221,E222,E223,E224, E225,E226,E227,E228, E229,E230,E231,E232, E233,E234,E235,E236, E237,E238,E239,E240 E301,E302,E303,E304, extrusion process 3 E305,E306,E307,E308, consisting of twelve(12) N/A N/A E309,E310,E311,E312 extrusion lines(ID Nos. E301 through E312) E401,E402,E403,E404, extrusion process 4 E405,E406,E407,E408, consisting often(10) N/A N/A E409,E410 extrusion lines(ID Nos. _...__._._.... -.._._....... E401 through E410)- -- - _... _......_..... _._..__... Permit No. 06409R18 Page 3 Emission Emission Source Control Control System Source ID __-Description _..._..__...... ._._------..----.System ID__...._...-----JDescription _.._._ �Lmetal machining L- — -N/A ��--�— N/A — —� AU ammonia usage N/A N/A PSB1 dry filter-type spray booth PW arts washer ..____________�_..___..___ p____--- ----_--------._--------._.____-� --------.--.-.__-----N/A......___..____--.-- N/A in accordance with the completed application 1800365.15A received April 23, 2015 including any plans, specifications,previous applications, and other supporting data, all of which are filed with the Department of Environment and Natural Resources, 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 Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0515, 2D .0521,2D .0535, 2D .0540;2D .0958 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 2016 calendar year. 3. PARTICULATE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from dry filter-type spray booth(ID No. PSB1) 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-" for P <= 30 tons/hr, or E= 55 * (P) 0-"- 40 for P>30 tons/hr Permit No. 06409RI 8 Page 4 4. 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. 5. 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, 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. 6. 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 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). Permit No. 06409R18 Page 5 7. 15A NCAC 2D .0958: WORK PRACTICES FOR SOURCES OF VOLATILE ORGANIC COMPOUNDS a. As required by 15A NCAC 2D .0958(c), for all sources at facilities that use volatile organic compounds (VOC) as solvents, carriers,material processing media, or industrial chemical reactants, or in similar uses that mix, blend, or manufacture volatile organic compounds, or emit volatile organic compounds as a product of chemical reactions;the Permittee shall adhere to the following required work practices: is The Permittee shall store all VOC-containing material not in use (including waste material) in containers covered with a tightly fitting lid that is free of cracks, holes, or other defects. ii. The Permittee shall clean up spills as soon as possible following proper safety procedures. iii. The Permittee shall store wipe rags in closed containers. iv. The Permittee shall not clean sponges, fabric, wood,paper products, and other absorbent materials. V. The Permittee shall drain solvents used to clean supply lines and other coating equipment into closable containers and close containers immediately after each use. vi. The Permittee shall clean mixing, blending, and manufacturing vats and containers by adding cleaning solvent, closing the vat or container before agitating the cleaning solvent. vii. The Permittee shall pour spent cleaning solvent into closable containers and close containers immediately after each use. b. As required by 15A NCAC 2D .0958(d), when cleaning parts with a solvent containing a volatile organic compound,the Permittee shall: i. flush parts in the freeboard area, ii. take precautions to reduce the pooling of solvent on and in the parts, iii. tilt or rotate parts to drain solvent and allow a minimum of 15 seconds for drying or until all dripping has stopped, whichever is longer, iv. not fill cleaning machines above the fill line, V. not agitate solvent to the point of causing splashing. Permit No. 06409R18 Page 6 8. 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: Chronic Acute Acute Pollutant Carcinogens Toxicants Systemic Irritants (lb/yr) (lb/day) Toxicants (Ib/hr) (lb/hr) Acetic acid(64-.19-7)_...__.___. .._...._.._�� � . _ 0.96 Ammonia(as NH3) Benzene (71 43-2)ry-^ g l Formaldehyde (5040�0) � 0.04 MEK(methyl ethyl ketone, 2- 78 F 22.4 butanone) (78-93-3) MIBK(methyl isobutyl ketone) 52 7.6 (108-10-1) Methyl chloroform^(71-55-6) 64 --^- Methylene chloride (75-09-2) _ 1600 � 0.39� Perchloroethylene 13000 (tetrachloroethylene) (127-18-4) L______- Phenol (108-95 2) 0.24 Toluene (108-88-3) _.._98 _.._ 14.4 Vinyl chloride (75-01-4) M v^26- ____...-... r(mixed isomers) (1330- 57 16.4 Permit No. 06409R18 Page 7 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: 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. Permit No. 06409R18 Page 8 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, 143-215.114B, 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 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. Permit No. 06409R18 Page 9 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 21) .2600 and follow all DAQ procedures including protocol approval, regional notification, report submittal, and test results approval. Permit issued this the 19th of May, 2015. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Ronald E. Slack Regional Supervisor By Authority of the Environmental Management Commission Air Permit No. 06409R18 ATTACHMENT to Permit No. 06409R18, May 19, 2015 Insignificant/Exempt Activities Source Exemption Source of Source of Title V Regulation TAPs? Pollutants? FC501 - cleaning process ]1 (Q Yes Yes IC502 - cleaning process 2Q .0102(c)(1)(C)(iv) Yes Yes IC503 - cleaning process 2Q .0102 iv) Yes Yes (c)(1)(C)( IC504 - cleaning process 0102(� )(C)(iv) Yes Yes IMPDE - five (5) MPDE storage silos 2Q .0102 No Yes (c)(2)(E)(i) -- IFR- flexible resin vacuum system 2Q .0102 venting to a fabric filter (c)(2)(E)(i) No Yes IAC - industrial air cleaner 2Q .0102 Yes Yes [IVH -vent hood 2Q .0102 Yes Yes (c)(2)(E)(i) ISH - four(4) oil evaporation lines each 12Q .0102 No Yes venting to a Smog Hog (c)(2)(E)(i) IE619 -research/saleable product 2Q .0102 extrusion line (c)(2)(E)(i) No Yes IE975 -research/saleable product 112Q .0102 extrusion line No Yes FI-SO - soldering operation � .0102 xii) ]F No No FI-_DR.Y-.nine (9) electric dryers (Q.0102)(L)(xii) No No 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."