HomeMy WebLinkAboutAQ_F_0800109_20150416_PRMT_Permit NER
North Carolina Department of Environment and Natural Resources
Pat McCrory Donald R.van der Vaart
Governor Secretary
April 16, 201 S
Mr. Wayne Black
Director Perdue Agribusiness
Perdue Foods LLC-Lewiston
Post Office Box 460
Lewiston,NC 27849
Subject: Air Permit No. 10265R02
Perdue Foods LLC - Lewiston
Lewiston Woodville,Bertie County, North Carolina
Permit Class: Synthetic Minor
Facility ID#0800109
Dear Mr. Black:
In accordance with your completed application received April 7, 2015, we are forwarding
herewith Permit No. 10265R02 to Perdue Foods LLC - Lewiston, Lewiston Woodville, Bertie
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.
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
Washington Regional Office-Division of Air Quality
943 Washington Square Mall,Washington,North Carolina 27889
Phone:252-946-6481/FAX:252-975-3716
Internet:www.ncdenr.gov
An Equal Opportunity 1 Affirmative Action Employer-Made in part by recycled paper
Mr. Wayne Black
April 16, 2015
Page 2
final and binding regardless of a request for informal modification unless a request for a hearing is
also made under G.S. 150B-23.
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 April 16, 2015 until September 30, 2017, 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. No.2 fuel oil has been added to
the boiler descriptions and permit Specific Conditions 3, 10 and 12. 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 Betsy Huddleston at 252-948-3836.
Sincerely,
57
Robert P. Fisher,Regional Supervisor
Division of Air Quality,NCDENR
eth/RPF
Enclosures
c: Washington Regional Office
(g:\AQ\Shared\Bertie08\00109\08A00109SMR02.doc)
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF AIR QUALITY
AIR PERMIT NO. 10265R02
Issue Date: April 16, 2015 Effective Date: April 16, 2015
Expiration Date: September 30, 2017 Replaces Permit: 10265ROI
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,
Perdue Foods LLC - Lewiston
3569 Governors Road
Lewiston, Bertie County,North Carolina
Permit Class: Synthetic Minor
Facility ID# 0800109
(the Permittee)is hereby authorized to construct and operate the air emissions sources and/or air
cleaning devices and appurtenances described below:
.. ..
Control _W W . :: w. . .: .._
Emission Emission Source'' Control System
System
Source ID Description ID Description
ES-1 Three(3)live poultry receiving and handling systems CD-1 bagfilters(2,800 square feet of
ES-2 CD-2 filter area,each)
ES 3 I CD-3
..._....... .... ............ ... .....
ES-4 F Two(2)natural /No.2 fuel oil/No.6 fuel oil-fired
N/A ES-5 boilers(20.3 million Btu per hour maximum heat input
capacity) gas
ES-22A Two(2)diesel-fired emergency/peak shaving generators
ES-22B 1(2628 horsepower engine output) N/A N/A
(NESHAP)
in accordance with the completed application 0800109.15A received April 7, 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:
Permit No. 10265ROl
Page 2
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 .0503,2D .0515,2D .0516, 2D .0521, 2D .0535, 2D .0540, 2D .0611, 2D
.1111 (40 CFR 63, Subparts JJJJJJ and ZZZZ), 2D .1806, 2Q .0315, and 2Q .0317
(Avoidance) .
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 .0503
"Particulates from Fuel Burning Indirect Heat Exchangers," particulate matter emissions
from the fuel burning indirect heat exchangers shall not exceed the allowable emission rates
listed below:
Emission Limit
Source (lbs/million Btu)
_ .....
_............ _..... _............. ............. ............_.__.........._.....__.._ __....: m ....._...... _... :
Natural gas/No 2 fuel oil/No. 6 fuel oil-fired boilers ID Nos. ES-
4 and ES-5 (20.3 million Btu per hour maximum heat input 0.42 (each)
capacity)
�...
.............................. ... i
4. PARTICULATE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0515
"Particulates from Miscellaneous Industrial Processes," particulate matter emissions from
the poultry receiving and handling systems 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) 0.11- 40 for P>30 tons/hr
5. SULFUR DIOXIDE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0516
"Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the
boilers and generators shall not exceed 2.3 pounds per million Btu heat input.
Permit No. 10265ROl
Page 3
6. 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.
7. 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.
8. 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. 10265ROI
Page 4
9. FABRIC FILTER REQUIREMENTS includingcartridge artridge filters,baghouses, and other dry
filter particulate collection devices -As required by 15A NCAC 2D .0611, particulate matter
emissions from the poultry receiving and handling systems shall be controlled by bagfilters
(ID Nos. CD-1, CD-2 and CD-3).
a. Inspection and Maintenance Requirements -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 bagfilter 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.
10. GENERALLY AVAILABLE CONTROL TECHNOLOGY-For the natural gas/No. 2 fuel
oil No. 6 fuel oil-fired boilers (ID Nos. ES-4 and ES-5) (20.3 million Btu per hour
maximum heat input capacity),the Permittee shall comply with all applicable provisions,
including the notification,testing, and monitoring requirements contained in Environmental
Management Commission Standard 15A NCAC 2D .1111, as promulgated in 40 CFR 63,
Subpart JJJJJJ, "National Emission Standards for Hazardous Air Pollutants for Area
Sources: Industrial, Commercial, and Institutional Boilers", including Subpart A "General
Provisions."
a. Compliance Dates (40 CFR 63.11196) - The owner or operator of an existing source
subject to a work practice or management practice standard of a tune-up was
required to comply with this final rule no later than March 21, 2012. The owner or
operator of an existing source subject to an energy assessment requirement is
required to comply with this final rule no later than March 21, 2014.
b. Compliance Requirements -As required by 15A NCAC 2D .1111,the Permittee
shall comply with the following requirements:
i. General Duty Clause(40 CFR 63.11205(a)) -At all times the Permittee shall
operate and maintain any affected source, including associated air pollution
control equipment and monitoring equipment, in a manner consistent with
safety and good air pollution control practices for minimizing emissions.
ii. Boiler Tune-up (40 CFR 63.11223) -An initial boiler tune-up was required
by March 21, 2012.A biennial tune-up is also required and shall be
conducted no more than 25 months after the previous tune-up. If the unit is
not operating on the required date for a tune-up,the tune-up must be
conducted within one week of startup. The tune-up shall include the
following:
Permit No. 10265R0l
Page 5
A. As applicable, inspect the burner, and clean or replace any
components of the burner as necessary (the Permittee may delay the
burner inspection until the next scheduled unit shutdown, but must
inspect each burner at least.once every 36 months).
B. Inspect the flame pattern, as applicable, and adjust the burner as
necessary to optimize the flame pattern. The adjustment should be
consistent with the manufacturer's specifications, if available.
C. Inspect the system controlling the air-to-fuel ratio, as applicable, and
ensure that it is correctly calibrated and functioning properly.
D. Optimize total emissions of carbon monoxide. This optimization
should be consistent with the manufacturer's specifications, if
available.
E. Measure the concentrations in the effluent stream of carbon monoxide
in parts per million, by volume, and oxygen in volume percent, before
and after the adjustments are made(measurements may be either on a
dry or wet basis, as long as it is the same basis before and after the
adjustments are made).
F. Maintain onsite a biennial report (see item c. below) containing:
I. The concentrations of CO in the effluent stream in parts per
million, by.volume, and oxygen in volume percent,measured
before and after the tune-up of the boiler.
II. A description of any corrective actions taken as a part of the
tune-up of the boiler.
III. The type and amount of fuel used over the 12 months prior to
the biennial tune-up of the boiler.
iii. Energy Assessment(40 CFR 63.11214(c)) -A one-time initial energy
assessment is required by March 21,2014.The energy assessment must be
performed by a qualified energy assessor. An energy assessment completed
on or after January 1, 2008,that meets or is amended to meet the energy
assessment requirements in this section satisfies the energy assessment
requirement. The energy assessment must include:
A. A visual inspection of the boiler system.
B. An evaluation of operating characteristics of the facility,
specifications of energy using systems, operating and maintenance
procedures, and unusual operating constraints.
C. Inventory of major systems consuming energy from affected boilers.
Permit No. 10265R0l
Page 6
D. A review of available architectural and engineering plans, facility
operation and maintenance procedures and logs, and fuel usage.
E. A list of major energy conservation measures.
F. A comprehensive report detailing the ways to improve efficiency, the
cost of specific improvements,benefits, and the time frame for
recouping those investments.
c. Notification and Reporting Requirements - In addition to the notification and
reporting requirements of the Environmental Protection Agency (EPA),the
Permittee is required to NOTIFY the Regional Supervisor,DAQ, in WRITING, of
the following:
i. Initial Notification(per 40,CFR 63.9(b) and 40 CFR 63.11225(a)(2))was
required by September 17, 2011.
ii. Notification of Compliance Status (40 CFR 63.11225(a)(4))was required by
July 19, 2012. If the compliance status notification for the energy assessment
is not included in the July 19, 2012 notification, a separate notification for
this requirement is required by July 19, 2014.
iii. Biennial Compliance Re o�rt must be prepared by March 1 of every other
year starting March 1, 2015 and submitted upon request. If the source
experiences any deviations from the applicable requirements,then a report
must be submitted by March 15. The report must meet the requirements of 40
CFR 63.11225(b)(1-4).
d. Recordkeeping Requirements - In addition to any other recordkeeping requirements
of the EPA,the Permittee shall maintain the following records as defined under 40
CFR 63.11225(c):
i. Copies of all required notifications.
ii. Maintain records to document conformance with the work practices, emission
reduction measures, and management practices:
A. Tune-up records records must identify each boiler, the date of tune-
up,the procedures followed for tune-up, and the manufacturer's
specifications to which the boiler was tuned.
B. A copy the Energy Assessment required by 40 CFR 63.11214(c).
C. Records documenting the fuel type(s)used monthly by each boiler,
including, but not limited to, a description of the fuel, including
whether the fuel has received a nonwaste determination by the
Permittee or EPA, and the total fuel usage amount with units of
measure. If the Permittee combusts nonhazardous secondary materials
that have been determined not to be solid waste pursuant to 40 CFR
Permit No. 10265ROI
Page 7
241.3(b)(1),the Permittee must keep a record which documents how
the secondary material meets each of the legitimacy criteria. The
records may be annual, monthly, or periodic, depending on fuel
delivery frequencies.
iii. Malfunction Records -Records of the occurrence and duration of each
malfunction of the boiler, or of the associated air pollution control and
monitoring equipment. Records of actions taken during periods of
malfunction to minimize emissions in accordance with the general duty to
minimize emissions in 40 CFR 63.11205(a), including corrective actions to
restore the malfunctioning boiler, air pollution control, or monitoring
equipment to its normal or usual manner of operation.
iv. Record Retention- You must keep each record for 5 years following the date
of each recorded action.
11. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS -As required by 15A
NCAC 2D .1806 "Control and Prohibition of Odorous Emissions" the Permittee shall not
operate the facility without implementing management practices or installing and operating
odor control equipment sufficient to prevent odorous emissions from the facility from
causing or contributing to objectionable odors beyond the facility's boundary.
12. LIMITATION TO AVOID 15A NCAC 2Q .0501 -Pursuant to 15A NCAC 2Q .0315
"Synthetic Minor Facilities, to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of
Section and Requirement for a Permit," as requested by the Permittee, facility-wide
emissions shall be less than the following:
;pollutant Emission Limit
(Tons per consecutive 12-month period)
S02 100
NOx 100 .
a. Recordkeeping Requirements
i. The Permittee shall record monthly:
A. the amounts of No. 6 fuel oil,No. 2 fuel oil, diesel fuel, and natural
gas combusted for the month,
B. the rolling 12-month totals of fuel combusted, and
C. the rolling 12-month facility-wide S02 and NOx emissions.
ii. The sulfur content in fuel oil shall not exceed 2.1 percent sulfur by weight.
Fuel supplier sulfur certifications shall be kept on-site and made available to
DAQ personnel upon request.
iii. The Permittee shall keep each record on file for a minimum of three years.
Permit No. 10265ROl
Page 8
b. Reporting_Requirements - Within 30 days after each calendar year,regardless of the
actual emissions,the Permittee shall submit the following:
i. for each calendar month,the rolling 12-month totals of each fuel combusted,
and
ii. for each calendar month,the rolling 12-month facility-wide S02 and NOx
emissions.
13. LIMITATION TO AVOID 15A NCAC 2D .0530 "PREVENTION OF SIGNIFICANT
DETERIORATION" -In accordance with 15A NCAC 2Q .0317,to comply with this permit
and avoid the applicability of 15A NCAC 2D .0530 "Prevention of Significant
Deterioration," as requested by the Permittee,facility-wide S02 and NOx emissions shall be
less than 250 tons per consecutive 12-month period.
a. Recordkegpin and nd Reporting Requirements -The Permittee shall comply with the
recordkeeping and reporting requirements listed in Specific Conditions 12.a. and
12.b. of this Permit.
14. 15A NCAC 2D 1111 "MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY" for the
generators(ID Nos. ES-22A and ES-22B), which are considered existing,non-emergency,
non-black start, compression ignition(CI) reciprocating internal combustion engines (RICE)
greater than 500 brake horsepower,the Permittee shall comply with all applicable
provisions, including the notification,testing,recordkeeping,reporting and monitoring
requirements contained in Environmental Management Commission Standard 15A NCAC
2D .1111, "Maximum Achievable Control Technology" as promulgated in 40 CFR 63,
Subpart ZZZZ, "National Emissions Standards for Hazardous Air Pollutants for Stationary
Reciprocating Internal Combustion Engines", including Subpart A "General Provisions."
a. Compliance Date- Pursuant to 40 CFR 63.6595(a)(1),the source(s)must be in
compliance with 40 CFR 63, Subpart ZZZZ by May 3,2013.
b. Emission Limits -Pursuant to 40 CFR 63.6603(a); the affected source must comply
with the following emission limits, except during periods of startup:
i. The concentration of carbon monoxide(CO) in the exhaust cannot exceed 23
ppmvd at 15 percent oxygen;
Or
ii. Reduce CO emissions by 70 percent or more.
c. Testing-Pursuant to 40 CFR 63.6612(a), 63.6615, 63.6620, 63.6630, 63.6640, and
63.6645 the Permittee must:
i. Conduct an emission test per 40 CFR 63.6620 and Table 4 of 40 CFR 63
Subpart ZZZZ within 180 days after the compliance date.
Permit No. 10265ROI
Page 9
ii. Per 40 CFR 63.6630(b), during the initial performance test,the Permittee
must establish each operating limitation identified in Table 2b of 40 CFR 63
Subpart ZZZZ (summarized below):
For each CI RICE com plying with he Permittee must establish and record during initial
p y g performance testing the following operating limitations . .
the requirement to . . .
�Reduce CO emissions and using an The pressure drop across the catalyst and the temperature at
'oxidation catalyst; he catalyst inlet.
1OR rhe temperature for the catalyst inlet must be greater than or
1 equal to 450°F and less than or equal to 1350 'F. The
Limit the concentration of CO in the Permittee may petition the director of DAQ pursuant to the
'RICE exhaust by using an oxidation requirements of 40 CFR 63.8(g) for a different temperature
icatalyst range.
Reduce CO emissions and not using
pan oxidation catalyst;
lOr
Comply with any operating limitations approved by the DAQ
iLimit the concentration of CO in the Regional Supervisor.
;RICE exhaust and not using an
oxidation catalyst
Per 40 CFR 63.6620(f), if complying with the emission limitation to reduce CO in the exhaust
without using an oxidation catalyst the Permittee must petition the DAQ Regional Supervisor for
operating limitations to be established during the initial performance test and continuously
monitored thereafter, or for approval of no operating limitation.'The Permittee must not conduct
the initial performance,test until after the petition has been approved by the Regional Supervisor.
The petition must include the information described in 40 CFR 63.6620(g) or(h).
iii. Per 40 CFR 63.6620(i),the engine percent load during a performance test
must be determined by documenting the calculations, assumptions, and
measurement devices used to measure or estimate the percent load in a
specific application. A written report of the average percent load
determination must be included in the notification of compliance status. The
following information must be included in the written report: the engine
model number,the engine manufacturer, the year of purchase, the
manufacturer's site-rated brake horsepower, the ambient temperature,
pressure, and humidity during the performance test, and all assumptions that
were made to estimate or calculate percent load during the performance test
must be clearly explained. If measurement devices such as flow meters,
kilowatt meters; beta analyzers, stain gauges, etc. are used,the model number
Permit No. 10265R0I
Page 10
of the measurement device, and an estimate of its accuracy in percentage of
true value must be provided.
iv. The Permittee shall perform such testing in accordance with 40 CFR 63.6645.
and 15A NCAC 2D.2600 (see GENERAL EMISSIONS TESTING AND
REPORTING REQUIREMENTS in Section B. of this Air Permit). The
procedures are outlined below:
A. The Permittee must notify DAQ in writing of their intent to conduct
the performance test at least 60 days before the scheduled
performance test in accordance with 40 CFR 63.6645(g) and 40 CFR
63.7(b)(1).
B. The Permittee shall submit a completed Protocol Submittal Form to
the DAQ Regional Supervisor at least 45 days prior to the scheduled
test date. A copy of the Protocol Submittal Form may be obtained
from the Regional Supervisor.
C. The Permittee shall notify the Regional Supervisor of the specific test
dates at least 15 days prior to testing in order to afford the DAQ the
opportunity to have an observer on-site during the sampling program.
If a specific test date cannot be identified due to the operational
requirements of the RICE, then the Permittee shall notify the Regional
Supervisor of the approximate test date. If a specific test date is
identified within the 15 day notification timeframe identified above,
then the Permittee must notify the Regional Supervisor as soon as the
test date is determined.
D. The Permittee shall submit two copies of the test report to the DAQ.
The test report shall be submitted to the Regional Supervisor-DAQ
not later than 60 days after completion of testing. The Permittee may
request an extension to submit the final test report. The DAQ
Regional Supervisor will approve an extension request if it is
determined that the extension request is a result of actions beyond the
control of the Permittee. The test report shall contain at a minimum
the following information:
I. a description of the training and air testing experience of the
person directing the test;
II. a certification of the test results by the sampling team leader
and facility representative;
III. a summary of emissions results and text detailing the
objectives of the testing program,the applicable state and
federal regulations, and conclusions about the testing and
compliance status of the emission source(s);
Permit No. 10265RO l
Page 11
IV. a detailed description of the tested emission source(s),process
flow diagrams, engineering drawings, and sampling location
schematics should be included as necessary;
V. all field, analytical, and calibration data necessary to verify
that the testing was performed as specified in the applicable
test methods;
VI. example calculations for at least one test run using equations
in the applicable test methods and all test results including
intermediate parameter calculations.
E. The testing requirement(s) shall be considered satisfied only upon
written approval of the test results by the DAQ.
F. The DAQ will review emission test results with respect exclusively to
the specified testing objectives as proposed by the Permittee and
approved by the DAQ.
d. Initial Compliance Demonstration -Pursuant to 40 CFR 63.6630(a), initial
compliance for each existing,non-emergency,non-black start, compression ignition
reciprocating internal combustion engine greater than 500 brake horsepower is
provided in Table 5 of 40 CFR 63 Subpart ZZZZ and'shall`be demonstrated as
follows:
Foreach CI RICE� ..,,...._...._..�._,� .�.............. ...... .. .__..�..,_......_.�_._
complying with the [ The Permittee will demonstrate initial compliance if. . .
requirement to . I
kleduce_CO emissions i The average reduction of emissions of CO determined from the initial
=and using an oxidation erformance test achieves the required CO percent reduction; and
;catalyst, and using a
`continuous parameter ii. The Permittee has installed a CPMS to continuously monitor catalyst
1 onitoring system inlet temperature according to the requirements in§63.6625(b); and
(CPMS)
'iii. The Permittee has recorded the catalyst.pressure drop and catalyst inlet
emperature during the initial performance test.
Limit the concentration i. The average CO concentration determined from the
of CO,using an initial performance test is less than or equal to the
;oxidation catalyst, and CO emission limitation; and
;using a CPMS
I The Permittee has installed a CPMS to
continuously monitor catalyst inlet temperature
according to the requirements in §63.6625(b); and
ill. The Permittee has recorded the catalyst pressure
drop and catalyst inlet temperature during the
initial performance test.
w.,..............
Permit No. 10265R01
Page 12
For each Cl RICE
complying with the The Permittee will demonstrate initial compliance if. . .
requirement to . . .
Reduce CO emissions i. The average reduction of emissions of CO determined from the initial
.and not using an performance test achieves the required CO percent reduction; and
oxidation catalyst
ii. The Permittee has installed a CPMS to continuously monitor operating
parameters approved by the Administrator(if any) according to the
requirements in §63.6625(b); and
:iii. The Permittee has recorded the approved operating parameters (if any)
_ during the initial performance test.
T,imit the concentration The average CO concentration determined from the initial performance
of CO and not using an test is less than or equal to the CO emission limitation; and
oxidation catalyst
U. The Permittee has installed a CPMS to continuously monitor operating
parameters approved by the Administrator(if any) according to the
requirements in §63.6625(b); and
f
iii. The Permittee has recorded the approved operating parameters (if any)
;during the initial performance test.
Reduce CO emissions i. The Permittee has installed a CEMS to continuously monitor CO and
and using a CEMS either 02 or CO2 at both the inlet and outlet of the oxidation catalyst
according to the requirements in §63.6625(a); and
ii. The Permittee has conducted a performance evaluation of the CEMS
sing PS 3 and 4A of 40 CFR part 60, appendix B; and
iii. The average reduction of CO calculated using §63.6620 equals or
exceeds the required percent reduction. The initial test comprises the first
4-hour period after successful validation of the CEMS. Compliance is
:based on the average percent reduction achieved during the 4ur period.
Limit the concentration i. The Permittee has installed a CEMS to continuously monitor CO
.of CO and using a CEMS and either 02 or CO2 at the outlet of the oxidation catalyst
according to the requirements in,§63.6625(a); and
ii. The Permittee has conducted a performance evaluation of the
CEMS using PS 3 and 4A of 40 CFR part 60, appendix B; and
iii. The average concentration of CO calculated using §63.6620 is
less than or equal to the CO emission limitation. The initial test
comprises the first 4-hour period after successful validation of the
CEMS. Compliance is based on the average concentration
measured during the 4 hour period
Permit No. 10265R01
Page 13
e. Operating Requirements -Pursuant to 40 CFR 63.6603(a), 63.6604, and
63.6625(b), (g), and(h),the Permittee must:
i. Minimize the engine's time spent at idle during startup and minimize the
engine's startup time to a period needed for appropriate and safe loading of
the engine,not to exceed 30 minutes, after which time the non-startup
emission limitations apply.
ii. If the engine is not equipped with a closed crankcase ventilation system the
Permittee must:
A. Install a closed crankcase ventilation system that prevents crankcase
emissions from being emitted.
OR
B. Install an open crankcase filtration emission control system that
reduces emissions from the crankcase by filtering the exhaust stream
to remove oil mist,particulates, and metals.
iii. Follow the manufacturer's maintenance requirements for operating and
maintaining the open or closed crankcase ventilations system and replacing
crankcase filters.
iv. If the engine displacement is less than 30,liters per cylinder then the
Permittee must use diesel fuel that meets the requirements in 40 CFR
80.510(b)for nonroad diesel fuel.
Sulfur content 15 ppm maximum.
Cetane index A minimum cetane index of 40;
'OR OR
t .
Aromatic content A maximum aromatic content of 35 volume percent.
i
f. Monitoring Requirements -
i. Per 40 CFR 63.6603(a),the Permittee must.meet each operating limitation as
follows:
Permit No. 10265R01
Page 14
.............
For each CI RICE
complying with The Permittee must meet the following operating
the re uirement to . . . limitation. . .
Reduce CO emissions and a. maintain the catalyst so that the pressure drop across the catalyst
using an oxidation catalyst; does not change by more than 2 inches of water at 100 percent load
plus or minus 10 percent from the pressure drop across the catalyst
OR that,was measured during the initial performance test; and
Limit the concentration of b. maintain the temperature of the RICE exhaust so that the catalyst
I inlet temperature is greater than or equal to 450 °F and less than or
ex CO in the RICE exhaust and equal to 1350 'F. The Permittee may petition the director of DAQ
using an oxidation catalyst pursuant to the requirements of 40 CFR 63.8(g) for a different
emperature range.
i
Reduce CO emissions and
not using an oxidation
:catalyst;
OR Comply with any operating limitations approved by the Regional
I Supervisor-DAQ.
Limit the concentration of
CO in the RICE exhaust and
of using an oxidation
:catalyst
ii. If the Permittee is required to install a continuous parameter monitoring
system(CPMS) as specified in the table in Section d. "Initial Compliance
Demonstration" above, the Permittee must install, operate, and maintain each
CPMS according to the following requirements:
A. The Permittee must prepare a site-specific monitoring plan that
addresses the monitoring system design, data collection, and the
quality assurance and quality control elements outlined below and in
§63.8(d). As specified in §63.8(f)(4),the Permittee may request
approval of monitoring system quality assurance and quality control
procedures alternative to those specified below in the site-specific
monitoring plan.
I. The performance criteria and design specifications for the
monitoring system equipment, including the sample interface,
detector signal analyzer, and data acquisition and calculations;
II. Sampling interface (e.g., thermocouple) location such that the
monitoring system will provide representative measurements;
III. Equipment performance evaluations, system accuracy audits,
or other audit procedures;
Permit No. 10265ROl
Page 15
IV. Ongoing operation and maintenance procedures in accordance
with provisions in 40 CFR 63.8(c)(1) and(c)(3); and
V. Ongoing reporting and recordkeeping procedures in
accordance with provisions in 40 CFR 63.10(c), (e)(1), and
(e)(2)(i)•
B. The Permittee must install, operate,and maintain each CPMS in
continuous operation according to the procedures in the site-specific
monitoring plan.
C. The CPMS must collect data at least once every 15 minutes.
D. A CPMS for measuring temperature range,the temperature sensor
must have a minimum tolerance of 2.8 degrees Celsius (5 degrees
Fahrenheit) or 1 percent of the measurement range, whichever is
larger.
E.. The Permittee must conduct the CPMS equipment performance
evaluation, system accuracy audits, or other audit procedures
specified in the site-specific monitoring plan at least annually.
F. The Permittee must conduct a performance evaluation of each CPMS
in accordance with the site-specific monitoring plan.
iii. If the Permittee is required to install a continuous emissions monitor (CEMS)
as specified in the table in Section d. Initial Compliance Demonstrations"
above,the Permittee must install, operate, and maintain a CEMS to monitor
CO and either oxygen or CO2 at both the inlet and the outlet of the control
device according to the following requirements:
A. Each CEMS must be installed, operated, and maintained according to
the applicable performance specifications of 40 CFR part 60,
appendix B.
B. The Permittee must conduct an initial performance evaluation and an
annual relative accuracy test audit(RATA) of each CEMS according
to the requirements in 40 CFR 63.8 and according to the applicable
performance specifications of 40 CFR part 60, appendix B as well as
daily and periodic data quality checks in accordance with 40 CFR part
60, appendix F,procedure 1.
C. As specified in 40 CFR 63.8(c)(4)(ii),each CEMS must complete a
minimum of one cycle of operation(sampling, analyzing, and data
recording) for each successive 15-minute period. The Permittee must
have at least two data points,with each representing a different 15-
minute period,to have a valid hour of data.
Permit No. 10265ROl
Page 16
D. The CEMS data must be reduced as specified in 40 CFR 63.8(g)(2)
and recorded in parts per million or parts per billion(as appropriate
for the applicable limitation) at 15 percent oxygen or the equivalent
CO2 concentration.
g. Continuous Compliance Demonstration- Pursuant to 40 CFR 63.6640(a),and
Table 6 of 40 CFR 63 Subpart ZZZZ, continuous compliance for each existing,non-
emergency,non-black start, compression ignition reciprocating internal combustion
engine greater than 500 brake horsepower shall be demonstrated as follows:
Complying with the The Permittee must demonstrate continuous compliance by. . .
requirement to . . .
Reduce CO emissions, or limit•. Conducting performance tests every 8,760 hours or 3 years,
the concentration of CO in thewhichever comes first,.for CO to demonstrate that the required CO
;RICE exhaust, and using an ercent reduction is achieved or that the emissions remain at or
'oxidation catalyst below the CO concentration limit( ; and
j 'i. Collecting the catalyst inlet temperature data according to
§63.6625(b); and
•ii. Reducing these data to 4-hour rolling averages; and
•v. Maintaining the 4-hour rolling averages within the operating
imitations for the catalyst inlet temperature; and
Measuring the pressure drop across the catalyst once per month
and demonstrating that the pressure drop across the catalyst is within
j he operating limitation established during the performance test.
If the reciprocating internal combustion engine is limited use (ie,
operates less than 100 hours per year), then demonstrate compliance
by conducting the same performance testing as item "i"above every
8,760 hours or S years, whichever comes first. A limited use engine
must also comply with items as through v above. _
Reduce CO emissions or limit i. Collecting the monitoring data according to §63.6625(a), reducing
the concentration of CO in the khe measurements to 1-hour averages, calculating the percent
RICE exhaust, and using a reduction or concentration of CO emissions according to §63.6620;
;GEMS bnd
ii. Demonstrating that the catalyst achieves the required percent
eduction of CO emissions over the 4-hour averaging period, or that
he emission remain at or below the CO concentration limit; and
'ii. Conducting an annual RATA of the CEMS using PS 3 and 4A of
40 CFR part 60, appendix B,as well as daily and periodic data
quality checks in accordance with 40 CFR part 60, appendix F,
procedure 1.
Permit No. 10265ROI
Page 17
Complying with the The Permittee must demonstrate continuous compliance by . . .
requirement to .
Reduce CO emissions, or limit'. Conducting performance tests every 8,760 hours or 3 years,
ahe concentration of CO in thewhichever comes first, for CO to demonstrate that the required CO
RICE exhaust, and not using percent reduction is achieved or that the emissions remain at or
An oxidation catalyst below the CO concentration limit(2) ; and
ii. Collecting the approved operating parameter (if any) data
according to §63.6625(b); and
t
ii. Reducing these data to 4-hour rolling averages; and
i iv. Maintaining the 4-hour rolling averages within the operating
limitations for the operating parameters established during the
erformance test.
�2)If the reciprocating internal combustion engine is limited use (ie,
operates less than 100 hours per year) then demonstrate compliance
by conducting the same performance testing as item "i"above every,
8,760 hours or 5 years, whichever comes first. A limited use engine
_ .. ..
ust also comply with items "ii"through "iv"above
J.
h. Recordkeeping Requirements -Pursuant to 40 CFR 63.6655,the Permittee must
keep the following records (in written or electronic format). The records must be
maintained for five (5) years.
L A copy of each notification and report submitted to comply with 40 CFR 63
Subpart ZZZZ.
ii. Occurrence and duration of each malfunction of operation(i.e., process
equipment) or the air pollution control and monitoring equipment.
iii. Performance tests and performance evaluations as required in 40 CFR
63.1 0(b)(2)(viii).
iv. All required maintenance performed on the air pollution control and
monitoring equipment.
V. Actions taken during periods of malfunction to minimize emissions in
accordance with 40 CFR 63.6605(b), including corrective actions to restore
malfunctioning process and air pollution control and monitoring equipment to
its normal or usual manner of operation.
vi. All records required to show continuous compliance with each emission or
operating limitations listed in Section g. above. {40 CFR 63.6655(d))
vii. If the Permittee uses CEMs or CPMS the following records shall be
maintained:
Permit No. 10265R01
Page 18
A. Records described in 40 CFR 63.1 0(b)(2)(vi)through(xi).
B. Previous (i.e., superseded) versions of the site-specific monitoring
plan as required in 40 CFR 63.8(d)(3).
C. Requests for alternatives to the relative accuracy test for CEMS or
CPMS as required in 40 CFR 63.8(f)(6)(i), if applicable.
i. Reuortinjj Requirements -
i. Pursuant to 40 CFR 63.6645(h), for each initial performance test required in
Section d. above,the Permittee is required to submit a Notification of
Compliance Status before the close of business on the 60fl'day following the
initial performance test according to 40 CFR 63.9(h)(2)(ii). For each
subsequent performance test conducted according to the requirements of
Section g above, the Permittee must submit the Notification of Compliance
Status, including the performance test results, before the close of business on
the 60th day following the completion of the performance test according to 40
CFR 63.10(d)(2).
ii. Pursuant to 40 CFR 63.6650,the Permittee shall submit a semi-annual report
by January 31 of each calendar year for the preceding six-month period
between July and December and by July 31 of each calendar year for the
preceding six-month period between January and June. If the RICE is
classified as "limited use" (operation limited to less than 100 hours per year)
and there is no deviation,then the report shall be submitted annually by
January 31 of each calendar year. The report shall contain the following:
A. Company name and address.
B. Statement by a responsible official,with that official's name,title, and
signature,certifying the accuracy of the content of the report.
C. Date of report and beginning and ending dates of the reporting period.
D. If a malfunction occurred during the reporting period,the compliance
report must include the number, duration, and a brief description for
each time of malfunction which occurred during the reporting period
and which caused or may have caused any applicable emission
limitation to be exceeded. The report must also include a description
of actions taken during a malfunction of an affected source to
minimize emissions in accordance with 63.6650(b), including actions
taken to correct a malfunction.
E. If there is no deviation(s),then provide a statement indicating that no
deviation(s) occurred during the reporting period:
F. If there is a deviation(s) during the reporting period,then provide
information in 40 CFR 63.6650(d) as follows:
Permit No. 10265R0l
Page 19
I. total operating time of the RICE at which the deviation
occurred during the reporting period.
II. the number, duration, and cause of deviation(including
unknown cause, if applicable), as applicable, and the
corrective action taken.
iii. If there are no periods during which the Continuous Monitoring System
(CMS - including CEMS and CPMS) was out of control,then a statement
that there were no periods during which the CMS was out of control during
the reporting period.
iv. If there were periods during which the CMS (including CEMS and CPMS)
was out-of-control:
A. The date and time that each malfunction started and stopped.
B. The date,time, and duration that each CMS was inoperative, except
for zero (low-level) and high-level checks.
C. The date,time, and duration that each CMS was out-of-control,
including the information in §63.8(c)(8).
D. The date and time that each deviation started and stopped, and
whether each deviation occurred during a period of malfunction or
during another period.
E. A summary of the total duration of the deviation during the reporting
period, and the total duration as a percent of the total source operating
time during that reporting period.
F. A breakdown of the total duration of the deviations during the
reporting period into those that are due to control equipment
problems,process problems, other known causes, and other unknown
causes.
G. A summary of the total duration of CMS downtime during the
reporting period, and the total duration of CMS downtime as a percent
of the total operating time of the RICE at which the CMS downtime
occurred during that reporting period.
H. An identification of each parameter and pollutant(CO or
formaldehyde)that was monitored at the RICE.
I. A brief description of the RICE and CMS.
J. The date of the latest CMS certification or audit.
K. A description of any changes in CMS,processes, or controls since the
last reporting period.
Permit No. 10265ROI
Page 20
B. GENERAL CONDITIONS AND LIMITATIONS
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:
r
Regional Air Quality Supervisor
North Carolina Division of Air Quality
Washington Regional Office
943 Washington Square Mall
Washington,NC 27889
252-946-6481
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-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 -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-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.
6. 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. The facility shall be properly operated and
maintained at all times in a manner that will effect an overall reduction in air pollution.
Permit No. 10265R0l
Page 21
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. This permit is nontransferable by the Permittee. Future owners and operators must obtain a
new air permit from the DAQ.
8. 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. 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. 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. The Permittee must comply 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- 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," 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
Permit No. 10265ROI
Page 22
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 16th of April,2015.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Robert P. Fisher
Regional Air Quality Supervisor
By Authority of the Environmental Management Commission
Air Permit No. 10265R02
ATTACHMENT to Permit No. 10265R02, April 16, 2015
Insignificant/Exempt Activities
w ...... _ ............_..._ .. .__.: ._ .w.
Exemption ource of Source of Title V '
Source Re ulation f TAPs? Pollutants?
_ ...... ..... . ... g..... .. ..... ....f. . . . . . . ..
IES-6 -refrigeration system 2Q .0102 Yes No
(c)(2)(E)(i)
....-_.....�:� ._....
IES-7 -propane-fired singers for poultry I
.
feathers (4.4 million Btu per hour maximum `(c)(2)(E)(i)
2Q 0102 No Yes
heat input)
w. _ .
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 .l 100 "Control of Toxic Air Pollutants" or 2Q .0711 "Emission Rates
Requiring a Permit."