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HomeMy WebLinkAboutAQ_F_0100301_20141104_PRMT_Permit AIRIA HE North Carolina Department of Environment and Natural Resources Pat McCrory John E. Skvaria, III Governor Secretary November 4, 2014 Mr. Stephen Botts Director of Environmental Management G&K Services, Co. - Graham Plant 5995 Opus Parkway Suite 500 MimZetonka, MN 55343 Subject: Air Permit No. 10141R02 G&K Services, Co. - Graham Plant Graham, Alamance County,North Carolina Permit Class: Synthetic Minor Facility ID# 0100301 Dear Mr, Botts: In accordance with your completed application received October 30, 2014, we are forwarding herewith Permit No. 10141R02 to G&K Services, Co. - Graham Plant, Graham, Alamance 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. 150B-22. This request must be submitted in writing to the Director and must identify the specific Winston-Salem Regional Office-Division of Air Quality 450 West Hanes Mill Road,Suite 300,Winston-Salem, North Carolina 27105 Phone:336-776-98001 FAX: Internet:www ncdenr.gov An Equal Opportunity 1 Affirmative Action Employer-Made in part by recycled paper Stephen Botts November 4, 2014 Page 2 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. 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- 215.11413. This permit shall be effective from November 4, 2014 until February 29, 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-enforeement-ction,-for-per-mit ter-minat-ion, r-evoeation-and r-eissu-ance,-or--modifc-alion,-or - for denial of a permit renewal application. Specific changes and additions are summarized below (note: this list may not include all changes and additions): • The emission limits in Condition A.3 pertaining to 15A NCAC 2D .0503 have been updated since TES-STEAMI was never installed and TES-STEAM2 is now known to be not subject. • The condition pertaining to 15A NCAC 2D .0515 has been removed with this revision because the dryers were previously considered subject incorrectly and now the only subject source (1ES-STEAM2) is exempt from permitting. • Please note the change in contact information for the Winston-Salem Regional Office located in Condition B.1. Should you have any questions concerning thus matter, please contact Read Plott at 336-776- 9800. Sincerely, Lisa Edwards, P.E., Regional Supervisor Division of Air Quality, NCDENR c: Winston-Salem Regional Office JRP Enclosures NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 10141R02 Issue Date: November 4, 2014 Effective Date: November 4, 2014 Expiration Date: February 29, 2016 Replaces Permit: 10141R01 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, G&K Services, Co. - Graham Plant 610 Woody Drive Graham, Alamance County, North Carolina Permit Class: Synthetic Minor Facility ID# 0100301 (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 ES-DRYERI Two (2) natural gas-fired industrial dryers (2.5 ES-DRYER2� million Btu/hr max heat input, indirect-fired) (660 N/A N/A lbs clean, dry batch process weight, each) ES-DRYERS Two (2) natural gas-fired industrial dryers (0.30 ES-DRYER4 MMBtu/hr max heat input, indirect-fired), (125 N/A N/A lbs clean, dry batch process weight, each) rBtu/hr ural gas-fired industrial dryer (2.8 million ES-DRYERS max heat input, indirect-fired; 700 lbs N/A N/A n, dry batch process weight) ES-WASHRI, ES-WASHR2, ES-WASHR3, Six (6) industrial washers (700 lbs clean, dry, N/A N/A ES-WASHR4, batch process weight, each) ES-WASHR5, ES-WASHR6 ES-WASHR9 industrial washer (250 lbs clean, dry batch process NIA NIA weight) I Permit No. 10141 R02 Page 2 Emission Emission Source Control Control System Source ID Description System ID Description Industrial washer (150 lbs clean, dry batch FES-WASHR10 NIA NIAprocess weight)WASHR10 in accordance with the completed application 0100301.14A received October 30, 2014 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—i-ncl-ud-i-ng Title 1 SA North-Carolina Administrative Code (NCAC) Subchapter-- 2D .0202, 2D .0503, 2D .0516, 2D .0521, 2D .0535, 2D .0540, 2D .1806, 2Q .0315,2Q .0317 (Avoidance) 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(1), 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 2014 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: Source Emission Limit (lbs/million Btu) 125 lbs batch dryers (ID Nos. ES-DRYER3 and ES-DRYER4) 0.487 660 lbs batch dryers (ID Nos. ES-DRYERI and ES-DRYER2) 0.487 Natural gas-fired industrial dryer (2.8 million,Btu/hr max heat input; F0.472 700 lbs clean, dry batch process weight) (ES-DRYERS) Permit No. 10141R02 Page 3 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 .I 110 "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, ii. the nature and cause of the malfunction or breakdown, iii. the time when the malfiinction 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 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: Permit No. 10141R02 Page 4 unloading and loading areas, process areas stockpiles, stock pile working, plant parking lots, and plant roads (including access roads and haul roads). 8. 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. 9. 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) VOC -. ...__ 100 Individual HAP s_.j-_..... Total HAPs 25 a. Recordkeeping Requirements i. The Permittee shall record monthly and 12-month totals for the previous 12 months of the following: A. The amount and types of textiles washed at this facility in pounds. B. The total facility-wide VOC, individual HAP, and total HAP emissions. 1. Calculations shall be based on the emission factors submitted with Application No. 0100301.13A. ii. The facility shall keep each record on file for a minimum of three (3) years. b. Reporting Requirements - Within 30 days after each calendar year, regardless of the actual emissions, the Permittee shall submit the following: i. A summary of the facility-wide monthly and 12 month total emissions of VOC, individual HAP, and total HAPs for the previous 12 month period. 10. 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, emissions shall be limited as follows: Permit No. 10 14 1 R02 Page 5 Affected Source(s) Pollutant Emission Limit (Tons Per Consecutive 12-month Period) Facility Wide FVOC, total 250 tons/year, 11. 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: F Chronic Acute SystemicFA Pollutant Carcinogens f Toxicants Toxicants (lblyr) (lb/day) (lb/hr) Ethylene dichloride (1,2- 260 d ichl oro ethane) (107-06-2) Hexane, n- (110-54-3) 23 F �— MEK (methyl ethyl ketone, 2- 78 22.4 butanone) (78-93-3) MIBK(methyl isobutyl ketone) (108-10-1) 52 7 6 Methylene chloride (75-09-2) 1600 0.39 �— Perchloroethylene r (tetrachloroethylene) (127-18-4) 13000 E (trichloroethylene) (79-01- 4000 �Toluene (108-88-3) --- ---� �98 _ 14.4 Xylene (mixed isomers) (1330- 57 16.4 �20-7) Permit No. 10141R02 Page 6 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 Winston-Salem Regional Office 450 West Hanes Mill Road Suite 300 Winston-Salem,NC 27105 336-776-9800 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, —an-y-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 anuival 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. 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 Permit No. 10 14 1 R02 Page 7 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 Penmittee. 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 sucfi 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 pen-nit 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 persomiel 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 Permit No. 10141R02 Page 8 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 0' of November, 2014. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Lisa Edwards, P.E. Regional Supervisor By Authority of the Environmental Management Commission Air Permit No, 10 14 1 R02 ATTACHMENT to Permit No. 10 14 1 R02, November 4, 2014 Insignificant 1 Exempt Activities Exemption Source of�Voljprl e of Title Source Regulation TAPS? E ollutants? IE SS TEAM2 -Natural gas, direct-fired steam 2Q .0102 tunnel (1.5 million Btulhr max heat input) (c)(2)(E)(i) Yes Yes IES-B1 - Natural gas-fired boiler (16.738 million . p ) .(2Q 1102 )( )( )O Yes Yes Btu per hour max heat input) c 2 B ii TES-WTP1 - industrial wastewater treatment plant, including associated chemical storage 2Q .0102 ' tanks, process equipment, and wastewater (c)(1)(F) Yes Yes storage tank 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."