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HomeMy WebLinkAboutAQ_F_1900015_20140110_PRMT_Permit A74*���*A NCDENR North Carolina Department of Environment and Natural Resources Division of Air Quality Pat McCrory Sheila C. Holman John E. Skvarla, III Governor Director Secretary January 10, 2014 Tom Quesenberry Site Manager Arauco Panels USA LLC 985 Corinth Rd. Moncure, North Carolina 27559 Dear Mr. Hillman: SUBJECT: Air Quality Permit No.03449T42 Facility ID: 1900015 Arauco Panels USA LLC Moncure,North Carolina Chatham County Fee Class: Title V In accordance with your completed Air Quality Permit Application for the modification of the Title V permit received on December 20, 2013, we are forwarding herewith Air Quality Permit No. 03449T42 to Arauco Panels USA LLC, 985 Corinth Road, Moncure, North Carolina authorizing the construction and operation, of the emission source(s) and associated air pollution control device(s) specified herein. Additionally, any emissions activities determined from your Air Quality Permit Application as being insignificant per 15A North Carolina Administrative Code 2Q .0503(8) have been listed for informational purposes as an "ATTACHMENT." Please note the requirements for the annual compliance certification are contained in General Condition P in Section 3. The current owner is responsible for submitting a compliance certification for the entire year regardless of who owned the facility during the year. This emission source (ID No. 3201) is listed as a minor modification per 15A NCAC 2Q .0515. The compliance certification as described in General Condition P is required. Unless otherwise notified by NC DAQ, the affected terms of this permit (excluding the permit shield as described General Condition R) for this source shall become final March 11, 2014. Until this date, the affected permit terms herein reflect the proposed operating language that the Permittee shall operate this source under pursuant to 15A NCAC 2Q .0515(f). As the designated responsible official it is your responsibility to review,understand, and abide by all of the terms and conditions of the attached permit. It is also your responsibility to ensure that any person who operates any emission source and associated air pollution control device subject to any term or condition of the attached permit reviews, understands, and abides by the condition(s) of the attached permit that are applicable to that particular emission source. If any parts, requirements, or limitations contained in this Air Quality Permit are unacceptable to you, Permitting Section 1641 Mail Service Center,Raleigh,North Carolina 27699-1641 217 West Jones Street,Raleigh,North Carolina 27603 Phone:919-707-8405/Fax:919-715-0717 Internet:www.ncair.org An Equal Opportunity\Affirmative Action Employer—Recycled\Post Consumer Paper Tom Quesenberry January 10,2014 Page 2 you have the right to request a formal adjudicatory hearing within 30 days following receipt of this pennit, identifying the specific issues to be contested. This hearing request must be in the forn of a written petition, conforming to NCGS (North Carolina General Statutes) 150B-23, and tiled with both the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, North Carolina 27699-6714 and the Division of Air Quality, Pennitting Section, 1641 Mail Service Center, Raleigh, North Carolina 27699-1641. The form for requesting a formal adjudicatory hearing may be obtained upon request from the Office of Administrative Hearings. Please note that this pen-nit will be stayed in its entirety upon receipt of the request for a hearing unless a request for a hearing is made pursuant to NCGS 150B-23, this Air Quality Permit shall be final and binding 30 days after issuance. You may request modification of your Air Quality Pen-nit through informal means pursuant to NCGS 150B-22. This request must be submitted in writing to the Director and must identify the specific provisions or issues for which the modification is sought. Please note that this Air Quality Permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under NCGS 150B-23. The construction of new air pollution emission source(s) and associated air pollution control device(s), or modifications to the emission source(s) and air pollution control device(s) described in this permit must be covered under an Air Quality Permit issued by the Division of Air Quality prior to construction unless the Permittee has fulfilled the requirements of GS 143-215-108A(b) and received written approval from the Director of the Division of Air Quality to commence construction. Failure to receive an Air Quality Permit or written approval prior to commencing construction is a violation of GS 143-215.108A and may subject the Permittee to civil or criminal penalties as described in GS 143-215.114A and 143-215.114B. This Air Quality Pen-nit shall be effective from January 10, 2014 until the earlier of December 31, 2018 or the renewal of permit 03449T34 has been issued or denied, is nontransferable to future owners and operators, and shall be subject to the conditions and limitations as specifie Should you have any questions concerning this matter, please contact Joseph Voelker,P.E. a 9) 707-8730. Sincerel urs, n der Vaart,Ph.D., P.E., J.D. Enclosure cc: Gregg Worley,EPA Region 4 Raleigh Regional Office Central Files ATTACHMENT to cover letter to Permit No. 03449T42 Insignificant Activities per 15A NCAC 2Q .0503(8) Emission Source ID Emission Source Description I-VENTS Roof ventilators I-GAS One 500 gallons above ground gasoline storage tank I-TANK], I-TANK2, I-TANK3, I- Four, 1000 gallons each,above ground propane storage tanks TANK4 I-LPA Log Processing Area 1. Because an activity is insignificant does not mean that the activity is exempted from an applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. 2. When applicable, emissions from stationary source activities identified above shall be included in determining compliance with the permit requirements for toxic air pollutants under 15A NCAC 2D .1100"Control of Toxic Air Pollutants"or 2Q .0711 "Emission Rates Requiring a Permit". 3. For additional information regarding the applicability of MACT see the DAQ page titled"The Regulatory Guide for Insignificant Activities/Pen-nits Exempt Activities". The link to this site is as follows: hitp://daq.state.nc.us/pemiits/insig/ ATTACHMENT to cover letter to Air Quality Permit No. 03449T42 Table of Changes New Existing Condition Changes Condition No. No. Cover Letter Same • Updated permit revision numbers, issue, effective dates, etc. • Removed existing2Q .0515minor modification reference • Added 2Q .0515minor modification reference Page 1 Same • Updated permit revision numbers, issue,effective dates, etc. Equipment List Same • Revised equipment descriptor for the Wellons burner to reflect the ability to now fire natural gas in its existing exhaust scenario(i.e.to the dryers)and the ability to fire natural gas only and exhaust uncontrolled directly to atmosphere • Added 2Q.0515 minor modification footnote as applicable 2.1.17.(applicable Same • Revised the equipment descriptor to read: sources) Wellons"Burner(ID No. 3201)operating in one of two scenarios: i. OS-1: Exhausting to drum dryers; or ii. OS-2: combusting natural gas only and exhausting directly to atmosphere 2.1.F. (applicable Same • Added"OS-1 only"to 2D .0504 to indicate that this regulation applies only in this regulations table) operating configuration • Added reference to 2D.0503 for operating scenario 2(OS-2)only • Added reference to 2D.I I I I (MACT 5D)for OS-2 only 2.l.F.l.a. Same • Added the language "Condition 2.I.F.1 applies only when the Permittee operates the Wellons(ID No. 3201)in operating scenario 1 (OS-1). 2.1.F.4.c. Same . Added language when"firing natural as" 2.1.F.5.c. Same • Added language(OS-1 only)to ID No. 3201 and added the footnote: * No observations are required for the Wellons burner(ID No. 3201)when operating in OS-2. NA 2.1.F.9 • Added 2D.I I I I condition to address MACT DDDD for the Wellons(ID No. 3201)when operating in OS-2. NA 2.1.F.10 • Added a 2D.0503 condition when operating in OS-2.No M/R/R will be required. NA 2.1.F.I I • Added a state enforceable only notification requirement for the initial operation of the Wellons in OS-2. State of North Carolina, Department of Environment, and Natural Resources Division of Air Quality NCDENR AIR QUALITY PERMIT Permit No. Replaces Permit No. Effective Date Expiration Date" 03449T42 NA January 10, 2014 December 31, 2018 *"This permit shall expire on the earlier of December 31, 2018 or the renewal of permit 03449T34 has been issued or denied. Until such time as this permit expires or is modified or revoked, the below named Permittee is permitted to construct and operate the emission source(s)and associated air pollution control device(s)specified herein,in accordance with the terms, conditions, and limitations within this permit. This permit is issued under the provisions of Article 21B of Chapter 143, General Statutes of North Carolina as amended, and Title 15A North Carolina Administrative Codes (15A NCAC), Subchapters 21)and 2Q,and other applicable Laws. Pursuant to Title 15A NCAC, Subchapter 2Q,the Permittee shall not construct, operate, or modify any emission source(s) or air pollution control device(s) without having first submitted a complete Air Quality Permit Application to the permitting authority and received an Air Quality Permit,except as provided in this permit. Permittee: Arauco Panels USA LLC Facility ID: 1900015 Facility Site Location: 985 Corinth Road City, County,State,Zip: Moncure, Chatham County, North Carolina 27559 Mailing Address: 985 Corinth Road City, County, State, Zip: Moncure, Chatham County, North Carolina 27559 Application Number: 1900015.13E Complete Application Date: December 20,2013 Primary SIC Codes: 2493 Division of Air Quality, Raleigh Regional Office Regional Office Address: 3800 Barrett Drive, Suite 101 Raleigh, North Carolina 27609 ermit issued t ' e 10th of January, 2014 van der Vaart, Ph.D., P.E.,J.D., Chief, Air Permits Section By Authority of the Environmental Management Commission Table of Contents SECTION 1: PERMITTED EMISSION SOURCE(S) AND ASSOCIATED AIR POLLUTION CONTROL DEVICES) AND APPURTENANCES SECTION 2: SPECIFIC LIMITATIONS AND CONDITIONS 2.1 - Emission Sources Specific Limitations and Conditions (Including specific requirements) 2.2 - Multiple Emission Source(s) Specific Limitations and Conditions 2.3 .- Schedule of Compliance 2.4 - Permit Shield for Non-applicable Requirements SECTION 3: GENERAL PERMIT CONDITIONS ATTACHMENT List of Acronyms Air Permit 03449T42 Page 3 SECTION I - PERMITTED EMISSION SOURCE(S) AND ASSOCIATED AIR POLLUTION CONTROL DEVICE(S) AND APPURTENANCES The following table contains a summary of all permitted emission sources and associated air pollution control devices and appurtenances: Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description Material Handling Sources 7001 or SP-1 Truck/Rail Chip Handling System, N/A None MACT DDDD Enclosed 7004 or SP-2 Truck/Rail Sawdust Handling N/A None MACT DDDD System,Enclosed 7010 Particle Board Mill Truck Dump N/A None MACT DDDD 7012,7014, Dump bunkers and CL dryer dump N/A None 7015, 7029 MACT DDDD 7052,7054, Wood residue bunkers N/A None 7055,7056 MACT DDDD 6001,7002-A, Wood chip piles-Medium Density N/A None 7002-B,7002-C, Fiberboard Mill 7002-D MACT DDDD 6003, 7006, Wood Fuel Pad and Boiler Transfers N/A None 7007, 7022 MACT DDDD 7005-D,7005-E, Sawdust transport to A-frame N/A None 7005-F,7005-G MACT DDDD 7025 Scale transfer conveyors N/A None MACT DDDD 7019,7026 Fiber dump and reject filter bins N/A None MACT DDDD 7027 Hog fuel hopper N/A None MACT DDDD 7040,7044,7046, Particleboard Mill chip transfer N/A None 7048,7050 MACT DDDD SP Fuel Sawdust and Chip Storage Piles N/A None MACT DDDD 7024 Particleboard Mill feed bins N/A None MACT DDDD Medium Density Fiberboard Facilities ES-01 Refiner CD-0I Refiner Abort Cyclone(66 inches MACT DDDD I I in diameter) ' ' For operation during startup,shutdown and malfunction only. Air Permit 03449T42 Page 4 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description CD02 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) in parallel with CD14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) ES-18,ES-19, Three natural gas-fired hot oil NA NA and ES-20 heaters(24 million Btu per hour NSPS De maximum heat input each) Case-by-Case MACT ES-02-A Energy System consisting of one CD02-A Urea/water injection system MACT DDDD dry/wet wood/woodwaste-fired CD02 Venturi and packed bed scrubber burner(205 million Btu per hour heat (35 gallons per minute minimum input) injection rate) in parallel with CD14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) ES-02-B Two Stage Dryer System CD02 Venturi and packed bed scrubber and and (35 gallons per minute minimum ES-02-C and Two backup natural gas-fired dryer injection rate) ES-02-D burners(78.5 and 17 million Btu per in parallel with MACT DDDD hour heat input respectively) CD 14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) ES-16 MDF Press CD16 Venturi and packed bed scrubber MACT DDDD ES-06-B MDF Board Cooler CD02 Venturi and packed bed scrubber MACT DDDD (35 gallons per minute minimum injection rate) in parallel with CD14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) ES-03 Fiber Sifter System CD03 Fabric Filter(12,290 square feet of MACT DDDD filter area) ES-04 Forming Line Clean-Up System CD04 Fabric Filter(9,346 square feet of MACT DDDD filter area) ES-05 Mat Reject System CD05 Fabric Filter(9,346 square feet of MACT DDDD filter area) ES-07 Saw System CD07 Fabric Filter(6793 square feet of MACT DDDD filter area) ES-08 Sander System No.I CDOS Fabric Filter(12,290 square feet of MACT DDDD filter area) ES-09 Recycled Fiber Silo No.1 CD09 Bin Vent Filter(226 square feet of MACT DDDD I filter area) Air Permit 03449T42 Page 5 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description ES-10 Sander System No.2 CD10 Fabric Filter(12,290 square feet of MACT DDDD filter area) ES-12 Sander Dust Silo No. 1 CD 12 Bin Vent Filter(226 square feet of MACT DDDD filter area) ES-13 Dry Sawdust Silo CD13 Bin Vent Filter(226 square feet of MACT DDDD filter area) ES-15 Recycled Fiber Silo No.2 CD 15 Bin Vent Filter(226 square feet of MACT DDDD filter area) ES-17 Sander Dust Silo No.2 CD17 Bin Vent Filter(226 square feet of MACT DDDD filter area) MDFR-1, MDFR- 2,MDFR-3, Four MDF resin storage tanks NA NA MDFR-4 MACT DDDD ES-21** Diesel Fuel-fired Emergency NA NA MACT ZZZZ Generator(]592 Brake Horsepower output) Particleboard Mill CD-SC High efficiency cyclone-72 3501 inches in diameter PSD Sawdust Rock and Metal Separator MACT DDDD CD-3501 Reverse flow bag filter with 2,410 square feet of surface area CD-1431 High efficiency multi-cyclone with Surface layer triple pass, rotary drum 2 tubes, each 132 inches in 1430 (#3)dryer with one wood suspension diameter PSD dust/natural gas-fired burner(60 CD-PB-WESP Wet electrostatic precipitator MACT DDDD million Btu per hour maximum rated heat input) CD-PB-PGT*** Packed bed scrubber with photochemical gas treatment CD-1421 High efficiency multi-cyclone with Core layer single pass,rotary drum 4 tubes, each 80 inches in diameter 1420 (#1)dryer with one wood suspension PSD dust/natural gas-fired burner (50 CD-PB-WESP Wet electrostatic precipitator MACT DDDD million Btu per hour maximum rated heat input) CD-PB-PGT*** Packed bed scrubber with hotochemical gas treatment CD-1411 High efficiency multi-cyclone with Core layer single pass,rotary drum 4 tubes, each 80 inches in diameter 1410 (#2)dryer with one wood suspension PSD dust/natural gas-fired burner (50 CD-PB-WESP Wet electrostatic precipitator MACT DDDD million Btu per hour maximum rated heat input) CD-PB-PGT*** Packed bed scrubber with photochemical gas treatment Air Permit 03449T42 Page 6 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description One "Wellons" unit operating as a: CD-1431 High efficiency multi-cyclone with 2 tubes,each 132 inches in a)wood suspension dust-fired burner diameter (40 million Btu per hour maximum rated heat input);or a AND/OR b)natural gas-fired burner(21.8 CD-1421 High efficiency multi-cyclone with million Btu per hour maximum rated 4 tubes,each 80 inches in diameter 3201 gB heat input); AND/OR PSD exhausting to either CD-1411, High efficiency multi-cyclone with MACT DDDD 4 tubes,each 80 inches in diameter surface layer triple pass,rotary drum AND (#3)dryer[ID No. 1430] and/or CD-PB-WESP Wet electrostatic precipitator core layer single pass,rotary drum(#1) dryer[ID No. 1420] and/or CD-PB-PGT*** Packed bed scrubber with photochemical gas treatment core layer single pass,rotary drum(#2) dryer[ID No. 1410] One"Wellons" unit operating as a: 3201 se c)natural gas-fired indirect heat NA NA MACT DDDDD exchanger(21.8 million Btu per hour maximum rated heat input) CD-3500, Simple cyclone-72 inches in diameter CD-3525AA 3515AA Reverse flow fabric filter with 6,918 PSD Surface Material Transport square feet of surface area MACT DDDD (SL fines from screening operation) CD-3512B Simple cyclone-72 inches in diameter CD-3515AA Reverse flow fabric filter with 5,767 square feet of surface area CD-3520A, Three(3)simple cyclones-each 96 3525 CD-3520B, inches in diameter PSD Surface Formers and Mat Dumps CD-3521 MACT DDDD CD-3525 Reverse flow fabric filter with 6,918 square feet of surface area CD-3530 Simple cyclone-84 inches in diameter CD-3531 Simple cyclone- 108 inches in 3535 Flying Cut Off Saw,Pretrim Saws,& diameter PSD Production Collection MACT DDDD CD-3533 Simple cyclone- 108 inches in diameter CD-3535 Reverse flow fabric filter with 6,918 square feet of filter area Air Permit 03449T42 Page 7 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description CD-2006 AA Reverse flow bag filter with 6,918 square feet of surface area 3545AA Particleboard Mill Steinemann CD-3570 High efficiency cyclone - 144 inches PSD Finishing Sander in diameter MACT DDDD CD-3575 Reverse flow bag filter with 1,159 square feet of surface area DEF-2010 CD-PB-PGT*** Packed bed scrubber with PSD Particleboard Press photochemical gas treatment MACT DDDD PB-BC N/A None PSD Particleboard Cooler MACT DDDD CD-5001 Reverse flow fabric filter with 6,918 square feet of surface area 3565 Particleboard Mill Steinemann CD-3570 High efficiency cyclone- 144 inches PSD Calibrating Sander in diameter MACT DDDD CD-3575 Reverse flow bag filter with 1,159 square feet of surface area CD-3522 High efficiency cyclone- 120 inches 3555 in diameter PSD Schelling Saw Board Trim MACT DDDD CD-4005 Reverse flow bag filter with 6,918 square feet of surface area CD-3570 High efficiency cyclone- 144 inches 3575 Sander Filter Transport for Filters 3545 in diameter PSD & 3565 MACT DDDD CD-3575 Reverse flow bag filter with 1,159 square feet of surface area 3585 CD-3585 Reverse flow bag filter with 4,880 PSD PZKR Green Chip Flakers square feet of surface area MACT DDDD 3595 CD-3595 Reverse flow bagfilter(Maximum MACT DDDD Oversize Material Pallmann Mill air-to-cloth ratio of 3.0 ACFM/total filter surface area). CD-3532 Simple cyclone-60 inches in 3577 diameter PSD Dry waste transport system MACT DDDD CD-3577 Reverse flow bag filter with 4,068 square feet of surface area ES-DFP-1** Diesel Fuel-fired Fire Pump CD-DFP Particulate Matter Filter MACT ZZZZ Engine(347 Brake Horsepower output) NSPS 111I ES-ODG** Diesel-fuel Fired Emergency Generator NA NA MACT ZZZZ (465 horsepower,3,026 million Btu per hour heat input) Laminator Mill 3593 and 3594 Two(2) Short Cycle Laminating CD-3593 Reverse flow bagfilter(Maximum Presses air-to-cloth ratio of 4.1 ACFM/total filter surface area). Air Permit 03449T42 Page 8 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description Pr-Heatl Natural gas or No.2 fuel oil-fired hot N/A None Case-by-Case oil heater(4.7 million Btu per hour MACT heat input)used with short cycle laminating presses * These emission sources and control devices indicated as the Medium Density Fiberboard Facilities are listed as a 15A NCAC 2Q .0501(c)(2)modification. The Permittee shall file a Title V Air Quality Permit Application on or before 12 months after commencing operation in accordance with General Condition NN.1. The permit shield described in General Condition R does not apply and compliance certification as described in General Condition P is not required. **These emission sources (ID Nos. ES-21, ES-DFP-1, ES-ODG) are listed as a minor modification per 15A NCAC 2Q .0515. The compliance certification as described in General Condition P is required. Unless otherwise notified by NC DAQ, the affected terns of this permit (excluding the permit shield as described General Condition R) for this source shall become final on July 19, 2011. Until this date, the affected pen-nit tenns herein reflect the proposed operating language that the Permittee shall operate this source under pursuant to 15A NCAC 2Q .0515(0. *** These control devices are listed as a 15A NCAC 2Q .0501(c)(2) modification. The Permittee shall file a Title V Air Quality Permit Application on or before 12 months after commencing operation in accordance with General Condition NN.1. The permit shield described in General Condition R does not apply and compliance certification as described in General Condition P is not required. a4 These emission sources and control devices (ID Nos. 3515 and 3545 and CD3525,3515 and -2006) are listed as a minor modification per 15A NCAC 2Q .0515. The compliance certification as described in General Condition P is required. Unless otherwise notified by NC DAQ, the affected terns of this pen-nit (excluding the permit shield as described General Condition R) for this source shall become final on April 1,2013, Until this date, the affected pennit terms herein reflect the proposed operating language that the Permittee shall operate this source under pursuant to 15A NCAC 2Q .0515(f). BB This emission source (ID No. 3201) are listed as a minor modification per 15A NCAC 2Q .0515, The compliance certification as described in General Condition P is required. Unless otherwise notified by NC DAQ,the affected terns of this pen-nit(excluding the permit shield as described General Condition R)for this source shall become final on March 11,2014. Until this date,the affected permit terms herein reflect the proposed operating language that the Permittee shall operate this source under pursuant to 15A NCAC 2Q.0515(f). Air Permit 03449T42 Page 9 SECTION 2 - SPECIFIC LIMITATIONS AND CONDITIONS 2.1 - Emission Source(s) and Control Devices(s) Specific Limitations and Conditions The emission source(s)and associated air pollution control device(s)and appurtenances listed below are subject to the following specific terms,conditions,and limitations,including the testing, monitoring,record keeping,and reporting requirements as specified herein: A. Material Handling Sources: Truck/Rail Chip Handling System (ID No. 7001 or SP-1); Truck/Rail Sawdust Handling System (ID No. 7004 or SP-2); Particleboard Mill Truck Dump (ID No. 7010); Dump Bunkers and CL Dryer Dump (ID Nos. 7012, 7014, 7015, and 7029); Wood Residue Bunkers (ID Nos. 7052, 7054, 7055 and 7056); Wood Chip Piles - Medium Density Fiberboard Mill (ID Nos. 6001, 7002-A, 7002-13, 7002-C, and 7002-D); Wood Fuel Pad and Boiler Transfers (ID Nos. 6003, 7006, 7007, 7022); Sawdust Transport to A-Frame (ID Nos. 7005-D, 7005-E, 7005-F, 7005-G); Fuel Sawdust and Chip Storage Piles (ID No. SP); Scale Transfer Conveyors (ID No. 7025); Fiber dump and reject filter bins (ID Nos. 7019 and 7026); Hog Fuel Hopper(ID No. 7027); Particleboard Mill Chip Transfer(ID Nos. 7040, 7044, 7046, 7048, and 7050); and Particleboard Mill Feed Lines (ID No. 7024) The following table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant Limits/Standards Applicable Regulation Visible emissions 20 percent opacity 15A NCAC 2D .0521(d) Odors Odorous emissions must be controlled-See Section 2.2.A.3; 15A NCAC 2D .1806 State-enforceable only 1. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. As required by 15A NCAC 2D.052l(d)"Control of Visible Emissions," visible emissions from the sources manufactured after July 1, 1971,shall not be more than 20 percent opacity when averaged over a six-minute period [15A NCAC 2D .0521(d)]. However, six minute averaging periods may exceed 20 percent opacity if i. No six-minute period exceeds 87 percent opacity", ii. No more than one six-minute period exceeds 20 percent opacity in any hour; and iii. No more than four six-minute periods exceed 20 percent opacity in any 24-hour period Testin [15A NCAC 2D.2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1.A.l.a.(above)for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitorins/Record keep ing/Reporting [15A NCAC 2Q .0508(f)] c. No monitoring,record keeping, or reporting is required for visible emissions from the following sources: truck/rail chip handling system(ID No. 7001 or SP-1);truck/rail sawdust handling system(ID No. 7004 or SP-2);particleboard mill truck dump(ID No.7010);dump bunkers and CL dryer dump(Ill Nos.7012, 7014, 7015,7029);wood residue bunkers(ID Nos. 7052,7054,7055,and 7056);wood chip piles-medium density fiberboard mill(ID Nos. 6001,7002-A,7002-B,7002-C,and 7002-D); wood fuel pad and boiler transfers (ID Nos.6003,7006,7007,7022);sawdust transport to A-frame (ID Nos.7005-D,7005-E,7005-F,7005-G); Fuel Sawdust and Chip Storage Piles(ID No. SP); scale transfer conveyors(ID No. 7025); fiber dump and reject filter bins(ID Nos.7019 and 7026);hog fuel hopper(ID No.7027);particleboard mill chip transfer(ID Nos. 7040,7044,7046,7048,and 7050);and particleboard mill feed lines(ID No.7024). Air Permit 03449T42 Page 10 B. Medium Density Fiberboard Facilities woodworking operations as presented in Table 2.1.B.1. Table 2.1.13.1 Emission Emission Source Description Control Control Device Description Source Device ID ID No. No. ES-03 Fiber Sifter System CD03 Fabric Filter(12,290 square feet of filter area) ES-04 Forming Line Clean-Up System CD04 Fabric Filter(9,346 square feet of filter area) ES-05 Mat Reject System CD05 Fabric Filter(9,346 square feet of filter area) ES-07 Saw System CD07 Fabric Filter(6,793 square feet of filter area) ES-08 Sander System No. 1 CD08 Fabric Filter(121290 square feet of filter area) ES-09 Recycled Fiber Silo No. 1 CD09 Bin Vent Filter(226 square feet of filter MACT area) DDDD ES-10 Sander System No. 2 CD10 Fabric Filter(12,290 square feet of filter area) ES-12 Sander Dust Silo No. 1 CD12 Bin Vent Filter(226 square feet of filter area) ES-13 Dry Sawdust Silo CD13 Bin Vent Filter(226 square feet of filter area) ES-15 Recycled Fiber Silo No. 2 CD15 Bin Vent Filter(226 square feet of filter MACT area) DDDD ES-17 Sander Dust Silo No. 2 CD 17 Bin Vent Filter(226 square feet of filter MACT area) DDDD The following table provides a summary of limits and/or standards for the woodworking operations in Table 2.I.B.1. Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter adequate duct work and properly designed collectors 15A NCAC 2D .0512 Visible emissions 20 percent opacity 15A NCAC 2D.0521 Volatile organic Work Practice Standards 15A NCAC 2D.0958 compounds See Section 2.2 A.I. Toxic air pollutants See Section 2.2 A.2; 15A NCAC 2D .1 100 State-enforceable only Odors See Section 2.2 A.3; 15A NCAC 2D .1806 State-enforceable only Hazardous air pollutants National Emission Standards for Hazardous Air 15A NCAC 2D .1 I I I Pollutants:Plywood and Composite Wood Products (40 CFR 63,Subpart See Section 2.2 AA DDDD) Volatile organic See Section 2.2 B.1. 15A NCAC 2Q .0317 compounds,Nitrogen (PSD Avoidance) oxides,PM2 ,PMio Air Permit 03449T42 Page 11 1. 15A NCAC 2D.0512: PARTICULATES FROM WOOD PRODUCTS FINISHING PLANTS a. The Permittee shall not cause,allow,or permit particulate matter caused by the working,sanding,or finishing of wood to be discharged from any stack,vent, or building into the atmosphere without providing, as a minimum for its collection,adequate duct work and properly designed collectors. In no case shall the ambient air quality standards be exceeded beyond the property line. Monitoring [15A NCAC 2Q .0508(f)] b. Particulate matter emissions from the MDF wood working operations shall be controlled as presented in Table 2.1.11.1.To assure compliance,the Permittee shall perform inspections and maintenance as recommended by the manufacturer, if any. As a minimum,the inspection and maintenance program shall include: i. monthly external inspection of the ductwork, cyclones, and bagfilters noting the structural integrity; and ii. annual(for each 12 month period following the initial inspection)internal inspection of the bagfilters noting the structural integrity and the condition of the filters. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0512 if the ductwork, cyclones and/or bagfilters and are not inspected and maintained. Recordkeeping[15A NCAC 2Q.0508(f)] c, The results of inspection and maintenance for the cyclones and bagfilters shall be maintained in a logbook (written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;and iii. the results of maintenance performed on any control device. The Permittee shall be deemed in noncompliance with 15A NCAC 2D.0512 if these records are not maintained. Reporting[15A NCAC 2Q .0508(f)] d. The Permittee shall submit the results of any maintenance performed on the control devices within 30 days of a written request by the DAQ. e. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this pen-nit must be clearly identified. 2. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the MDF wood working operations listed in Table 2.1.B.1.shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[15A NCAC 2D.2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ. If the results of this test are above the limit given in Section 2,1.13.2.a. above,the Penmittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring [15A NCAC 2Q .0508(f)] c. To assure compliance,once a week the Permittee shall observe the emission points of this source for any visible emissions above normal.The weekly observation must be made for each week of the calendar year period to ensure compliance with this requirement. The Permittee shall establish normal for the source within 30 days of initial startup, If visible emissions from this source are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below, or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 2D .2601 (Method 9)for 12 minutes is below the limit given in Section 2.1.B.2.a. above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D .0521. Air Permit 03449T42 Page 12 Recordkeeping [15A NCAC 2Q .0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format) on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions; and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521 if these records are not maintained. Reporting [15A NCAC 2Q.0508(f)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. C. One Energy System (ID No. ES-02-A) configured as follows in Table 2.1.C.1. Table 2.1.C.1. Emission Emission Source Control Control Device Description Configuration Source Description Device 1D ID No. No. CD02-A Urea/water injection system in series with CD02 and CD14 Energy System consisting Venturi and packed bed of a dry/wet CD02 scrubber(35 gallons per ES-02-A wood/woodwaste-fired minute minimum injection CD02 in parallel with burner(205 million Btu rate) CD 14 with emission per hour heat input) Venturi and packed bed points EP02 and EP14 CD14 scrubber(35 gallons per minute minimum injection rate) The following table provides a summM of limits and standards for the energy system described above: -Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter 0.325 lb/million Btu(ID No. ES-02A) 15A NCAC 2D .0504 Sulfur dioxide 2.3 pounds per million Btu heat input 15A NCAC 2D.0516 Volatile organic Work Practice Standards 15A NCAC 2D.0958 compounds See Section 2.2 A.1. Visible emissions 20 percent opacity 15A NCAC 2D.052I(d) Toxic air pollutants See Section 2.2 A.2; 15A NCAC 2D.1 100 State-enforceable only Odors See Section 2.2 A.3; 15A NCAC 2D .1806 State-enforceable only Hazardous air National Emission Standards for Hazardous Air Pollutants: 15A NCAC 2D .I 1 1 1 pollutants Plywood and Composite Wood Products (40 CFR 63, Subpart DDDD) See Section 2.2 A.4. Volatile organic See Section 2.2 B.1. 15A NCAC 2Q.0317 compounds, (PSD Avoidance) Nitrogen oxides, PM2.5,PMio Air Permit 03449T42 Page 13 1. 15A NCAC 2D.0504: PARTICULATES FROM WOODBURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of wood that are discharged from the biomass-fired Energy System(ID No.ES-02-A)into the atmosphere shall not exceed 0.325 pounds per million Btu heat input. Testing[15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 C. La.above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0504. Testing [15A NCAC 2D .2601] c. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limit(s)above by testing the emission sources in Table 2.I.C.1 in accordance with a testing protocol approved by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 -General Condition JJ. Testing shall be completed not later than 180 days of the issuance date of Permit No. 03449T38 and annually thereafter. The Penmittee shall submit a written report of the test(s)results to the Regional Supervisor,DAQ within 60 days of completion of the test. If the results of this test are above the limit given in Section 2.1 C. 1.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0504. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] d. Particulate matter emissions from the biomass-fired Energy System (1D No. ES-02-A)shall be controlled by venturi and packed bed scrubbers(ID Nos. CD02-A,CD-02 and CD-14). e. Monitoring/recordkeeping requirements in Section 2.1 D.1.c.through f. shall be sufficient to assure compliance with 15A NCAC 2D .0504. If the requirements of Section 2.1 D.I.c. through f. are not complied with, the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0504. Reporting [15A NCAC 2Q .0508(f)] f. Reporting requirements in Section 2.1 D.Lg. shall be sufficient to assure compliance with 15A NCAC 2D .0504. 2. 15A NCAC 2D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from Energy System (1D No. ES-02-A)shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. [15A NCAC 2D.0516] Testin [15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of this test are above the limit given in Section 2.1.C.2.a.above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0516. Monitoring/Recordkeepin2/Reportin2 [I5A NCAC 2Q .0508(f)] c. No monitoring,recordkeeping or reporting is required for sulfur dioxide emissions from wood combustion for the Energy System(ID No. ES-02-A). 3. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this source Energy System (ID No. ES-08-A) shall not be more than 20 percent opacity when averaged over a six-minute period. However, six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing [15A NCAC 2Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ, If the results of this test are above the limit given in Section 2.1 A.3.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Air Permit 03449T42 Page 14 Monitoring [15A NCAC 2Q .0508(f)] c. To assure compliance,once a day the Permittee shall observe the emission points of this source Energy System(ID No. ES-08-A) for any visible emissions above normal. The daily observation must be made for each day of the calendar year period that this emission source is in operation to ensure compliance with this requirement. For days when this emission source is not operating,the client shall document"not operating" in the recordkeeping associated with this permit condition. The Pennittee shall be allowed three(3)days of absent observations per semi-annual period. The Permittee shall establish "normal" for the source in the. first 30 days following the effective date of the permit. If visible emissions from this source are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below, or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 2D.2610(Method 9)for 12 minutes is below the limit given in Section 2.1 A.3.a.above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D.0521. Recordkeeping [15A NCAC 2Q .0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions; and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 2D.0521 if these records are not maintained. _Reporting [15A NCAC 2Q .0508(f)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. D. Medium Density Fiberboard Facilities Operations as presented in Table 2.1.D.1. Table 2.1.D.1. Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description ES-0I Refiner CDO1 Refiner Abort Cyclone(66 inches in diameter)'- CD02 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) in parallel with CD14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) 2 For operation during startup,shutdown and malfunction only. Air Permit 03449T42 Page 15 Emission Emission Source Control Control Device Source ID No. Description Device ID No. Description ES-02-B Two Stage Dryer System CD02 Venturi and packed bed scrubber and and (35 gallons per minute minimum ES-02-C and Two backup natural gas-fired dryer injection rate) ES-02-D burners(78.5 and 17 million Btu per in parallel with hour heat input respectively) CD14 Venturi and packed bed scrubber (35 gallons per minute minimum injection rate) ES-06-B MDF Board Cooler ES-16 MDF Press CD16 Venturi and packed bed scrubber The following table provides a summary of limits and/or standards for the operations in Table 2.1.D.1. Regulated Limits/Standards Applicable Regulation Pollutant Particulate E=4.10P 0.67 or E=55.0(P) -40 15A NCAC 2D.0515 matter where;E=allowable emission rate in pounds per hour P=process weight in tons per hour Visible 20 percent opacity 15A NCAC 2D .0521 emissions Volatile organic Work Practice Standards 15A NCAC 2D .0958 -compounds See Section 2.2 A.1. Toxic air See Section 2.2 A.2; 15A NCAC 2D .l 100 pollutants State-enforceable only Odors See Section 2.2 A.3; 15A NCAC 2D .1806 State-enforceable only Hazardous air National Emission Standards for Hazardous Air Pollutants: 15A NCAC 2D.I I I 1 pollutants Plywood and Composite Wood Products (40 CFR 63, Subpart DDDD) See Section 2.2 A.4. Volatile organic See Section 2.2 B.1. 15A NCAC 2Q.0317 compounds, (PSD Avoidance) Nitrogen oxides, PM2.5,PMio 1. 15A NCAC 2D.0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the emission sources in Table 2.1.D.1.shall not exceed an allowable emission rate as calculated by the following equation(s): Process Rate Allowable Emission Rate Equation Less than or equal to 30 tons 0.61 per hour E=4.10 x P Greater than 30 tons per hour E=55.0(P)011 -40 Where E=allowable emission rate in pounds per hour P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing [15A NCAC 2D .2601] b. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limit(s)above by testing the emission sources in Table 2.LD.1 in accordance with a testing protocol approved Air Pen-nit 03449T42 Page 16 by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 - General Condition JJ. Testing shall be completed not later than 60 dayss after the effective date of this pen-nit. The Permittee shall submit a written report of the test(s)results to the Regional Supervisor, DAQ within 60 days of completion of the test. If the results of this test are above the limit given in Section 2.1 D. 1. a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0515. Monitoring [15A NCAC 02Q .0508(f)] c. Particulate matter emissions from these sources shall be controlled as described in Table 2.1.D.1. To assure compliance,the Permittee shall perform inspections and maintenance as recommended by the manufacturer. d. The Permittee shall submit a permit application to the Regional Supervisor,DAQ to include control device monitoring parameters.The application shall be submitted within 60 days of completion of the compliance testing required in condition b. above. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if the monitoring requirements in conditions c. and d. are not met. Recordkeeping[15A NCAC 02Q .0508(f)] e. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on- site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed on the control devices;and iv. any variance from manufacturer's recommendations, if any,and corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if the recordkeeping requirements in condition e. are not met. Reporting[15A NCAC 02Q .0508(f)] f. The Permittee shall submit the results of any maintenance performed on the control devices within 30 days of a written request by the DAQ. g. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 2. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the emission sources in Table 2.1.D.1 shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. [15A NCAC 02D .0521 (d)] Testing[15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D.2601 and General Condition JJ. If the results of this test are above the limit given in Section 2.1.D.2.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring [15A NCAC 2Q.0508(f)] c. To assure compliance, once a week the Permittee shall observe the emission points of this source for any visible emissions above normal. The weekly observation must be made for each week of the calendar year period to ensure compliance with this requirement. The Permittee shall establish normal for the source within 30 days of initial startup. If visible emissions from this source are observed to be above normal,the Permittee shall either: i, take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii, demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 2D.2601 (Method 9)for 12 minutes is below the limit given in Section 2.1.D.2.a.above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D .0521. Air Permit 03449T42 Page 17 Recordkeeping[15A NCAC 2Q.0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions; and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521 if these records are not maintained. Reporting[15A NCAC 2Q.0508(f)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. E. Three natural gas-fired hot oil heaters (24 million Btu per hour maximum heat input, each) for the Medium Density Fiberboard Facilities (ID Nos. ES-18, ES-19 and ES-20) The following table provides a summary of limits and/or standards for the emission sources above: Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter 0.35 pounds per million Btu heat input 15A NCAC 213 ,0503 Sulfur dioxide 2.3 pounds per million Btu heat input 15A NCAC 2D .0516 Visible emissions 20 percent opacity 15A NCAC 2D .0521 NA Notification and Recordkeeping 15A NCAC 2D .0524 (NSPS Subpart Dc) HAPs Best Combustion Practices 15A NCAC 2D .1 109 Volatile organic Work Practice Standards 15A NCAC 2D .0958 compounds See Section 2.2 A.1. Odors See Section 2.2 A.3; 15A NCAC 2D.1806 State-enforceable only Volatile organic See Section 2.2 B.1. 15A NCAC 2Q.0317 compounds,Nitrogen (PSD Avoidance) oxides,PM2.5,PMio 1. 15A NCAC 2D.0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of natural gas,that are discharged from this source into the atmosphere shall not exceed 0.35 pounds per million Btu heat input. Testing[15A NCAC 02D.2601] b. If emissions testing is required,the testing shall be performed in accordance General Condition JJ. If the results of this test are above the limit given in Section 2.1 E.La.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0503. Monitoring/Recordkeeping/Reporting [15A NCAC 02Q .0508(f)] c. No monitoring/recordkeeping/reporting is required for particulate emissions from the firing of natural gas in this source. 2. 15A NCAC 2D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from this source shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Air Permit 03449T42 Page 18 Testin [15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 21) 2601 and General Condition JJ found in Section 3. If the results of this test are above the limit given in Section 2.1 E.1.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0516. Monitoring/Recordkeeping[15A NCAC 02Q .0508(f)and I5A NCAC 02D .2601] c. No monitoring/recordkeeping is required for sulfur dioxide emissions from natural gas for this source. 3. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this source shall not be more than 20 percent opacity when averaged over a six-minute period. However, six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testin [15A NCAC 21) .2601 J b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 21) .2601 and General Condition JJ. If the results of this test are above the limit given in Section 2.1 A. 2. a. above,the Penmittee shall be deemed in noncompliance with 15A NCAC 02D .0521. Mon itoring/Recordkeeping/Reportin2 [15A NCAC 02Q .0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of natural gas in this source. 4. 15A NCAC 2D.0524: NEW SOURCE PERFORMANCE STANDARDS a. The Permittee shall comply with all applicable provisions, including the notification,testing,recordkeeping, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 21) .0524"New Source Performance Standards(NSPS)as promulgated in 40 CFR Part 60 Subpart Dc, including Subpart A"General Provisions." Initial Notification Requirements [40 CFR 60.7] b. In addition to any other notification requirements to the Enviromnental Protection Agency per 40 CFR 60.7,the Permittee is required to notify the Regional Supervisor, DAQ, in writing, of the following: i. A notification of the date construction of an affected facility is commenced postmarked no later than 30 days after such date. ii. A notification of the actual date of initial startup of an affected facility postmarked within 15 days after such date. The Penmittee shall be deemed in noncompliance with 15A NCAC 21) .0524 if the initial notification requirements in condition b. are not met. Recordkeeping Requirements[15A NCAC 2Q .0508(f)] c. Pursuant to 40 CFR 60.48c(g)(2),the Permittee shall record and maintain records of the amount of fuel combusted during each calendar month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524 if the recordkeeping requirements in condition c. are not met. 5. 15A NCAC 2D.1109: Case-by-Case MACT a. The Permittee shall use best combustion practices when operating the affected heaters(ID Nos. ES-18, ES-19 and ES-20). The initial compliance date for this work practice standard and the associated monitoring,recordkeeping, and reporting requirements is October 18,2013. These conditions need not be included on the annual compliance certification until after the initial compliance date. Monitoring/Recordkeep in 2 b. To assure compliance,the Pennittee shall perform an annual boiler inspection and maintenance as recommended by the manufacturer,or as a minimum,the inspection and maintenance requirement shall include the following: i. Inspect the burner,and clean or replace any components of the burner as necessary; ii. Inspect the flame pattern and make any adjustments to the burner necessary to optimize the flame Air Permit 03449T42 Page 19 pattern;and, iii. Inspect the system controlling the air-to-fuel ratio,and ensure that it is correctly calibrated and functioning properly. The Permittee shall conduct at least one tune-up per calendar year to demonstrate compliance with this requirement. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .1109 if the affected heaters are not inspected and maintained as required above. c. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format) on-site and made available to an authorized representative upon request. The logbook shall record the following: i. The date of each recorded action; ii. The results of each inspection;and, iii. The results of any maintenance performed on the heaters. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .1109 if these records are not maintained. Reporting[15A NCAC 2Q .0508(f)] d. No reporting is required. F. Particleboard Mill (ID No. PB): Sawdust Rock and Metal Separator (ID No. 3501) Surface Layer Dryer(ID No. 1430) Core Layer Dryer No. 1 (ID No. 1420) Core Layer Dryer No. 2 (ID No. 1410) Surface Material Transport(ID No. 3515) Surface Formers and Mat Dumps (ID No. 3525) Flying Cut Off Saw, Pretrim Saws, and Production Collection (ID No. 3535) Particleboard Press (ID No. DEF-2010) Particleboard Cooler (ID No. PB-BC) Particleboard Steinemann Calibrating Sander (ID No. 3565) Particleboard Steinemann Finishing Sander(ID No. 3545) Schelling Saw Board Trim (ID No. 3555) Sander Filter Transport for Filters 3545 and 3565 (ID No.3575) PZKR Green Chip Flakers (ID No. 3585) Oversized Material Pallmann Mill (ID No. 3595) Dry Waste Transport System (ID No. 3577) "Wellons" Burner(ID No. 3201) operating in one of two scenarios (OS) only: i) OS-1: Exhausting to drum dryers; or ii) OS-2: combusting natural gas only and exhausting directly to atmosphere Air Permit 03449T42 Page 20 The following table provides a summary of limits and/or standards for the particleboard mill. Regulated Limits/Standards Applicable Pollutant Regulation Particulate matter 0.30 lb/million Btu(ID No.3201)(OS-2 only) 15A NCAC 21) .0503 Particulate matter 0.365 lb/million Btu(ID No.3201)(OS-1 only) 15A NCAC 2D .0504 Particulate matter adequate duct work and properly designed collectors 15A NCAC 2D .0512 Affected facilities: Sawdust Rock and Metal Separator(ID No.3501) Surface Material Transport(ID No.3515) Surface Formers and Mat Dumps(ID No.3525) Flying Cut Saw, Pretrim Saws, &Production Collection(ID No.3535) Particleboard Press(ID No. DEF-2010) Particleboard Cooler(ID No. PB-BC) Particleboard Mill Steinemann Calibrating Sander(ID No.3565) Particleboard Mill Steinemann Finishing Sander(ID No.3545) Schelling Saw Board Trim(ID No. 3555) Sander Filter Transport for Filters 3545 and 3565 (ID No.3575) PZKR Green Chip Flakers(ID No.3585) Dry Waste Transport System(ID No.3577) Oversized Material Pallmann Mill(ID No.3595) Particulate matter E=4.IOP U.67 when P<30 tons per hour 15A NCAC 2D where E=allowable emission rate in pounds per hour .0515 P=process weight in tons per hour E=55.OP 0'' when P>30 tons per hour where E=allowable emission rate in pounds per hour P=process weight in tons per hour Affected facilities: Surface Layer Dryer(ID No. 1430) Core Layer Dryer No. 1 (ID No. 1420) Core Layer Dryer No.2 ID No. 1410) Sulfur dioxide* 2.3 pounds per million Btu heat input 15A NCAC 2D .0516(a) Affected facilities: Surface Layer Dryer(ID No. 1430) Core Layer Dryer No. 1 (ID No. 1420) Core Layer Dryer No.2(ID No. 1410) "Wellons"Burner(ID No. 3201) Visible emissions 20 percent opacity 15A NCAC 2D .0521(d) PM,o 15A NCAC 2D Carbon monoxide .0530 Volatile organic See Section 2.1 F.6. compounds Nitrogen dioxide Visible emissions Volatile organic Work Practice Standards 15A NCAC 2D compounds See Section 2.2 A.1. .0958 Toxic air See Section 2.I.F.7 and Section 2.2 A.2; 15A NCAC 2D pollutants State-enforceable only .1100 Odors See Section 2.2 A.3; 15A NCAC 2D State-enforceable only .1806 Air Permit 03449T42 Page 21 Regulated Limits/Standards Applicable Pollutant Re ulation Hazardous air National Emission Standards for Hazardous Air Pollutants: Plywood and 15A NCAC 2D pollutants Composite Wood Products .11 1 1 See Section 2.2 A.4. (40 CFR 63, Subpart DDDD) Hazardous air National Emission Standards for Hazardous Air Pollutants for Major 15A NCAC 2D pollutants Sources: Industrial, Commercial,and Institutional Boilers and Process .1 11 1 Heaters (40 CFR 63, (ID No.3201)(OS-2 only) Subpart DDDDD) 1. 15A NCAC 2D.0504: PARTICULATES FROM WOODBURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of wood that are discharged fi-om the "Wellons" burner (No.320I)into the atmosphere shall not exceed 0.365 pounds per million Btu heat input. i. Condition 2.1.F.1 applies only when the Permittee operates the Wellons(ID No.3201) in operating scenario 1 (OS-1). Testing[15A NCAC 2D.2601] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 F. 1. a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0504. Monitoring/Recordkeeping[15A NCAC 2Q.0508(f)] c. Particulate matter emissions from the"Wellons"burner[No.3201] shall be controlled by multiclones(ID Nos. CD-1411,CD-1421,and CD-1431)and wet ESP(ID No. CD-PB-WESP). d. Monitoring/recordkeeping requirements in Section 2.1 F.6.d.through 1. shall be sufficient to assure compliance with 15A NCAC 2D .0504. If the requirements of Section 2.1 F.6.d.ii., f., h.,j., and 1. are not complied with, the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0504. Reporting[15A NCAC 2Q.0508(f)] e. Reporting requirements in Section 2.1 F.6. m. and n. shall be sufficient to assure compliance with 15A NCAC 2D .0504. 2. 15A NCAC 2D.0512: PARTICULATES FROM WOOD PRODUCTS FINISHING PLANTS a. The Permittee shall not cause,allow,or pen-nit particulate matter caused by the working, sanding,or finishing of wood to be discharged from any stack,vent, or building into the atmosphere without providing,as a minimum for its collection,adequate duct work and properly designed collectors. In no case shall the ambient air quality standards be exceeded beyond the property line. Monitoring/Recordkeeping[15A NCAC 2Q.0508(f)] b. Particulate matter emissions from the units in the particleboard mill [ID No. PB] including the sawdust rock and metal separator [ID No.3501],surface material transport[ID No.3515], surface formers and mat dumps [ID No.3525], flying cut off saws,pretrim saws,and production collection [ID No. 3535],particleboard Steinemann calibrating sander[ID No.3565],particleboard Steinemann finishing sander[ID No.3545], Schelling saw board trim[ID Nos.3555],sander filter transport for filters 3545 and 3565 [ID No.3575], PZKR green chip flakers [ID No.35851,Oversized Material Pallmann Mill [ID No.3595],and dry waste transport system [ID No.3577] shall be controlled by 12 (twelve)cyclones(ID Nos. SC, CD-3500, CD-351213, CD- 3520A,CD-3520B,CD-3521,CD-3530,CD-3531,CD-3533,CD-3522,CD-3570,and CD-3532), and 1 1 (eleven)fabric filters(ID Nos. CD-3501,CD-3515,CD-3525,CD-3535,CD-5001,CD-2006,CD-4005, CD- 3575,CD-3585,CD-3595,and CD-3577). i. No monitoring,recordkeeping or reporting shall be required for the particulate matter emissions from the particleboard press(ID No.DEF-2010)and particleboard cooler(ID No. PB-BC). c. To ensure compliance,the Permittee shall perform inspections and as follows: i. monthly external inspection of the duct work and cyclones,noting the structural integrity;and Air Permit 03449T42 Page 22 ii. internal inspection of the bag filters, every 12 months, noting the structural integrity and the condition of the filters. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0512 if the ductwork, cyclones, and bag filters are not inspected and maintained. d. The results of inspection and maintenance for the cyclones, and bag filters shall be maintained in a logbook (written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;and iii. the results of maintenance perfor reed on any control device. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0512 if these records are not maintained. Reporting[15A NCAC 2Q.0508(f)] e. The Permittee shall submit the results of any maintenance performed on ductwork,the 12(twelve)cyclones (ID Nos. SC,CD-3500, CD-3512113,CD-3520A,CD-352013,CD-3521, CD-3530,CD-3531, CD-3533,CD- 3522,CD-3570,and CD-3532), and 11 (eleven)fabric filters(ID Nos. CD-3501,CD-3515, CD-3525,CD- 3535,CD-5001,CD-2006,CD-4005,CD-3575,CD-3585,CD-3595,and CD-3577)within 30 days of a written request by the DAQ. f. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 3. 15A NCAC 2D.0515: PARTICULATE EMISSIONS FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the units in the particleboard mill (ID No. PB)Surface Layer Dryer(II) No. 1430), Core Layer Dryer No. 1 (ID No. 1420),and Core Layer Dryer No. 2(ID No. 1410)that are discharged into the atmosphere shall not exceed an allowable emission rate as calculated by the following equations: E=4.1OxPo.6� Where E=allowable emission rate in pounds per hour calculated to three significant figures P=process weight rate in tons per hour Or, for units with process weight rates greater than 30 tons per hour, E=55.0(P)o"-40 Where E=allowable emission rate in pounds per hour calculated to three significant figures P=process weight rate in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing [15A NCAC 2D ,2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1 F.3.a.above for particulate matter,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515, Monitoring/Recordkeeping[15A NCAC 2Q.0508(f)] c. Particulate matter emissions from the units in the particleboard mill [ID No. PB] shall be controlled as follows: i. Emissions from the following units shall be combined and controlled by a wet electrostatic precipitator (PB-WESP):the surface layer dryer(ID No. I430)and the associated multi-cyclone(I.D No. CD-1431) the core layer dryer# 1 (ID No. 1420)and the associated multi-cyclone(ID No. CD-1.421), and the core layer dryer#2(ID No. 1410)and the associated multi-cyclone(ID No.CD-1411). d. The Monitoring, Recordkeeping,and Reporting requirements required in 2.1 F.6.d.ii., f., h.,j., I., m., and n. Air Permit 03449T42 Page 23 shall be followed in order to demonstrate compliance with 15A NCAC 2D .0515. 4. 15A NCAC 2D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Sulfur dioxide from the particleboard mill(ID No. PB)Surface Layer Dryer(ID No. 1430),Core Layer Dryer No. 1 (ID No. 1420),Core Layer Dryer No.2(ID No. 1410),and "Wellons" Burner(ID No.3201)shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels, wastes,ores,and other substances shall be included when determining compliance with this standard. Testing[15A NCAC 2D .2601] b. if emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D.2601 and General Condition JJ found in Section 3. If the results of this test are above the limit given in Section 2.1. FA.a. above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D .0516. Monitoring/Recordkeeping/Reporting[15A NCAC 2Q.0508(f)] c. No monitoring,record keeping,or reporting is required for sulfur dioxide emissions from the firing of wood or natural gas in rotary drum dryers(ID Nos. 1410,1420,and 1430)and from the firing of wood or natural gas in the "Wellons"burner(ID No.3201). 5. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. As required by 15A NCAC 2D .0521(d)"Control of Visible Emissions,"visible emissions from the units in the particleboard mill(ID No.PB)manufactured after July 1, 1971,shall not be more than 20 percent opacity when averaged over a six-minute period [15A NCAC 2D .0521(d)]. However, six minute averaging periods may exceed 20 percent opacity if: i. No six-minute period exceeds 87 percent opacity; ii. No more than one six-minute period exceeds 20 percent opacity in any hour;and iii. No more than four six-minute periods exceed 20 percent opacity in any 24-hour period. Testin [15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D 2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1 F.5.a.above for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] c. To ensure compliance,the Permittee shall observe,on a weekly basis,the following emission points in the Particleboard mill for any visible emissions above normal: Emission Source Description and ID No. Emission Point ID No. Sawdust Rock and Metal Separator(ID No. 3501) CD-3501 Surface Layer Dryer(ID No. 1430) Core Layer Dryer#1 (ID No. 1420) CD-PB-PGT Core Layer Dryer#2(ID No. 1410) "Wellons"Burner(ID No.3201)(OS-1 only)* Particleboard Press(ID No.DEF-2010) CD-PB-PGT Surface Material Transport(ID No.3515) CD-3515 and CD-3525 Surface Formers and Mat Dumps(ID No.3525) CD-3525 Flying Cut Off Saw,Pretrim Saws, and Production Collection (ID No.3535) CD-3535 Board Cooler(ID No. PB-BC) PB-BC Particleboard Mill Steinemann Calibrating Sander(ID No. 3565) CD-3575 Particleboard Mill Steinemann Finishing Sander(ID No.3545) CD-3575 and CD-2006 Schelling Saw Board Trim(ID No.3555) CD-4005 Sander Filter Transport for Filters 3545 and 3565(ID No.3575) CD-3575 PZKR Green Chip Flakers(ID No.3585) CD-3585 Oversized Material Pallmann Mill(ID No.3595) CD-3595 Dry Waste Transport System(ID No.3577) CD-3577 Air Permit 03449T42 Page 24 * No observations are required for the Wellons burner(ID No.3201)when operating in OS-2. The weekly observation must be made for each week of the calendar year period to ensure compliance with this requirement. The Permittee shall establish normal for the emission sources controlled by the scrubber(ID No. CD-PB-PGT)within the first 30 days of the initial start up of the scrubber(ID No.CD-PB-PGT)following the effective date of air permit no, 03449T39. The Pennittee shall re-establish normal for the emission sources ES- 3515 and ES-3545 within the first 30 days of their initial start up following the effective date of air permit no. 03449T41. If visible emissions from these sources are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii, demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 2D.2610(Method 9)for 12 minutes is below the limit given in Section 2.1 F.5,a. above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D.0521. d. The results of the monitoring for visible emissions shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. To ensure quality, entries in the logbook should be signed by personnel responsible for the effective operation of the units in the particleboard mill and their air pollution control devices. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521 if these records are not maintained. Reporting [15A NCAC 2Q .0508(f)] e. The Permittee shall submit a summary report of monitoring and record keeping activities by January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 6. 15A NCAC 2D.0530: PREVENTION OF SIGNIFICANT DETERIORATION a. For PSD purposes,the following"Best Available Control Technology"(BACT)pen-nit limitations shall not be exceeded for units in the particleboard mill(ID No. PB): Emission Source Pollutants Emission Limits Control Technology Sawdust Rock and Metal Separator PM,o 0.02 lbs/hr cyclone and baghouse (ID No.3501) Volatile Organic 5.56 1bs/hr,as C none Compounds Opacity 20 percent cyclone and baghouse Surface Layer Dryer(ID No. 1430) PMip 28.3 lbs/hr good combustion Core Layer Dryer # 1(ID No. 1420) control with Core Layer Dryer#2 (ID No. 1410) existing multiclones and wet ESP Volatile Organic 163.3 lbs/hr, as C good combustion Compounds control with existing wet ESP Carbon Monoxide 329.4 lbs/hr good combustion control Nitrogen Oxides 94.7 lbs/hr good combustion control Surface Material Transport (ID No. PM10 0.02 lbs/hr cyclones and 3515) baghouse Air Permit 03449T42 Page 25 Emission Source Pollutants Emission Limits* Control Technology Volatile Organic 46.5 lbs/hr,as C none Compounds Opacity 20 percent cyclones and baghouse Surface Formers and Mat Dumps(ID PMto 0.06 lbs/hr cyclones and No.3525) baghouse Volatile Organic 1.95 lbs/hr, as C none Compounds Opacity 20 percent cyclones and baghouse Flying Cut Off Saw,Pretrim Saws, PM,o 0.005 lbs/hr cyclones and and Production Collection(ID No. baghouse 3535) Volatile Organic 1.77 lbs/hr, as C none Compounds Opacity 20 percent cyclones and baghouse Particleboard Press(ID No.DEF- PM10 3.29 lbs/hour none 2010)and Board Cooler(ID No. PB- BC) Volatile Organic 32.1 lbs/hour as C none Compounds Opacity 20 percent none Particleboard Steinemann Calibrating PMjo 0.02 lbs/hour cyclone and Sander(ID No.3565) baghouses Volatile Organic 1.08 lbs/hour as C none Compounds Opacity 20 percent cyclone and baghouses Particleboard Steinemann Finishing PM10 1.2 lbs/hour cyclone and Sander(ID No.3545) baghouses Volatile Organic 0.35 lbs/hour as C none Compounds Opacity 20 percent cyclone and baghouses Schelling Saw Board Trim(ID No. PM10 0.01 lbs/hour cyclone and baghouse 3522) Volatile Organic 0.72 lbs/hour as C none Compounds Opacity 20 percent cyclone and baghouse Sander Filter Transport for Filters PM 4.0 lbs/hour cyclone and baghouse 3545 and 3565 (ID No.3575) Volatile Organic 1.77 lbs/hour as C none Compounds Opacity 20 percent cyclone and baghouse PZKR Green Chip Flakers(ID No. PM10 1.0 lbs/hour baghouse 3585) Volatile Organic 0.64 lbs/hour as C none Compounds Opacity 20 percent baghouse Oversized Material Pallmann Mill PM10 0.005 lbs/hour baghouse (ID No.3595) Volatile Organic 1.77 lbs/hour as C none Compounds Opacity 20 percent baghouse Air Permit 03449T42 Page 26 Emission Source Pollutants Emission Limits* Control Technology Dry Waste Transport System(ID No. PM10 0.005 lbs/hour cyclone and baghouse 3577) Volatile Organic 1.77 lbs/hour as C none Compounds Opacity 20 percent cyclone and baghouse BACT limits shall apply at all times. However, emissions resulting fi•om startup, shutdown or malfunction as defined under 15A NCAC 2D .0535,exceeding the limits in Section 2.1 F.6.a.above are permitted,provided that the Permittee,to the extent practicable,maintains and operates each emission source including any associated air pollution control equipment listed in this Table,in a manner consistent with good air pollution control practice for minimizing emissions. ;# BACT emission limits are a total for three particleboard dryers(ID Nos. 1410, 1420,and 1430). *** All BACT limits were established prior to the installation of the scrubber(ID No.CD-PB-PGT). Testing(P1 of[15A NCAC 2D.2601] b. If testing is required for emissions of PM10,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ. If the results of this test exceed the limits given in Section 2.1 1:.6.a. above, the Pennittee shall be deemed in noncompliance with 15A NCAC 2D .0530. c. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limits in Section 2.1 F.6.a. above by testing the particleboard dryers (ID Nos. 1410, 1420,and 1430) for PM10 (filterable and condensible both) in accordance with a testing protocol approved by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 -General Condition JJ of the permit. All three dryers shall be in operation during this source testing. Testing shall be completed and the results submitted within 180 days from the issuance date of air permit 03449T31. All three dryers or all operational dryers shall be included in this source testing. The Pennittee shall conduct another stack test and submit the results within 90 days of start-up of particleboard dryer(ID No. 1410), if this dryer was not operational during the stack test as required above. All three dryers shall be in operation during this source testing. If the results of any tests for PM10 are above the limits in Section 2.1 F.6.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. Monitoring(PM,ol[15A NCAC 2Q.0508(f)] d. PM10 emissions from the units in the particleboard mill JD No. PB] shall be controlled as follows: i. In the sawdust rock and metal separator(ID No.3501),raw materials shall be sorted to remove unusable material and transported through a high efficiency cyclone(1D No.SC), which is 72 inches in diameter. Emissions from the cyclone shall be exhausted to a fabric filter(ID No. CD-3501)with 2,410 square feet of filter surface area. ii. Emissions from the following units shall be combined and controlled by a wet electrostatic precipitator(ID No. PB-WESP). 1. the surface layer dryer(ID No. 1430), its associated multi-cyclone(ID No. CD-1431)with two tubes, each 80 inches in diameter, 2. the core layer dryer# I (ID No. 1420),its associated multi-cyclone(ID No.CD-1421)with 4 tubes, each 80 inches in diameter,and 3. the core layer dryer#2 (ID No. 1410)), its associated multi-cyclone(ID No. CD-1411)with 4 tubes, each 80 inches in diameter. iii. In the surface material transport(ID No.3515),emissions are controlled by two systems in parallel: one simple cyclone(ID No. CD-3500)followed by a fabric filter with 6,918 square feet of filter surface area (ID No.CD-3525) in parallel with one simple cyclone(ID No.CD-3512B)followed by a fabric filter with 5,767 square feet of filter surface area(1D No. CD-3515) iv. In the surface formers and mat dumps(ID No.3525), emissions shall be controlled by 3 (three)simple cyclones(ID Nos. CD-3520A,CD-3520B,and CD-3521),each 96 inches in diameter. Emissions fi-om the cyclones shall be captured by a fabric filter(ID No.CD-3525)with 6,918 square feet of filter surface Air Permit 03449T42 Page 27 area, v, in the flying cut off saw,pretrim saws,and production collection(ID No.3535), emissions shall be controlled by one simple cyclone(ID No. CD-3530),which is 84 inches in diameter,and two simple cyclones(ID Nos. CD-3531 and CD-3533),each 108 inches in diameter,followed by a fabric filter(ID No. CD-3535)with 6,918 square feet of filter surface area. vi. Emissions from the particleboard Steinemann calibrating sander(ID No.3565), shall be captured by a fabric filter(ID No. CD-5001) with 6,918 square feet of filter surface area. Emissions from the fabric filter (ID No.5001)shall be vented to a simple cyclone(ID No.CD-3570)and in turn to another fabric filter (ID No.CD-3575). vii. Emissions from the particleboard Steinemann finishing sander(ID No.3545),shall be filtered by a fabric filter(ID No. CD-2006)with 6,918 square feet of filter surface area. Emissions from the fabric filter(ID No. CD-2006)shall be vented to a simple cyclone(ID No. CD-3570)and in turn by another fabric filter (ID No. CD-3575). viii.Emissions from the Schelling saw board trim(ID No.3555)shall be captured by a simple cyclone(ID No. CD-3522),which is 120 inches in diameter,followed by a fabric filter(ID No.CD-4005)with 6,918 square feet of filter surface area. ix. Emissions from the sander filter transport for filters 3545 and 3565 (ID No.3575)shall be captured by a simple cyclone(ID No.CD-3570),which is 144 inches in diameter,followed by a fabric filter(ID No. CD-3575)with 1,159 square feet of filter surface area. x. Emissions from the PZKR green chip flakers(ID No.3585),shall be collected by a fabric filter(ID No. CD-3585)with 4,880 square feet of filter surface area. xi. Emissions from the oversize material Pallmann mill (ID No.3595),shall be captured by a reverse flow fabric filter(ID No. CD-3595)with a maximum air to cloth ratio(ACFM/total filter surface area)of 3.0 square feet of filter surface area. xii. For the dry waste transport system(ID No.3577),emissions shall be routed through a high efficiency cyclone(ID No. CD-3532),which is 60 inches in diameter,to a fabric filter(ID No. CD-3577)with 4,068 square feet of surface area. For the cyclones(ID Nos. CD-SC,CD-3500,CD-3512B,CD-3520A,CD-3520B,CD-3521,CD-3530,CD- 3531,CD-3533,CD-3522,CD-3570,and CD-3532): e. To ensure compliance and effective operation,the Permittee shall perform inspections and maintenance, as a minimum,the inspection and maintenance requirement shall include the following: i. a monthly visual inspection of the system ductwork and material collection unit for leaks;and, ii. an annual(for each 12 month period following the initial inspection) internal inspection of the cyclones's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the ductwork,bagfilter and cyclones are not inspected and maintained. For the multi-cyclones(ID Nos.CD-1411,CD-1421, and CD-1431): f. To ensure compliance and effective operation,the Permittee shall perform inspections and maintenance, as a minimum,the inspection and maintenance requirement shall include the following: i. a weekly external visual inspection of the cyclones,the system ductwork,and the material collection unit for leaks,and ii. an annual (for each 12 month period from initial inspection)internal inspection of the multi-cyclone's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the multi-cyclones and ductwork are not inspected and maintained. For the fabric filters(ID Nos. CD-3501,CD-3515,CD-3525,CD-3535,CD-5001,CD-2006,CD-4005,CD- 3575,CD-3585,CD-3595,and CD-3577): g. To ensure compliance and effective operation,the Permittee shall perform inspections and maintenance, as a minimum,the inspection and maintenance requirement shall include the following: i. a monthly visual inspection of the system ductwork and material collection unit for leaks; and Air Permit 03449T42 Page 28 ii. an annual(for each 12 month period following the initial inspection)internal inspection of the bagfilter's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530 if the ductwork, bagf lter and cyclone are not inspected and maintained. For the wet electrostatic precipitator(ID No.CD-PB-WESP) h. To ensure compliance and the effective operation of the wet electrostatic precipitator(ID No.CD-PB-W ESP), the Pennittee shall: i. operate the wet electrostatic precipitator with a minimum of two of the possible three fields, excluding periods when one of the two fields is in a wash cycle; ii. monitor and record the primary voltage and current through the precipitator daily.The daily observation must be made for each day of the calendar year period.The Pennittee shall be allowed three(3)days of absent observations per semi-annual period. The lower limits are given below: Field No. Minimum Primary Voltage,kilovolts Minimum Current, milliam s 1 0.109 0.244 2 0.122 0.244 3 0.244 0.244 The Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530 if: i. the voltage or current readings are not monitored or recorded,excluding periods of start-up, shut-down, malfunction,and monitor downtime;and as provided in i, above;or ii, the voltage or current fall below the lower limits as established above in 2.1 F.6.h.ii. Recordkeepin2(PM1ol[15A NCAC 2Q.0508(f)] For the cyclones(ID Nos.CD-SC,CD-3500,CD-3512B,CD-3520A,CD-3520B, CD-3521,CD-3530,CD- 3531,CD-3533,CD-3522,CD-3570,and CD-3532): i. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format) on- site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;the results of any maintenance performed on the cyclones;and iii. any corrections made. The Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530 if these records are not maintained. For the multi-cyclones(ID Nos.CD-1411,CD-1421,and CD-1431): j. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format) on- site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii, the results of any maintenance performed on the multi-cyclones and ductwork;and iv. any corrections made. The Pennittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if these records are not maintained. For the fabric filters(ID Nos.CD-3501,CD-3515,CD-3525,CD-3535, CD-5001,CD-2006,CD-4005,CD- 3575,CD-3585,CD-3595,and CD-3577): k. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format) on- site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed on the bagfilters; and iv. any corrections made. The Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530 if these records are not maintained. For the wet electrostatic precipitator(ID No.CD-PB-WESP) 1. The results of inspection and maintenance activities, discussed above for the wet electrostatic precipitator,shall Air Permit 03449T42 Page 29 be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative of DAQ upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;and iii. any corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if these records are not maintained. Reporting(PMyo)[15A NCAC 2Q.0508(f)] m. The Permittee shall submit the results of any maintenance performed on the cyclones(ID Nos.CD-SC,CD- 3500,CD-3512B,CD-3520A,CD-3520B,CD-3521,CD-3530,CD-3531,CD-3533,CD-3522,CD-3570, and CD-3532),fabric filters(ID Nos.CD-3501,CD-3515,CD-3525,CD-3535,CD-5001,CD-2006,CD- 4005,CD-3575,CD-3585,CD-3595,and CD-3577),multi-cyclones(ID Nos.CD-1411,CD-1421,and CD- 1431),and wet electrostatic precipitator(ID No. CD-PB-WESP)within 30 days of a written request by the DAQ. n. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. Testing(Carbon Monoxide)[15A NCAC 2D .2601] o. If emissions testing is required,the testing shall be performed in accordance with 40 CFR Part 60 Appendix A, Method 10 and General Condition JJ found in Section 3. If the results of the test perfonned exceed the limits given in Section 2.1 F.6.a. above for emissions of carbon monoxide,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. p. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limits in Section 2.1 F.6.a. above by testing the particleboard dryers(ID Nos. 1410, 1420,and 1430) for carbon monoxide in accordance with a testing protocol approved by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 -General Condition JJ of the permit. All three dryers shall be in operation during this source testing. Testing shall be completed and the results submitted within 90 days of start-up of particleboard dryer(ID No. 1410). If the results of any tests for carbon monoxide are above the limits in Section 2.1 F.6.a, above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring(Carbon Monoxide)[15A NCAC 2Q.0508(f)] q. To ensure compliance and effective operation,the Permittee shall perform inspections and maintenance of the particleboard dryers(ID Nos. 1410, 1420,and 1430). At a minimum,the inspection and maintenance requirement shall include the following: i.a weekly inspection of burners,fans,blowers,and associated process control equipment. ii. an annual (for each 12 month period following the initial inspection)internal inspection of the particleboard dryers(ID Nos. 1410, 1420,and 1430)for structural integrity. If the required inspections are not conducted,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D .0530. Recordkeepine(Carbon Monoxide) [15A NCAC 2Q .0508(f)] r. The results of inspection and maintenance of the particleboard dryers(ID Nos. 1410, 1420,and 1430)shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed on the particleboard dryers(ID Nos. 1410, 1420,and 1430);and iv. any variance from manufacturer's recommendations, if any, and corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if these records are not maintained. Reporting(Carbon Monoxide) [15A NCAC 2Q .0508(o] Air Permit 03449T42 Page 30 s. The Permittee shall submit the results of any maintenance performed on the particleboard dryers (ID Nos. 1410, 1420,and 1430)within 30 days of a written request by the DAQ. t. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. Testing(Volatile Organic Compounds) [15A NCAC 2D .2601] u. If testing is required for emissions of volatile organic compounds,the testing shall be performed in accordance with 15A NCAC 21).2601 and General Condition JJ. If the results of this test exceed the limit given in Section 2.1 F.6.a.above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530. v. Under the provisions of NCGS 143-215.108,the Pennittee shall demonstrate compliance with the emission limits in Section 2.1 F.6.a. above by testing the particleboard dryers(ID Nos. 1410, 1420,and 1430) for volatile organic compounds in accordance with a testing protocol approved by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 -General Condition JJ of the permit. All three dryers shall be in operation during this source testing. Testing shall be completed and the results submitted within 90 days of start-up of particleboard dryer(ID No. 1410). If the results of any tests for volatile organic compounds are above the limits in Section 2.1 F.6.a.above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530. Monitorin2/Recordkeepin2(VOC) [15A NCAC 2Q .0508(f)] w. Monitoring/recordkeeping requirements in Section 2.1 F.6.q. and r. above shall be sufficient to assure compliance with 15A NCAC 2D .0530. If the requirements of Section 2.1 F.6.q. and r, are not complied with, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. x. During the stack test for VOC as required in Section 2.1 F.6.v. above, the Permittee shall collect data for water injection rates for wet ESP and establish minimum water injection rate to assure compliance with the VOC emission limit in Section 2.1 F.6.a. above. The Permittee shall request a permit revision to include the minimum water injection rate for wet ESP established in Section 2.1 F.6.x.through an "administrative permit amendments" procedure within 90 days from the submittal of stack test results in Section 2.1 F.6.v. above. The Pennittee shall be deemed in noncompliance with 15A NCAC 21) .0530 if the requirements of the Section 2.1 F.6.x. are not complied with. Reporting[15A NCAC 2Q .0508(f)] y. Reporting requirements in Section 2.1 F. 6. s. and t. shall be sufficient to assure compliance with 15A NCAC 2D .0530. Testing(Nitrogen Oxides)Testing [15A NCAC 2D .2601] z. if emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D.2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1 F.6.a.above for emissions of nitrogen oxides,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. aa. Under the provisions of NCGS 143-215,108,the Permittee shall demonstrate compliance with the emission limits in Section 2.1 F.6.a. above by testing the particleboard dryers(ID Nos. 1410, 1420,and 1430) for nitrogen oxides in accordance with a testing protocol approved by the DAQ. Details of the emissions testing and reporting requirements can be found in Section 3 -General Condition JJ of the permit. All three dryers shall be in operation during this source testing. Testing shall be completed and the results submitted within 90 days of start-up of particleboard dryer (1 D No. 1410). If the results of any tests for nitrogen oxides are above the limits in Section 2.1 F.6.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. Monitoring/Recordkeeping(NOx) [15A NCAC 2Q .0508(f)] bb. Mon itoring/recordkeeping requirements in Section 2.1 F.6.q. and r. above shall be sufficient to assure compliance with 15A NCAC 21) .0530. If the requirements of Section 2.1 F.6.q. and r. are not complied with, the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. Air Pen-nit 03449T42 Page 31 Reporting [15A NCAC 2Q .0508(f)] cc. Reporting requirements in Section 2.1 F.6, s. and t. shall be sufficient to assure compliance with 15A NCAC 2D.0530. Testing(Visible Emissions) [15A NCAC 2D.2601] dd. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1 F.6.a.above for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring/Recordkeeping(VE) [15A NCAC 2Q .0508(f)] ee. Monitoring / recordkeeping requirements in Section 2.1 F.S.c. and d. above shall be sufficient to assure compliance with 15A NCAC 2D .0530 for all PSD affected sources except particleboard dryers.' If the requirements of Section 2.1 F.S.c. and d. are not complied with, the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0530. Reporting [15A NCAC 2Q .0508(f)] ff. Reporting requirements in Section 2.1 F.5.e. shall be sufficient to assure compliance with 15A NCAC 2D .0530. Monitorin2/Recordkeeping(PM,o,CO,VOC,NOyand VE)[15A NCAC 2Q.0508(f)] gg. The total particleboard production at the Particleboard Mill(ID No. PB)during any consecutive 12-month period shall not exceed 180,000,000 square feet on a'/4-inch basis. The Permittee shall maintain monthly records of the total amount of particleboard produced in a logbook(written or in electronic format). Such records shall indicate the amount of particleboard produced during the preceding month and the total amount of particleboard produced over the preceding 12-month period. The Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0530 if the particleboard production records are not maintained or the production limit is exceeded. hh. The operating hours for particleboard dryers(ID Nos. 1410, 1420 and 1430)shall not exceed 8,500 hours each during any consecutive 12-month period. The Permittee shall keep monthly records of the hours of operation for each particleboard dryer. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if these records are not kept or operating hours of any particleboard dryers exceed 8,500 hours during any consecutive 12-month period. Reporting(PM,PM,o,CO,VOC,NO,VE) [15A NCAC 2Q.0508(f)] ii. By January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June,the following shall be reported to the Regional Supervisor,Division of Air Quality: a. the annual production rate at the Particleboard Mill (ID No.PB)in square feet on a 3/4-inch basis. The annual production rate must be calculated for each of the six twelve-month periods over the previous seventeen months. b. the hours of operation for each particleboard dryer(ID Nos. 1410, 1420 and 1430) for each of the six twelve-month periods over the previous seventeen months, All instances of deviations from the requirements of this permit must be clearly identified. 7. 15A NCAC 2D.0614: COMPLIANCE ASSURANCE MONITORING 140 CFR 641 a. The particleboard dryers(ID Nos. 1410, 1420,and 1430)shall comply with all applicable requirements of 15A NCAC 2D .06I4"Compliance Assurance Monitoring". b. Three multiclones (ID Nos. CD-1411, CD-1421, and CD-1431) and one wet ESP (ID No. CD-PB-WESP) shall be properly operated and maintained to control PM10 emissions from the particleboard dryers (ID Nos. 1410, 1420,and 1430). Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] c. Monitoring and record keeping requirements for multiclones (ID Nos. CD-1411, CD-1421, and CD-1431) in ' Particleboard dryers are not subject any VE BACT. Air Permit 03449T42 Page 32 Section 2.1 F.6.d.ii., f.,h.,j.,and 1. above shall be sufficient to assure compliance with 15A NCAC 2D .0614. d. During the stack test for PM10 as required in Section 2.1 F.6. c. above,the Permittee shall collect data for primary voltage and primary current on each of the three fields of wet ESP(ID No.CD-PB-WESP). The Pernittee shall establish correlation between emissions of PM10,and primary voltage and primary current of wet ESP,and request a permit revision through an "administrative permit amendments"procedure within 90 days from the submittal of stack test results in Section 2.1 F.6.c. above. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0614 if the requirements of the Section 2.1 F,7.d. are not complied with. Reporting[15A NCAC 2Q .0508(f)] e. Reporting requirements for multiclones(ID Nos.CD-1411,CD-1421,and CD-1431)in Section 2.1 F.6.m. and n. shall be sufficient to assure compliance with 15A NCAC 2D .0614. STATE ENFORCEABLE ONLY 8. 15A NCAC 2D.1100: CONTROL OF TOXIC AIR POLLUTANTS Applicability a. The sources controlled by the scrubber(ID No. CD-PB-PGT)are subject to 15A NCAC 2D .1100"Control of Toxic Air Pollutants"but have not been considered in an evaluation pursuant to 15A NCAC 2Q .0706 "Modifications." b. The Division shall notify the Permittee 60 days prior to reopening the permit, if necessary,to establish emission limitations, monitoring,recordkeeping or reporting necessary to ensure compliance with 15A NCAC 2D .1100. [NCGS 143-215.108(c)] Air Permit 03449T42 Page 33 9. 15A NCAC 2D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY Applicability[40 CFR 63.7485] a. For this existing process heater designed to burn gas I fuels(ID No.3201),the Permittee shall comply with all applicable provisions, including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .I I I I "Maximum Achievable Control Technology" (MACT) as promulgated in 40 CFR 63, Subpart DDDDD . "National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial,Commercial, and Institutional Boilers and Process Heaters"and Subpart A"General Provisions." i. Condition 2.1.F.9 applies only when the Permittee operates the Wellons(ID No.3201)in operating scenario 2 (OS-2). Definitions and Nomenclature [40 CFR 63.7575] b. For the purpose of this permit condition,the definitions and nomenclature contained in 40 CFR 63.7575 shall apply. 40 CFR Part 63 Subpart A General Provisions [40 CFR 63,7565] c. The Pennittee shall comply with the requirements of 40 CFR 63 Subpart A General Provisions according to the applicability of Subpart A to such sources as identified in Table 10 to 40 CFR Part 63, Subpart DDDDD. Compliance Date 140 CFR 63.7495(b)] d. The Pennittee shall complete the initial tune up and the one-time energy assessment no later than January 31, 2016. 140 CFR 63.7495(b), 63.7510(e)] i. If the Wellons(ID No.3201)is not operated in OS-2 prior to January 1,2016,the Permittee shall complete the initial tune up no later than 30 days after startup. [40 CFR 63.75100)] Notifications 140 CFR 63.7545,63.7530(d),(e),(f)] e. The Pennittee shall submit a Notification of Compliance Status. The notification shall contain the following: i. A description of the affected unit(s)including identification of which subcategories the unit is in,the design heat input capacity of the unit,and description of the fue](s)burned. ii. the following certification(s)of compliance,as applicable: i.-"This facility complies with the required initial tune-up according to the procedures in condition g.i.through g.v.and in. ii.' (40 CFR 63.7540(a)(10)(i)through(vi));and ii.-"This facility has had an energy assessment performed according to condition k. (40 CFR 63.7530(e))." The notification must be signed by a responsible official and sent before the close of business on the 60th day following the completion of the initial tune up and one time energy assessment(whichever is later). General Compliance Requirements 140 CFR 63.7505(a),63.7500(f)] f. The Pennittee shall be in compliance with the work practice standards in this subpart. These standards apply at all times the affected unit is operating. Work Practice Standards[15A NCAC 02Q.0508(f)] g. The Pennittee shall conduct a tune-up of the process heater annually as specified below. i. As applicable, inspect the burner,and clean or replace any components of the burner as necessary(you may delay the burner inspection until the next scheduled unscheduled unit shutdown; ii. 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; iii. Inspect the system controlling the air-to-fuel ratio,as applicable, and ensure that it is correctly calibrated and functioning properly(you may delay the inspection until the next scheduled unit shutdown)' iv. Optimize total emissions of carbon monoxide.This optimization should be consistent with the manufacturer's specifications,if available,and with any NOx requirement to which the unit is subject. Air Pen-nit 03449T42 Page 34 v. 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). Measurements may be taken using a portable CO analyzer. [40CFR 63.7500(a),63.7540(a)(10)] h. Each annual tune-up shall be conducted no more than 13 months after the previous tune-up. [40CFR 63.7515(d)] i. If the unit is not operating on the required date for a tune-up, the tune-up must be conducted within 30 calendar days of startup. [40 CFR 63.7540(a)(13),63.7515(g)] j. At all times,you must 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. Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator that may include,but is not limited to,monitoring results,review of operation and maintenance procedures,review of operation and maintenance records, and inspection of the source. [40 CFR 63.7500(a)(3)] The Pennittee shall be deemed in noncompliance with 15A NCAC 02D .1111 if the requirements in f.through i. are not met. Energy Assessment Requirements [15A NCAC 02Q.0508(b)] k. The Pennittee shall have a one-time energy assessment performed by a qualified energy assessor.The energy assessment must include the following items: i. A visual inspection of the boiler system; ii. An evaluation of operating characteristics of the affected boiler systems, specifications of energy use systems, operating and maintenance procedures,and unusual operating constraints; iii. An inventory of major energy use systems consuming energy from affected boiler(s)and which are under control of the boiler owner or operator; iv. A review of available architectural and engineering plans,facility operation and maintenance procedures and logs,and fuel usage; v. A list of major energy conservation measures that are within the facility's control; vi. A list of the energy savings potential of the energy conservation measures identified;and vii. A comprehensive report detailing the ways to improve efficiency,the cost of specific improvements, benefits, and the time frame for recouping those investments. 1. The energy assessment will be 8 on-site technical labor hours in length maximum,but may be longer at the discretion of the owner or operator of the affected source. The boiler system(s)and any on-site(excluding MDF plant)energy use system(s)accounting for at least 50 percent of the affected boiler(s)energy(e.g.,steam, hot water, process heat,or electricity)production,as applicable,will be evaluated to identify energy savings opportunities, within the limit of performing an 8-hour on-site energy assessment. [40 CFR 63.7500(a)(1),Table 3] The Pennittee shall be deemed in noncompliance with 15A NCAC 02D .l I I I if the requirements in k, through1. are not met. Recordkeeping Requirements [15A NCAC 02Q .0508(f),40 CFR 63.7555] m. The Permittee shall keep the following: i. A copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,or semiannual compliance report that has been submitted,according to the requirements in 40 CFR 63.10(b)(2)(xiv). [40 CFR 63.7555(a)(1)] ii. Maintain on-site and submit, if requested by the Administrator, an annual report containing the information in Air Permit 03449T42 Page 35 paragraphs(A)through(C)below: (A) The concentrations of carbon monoxide in the effluent stream in parts per million by volume, and oxygen in volume percent,measured before and after the adjustments of the source; (B) A description of any corrective actions taken as a part of the combustion adjustment;and (C) The type and amount of fuel used over the 12 months prior to the annual adjustment,but only if the unit was physically and legally capable of using more than one type of fuel during that period. Units sharing a fuel meter may estimate the fuel use by each unit, [40 CFR 63.7540(a)(10)(vi)] iii. The associated records for conditions f.through 1. including: (A) the occurrence and duration of each malfunction of operation (i.e.,process equipment)or the required air pollution control and monitoring equipment. [40 CFR 63.1 0(b)(2)(ii)] iv. maintain records of the calendar date,time,occurrence and duration of each startup and shutdown. [40 CFR 63.7555(i)] v. maintain records of the type(s)and amount(s)of fuels used during each startup and shutdown. [40 CFR 63.75550)] n. The Permittee shall: i. maintain records in a form suitable and readily available for expeditious review; ii. keep each record for 5 years following the date of each occurrence,measurement,maintenance, corrective action,report,or record;and iii. keep each record on site for at least 2 years after the date of each occurrence,measurement,maintenance, corrective action, report, or record. The Permittee can keep the records offsite for the remaining 3 years. [40 CFR 63,7560, 63.10(b)(1)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.I I I I if records are not maintained per conditions in.through n. Reporting Requirements [15A NCAC 02Q .0508(f)] o. In lieu of a 1-year reporting requirement pursuant to 40 CFR 63.7550(b),the Permittee has elected to submit compliance reports to the DAQ on a semi-annual basis.The Permittee shall submit the compliance report postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. i. The first report shall cover the period beginning on January 31,2016 and shall be postmarked on or before July 30,2016. ii. These reports must also be submitted electronically through the EPA's Central Data Exchange(CDX) (www.epa.gov/cdx). However,if the reporting form specific to this subpart is not available in CEDRI at the time that the report is due the report the Permittee submit the report to the at the appropriate address listed in 40 CFR 63.13. [40 CFR 63.7550(h)(3)] A. The Permittee may submit the CDX report in condition o.ii. above on a 1-year basis as allowed pursuant to 40 CFR 63.7550(b). p. The compliance report must contain the following information: i. Company name and address; ii. Process unit infonnation,emissions limitations,and operating parameter limitations; iii. Date of report and beginning and ending dates of the reporting period; iv. The total operating time during the reporting period; iv. If there are no deviations from the requirements of the work practice requirements in condition g, above, a statement that there were no deviations from the work practice standards during the reporting period; and v. Include the date of the most recent tune-up for each unit required to conduct an annual tune-up according to condition g.Include the date of the most recent burner inspection if it was not done annually and was delayed Air Permit 03449T42 Page 36 until the next scheduled or unscheduled unit shutdown. [40 CFR 63.7550(a)and(c),Table 91 q. If there is a deviation from a work practice standard during the reporting period,the report must contain the following information: i. A description of the deviation and which emission limit or operating limit from which you deviated;and ii. Information on the number,duration,and cause of deviations(including unknown cause),as applicable,and the corrective action taken. [40 CFR 63.7550(a)and(d), 63.7540(b),Table 9] The Pennittee shall be deemed in noncompliance with 15A NCAC 02D.1 111 if the reporting requirements in o. through q, are not met. 10. 15A NCAC 2D.0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the Wellons(ID No 3201,when operating in OS-2 only)that are discharged from this source into the atmosphere shall not exceed 0.33 pounds per million Btu heat input. [15A NCAC 2D .0503(a)] Testin [15A NCAC 2Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a. above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0503. Mon itoring/Recordkeeping/Reporting [15A NCAC 2Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for particulate emissions from the firing of natural gas in this source. STATE-ENFORCEABLE ONLY 11. NOTIFICATION REQUIREMENT-The Permittee shall notify the Regional Supervisor in writing within 15 days of the initial start date of operation in operating scenario 2(OS-2)for the Wellons(ID No.3201). Air Permit 03449T42 Page 37 G. Laminating Mill: One bagfilter (ID No. CD-3593) installed on two presses: Short Cycle Laminating Press (ID No.3593) Short Cycle Laminating Press (ID No. 3594) One Natural Gas and No. 2 oil-fired Hot Oil Heater(ID No. Pr-Heatl) The following table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter Affected source: Hot Oil Heater(ID No.Pr-Heatl) 15A NCAC 2D .0503 0.60 pounds per million Btu heat input Affected source: Short cycle laminating,presses(ID Nos.3593 and 3594) 15A NCAC 2D .0515 E=4.10P 0.67 where;E=allowable emission rate in pounds per hour P=process weight in tons per hour Sulfur dioxide Affected source: Hot Oil Heater(ID No. Pr-Heatl) 15A NCAC 2D .0516 2.3 pounds per million Btu heat input Visible emissions 20 percent opacity 15A NCAC 2D.0521(d) HAPs Affected source: Hot Oil Heater(ID No. Pr-Heatl) 15A NCAC 2D .1 109 Best Combustion Practices Volatile organic Work Practice Standards 15A NCAC 2D.0958 compounds See Section 2.2 A.1. Toxic air pollutants See Section 2.2 A.2; 15A NCAC 21).1 100 State-enforceable only Odors See Section 2.2 A.3; 15A NCAC 2D .1806 State-enforceable only 1. 15A NCAC 2D.0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of No. 2 oil,natural gas, and used oil fi•orn the hot oil heater(ID No. Pr-Heatl)into the atmosphere shall not exceed 0.60 pounds per million Btu heat input. Testin [I 5A NCAC 21).2601] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test exceed the limit given in Section 2.1.G.1.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 213 .0503. Mon itoring/Recordkeepinj!/ReportinE[15A NCAC 2Q .0508(f)] c. No monitoring,record keeping,or reporting is required for particulate emissions from the firing of No.2 fuel oil and natural gas in the hot oil heater(ID No.Pr-Heatl), 2. 15A NCAC 2D.0515: PARTICULATE EMISSIONS FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the units in the short cycle laminating presses(ID Nos.3593 and 3594) that are discharged into the atmosphere shall not exceed an allowable emission rate as calculated by the following equations: E=4.10Xpl.6' Where E=allowable emission rate in pounds per hour calculated to three significant figures P=process weight rate in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing[15A NCAC 213.2601] Air Permit 03449T42 Page 38 b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section 2.1 G.2.a.(above)for particulate matter,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515. Monitoring/Recordkeeping/Reporting [15A NCAC 2Q .0508(f)] c. Particulate matter emissions from the short cycle laminating presses(ID Nos.3593 and 3594)shall be controlled using the reverse flow bagfilter(ID No. CD-3593). To assure compliance,the Permittee shall perform inspections and maintenance as recommended by the manufacturer. In addition to the manufacturer=s inspection and maintenance recommendations,or if there is no manufacturer=s inspection and maintenance recommendations,as a minimum,the inspection and maintenance requirement shall include the following: i. a monthly visual inspection of the system ductwork and material collection unit for leaks;and ii, an annual(for each 12 month period following the initial inspection)internal inspection of the bagfilter's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D.0515 if the ductwork and bagfilters are not inspected and maintained. d. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on- site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; and iii. the results of maintenance performed on any control device. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if these records are not maintained. Reporting[15A NCAC 2Q.0508(f)] e. The Permittee shall submit the results of any maintenance performed on the bagfilter(ID No. CD-3593)within 30 days of a written request by the DAQ. f. The Pennittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 3. 15A NCAC 2D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Sulfur dioxide emissions from the hot oil heater(ID No. Pr-Heatl)shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testin [15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of this test are above the limit given in Section 2.1 G.3.a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0516. Monitoring/Recordkeepin2 [15A NCAC 2Q .0508(f)] c. No monitoring,record keeping,or reporting is required for sulfur dioxide emissions from the firing of natural gas or No.2 fuel oil in the hot oil heater(ID No.Pr-Heatl). 4. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. As required by 15A NCAC 2D .0521(d) "Control of Visible Emissions," visible emissions from the units in the Laminating Mill, including the short cycle laminating presses(ID Nos.3593 and 3594)and hot oil heater(ID No. Pr-Heatl), shall not be more than 20 percent opacity when averaged over a six-minute period [15A NCAC 2D .0521(d)]. However, six minute averaging periods may exceed 20 percent opacity if: i. No six-minute period exceeds 87 percent opacity; ii. No more than one six-minute period exceeds 20 percent opacity in any hour;and iii. No more than four six-minute periods exceed 20 percent opacity in any 24-hour period Testing[15A NCAC 2D .2601] b. If emissions testing is required,the testing shall be performed in accordance with 15A NCAC 2D.2601 and General Condition JJ found in Section 3. If the results of the test performed exceed the limits given in Section Air Permit 03449T42 Page 39 2.1 GA.a. (above)for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring/Recordkeeping[15A NCAC 2Q .0508(f)] c. To ensure compliance,the Permittee shall observe,on a weekly basis,the following emission points in the Particleboard mill for any visible emissions above normal: Emission Source I Emission Point ID No. short cycle laminating presses(ID Nos.3593 and 3594) CD-3593 hot oil heater(ID No.Pr-Heatl) Pr-HeatI The weekly observation must be made for each of the calendar year period to ensure compliance with this requirement. If visible emissions from the short cycle laminating presses and/or hot oil heater are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 2D .2601 (Method 9)for 12 minutes is below the limit given in Section 2.1 GA. a. above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D .0521. d. The results of the monitoring for visible emissions shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request.To ensure quality,entries in the logbook should be signed by personnel responsible for the effective operation of the units in the particleboard mill and their air pollution control devices, The logbook shall record the following: i. The date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521 if these records are not maintained. Reporting[15A NCAC 2Q.0508(f)] e. The Permittee shall submit a summary report of monitoring and record keeping activities by January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 5. l 5A NCAC 2D.1109: Case-by-Case MACT a. The Permittee shall use best combustion practices when operating the affected heater(ID No. Pr-Heatl). The initial compliance date for this work practice standard and the associated monitoring,recordkeeping, and reporting requirements is October 18,2013. These conditions need not be included on the annual compliance certification until after the initial compliance date. Monitorin2/Recordkeeping b. To assure compliance,the Permittee shall perform an annual boiler inspection and maintenance as recommended by the manufacturer,or as a minimum,the inspection and maintenance requirement shall include the following: i. Inspect the burner,and clean or replace any components of the burner as necessary; ii. Inspect the flame pattern and make any adjustments to the burner necessary to optimize the flame pattern; and, iii. Inspect the system controlling the air-to-fuel ratio,and ensure that it is correctly calibrated and functioning properly. The Permittee shall conduct at least one tune-up per calendar year to demonstrate compliance with this requirement. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .1109 if the affected heater is not inspected and maintained as required above. c. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on- site and made available to an authorized representative upon request. The logbook shall record the following: i. The date of each recorded action; Air Permit 03449T42 Page 40 ii. The results of each inspection;and, iii. The results of any maintenance performed on the heater. The Permittee shall be deemed in noncompliance with 15A NCAC 2D.1109 if these records are not maintained. Reporting [15A NCAC 2Q.0508(f)] d. No reporting is required. H. Four MDF Resin Storage Tanks (ID Nos. MDFR-1, MDFR-2, MDFR-3, MDFR-4) The following table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant Limits/Standards Applicable Regulation Volatile organic Work Practice Standards 15A NCAC 2D.0958 compounds See Section 2.2 A.1. Toxic air pollutants See Section 2.2 A.2;State-enforceable only 15A NCAC 2D .1100 Odors Odorous emissions must be controlled 15A NCAC 2D .1806 Section 2.2.A.3; State-enforceable only I. The following combustion source: Table I. Emission Source ID Emission Source Description Control Device ID No. Control Device No. Description DFP-1 Diesel fuel-fired Fire Pump CD-DFP Particulate matter MACT ZZZZ Engine(347 Brake Horsepower output) filter NSPS IIII The following table provides a summary of limits and/or standards for the emission sources above: -Regulated Pollutant Limits/Standards Applicable Regulation Visible emissions 20 percent opacity 15A NCAC 2D .0521 Various New Source Performance Standards 15A NCAC 2D .0524 [40 CFR Part 60,Subpart 1111] Toxic Air Pollutants State-enforceable only 15A NCAC 2D ,I 100 Hazardous Air Maximum Achievable Control Technology(No 15A NCAC 2D .l 11 I Pollutants applicable requirements) [40 CFR Part 63, Subpart ZZZZ] Odors See Section 2.2 A.3; 15A NCAC 2D .1806 State-enforceable only 1. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this source shall not be more than 20 percent opacity when averaged over a six-minute period. However, six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. [15A NCAC 2D .0521 (d)] Testing[15A NCAC 2Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D.0521. Monitoring/Recordkeepin2/Reportin2[15A NCAC 2Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of diesel fuel in this Air Permit 03449T42 Page 41 source. 2. 15A NCAC 2D .0524: NEW SOURCE PERFORMANCE STANDARDS a. The Pennittee shall comply with all applicable provisions, including the requirements for emission standards, notification,testing,reporting,record keeping,and monitoring,contained in Environmental Management Commission Standard 15A NCAC 21) .0524 "New Source Performance Standards(NSPS)" as promulgated in 40 CFR Part 60 Subpart 1111, including Subpart A"General Provisions". Emission Standards b. The Pennittee shall comply with the emission standards in Table 4 to Subpart IIII of 40CFR 60, for all pollutants. [40CFR 60.4205(c)] c. The Pennittee shall use diesel fuel in the engine with: i. a maximum sulfur content of 15 ppm;and ii. a minimum cetane index of 40 or a maximum aromatic content of 35 volume percent. [40CFR 60.4207(b)and 40CFR 80.510(b)] Testing[15A NCAC 2Q.0508(f)]] d. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limits given in conditions b.and c, above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0524. Monitoring [15A NCAC 2Q.0508(f)] e. The engine has the following monitoring requirements: i. The engine shall be equipped with a non-resettable hour meter prior to startup. [40CFR 60.4209(a)] ii. The engine,which is equipped with a diesel particulate filter must be installed with a backpressure monitor that notifies the owner or operator when the high backpressure limit of the engine is approached. [40CFR 60.4209(b)] Compliance Requirements [15A NCAC 2Q.0508(b)] f. The Pennittee shall operate and maintain the engine in accordance with the manufacturer's written instructions or procedures developed by the Permittee that are approved by the engine manufacturer over the entire life of the engine.The Permittee may only change engine settings that are permitted by the manufacturer. The Permittee shall also meet the requirements of 40 CFR 89,94 and/or 1068 as applicable. [40CFR 60.4206 and 60,4211(a)] g. The Permittee shall purchase the engine certified to the emission standards in 40 CFR 60.4205(c).The engine shall be installed and configured according to the manufacturer's specifications. [40CFR 60.42 1 1(c)] h. The Permittee may operate the engine for maintenance checks and readiness testing for up to 100 hours per year provided that the tests are recommended by Federal,State,or local government,the manufacturer,the vendor,or the insurance company associated with the engine. Operation during an actual emergency shall not be subject to a limit on hours. The Pennittee may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing,but a petition is not required if the Permittee maintains records indicating that Federal, State,or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Because the Permittee is required to comply with emission standards under 40CFR 60.4205 for the engine and not under 40CFR 60.4204,any operation other than emergency operation,and maintenance and testing as allowed in 40 CFR 60.4211 is prohibited. [40CFR 60.4211(e)] The Pennittee shall be deemed in noncompliance with 15A NCAC 2D .0524, if the requirements in conditions e.through h.are not met. Recordkeeping [15A NCAC 2Q .0508(f)] i. To assure compliance,the Permittee shall perform inspections and maintenance on the engine as recommended Air Permit 03449T42 Page 42 by the manufacturer per 40CFR 60.4206 and 40 CFR 60.4211(a). The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed on the engine; iv. any variance from manufacturer's recommendations, if any, and corrections made; and v. the hours of operation during maintenance and readiness testing and during emergency service. vi. records of any corrective action taken after the backpressure monitor has notified the owner or operator that the high backpressure limit of the engine is approached [40 CFR60.4214(c)] The Permittee shall be deemed in noncompliance with 15A NCAC 2D.0524 if these records are not maintained. Reporting [15A NCAC 2Q.0508(f)] j. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit shall be clearly identified. 3. 15A NCAC 2D.l l 11: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY Applicability [40 CFR 63.2231] a. The Permittee shall comply with all applicable provisions,including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .1 I I 1 "Maximum Achievable Control Technology" (MACT)as promulgated in 40 CFR 63, Subpart ZZZZ . "National Emission Standards for Hazardous Air Pollutants For Stationary Reciprocating Internal Combustion Engines." Stationary RICE subject to Regulations under 40 CFR Part 60[40 CFR 63.6590(c)] b. Pursuant to 40 CFR 63.6590(c),the engine must meet the requirements of 40 CFR 63 Subpart ZZZZ and Subpart A by meeting the requirements of 40 CFR part 60 subpart IIII.No further requirements apply for this engine under 40 CFR 63 Subpart ZZZZ and Subpart A. If the requirements in condition b.are not met,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .1111. STATE ENFORCEABLE ONLY 4. 15A NCAC 2D.1100: CONTROL OF TOXIC AIR POLLUTANTS Applicability a. This source is subject to 15A NCAC 2D .1100"Control of Toxic Air Pollutants"but has not been considered in an evaluation pursuant to 15A NCAC 2Q .0706"Modifications." b. The Division shall notify the Permittee 60 days prior to reopening the permit, if necessary,to establish emission limitations,monitoring,recordkeeping or reporting necessary to ensure compliance with 15A NCAC 2D .1100. [NCGS 143-215.108(c)] Air Permit 03449T42 Page 43 J. The following combustion sources: Table J. Emission Source ID Emission Source Description Control Device ID No. Control Device No. Description ES-21 Diesel Fuel-fired Emergency NA NA MACT ZZZZ Generator(]592 Brake Horsepower output) ES-ODG Diesel-fuel Fired Emergency Generator NA NA MACT ZZZZ (465 horsepower,3,026 million Btu per hour heat input) The following table provides a summary of limits and/or standards for the emission sources above: Regulated Pollutant Limits/Standards Applicable Regulation Sulfur dioxide 2.3 pounds per million Btu heat input 15A NCAC 2D.0516 Visible emissions 20 percent opacity 15A NCAC 2D .0521 Toxic Air Pollutants State-enforceable only 15A NCAC 2D .1100 ID No. ES-21 only Hazardous Air 15A NCAC 2D.I I I 1 Pollutants Maximum Achievable Control Technology [40 CFR Part 63, Subpart ZZZZ] Odors See Section 2.2 A.3. 15A NCAC 2D .1806 State-enforceable only 1. 15A NCAC 2D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from these sources shall not be more than 20 percent opacity when averaged over a six- minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. [15A NCAC 2D.0521 (d)] Testing [I5A NCAC 2Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring/Recordkeeping/Reporting [15A NCAC 2Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of diesel fuel in this source. 2. 15A NCAC 2D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from these sources shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels, wastes, ores, and other substances shall be included when determining compliance with this standard. [15A NCAC 2D .0516] Testing [15A NCAC 2Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ found in Section 3. If the results of this test are above the limit given in condition a. above,the Pennittee shall be deemed in noncompliance with 15A NCAC 2D.0516. Monitoring/Recordkeeping[15A NCAC 2Q .0508(f)] c. No monitoring/recordkeeping is required for sulfur dioxide emissions from the firing of diesel fuel in this Air Permit 03449T42 Page 44 source. 3. 15A NCAC 2D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY Applicability [40 CFR 63,2231] a. The Permittee shall comply with all applicable provisions, including the monitoring,recordkeeping, and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .l 1 1 1 "Maximum Achievable Control Technology" (MACT)as promulgated in 40 CFR 63, Subpart ZZZZ , "National Emission Standards for Hazardous Air Pollutants For Stationary Reciprocating Internal Combustion Engines." Stationary RICE subject to limited requirements [40 CFR 63.6590(b] b. Pursuant to 40 CFR 63.6590(b)(3),the emergency generator(I )No. ES-21)does not have to meet the requirements of this subpart and of subpart A of this part, including initial notification requirements: c. The permittee shall submit a permit application demonstrating compliance with this rule by May 3,2013 for the emergency generator(I )No.ES-ODG),which is an existing emergency stationary RICE at a major source of HAP emissions. STATE ENFORCEABLE ONLY 4. 15A NCAC 2D.1100: CONTROL OF TOXIC AIR POLLUTANTS Applicability a. This source(ID No.ES-21) is subject to 15A NCAC 2D .1100"Control of Toxic Air Pollutants" but has not been considered in an evaluation pursuant to 15A NCAC 2Q .0706"Modifications." b. The Division shall notify the Permittee 60 days prior to reopening the permit, if necessary,to establish emission limitations,monitoring,recordkeeping or reporting necessary to ensure compliance with 15A NCAC 2D .1100. [NCGS 143-215.108(c)] Air Permit 03449T42 Page 45 2.2 - Multiple Emission Source(s) Specific Limitations and Conditions A. Facility-wide affected emission sources The following table provides a summary of limits and standards applicable facility wide: Regulated Pollutant Limits/Standards Applicable Regulation volatile organic compounds Work Practice Standards 15A NCAC 2D .0958 toxic air pollutants State enforceable only 15A NCAC 2D .1100 odors Odorous emissions must be controlled 15A NCAC 2D.1806 State enforceable only Hazardous air pollutants National Emission Standards for Hazardous Air 15A NCAC 2D .I 1 I 1 Pollutants: Plywood and Composite Wood (40 CFR 63, Subpart DDDD) Products 1. 15A NCAC 2D.0958: WORK PRACTICES FOR SOURCES OF VOLATILE ORGANIC COMPOUNDS a. Pursuant to 15A NCAC 2D ,0958 and 2D .0902, for all sources 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: i. store all material,including waste material,containing volatile organic compounds in tanks or in containers covered with a tightly fitting lid that is free of cracks, holes, or other defects,when not in use, ii. clean up spills of volatile organic compounds as soon as possible following proper safety procedures, iii. store wipe rags containing volatile organic compounds in closed containers, iv. not clean sponges,fabric,wood,paper products,and other absorbent materials with volatile organic compounds, v. transfer solvents containing volatile organic compounds used to clean supply lines and other coating equipment into close able containers and close such containers immediately after each use, or transfer such solvents to closed tanks,or to a treatment facility regulated under section 402 of the Clean Water Act, and vi. clean mixing,blending,and manufacturing vats and containers containing volatile organic compounds by adding cleaning solvent and close the vat or container before agitating the cleaning solvent.The spent cleaning solvent shall then be transferred into a closed container,a closed tank or a treatment facility regulated under section 402 of the Clean Water Act. [15A NCAC 2D .0958(c)] b. 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, and v. not agitate solvent to the point of causing splashing. [I 5A NCAC 2D .0958(d)] Monitoring[15A NCAC 2Q.0508(f)] c. To ensure compliance with this standard,the Pennittee shall,at a minimum,perform a monthly visual inspection of all operations and processes utilizing volatile organic compounds. The inspection shall include, but not be limited to,VOC storage,cleaning,and transfer operations to detennine compliance with the requirements specified in Conditions 2.2.A.La.and b. above. The inspections shall be conducted during normal operations. If the required monthly inspections are not conducted the Permittee shall be deemed to be in noncompliance with 15A NCAC 2D .0958. Recordkeepin2 [15A NCAC 2Q .0508(f)] d. The results of the inspections shall be maintained in a log(written or electronic format)on-site and made available to an authorized representative upon request. The log shall record the following: i. the date and time of each inspection; and ii. the results of each inspection noting whether or not noncompliant conditions were observed. If the required records are not maintained the pennittee shall be deemed to be in noncompliance with 15A NCAC 2D .0958. Air Permit 03449T42 Page 46 Reporting [15A NCAC 2Q .0508(f)] e. The Permittee shall submit a summary report of the observations by January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. STATE ENFORCEABLE ONLY 2. 15A NCAC 02Q.0705(c): EXISTING FACILITES AND SIC CALLS a. As of October 14,2009 the Permittee demonstrated compliance with 15A NCAC 2D .1100 on a facility-wide basis. STATE ENFORCEABLE ONLY 3. 15A NCAC 2D.1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. 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. Air Permit 03449T42 Page 47 4. 15A NCAC 2D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY a. For the emission sources subject to"MACT DDDD"as indicated in the permitted equipment list,the Permittee shall comply with all applicable provisions, including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .11 I l "Maximum Achievable Control Technology"(MACT)as promulgated in 40 CFR 63, Subpart DDDD,National Emission Standards for Hazardous Air Pollutants: Plywood and Composite Wood Products. i. The Permittee shall submit a permit application to the Regional Supervisor to modify the permit to include specific monitoring requirements for the emission sources NOT subject to the compliance schedule described in Section 2.3,as established in the Special Order by Consent(ORDER)no.2008-002.The penmit application shall be submitted following completion of the initial performance testing of the add-on control devices used to comply with MACT DDDD. The permit application shall be submitted with the Notification of Compliance Status described in condition x.ii. below. ii. The Permittee shall submit a permit application to the Regional Supervisor to modify the pen-nit to include specific monitoring requirements for the emission sources subject to the compliance schedule described in Section 2.3,as established in the Special Order by Consent(ORDER)no, 2008-002.The pennit application shall be submitted following completion of the initial performance testing of the add-on control devices used to comply with MACT DDDD. The permit application shall be submitted with the Notification of Compliance Status described in condition x.ii.below. Definitions and Nomenclature [40 CFR 63.2292] b. For the purpose of this permit condition,the definitions and nomenclature contained in 40 CFR 63.2292 shall apply. 40 CFR Part 63 Subpart A General Provisions [40 CFR 63.22901 c. The Permittee shall comply with the requirements of 40 CFR Fi 63 Subpart A General Provisions according to the applicability of Subpart A to such sources, as identified in Table 10 to 40 CFR Part 63, Subpart DDDD _Operating Requirements [15A NCAC 02Q .0508(f)] d. For the emission sources subject to"MACT DDDD"as indicated in the permitted equipment list the Permittee shall comply with compliance options and operating requirements described in Tables I A, 1 B, and 2 to 40 CFR 63 and in paragraph 40 CFR 63.2240(c)by using one or more of the compliance options listed in paragraphs (a), (b), and(c)of 40 CFR 63.2240 for each process unit. [40 CFR 63.2240] e. The Pennittee must always operate and maintain the affected source, including air pollution control and monitoring equipment,according to the provisions in 40 CFR 63.6(e)(1)(i). [40 CFR 63.2250(b)] f. The Permittee must develop a written Startup, Shutdown,and Malfunction Plan(SSMP)according to the provisions in 40 CFR 63.6(e)(3). [40 CFR 63.2250(c)] g. To the extent practical, startup and shutdown of emission control systems must be scheduled during times when process equipment is also shut down. [40 CFR 63.2251(e)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.I I I I if the operating requirements in d.through g.are not met. Work Practice Requirements [15A NCAC 02Q .0508(f)] h. The Permittee shall meet each work practice requirement per 40 CFR 63.2241, as applicable. [40 CFR 63.2241] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.I I I I if the work practice requirements in condition h.are not met. Affected Sources Not Subject to Operating Requirements [40 CFR 63.2252] i. For process units not subject to the operating requirements in paragraph(d)through(g),The Permittee is not required to comply with the compliance options, work practice requirements,performance testing, monitoring, SSM plans, and recordkeeping or reporting requirements of this 40 CFR 63 Subpart DDDD,or any other requirements in 40 CFR 63 Subpart A except for the initial notification requirements in 40 CFR 63.9(b). Testin [15A NCAC 02D .2601] j. If emissions testing is required,the testing shall be performed in accordance General Condition JJ. If the results of this test are above the limits given in paragraph d. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.1112. Air Permit 03449T42 Page 48 Initial Compliance requirements [15A NCAC 02D.2601,40 CFR 63.2260 through 40 CFR 63.2269] k. To demonstrate initial compliance with the compliance options and operating requirements,the Pennittee must conduct performance tests and establish each site-specific operating requirement in Table 2 to 40 CFR 63 Subpart DDDD according to the requirements in 40CFR 63.2262 and Table 4 to 40 CFR 63 Subpart DDDD. Combustion units that accept process exhausts into the flame zone are exempt from the initial performance testing and operating requirements for thennal oxidizers. 1. The Permittee must demonstrate initial compliance with each compliance option, operating requirement, and work practice requirement that applies to the Permittee according to Tables 5 and 6 to 40 CFR 63 Subpart DDDD and according to 40 CFR 63,2260 through 40 CFR 63,2269. in. The Permittee shall conduct performance tests no later than 180 calendar days after initial startup or no later than 180 calendar days after the compliance date that is specified for your source in 40 CFR63.2233 and according to according to 40 CFR 63.7(a)(2),whichever is later. n. The Permittee shall conduct initial compliance demonstrations that do not require performance tests upon initial startup or no later than 30 calendar days after the compliance date that is specified for your source in 40 CFR 63.2233,whichever is later. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .l 1 1 I if the initial compliance requirements in conditions k.through n, are not met. Monitoring and Continuous Compliance Requirements [15A NCAC 02Q .0508(f)] o. The Permittee shall monitor and collect data according to 40 CFR 63.2270. p. The Permittee shall demonstrate continuous compliance with the compliance options,operating requirements, and work practice requirements in 40CFR 63.2240 and 63.2241 that apply according to the methods specified in Tables 7 and 8 to 40 CFR 63 Subpart DDDD. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .1 l 1 l if the requirements in conditions o.and p.are not met. Recordkeeping Requirements [15A NCAC 02Q .0508(f),40 CFR 63,2282 and .2283] q. The Pennittee must keep the records listed in 40 CFR 63.2282(a). r. The Permittee must keep the records required in Tables 7 and 8 to 40 CFR 63 Subpart DDDD to show continuous compliance with each compliance option,operating requirement, and work practice requirement that applies.[40CFR 63.2282(b)] s. The Permittee must maintain records in a form suitable and readily available for expeditious review as specified in 40 CFR 63.10(b)(1). [40 CFR 63.2283(a)] t. As specified in 40 CFR 63.10(b)(1),the Permittee must keep each record for 5 years following the date of each occurrence,measurement,maintenance,corrective action,report,or record. [40 CFR 63.2283(b)] u. The Permittee must keep each record on site for at least 2 years after the date of each occurrence, measurement, maintenance,corrective action,report,or record according to 40 CFR 63.10(b)(1).The Permittee can keep the records offsite for the remaining 3 years. [40 CFR 63.2283(c)] The Pennittee shall be deemed in noncompliance with 15A NCAC 02D .11 11 if records are not maintained per conditions q.through u. Notification Requirements [40 CFR 63.2280] v. The Permittee must submit all of the notifications in 40 CFR 63.7(b)and(c),63.8(e),(f)(4)and(f)(6),63.9 (b) through(e),and(g)and(h)by the dates specified. [40 CFR 63.2280(a)] w. If you are required to conduct a performance test,you must submit a written notification of intent to conduct a performance test at least 60 calendar days before the performance test is scheduled to begin as specified in §63.7(b)(1). x. If you are required to conduct a performance test,design evaluation,or other initial compliance demonstration as specified in Tables 4, 5, and 6 to 40 CFR 63 Subpart DDDD,you must submit a Notification of Compliance Status as specified in 40 CFR 63.9(h)(2)(ii). i. For each initial compliance demonstration required in Table 5 or 6 to 40 CFR 63 Subpart DDDD that does not include a performance test,you must submit the Notification of Compliance Status before the close of business on the 30th calendar day following the completion of the initial compliance demonstration. ii. For each initial compliance demonstration required in Tables 5 and 6 to 40 CFR 63 Subpart DDDD that includes a performance test conducted according to the requirements in Table 4 to 40 CFR 63 Subpart DDDD,you must submit the Notification of Compliance Status, including the performance test results, before the close of business on the 60th calendar day following the completion of the perfonmance test according to 40 CFR 63.10(d)(2). y. If you use the emissions averaging compliance option in 40 CFR 63.2240(c),you must submit an Emissions Air Permit 03449T42 Page 49 Averaging Plan to the EPA Administrator for approval no later than 1 year before the compliance date or no later than 1 year before the date you would begin using an emissions average,whichever is later.The Emissions Averaging Plan must include the information in 40 CFR 63.2280(f). z. The Permittee must notify the EPA Administrator within 30 days before any of the following actions are taken: [40 CFR 63.2280(g)] i. The modification or replacement the control system for any process unit subject to the compliance options and operating requirements in paragraph(d). ii. The shut down of any process unit included in the Emissions Averaging Plan. iii. The change in a continuous monitoring parameter or the value or range of values of a continuous monitoring parameter for any process unit or control device. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.I I I I if the notification requirements in conditions v.through z. are not met. Reporting Requirements[15A NCAC 02Q.0508(f),40 CFR 63.2281] aa. The permittee shall submit a compliance report semiannually postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June [40 CFR 63.2281(b)(5)] bb. The compliance report must contain the information in 40 CFR 63.2281(c). cc. For each deviation from a compliance option or operating requirement and for each deviation from the work practice requirements in Table 8 to 40 CFR 63 Subpart DDDD that occurs at an affected source where you are not using a CMS to comply with the compliance options,operating requirements,or work practice requirements in this subpart,the compliance report must contain the information in 40 CFR 63.2281(c)(1) through(6)and(d)(1)and(2).This includes periods of startup,shutdown,and malfunction and routine control device maintenance. [40 CFR 63.2281(d)] dd. For each deviation from a compliance option or operating requirement occurring at an affected source where you are using a CMS to comply with the compliance options and operating requirements in 40 CFR 63 Subpart DDDD,you must include the information 40 CFR 63.2281(c)(1)through(6)and paragraphs(e)(1)through (11).This includes periods of startup, shutdown,and malfunction and routine control device maintenance. [40 CFR 63.2281(e)] ee. If you comply with the emissions averaging compliance option in 40 CFR 63.2240(c),you must include in your semiannual compliance report calculations based on operating data from the semiannual reporting period that demonstrate that actual mass removal equals or exceeds the required mass removal. [40 CFR 63.2281(0] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.I I I l if the reporting requirements in aa,through ee.are not met B. Medium Density Fiberboard Facilities 1. 15A NCAC 2Q.0317: AVOIDANCE OF PREVENTION OF SIGNIFICANT DETERIORATION- AVOIDANCE CONDITION a. In order to the avoid the applicability of 15A NCAC 2D .0530,the combined emissions from the sources indicated in the permitted equipment list in Section 1 as the Medium Density Fiberboard Facilities shall not exceed the following limits: i. PM-10 emissions shall not exceed 75.7 tons per consecutive 12-month period. ii. Nitrogen oxide emissions shall not exceed 177.8 tons per consecutive 12-month. iii. VOC emissions shall not exceed 406 tons per consecutive 12-month period. iv. PM-2.5 emissions shall not exceed 70.7 tons per consecutive 12-month period. Testing [15A NCAC 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of this test are above any limit given in Section 2.2 B.La. above,the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. c. Under the provisions of NCGS 143-215.108,the Permittee shall test the following sources: Emission Point Pollutant Emission Rate,Ib/hr,total fro both emission points Venturi/packed bed scrubber NOx 33.88 (ID No.CD02)exhaust VOC 54.28 Air Permit 03449T42 Page 50 Emission Point Pollutant_ Emission Rate,lb/hr,,total fro both emission points and Venturi/packed bed PM10 9.5 scrubber(ID No.CD14) PM2.5 9.5 exhaust If the testing demonstrates that the emission rate is greater than the corresponding emission rate in the above table, the permittee shall submit an application including a re-evaluation of PSD applicability. Testing shall be completed not later than 180 days after the start-up of the affected facility. The Pennittee shall submit a written report of the test(s)results to the Regional Supervisor,DAQ within 60 days of completion of the test. d. The Permittee shall submit a permit application to the Regional Supervisor to modify the permit to include specific monitoring requirements for the urea/water injection system (ID No. CD-02-A). The permit application shall be submitted within 60 days of completion of the test required under condition c. Mon itoring/Record keep ing/Reporting [15A NCAC 2Q .0508 (f)] e. The Permittee shall submit a report within 30 days after each calendar year quarter, due and post marked on or before January 30 of each calendar year for the preceding three-month period between October and December, April 30 of each calendar year for the preceding three-month period between January and March, July 30 of each calendar year for the preceding three-month period between April and June, and October 30 for the calendar year for the preceding three-month period between July and September. The report shall contain the monthly PM,.S_ PM10, NO,,, and VOC emissions from the Medium Density Fiberboard Facilities for the previous 14 months. The emissions must be calculated for each of the 12-month periods over the previous 14 months. The initial report shall be submitted for the quarter in which the Medium Density Fiberboard Facilities achieve initial startup. Air Permit 03449T40 Page 51 2.3- Schedule of Compliance The operations considered"affected units" for MACT requirements under 40 CFR Part 63 Subpart DDDD are subject to the compliance schedule described below as established in the Special Order by Consent(ORDER)no. 2008-002, This schedule does not include the affected units known collectively as the Medium Density Fiberboard Facilities as indicated in the permitted equipment list in Section 1. This compliance schedule is an enforceable sequence of actions with milestones leading to compliance with applicable requirements for which the source is in noncompliance at the time of permit issuance. Any judicial consent decree or an administrative order to which the source is subject shall be supplemental to and shall not sanction noncompliance with other applicable requirements on which it is based[15A NCAC 2Q.0508(i)(]6)and(m)]. The original ORDER was agreed to on July 10, 2008. It has been subsequently modified and agreed to on March 19, 2010. This Special Order by Consent shall expire not later than January 1, 2012 or upon completion of the requirements included in this ORDER,whichever occurs first. I. Actions to be Taken by the Permittee-The Permittee,desiring to operate in a safe and environmentally sound manner in accordance with the rules and regulations of the COMMISSION,does hereby agree to perform the following activities: A. The COMPANY shall submit an equivalency-by-permit(EBP)demonstration to the DAQ by November 13,2009. This date in the order has been met. B. If the DAQ denies the EBP,the COMPANY shall design,purchase, and install a water-based system with chemical injection for its dryers within nine months of DAQ's denial but by no later than August 31,2011. C. If the DAQ denies the EBP,the COMPANY shall design, purchase, and install one of the following control options within nine months of DAQ's denial but no later than August 31,2011: i. A biofilter, ii. A separate water-based system with chemical injection for the press,or iii. Ductwork to take the press exhaust to the dryer water-based system with chemical injection D. If the DAQ denies the EBP,the COMPANY shall complete shakedown and compliance testing of the water-based system with chemical injection for its dryers and the selected control option specified under Paragraph H.C.for its press within four months of installation but by no later than January 1, 20I2, The compliance test report shall also be submitted within four months of installation but by no later than January 1,2012. There will be no further extensions of the testing deadline. Air Permit 03449T42 Page 52 2.4- Permit Shield for Non-applicable Requirements The Permittee is shielded from the following non-applicable requirements [15A NCAC 2Q .0512(a)(1)(A) and (B)J. A. New Source Performance Standard(NSPS)Subpart Db is not applicable to the bio-mass fired Energy System (ID No. ES-02A)because the system is considered a process heater and the primary purpose is to produce a final product.The system (ID No. ES-02A)consists of: Emission Emission Source Control Control Device Configuration Source Description Device ID Description ID No. No. CD02-A Urea/water injection system in series with CD02 and CD 14 Energy System Venturi and packed bed consisting of a dry/wet CD02 scrubber(35 gallons per ES-02-A wood/woodwaste-fired minute minimum injection CD02 in parallel with burner(205 million Btu rate) CD14 with emission per hour heat input) Venturi and packed bed points EP02 and EP 14 CD14 scrubber(35 gallons per minute minimum injection rate) Air Permit 03449T42 Page 53 SECTION 3 - GENERAL CONDITIONS (version 3.6,01/31/12) A. General Provisions [NCGS 143-215 and 15A NCAC 2Q .0508(i)(16)] I. Terns not otherwise defined in this permit shall have the meaning assigned to such terns as defined in 15A NCAC 2D and 2Q. 2. The terms, conditions, requirements, limitations, and restrictions set forth in this permit are binding and enforceable pursuant to NCGS 143-215.114A and 143-215.114B, including assessment of civil and/or criminal penalties. Any unauthorized deviation from the conditions of this permit may constitute grounds for revocation and/or enforcement action by the DAQ. 3. This permit is not a waiver of or approval of any other Department pen-nits that may be required for other aspects of the facility which are not addressed in this permit. 4. This permit does not relieve the Permittee from liability for harm or injury to human health or welfare,animal or plant life, or property caused by the construction or operation of this pennitted facility, or from penalties therefore, nor does it allow the Permittee to cause pollution in contravention of state laws or rules, unless specifically authorized by an order from the North Carolina Environmental Management Commission. 5. Except as identified as state-only requirements in this permit, all terns and conditions contained herein shall be enforceable by the DAQ,the EPA,and citizens of the United States as defined in the Federal Clean Air Act, 6. Any stationary source of air pollution shall not be operated, maintained, or modified without the appropriate and valid permits issued by the DAQ,unless the source is exempted by rule. The DAQ may issue a pen-nit only after it receives reasonable assurance that the installation will not cause air pollution in violation of any of the applicable requirements. A permitted installation may only be operated, maintained, constructed, expanded, or modified in a manner that is consistent with the terns of this permit. B. Permit Availability [15A NCAC 2Q.0507(k)and.0508(i)(9)(B)] The Permittee shall have available at the facility a copy of this permit and shall retain for the duration of the pennit term one complete copy of the application and any information submitted in support of the application package. The permit and application shall be made available to an authorized representative of Department of Environment and Natural Resources upon request. C. Severability Clause [15A NCAC 2Q.0508(i)(2)] In the event of an administrative challenge to a final and binding permit in which a condition is held to be invalid,the provisions in this permit are severable so that all requirements contained in the permit,except those held to be invalid, shall remain valid and must be complied with. D. Submissions[15A NCAC 2Q.0507(e)and 2Q.0508(i)(16)] Except as otherwise specified herein,two copies of all documents,reports,test data,monitoring data,notifications, request for renewal, and any other information required by this permit shall be submitted to the appropriate Regional Office. Refer to the Regional Office address on the cover page of this pen-nit. For continuous emissions monitoring systems(CEMS)reports,continuous opacity monitoring systems(COMS)reports,quality assurance(QA)/quality control(QC)reports,acid rain CEM certification reports,and NOx budget CEM certification reports,one copy shall be sent to the appropriate Regional Office and one copy shall be sent to: Supervisor,Stationary Source Compliance North Carolina Division of Air Quality 1641 Mail Service Center Raleigh,NC 27699-1641 All submittals shall include the facility name and Facility ID number(refer to the cover page of this pen-nit), E. Duty to Comply[15A NCAC 2Q.0508(i)(2)] The Permittee shall comply with all terns,conditions,requirements, limitations and restrictions set forth in this permit.Noncompliance with any permit condition except conditions identified as state-only requirements constitutes a violation of the Federal Clean Air Act. 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. Air Permit 03449T42 Page 54 F. Circumvention-STATE ENFORCEABLE ONLY 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 pollution control device(s)and appurtenances. G. Permit Modifications 1. Administrative Permit Amendments[15A NCAC 2Q.0514] The Pennittee shall submit an application for an administrative permit amendment in accordance with 15A NCAC 2Q.0514. 2. Transfer in Ownership or Operation and Application Submittal Content[15A NCAC 2Q.0524 and 2Q .0505] The Pennittee shall submit an application for an ownership change in accordance with 15A NCAC 2Q.0524 and 2Q .0505. 3. Minor Permit Modifications[15A NCAC 2Q .0515] The Permittee shall submit an application for a minor permit modification in accordance with 15A NCAC 2Q .0515. 4. Significant Permit Modifications[15A NCAC 2Q .0516] The Pennittee shall submit an application for a significant permit modification in accordance with 15A NCAC 2Q .0516. 5. Reopening for Cause[15A NCAC 2Q .0517] The Permittee shall submit an application for reopening for cause in accordance with 15A NCAC 2Q .0517. H. Changes Not Requiring Permit Modifications 1. Reporting Requirements Any of the following that would result in new or increased emissions from the emission source(s)listed in Section 1 must be reported to the Regional Supervisor,DAQ: a. changes in the infonnation submitted in the application; b. changes that modify equipment or processes;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. 2. Section 502(b)(10)Changes[15A NCAC 2Q .0523(a)] a. "Section 502(b)(]0)changes"means changes that contravene an express permit tenn or condition. Such changes do not include changes that would violate applicable requirements or contravene federally enforceable permit terns and conditions that are monitoring(including test methods),recordkeeping, reporting,or compliance certification requirements. b. The Pennittee may make Section 502(b)(10)changes without having the permit revised if. i. the changes are not a modification under Title l of the Federal Clean Air Act; ii. the changes do not cause the allowable emissions under the permit to be exceeded; iii. the Pennittee notifies the Director and EPA with written notification at least seven days before the change is made;and iv. the Permittee shall attach the notice to the relevant permit. c. The written notification shall include: i. a description of the change; ii. the date on which the change will occur; iii. any change in emissions;and iv. any permit tern or condition that is no longer applicable as a result of the change. d. Section 502(b)(10)changes shall be made in the permit the next time that the permit is revised or renewed, whichever comes first. 3. Off Permit Changes [15A NCAC 2Q.0523(b)] The Pennittee may make changes in the operation or emissions without revising the pen-nit if: a. the change affects only insignificant activities and the activities remain insignificant after the change;or b. the change is not covered under any applicable requirement. 4. Emissions Trading[15A NCAC 2Q.0523(c)] To the extent that emissions trading is allowed under 15A NCAC 2D,including subsequently adopted maximum achievable control technology standards,emissions trading shall be allowed without permit revision pursuant to Air Permit 03449T42 Page 55 15A NCAC 2Q.0523(c). I.A. Reportins Requirements for Excess Emissions and Permit Deviations [15A NCAC 2D.0535(f)and 2Q.0508(f)(2)] "Excess Emissions"-means an emission rate that exceeds any applicable emission limitation or standard allowed by any rule in Sections.0500, .0900, .1200,or.1400 of Subchapter 21);or by a permit condition;or that exceeds an emission limit established in a permit issued under 15A NCAC 2Q .0700. (Note: Definitions o1'excess emissions under 2D.1110 and 2D.I I I I shall apply where defined by rule.) "Deviations"-for the purposes of this condition,any action or condition not in accordance with the terms and conditions of this permit including those attributable to upset conditions as well as excess emissions as defined above lasting less than four hours. Excess Emissions 1. If a source is required to report excess emissions under NSPS(15A NCAC 2D.0524),NESHAPS(15A NCAC 2D.1110 or.1111),or the operating permit provides for periodic(e.g.,quarterly)reporting of excess emissions, reporting shall be performed as prescribed therein. 2. If the source is not subject to NSPS(15A NCAC 2D.0524),NESHAPS(15A NCAC 2D.1 110 or,I I I I), or these rules do NOT define"excess emissions,"the Permittee shall report excess emissions in accordance with 15A NCAC 2D.0535 as follows: a. Pursuant to 15A NCAC 2D.0535, if excess emissions last for more than four hours resulting from a malfunction,a breakdown of process or control equipment,or any other abnormal condition,the owner or operator shall: i. notify the Regional Supervisor or Director 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 provide: • name and location of the facility; • nature and cause of the malfunction or breakdown; • time when the malfunction or breakdown is first observed; • expected duration;and • estimated rate of emissions; ii, notify the Regional Supervisor or Director immediately when corrective measures have been accomplished;and iii. submit to the Regional Supervisor or Director within 15 days a written report as described in 15A NCAC 2D.0535(f)(3). Permit Deviations 3. Pursuant to 15A NCAC 2Q.0508(f)(2),the Permittee shall report deviations from permit requirements(terms and conditions)as follows: a. Notify the Regional Supervisor or Director of all other deviations from permit requirements not covered under 15A NCAC 2D.0535 quarterly. A written report to the Regional Supervisor shall include the probable cause of such deviation and any corrective actions or preventative actions taken. The responsible official shall certify all deviations from permit requirements. L13. Other Requirements under 15A NCAC 2D.0535 The Permittee shall comply with all other applicable requirements contained in 15A NCAC 2D.0535, including 15A NCAC 2D.0535(c)as follows: 1. Any excess emissions that do not occur during start-up and shut-down shall be considered a violation of the appropriate rule unless the owner or operator of the sources demonstrates to the Director,that the excess emissions are a result of a malfunction. The Director shall consider,along with any other pertinent information, the criteria contained in 15A NCAC 2D.0535(c)(1)through(7). 2. 15A NCAC 2D.0535(g). Excess emissions during start-up and shut-down shall be considered a violation of the appropriate rule if the owner or operator cannot demonstrate that excess emissions are unavoidable. J. Emer2ency Provisions[40 CFR 70.6(g)] The Permittee shall be subject to the following provisions with respect to emergencies: 1. An emergency means any situation arising from sudden and reasonably unforeseeable events beyond the control of the facility,including acts of God,which situation requires immediate corrective action to restore normal Air Permit 03449T42 Page 56 operation,and that causes the facility to exceed a technology-based emission limitation under the permit,due to unavoidable increases in emissions attributable to the emergency. An emergency shall not include noncompliance to the extent caused by improperly designed equipment,lack of preventive maintenance,careless or improper operation,or operator error. 2. An emergency constitutes an affirmative defense to an action brought for noncompliance with such technology- based emission limitations if the conditions specified in 3.below are met. 3. The affirmative defense of emergency shall be demonstrated through properly signed contemporaneous operating logs or other relevant evidence that include information as follows: a. an emergency occurred and the Permittee can identify the cause(s)of the emergency; b. the permitted facility was at the time being properly operated; c. during the period of the emergency the Permittee took all reasonable steps to minimize levels of emissions that exceeded the standards or other requirements in the permit;and d. the Permittee submitted notice of the emergency to the DAQ within two working days of the time when emission limitations were exceeded due to the emergency. This notice must contain a description of the emergency,steps taken to mitigate emissions,and corrective actions taken. 4. In any enforcement proceeding,the Permittee seeking to establish the occurrence of an emergency has the burden of proof. 5. This provision is in addition to any emergency or upset provision contained in any applicable requirement specified elsewhere herein. K. Permit Renewal[15A NCAC 2Q.0508(e)and 2Q.0513(b)] This 15A NCAC 2Q .0500 permit is issued for a fixed term not to exceed five years and shall expire at the end of its term. Permit expiration terminates the facility's right to operate unless a complete 15A NCAC 2Q .0500 renewal application is submitted at least nine months before the date of pen-nit expiration. If the Pennittee or applicant has complied with 15A NCAC 2Q .0512(b)(1),this 15A NCAC 2Q.0500 pen-nit shall not expire until the renewal pen-nit has been issued or denied. Permit expiration under 15A NCAC 2Q .0400 terminates the facility's right to operate unless a complete 15A NCAC 2Q .0400 renewal application is submitted at least six months before the date of pennit expiration for facilities subject to 15A NCAC 2Q .0400 requirements. In either of these events, all terms and conditions of these permits shall remain in effect until the renewal permits have been issued or denied. L. Need to Halt or Reduce Activity Not a Defense[15A NCAC 2Q.0508(i)(4)] It shall not be a defense for a Permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity in order to maintain compliance with the conditions of this permit. M. _Duty to Provide Information(submittal of information)[15A NCAC 2Q.0508(i)(9)] 1. The Permittee shall furnish to the DAQ,in a timely manner,any reasonable infonnation that the Director may request in writing to determine whether cause exists for modifying,revoking and reissuing,or terminating the permit or to determine compliance with the permit. 2. The Permittee shall furnish the DAQ copies of records required to be kept by the permit when such copies are requested by the Director.For infonnation claimed to be confidential,the Pennittee may furnish such records directly to the EPA upon request along with a claim of confidentiality. N. Duty to Supplement[15A NCAC 2Q.0507(f)] The Permittee,upon becoming aware that any relevant facts were omitted or incorrect infonnation was submitted in the permit application,shall promptly submit such supplementary facts or corrected information to the DAQ. The Permittee shall also provide additional information as necessary to address any requirement that becomes applicable to the facility after the date a complete permit application was submitted but prior to the release of the draft permit. O. Retention of Records[15A NCAC 2Q.0508(f)and 2Q.0508(1)] The Permittee shall retain records of all required monitoring data and supporting infonnation for a period of at least five years from the date of the monitoring sample,measurement,report,or application. Supporting information includes all calibration and maintenance records and all original strip-chart recordings for continuous monitoring information,and copies of all reports required by the permit. These records shall be maintained in a form suitable and readily available for expeditious inspection and review. Any records required by the conditions of this permit shall be kept on site and made available to DAQ personnel for inspection upon request. Air Permit 03449T42 Page 57 P. Compliance Certification [15A NCAC 2Q.0508(n)] The Permittee shall submit to the DAQ and the EPA(Air and EPCRA Enforcement Branch, EPA, Region 4,61 Forsyth Street,Atlanta,GA 30303)postmarked on or before March 1 a compliance certification(for the preceding calendar year)by a responsible official with all federally-enforceable terms and conditions in the pen-nit, including emissions limitations,standards,or work practices. It shall be the responsibility of the current owner to submit a compliance certification for the entire year regardless of who owned the facility during the year. The compliance certification shall comply with additional requirements as may be specified under Sections 114(a)(3)or 504(b)of the Federal Clean Air Act. The compliance certification shall specify: 1. the identification of each term or condition of the pen-nit that is the basis of the certification; 2. the compliance status(with the terns and conditions of the pen-nit for the period covered by the certification); 3. whether compliance was continuous or intermittent;and 4. the method(s)used for determining the compliance status of the source during the certification period. Q. Certification by Responsible Official[15A NCAC 2Q.0520] A responsible official shall certify the truth,accuracy,and completeness of any application form,report,or compliance certification required by this permit. All certifications shall state that based on information and belief formed after reasonable inquiry,the statements and information in the document are true,accurate,and complete. R. Permit Shield for Applicable Requirements[15A NCAC 2Q.0512] 1. Compliance with the terns and conditions of this permit shall be deemed compliance with applicable requirements,where such applicable requirements are included and specifically identified in the pen-nit as of the date of permit issuance. 2. A permit shield shall not alter or affect: a. the power of the Commission, Secretary of the Department,or Governor under NCGS 143-215.3(a)(12),or EPA under Section 303 of the Federal Clean Air Act; b. the liability of an owner or operator of a facility for any violation of applicable requirements prior to the effective date of the permit or at the time of pen-nit issuance; c. the applicable requirements under Title IV;or d. the ability of the Director or the EPA under Section 114 of the Federal Clean Air Act to obtain information to detennine compliance of the facility with its permit. 3. A permit shield does not apply to any change made at a facility that does not require a permit or permit revision made under 15A NCAC 2Q .0523. 4. A permit shield does not extend to minor pennit modifications made under 15A NCAC 2Q.0515. S. Termination Modification and Revocation of the Permit [15A NCAC 2Q.0519] The Director may terminate,modify,or revoke and reissue this permit if- ]. the information contained in the application or presented in support thereof is determined to be incorrect; 2. the conditions under which the permit or permit renewal was granted have changed; 3. violations of conditions contained in the permit have occurred; 4. the EPA requests that the permit be revoked under 40 CFR 70.7(g)or 70.8(d);or 5. the Director finds that termination,modification,or revocation and reissuance of the pen-nit is necessary to carry out the purpose of NCGS Chapter 143,Article 21B. T. Insignificant Activities[15A NCAC 2Q.0503] Because an emission source or activity is insignificant does not mean that the emission source or activity is exempted from any applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. The Permittee shall have available at the facility at all times and made available to an authorized representative upon request,documentation,including calculations, if necessary,to demonstrate that an emission source or activity is insignificant. U. Property Rights[15A NCAC 2Q.0508(i)(8)] This permit does not convey any property rights in either real or personal property or any exclusive privileges. V. Inspection and Entry[15A NCAC 2Q.0508(1)and NCGS 143-215.3(a)(2)] 1. Upon presentation of credentials and other documents as may be required by law,the Permittee shall allow the DAQ,or an authorized representative,to perform the following: Air Permit 03449T42 Page 58 a. enter the Permittee's premises where the permitted facility is located or emissions-related activity is conducted,or where records are kept under the conditions of the permit; b. have access to and copy,at reasonable times,any records that are required to be kept under the conditions of the pen-nit; c. inspect at reasonable times and using reasonable safety practices any source,equipment(including monitoring and air pollution control equipment),practices,or operations regulated or required under the permit;and d. sample or monitor substances or parameters,using reasonable safety practices, for the purpose of assuring compliance with the permit or applicable requirements at reasonable times. Nothing in this condition shall limit the ability of the EPA to inspect or enter the premises of the Pennittee under Section 114 or other provisions of the Federal Clean Air Act. 2. No person shall refuse entry or access to any authorized representative of the DAQ who requests entry for purposes of inspection,and who presents appropriate credentials,nor shall any person obstruct,hamper,or interfere with any such authorized 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. W. Annual Fee Payment[15A NCAC 2Q .0508(i)(10)] 1. The Permittee shall pay all fees in accordance with 15A NCAC 2Q.0200. 2. Payment of fees may be by check or money order made payable to the N.C.Department of Environment and Natural Resources. Annual permit fee payments shall refer to the permit number. 3. If,within 30 days after being billed,the Permittee fails to pay an annual fee,the Director may initiate action to terminate the permit under 15A NCAC 2Q.0519. X. Annual Emission Inventory Requirements [15A NCAC 2Q .0207] The Pennittee shall report by June 30 of each year the actual emissions of each air pollutant listed in 15A NCAC 2Q .0207(a)from each emission source within the facility during the previous calendar year. The report shall be in or on such form as may be established by the Director. The accuracy of the report shall be certified by a responsible official of the facility. Y. Confidential Information [15A NCAC 2Q.0107 and 2Q, 0508(i)(9)] Whenever the Pennittee submits information under a claim of confidentiality pursuant to 15A NCAC 2Q .0107,the Permittee may also submit a copy of all such information and claim directly to the EPA upon request. All requests for confidentiality must be in accordance with 15A NCAC 2Q.0107. Z. Construction and Operation Permits[15A NCAC 2Q.0100 and.0300] A construction and operating permit shall be obtained by the Permittee for any proposed new or modified facility or emission source which is not exempted from having a permit prior to the beginning of construction or modification,in accordance with all applicable provisions of 15A NCAC 2Q ,0100 and .0300. AA.Standard Application Form and Required Information [15A NCAC 2Q.0505 and.0507] The Permittee shall submit applications and required information in accordance with the provisions of 15A NCAC 2Q .0505 and.0507. BB. Financial Responsibility and Compliance History[15A NCAC 2Q .0507(d)(4)] The DAQ may require an applicant to submit a statement of financial qualifications and/or a statement of substantial compliance history. CC.Refrigerant Requirements(Stratospheric Ozone and Climate Protection)[15A NCAC 2Q .0501(e)] 1. If the Permittee has appliances or refrigeration equipment, including air conditioning equipment,which use Class I or II ozone-depleting substances such as chlorofluorocarbons and hydrochlorofluorocarbons listed as refrigerants in 40 CFR Part 82 Subpart A Appendices A and B,the Pennittee shall service,repair,and maintain such equipment according to the work practices,personnel certification requirements,and certified recycling and recovery equipment specified in 40 CFR Part 82 Subpart F. 2. The Permittee shall not knowingly vent or otherwise release any Class I or II substance into the environment during the repair,servicing, maintenance, or disposal of any such device except as provided in 40 CFR Part 82 Subpart F. Air Permit 03449T42 Page 59 3. The Permittee shall comply with all reporting and recordkeeping requirements of 40 CFR ❑ 82.166. Reports shall be submitted to the EPA or its designee as required. DD.Prevention of Accidental Releases-Section 112(r) [15A NCAC 2Q .0508(h)] If the Permittee is required to develop and register a Risk Management Plan with EPA pursuant to Section 112(r)of the Clean Air Act,then the Pennittee is required to register this plan in accordance with 40 CFR Part 68. EE. Prevention of Accidental Releases General Duty Clause-Section 112(r)(1)- FEDERALLY-ENFORCEABLE ONLY Although a risk management plan may not be required, if the Pennittee 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. FF. Title IV Allowances [15A NCAC 2Q .0508(i)(1)] This permit does not limit the number of Title IV allowances held by the Permittee,but the Pennittee may not use allowances as a defense to noncompliance with any other applicable requirement. The Pennittee's emissions may not exceed any allowances that the facility lawfully holds under Title IV of the Federal Clean Air Act. GG.Air Pollution Emergency Episode[15A NCAC 2D.0300] Should the Director of the DAQ declare an Air Pollution Emergency Episode,the Permittee will be required to operate in accordance with the Pernittee's previously approved Emission Reduction Plan or, in the absence of an approved plan,with the appropriate requirements specified in 15A NCAC 2D.0300. HH.Registration of Air Pollution Sources [15A NCAC 2D.0200] The Director of the DAQ may require the Permittee to register a source of air pollution. If the Perrittee is required to register a source of air pollution,this registration and required information will be in accordance with 15A NCAC 2D .0202(b). I1. Ambient Air Quality Standards[15A NCAC 2D.0501(c)] In addition to any control or manner of operation necessary to meet emission standards specified in this permit,any source of air pollution shall be operated with such control or in such manner that the source shall not cause the ambient air quality standards in 15A NCAC 2D.0400 to be exceeded at any point beyond the premises on which the source is located. When controls more stringent than named in the applicable emission standards in this permit are required to prevent violation of the ambient air quality standards or are required to create an offset,the permit shall contain a condition requiring these controls. JJ. General Emissions Testing and Reporting Requirements[15A NCAC 2Q.0508(i)(16)] Emission compliance testing shall be by the procedures of Section ,2600, except as may be otherwise required in Rules .0524, .0912, .1110, .1111,or.1415 of Subchapter 2D. If emissions testing is required by this permit or the DAQ or if the Permittee submits emissions testing to the DAQ to demonstrate compliance,the Pennittee shall perform such testing in accordance with 15A NCAC 2D .2600 and follow the procedures outlined below: I. The owner or operator of the source shall arrange for air emission testing protocols to be provided to the Director prior to air pollution testing. Testing protocols are not required to be pre-approved by the Director prior to air pollution testing. The Director shall review air emission testing protocols for pre-approval prior to testing if requested by the owner or operator at least 45 days before conducting the test. 2. Any person proposing to conduct an emissions test to demonstrate compliance with an applicable standard shall notify the Director at least 15 days before beginning the test so that the Director may at his option observe the test. 3. The owner or operator of the source shall arrange for controlling and measuring the production rates during the period of air testing. The owner or operator of the source shall ensure that the equipment or process being tested is operated at the production rate that best fulfills the purpose of the test. The individual conducting the emission test shall describe the procedures used to obtain accurate process data and include in the test report the average production rates detennined during each testing period. 4. Two copies of the final air emission test report shall be submitted to the Director not later than 30 days after sample collection unless otherwise specified in the specific conditions. The owner or operator may request an Air Permit 03449T42 Page 60 extension to submit the final test report.The Director shall approve an extension request if he finds that the extension request is a result of actions beyond the control of the owner or operator. a. The Director shall make the final determination regarding any testing procedure deviation and the validity of the compliance test. The Director may: (1) Allow deviations from a method specified under a rule in this Section if the owner or operator of the source being tested demonstrates to the satisfaction of the Director that the specified method is inappropriate for the source being tested. (2)Prescribe alternate test procedures on an individual basis when he finds that the alternative method is necessary to secure more reliable test data. (3)Prescribe or approve methods on an individual basis for sources or pollutants for which no test method is specified in this Section if the methods can be demonstrated to detenmine compliance of permitted emission sources or pollutants. b. The Director may authorize the Division of Air Quality to conduct independent tests of any source subject to a rule in this Subchapter to determine the compliance status of that source or to verify any test data submitted relating to that source. Any test conducted by the Division of Air Quality using the appropriate testing procedures described in Section 2D.2600 has precedence over all other tests. KK_.Reopening for Cause[15A NCAC 2Q.0517] 1. A pen-nit shall be reopened and revised under the following circumstances: a, additional applicable requirements become applicable to a facility with remaining permit term of three or more years; b. additional requirements(including excess emission requirements)become applicable to a source covered by Title IV; c. the Director or EPA finds that the pen-nit contains a material mistake or that inaccurate statements were made in establishing the emissions standards or other terms or conditions of the pen-nit;or d. the Director or EPA determines that the permit must be revised or revoked to assure compliance with the applicable requirements. 2. Any pen-nit reopening shall be completed or a revised pen-nit issued within I8 months after the applicable requirement is promulgated. No reopening is required if the effective date of the requirement is after the expiration of the permit tern unless the term of the permit was extended pursuant to 15A NCAC 2Q.0513(c). 3. Except for the state-enforceable only portion of the permit,the procedures set out in 15A NCAC 2Q.0507, .0521, or.0522 shall be followed to reissue the permit. If the State-enforceable only portion of the permit is reopened, the procedures in 15A NCAC 2Q.0300 shall be followed. The proceedings shall affect only those parts of the permit for which cause to reopen exists. 4. The Director shall notify the Permittee at least 60 days in advance of the date that the pen-nit is to be reopened, except in cases of imminent threat to public health or safety the notification period may be less than 60 days. 5. Within 90 days,or 180 days if the EPA extends the response period,after receiving notification from the EPA that a permit needs to be terminated,modified,or revoked and reissued,the Director shall send to the EPA a proposed detennination of tennination,modification,or revocation and reissuance,as appropriate. LL. Reporting Requirements for Non-Operating Equipment [15A NCAC 2Q.0508(i)(16)] The Pennittee shall maintain a record of operation for permitted equipment noting whenever the equipment is taken from and placed into operation. During operation the monitoring recordkeeping and reporting requirements as prescribed by the permit shall be implemented within the monitoring period. MM. Fugitive Dust Control Requirement[15A NCAC 2D.0540] -STATE ENFORCEABLE ONLY As required by 15A NCAC 2D.0540"Particulates from Fugitive Dust Emission Sources,"the Penmittee 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 from process operations 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). Air Permit 03449T42 Page 61 NN.Specific Permit Modifications[15A NCAC 2Q.0501 and.0523] 1. For modifications made pursuant to 15A NCAC 2Q.0501(c)(2),the Permittee shall file a Title V Air Quality Pen-nit Application for the air emission source(s)and associated air pollution control device(s)on or before 12 months after commencing operation. 2. For modifications made pursuant to 15A NCAC 2Q.0501(d)(2),the Permittee shall not begin operation of the air emission source(s)and associated air pollution control device(s)until a Title V Air Quality Permit Application is filed and a construction and operation permit following the procedures of Section .0500(except for Rule .0504 of this Section) is obtained. 3. For modifications made pursuant to 502(b)(10),in accordance with 15A NCAC 2Q.0523(a)(1)(C),the Permittee shall notify the Director and EPA(EPA-Air Planning Branch,61 Forsyth St.,Atlanta,GA 30303) in writing at least seven days before the change is made. The written notification shall include: a. a description of the change at the facility; b. the date on which the change will occur; c. any change in emissions;and d. any permit tern or condition that is no longer applicable as a result of the change. In addition to this notification requirement, with the next significant modification or Air Quality Permit renewal,the Permittee shall submit a page "E5" of the application forms signed by the responsible official verifying that the application for the 502(b)(10)change/modification, is true, accurate, and complete. Further note that modifications made pursuant to 502(b)(10)do not relieve the Permittee from satisfying preconstruction requirements. 00.Third Party Participation and EPA Review[15A NCAC 2Q.0521, .0522 and.0525(7)] For permits modifications subject to 45-day review by the federal Environment Protection Agency(EPA), EPA's decision to not object to the proposed permit is considered final and binding on the EPA and absent a third party petition,the failure to object is the end of EPA's decision-making process with respect to the revisions to the permit.The time period available to submit a public petition pursuant to 15A NCAC 2Q .0518 begins at the end of the 45-day EPA review period. Air Pen-nit 03449T42 Page 62 ATTACHMENT List of Acronyms AOS Alternate Operating Scenario BACT Best Available Control Technology Btu British thermal unit CEM Continuous Emission Monitor CFR Code of Federal Regulations CAA Clean Air Act CAIR Clean Air Interstate Rule DAQ Division of Air Quality DENR Department of Environment and Natural Resources EMC Environmental Management Commission EPA Environmental Protection Agency FR Federal Register GACT Generally Available Control Technology HAP Hazardous Air Pollutant MACT Maximum Achievable Control Technology NAA Non-Attainment Area NCAC North Carolina Administrative Code NCGS North Carolina General Statutes NESHAPS National Emission Standards for Hazardous Air Pollutants NOx Nitrogen Oxides NSPS New Source Performance Standard OAH Office of Administrative Hearings PM Particulate Matter PMI0 Particulate Matter with Nominal Aerodynamic Diameter of 10 Micrometers or Less POS Primary Operating Scenario PSD Prevention of Significant Deterioration RACT Reasonably Available Control Technology SIC Standard Industrial Classification SIP State Implementation Plan SOz Sulfur Dioxide tpy Tons Per Year VOC Volatile Organic Compound