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HomeMy WebLinkAboutAQ_F_0600015_20140214_PRMT_Permit 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 February 14,2014 Mr. Andrew G. Bradley Vice President of Environmental Affairs Unimin Corporation 258 Elm Street New Canaan, CT 06840 Subject: Air Permit No. 04000R20 Unimin Corporation- Schoolhouse Quartz Plant Spruce Pine, Avery County,North Carolina Permit Class: Synthetic Minor Facility ID# 0600015 Dear Mr. Bradley: In accordance with an administrative amendment dated November 18,2013,we are forwarding herewith Permit No. 04000R20 to Unimin Corporation, Schoolhouse Quartz Plant, Spruce Pine,Avery County,North Carolina for the construction and operation of air emissions sources or air cleaning devices and appurtenances. Additionally, any emissions activities determined from your air permit application as meeting the exemption requirements contained in 15A NCAC 2Q .0102 or 15A NCAC 2Q .0503 have been listed for information purposes as an "ATTACHMENT" to the enclosed air permit. Please note the records retention requirements are contained in General Condition 2 of the General Conditions and Limitations. If any parts, requirements,or limitations contained in this permit are unacceptable to you, you have the right to request a formal adjudicatory hearing within 30 days following receipt of this permit,identifying the specific issues to be contested. Such a request will stay the effectiveness of the entire permit. This hearing request must be in the form of a written petition, conforming to G.S. 150B-23 of the North Carolina General Statutes, and filed with the Office of Administrative Hearings, 6714 Mail Service Center,Raleigh,NC 27699-6714. The form for requesting a formal adjudicatory hearing may be obtained upon request from the Office of Administrative Hearings. Unless a request for a hearing is made pursuant to G.S. 15013-23,this air permit shall be final and binding. You may request modification of your air permit through informal means pursuant to G.S. 15013-22. This request must be submitted in writing to the Director and must identify the specific provisions or issues for which the modification is sought. Please note that the permit will become Asheville Regional Office-Division of Air Quality 2090 U.S.Highway 70,Swannanoa,North Carolina 28778 Phone:828-296-45001 FAX:828-299-7043 Internet:www.ncair.org An Equal Opportunity 1 Affirmative Action Employer-Made in part by Recycled Paper Mr. Andrew G. Bradley February 14, 2014' Page 2 final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Unless exempted by a condition of this permit or the regulations, construction of new air pollution sources or air cleaning devices, or modifications to the sources or air cleaning devices described in this permit must be covered under a permit issued by the Division of Air Quality prior to construction. Failure to do so is a violation of G.S. 143-215.108 and may subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143- 215.114B. This permit shall be effective from February 14, 2014 until November 30, 2014, is nontransferable to future owners and operators, and shall be subject to the conditions and limitations as specified therein. Changes have been made to the permit stipulations. The Permittee is responsible for carefully reading the entire permit and evaluating the requirements of each permit stipulation. The Permittee shall comply with all terms, conditions, requirements, limitations and restrictions set forth in this permit.Noncompliance with any permit condition is grounds for enforcement action, for permit termination, revocation and reissuance, or modification, or for denial of a permit renewal application. Specific changes and additions are summarized below (note: this list may not include all changes and additions): • The testing requirement for the wet scrubber(ID No. WS-03) installed on the two acid storage tanks (ID No. ES-S) is removed; and • The description of Bagfilter DC-01 is updated to reflect that the unit now has 252 square feet of filter area rather than 300 square feet. Should you have any questions concerning this matter,please contact Christopher Scott at (828) 296-4500. Sincerely, l Paul K. Muller, P.E. Regional Air Quality Supervisor PKM:ces Enclosures c: Central Files Asheville Regional Office Shannon Vogel, permit only NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 04000R20 Issue Date: February 14, 2014 Effective Date: February 14, 2014 Expiration Date: November 30, 2014 Replaces Permit: 04000R19 To construct and operate air emission source(s) and/or air cleaning device(s), and for the discharge of the associated air contaminants into the atmosphere in accordance with the provisions of Article 21 B of Chapter 143, General Statutes of North Carolina (NCGS) as amended, and other applicable Laws, Rules and Regulations, Unimin Corporation- Schoolhouse Quartz Plant 107 Harris Mining Rd Spruce Pine, Avery County,North Carolina Permit Class: Synthetic Minor Facility ID# 0600015 (the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenances described below: Emission Emission Source Control Control System Source ID Description System ID Description ES-06 one lime storage silo DC-01 one bagfilter (252 square feet of filter area) ES-2 acid day storage tanks room WS-02 one packed tower wet scrubber (20 gallons per minute minimum water injection rate) ES-3 one propane-fired fluid bed dryer WS-01, one packed tower (4.7 million Btu per hour maximum heat wet scrubber (26 input) gallons per minute minimum water injection rate), in series with CY-20 one mechanical cyclone (54 inches in diameter) Permit No. 04000R20 Page 2 Emission Emission Source Control Control System Source ID Description System ID Description ES-5 two (2) acid storage tanks (hydrofluoric WS-03 one wet scrubber acid tank capacity of 8,000 gallons and (35 gallons per sulfuric acid tank capacity is 10,000 minute minimum gallons) water injection rate) ES-7 one lime storage silo DC-05 one bagfilter (300 square feet of filter area) BS-V one central vacuum system DC-04 one cartridge/HEPA bagfilter (364 square feet of filter area) Crushing Opera ion (Group 1; ID No. GRI), consisting of the following ES-GR-01 one 50 inches by 20 feet grizzly feeder ES-CR-01 one 35 inches by 46 inches jaw crusher NSPS (475 tons per hour maximum rated capacity) equipped with water sprays ES-CR-02 one 44 inches in diameter cone crusher NSPS (430 tons per hour maximum rated capacity) equipped with water sprays N/A N/A ES-VS-01 one 6 feet by 14 feet double deck screen NSPS ES-BC-01 one 42-inch wide belt conveyor NSPS BC-02, BC-03 three (3) 30-inch wide belt conveyors and BC-05 NSPS Permit No. 04000R20 Page 3 Emission Emission Source Control Control System Source ID Description System ID Description Quartz Plant Grou 2; ID No. GR2 , consisting of the followin ES-BN-01 one truck dump hopper ESTE-01 one vibrating feeder BC-04 and two (2) 30-inch wide belt conveyors BC-06 NSPS ESTE-2 five (5)vibrating feeders through ESTE-6 BN-02 NSPS one storage bin N/A N/A BC-7, BC-8, five (5) 24-inch wide belt conveyors BC-9, BC-20 and BC-21 NSPS ES-VS-02 one 6 feet by 16 feet vibrating screen NSPS ES-CR-03 one water flush cone crusher NSPS (100 tons per hr maximum rated capacity) Recycling Quartz Sand System (Group 3; ID No. G113), consisting of the following ES-BN-21 one storage bin N/A N/A NSPS ES-BC-19 one 24-inch wide belt conveyor DC-03 one bagfilter NSPS (576 square feet of filter area) ES-VS-21 one vibrating screen NSPS ES-BN-22 one storage bin NSPS ES-BC-24 one 18-inch wide belt conveyor N/A N/A NSPS Permit No. 04000R20 Page 4 Emission Emission Source Control Control System Source ID Description System ID Description Enclosed Screening and Magnetic Separation System Processing Quartz Sand (Group 4; ID No. GR4), consisting of the following ES-BN-6 thirteen(13) storage bins DC-02 one bagfilter through (7,395 square feet ES-BN-15 of filter area) ES-BN-07A, ES-BN-17 and BN-19 NSPS BC-25 and BC-30 NSPS two 18-inch wide belt conveyors ES-VS-03A ES-VS-04A forty-eight(48) vibrating screens ES-VS-3 through ES-VS-16 ES-VS-18 ES-VS-23 through ES-VS-26 ES-VS-30 through ES-VS-44 ES-VS-50 ES-VS-51 ES-VS-60 through ES-VS-69 NSPS VS-22 and two (2) vibrating wet screens VS-27 NSPS BE-2, BE-3 six (6) bucket elevators BE-4, BE-6 BE-7 and BE-8 NSPS SE-1 and SE-2 two (2) drum loading station NSPS Feldspar Drain Piles (Group 5; ID No. GR5), consisting of the following F13A and F13B two (2) feldspar drain piles processing N/A N/A feldspar concentrate Permit No. 04000R20 Page 5 Emission Emission Source Control Control System Source ID Description System ID Description Mica Discharge Conve or System (Group 6; ID No. GR6 , consisting of the followin VS-19 and two (2) vibrating wet screens VS-20 NSPS BN-3 and BN-4 two (2) storage bins N/A N/A NSPS BC-22 and two (2) 30-inch wide belt conveyors BC-23 NSPS Wet Grinding O eration (Group 7; ID No. G117 , consisting of the following BN-05 one storage bin N/A N/A NSPS RM-1 and two (2)rod mills RM-2 NSPS N/A N/A in accordance with an administrative amendment 0600015.13A dated November 18, 2013 including any plans, specifications, previous applications, and other supporting data, all of which are filed with the Department of Environment and Natural Resources,Division of Air Quality(DAQ) and are incorporated as part of this permit. This permit is subject to the f6llowing specified conditions and limitations including any TESTING,REPORTING, OR MONITORING REQUIREMENTS: A. SPECIFIC CONDITIONS AND LIMITATIONS I. Any air emission sources or control devices authorized to construct and operate above must be operated and maintained in accordance with the provisions contained herein. The Permittee shall comply with applicable Environmental Management Commission Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0509, 2D .0510, 2D .0515, 2D .0516, 2D .0521, 2D .0524 (40 CFR 60, Subpart 000), 2D .0535; 2D .0540, 2D .1806, 2Q .0315 and 2Q .0711. 2. PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT - The Permittee, at least 90 days prior to the expiration date of this permit, shall request permit renewal by letter in accordance with 15A NCAC 2Q .0304(d) and (f). Pursuant to 15A NCAC 2Q .0203(i),no permit application fee is required for renewal of an existing air permit(without a modification request). The renewal request(with AA application form) should be submitted to the Regional Supervisor, DAQ. Also, at least 90 days prior to the expiration date of this permit,the Permittee shall submit the air pollution emission inventory report(with Certification Sheet) in accordance with 15A NCAC 2D .0202, pursuant to N.C. General Statute 143 215.65. The report shall be submitted to the Regional Supervisor, DAQ and shall document air pollutants emitted for the 2013 calendar year. Permit No. 04000R20 Page 6 3. PARTICULATE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0509 "Particulates from Mica or Feldspar Processing Operations," for the sources including the mica discharge conveyor system (ID No. GR6),the following limitations shall apply: a. Particulate matter emissions that are discharged from any chimney, stack, vent, or outlet shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0509, a function of the process weight rate and shall be determined by the following equations(s), where P is the process throughput rate in tons per hour(tons/hr) and E is the allowable emission rate in pounds per hour (lbs/hr). E=4.00 * (P) 0.677 for P <=30 tons/hr, or E=20.421 * (P) 0.1977 for P> 30 tons/hr, but< 1,000 tons/hr, or E=38.147 * (P) 0.1072 for P>= 1000 tons/hr,but< 3,000 tons/hr, or E= 90.00 lbs/hr for P>=3,000 tons/hr b. Fugitive dust emissions shall be controlled in accordance with 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources." c. Particulate emissions from the conveyors, screens and transfer points shall be controlled in accordance with 15A NCAC 2D .0521 "Control of Visible Emissions," or with 15A NCAC 2D .0524 "New Source Performance Standards," as applicable. d. The Permittee of any mica or feldspar plant shall control process-generated emissions: i. From crushers with wet suppression, and ii. From conveyors, screens, and transfer points, such that the applicable opacity standards in Rule .0521 or .0524, of this Section, are not exceeded. 4. PARTICULATE CONTROL REQUIREMENT- As required by 15A NCAC 2D .0510 "Particulates from Sand, Gravel, or Crushed Stone Operations," the following requirements apply: a. The Permittee of a sand, gravel, or crushed stone operation shall not cause, allow, or permit any material to be produced,handled, transported,or stockpiled without taking measures to reduce to a minimum any particulate matter from becoming airborne to prevent exceeding the ambient air quality standards beyond the property line for particulate matter,both PM10 and total suspended particulates. b. Fugitive dust emissions from sand, gravel, or crushed stone operations shall be controlled by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources." Permit No. 04000R20 Page 7 c. The Permittee of any sand, gravel, or crushed stone operation shall control process- generated emissions: i. From crushers with wet suppression; and ii. From conveyors, screens, and transfer points such that the applicable opacity standards in 15A NCAC 2D .0521 Control of Visible Emissions," or 15A NCAC 2D .0524 "New Source Performance standards" are not exceeded. 5. PARTICULATE CONTROL REQUIREMENT- As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the propane-fired fluid bed dryer (ID No. ES-3) and lime storage silos (ID No. ES-06 and ES-7) shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0515, a function of the process weight rate and shall be determined by the following equation(s), where P is the process throughput rate in tons per hour(tons/hr) and E is the allowable emission rate in pounds per hour (lbs/hr). E=4.10 * (P) 0.17 for P <= 30 tons/hr, or E= 55 * (P) all- 40 for P >30 tons/hr 6. SULFUR DIOXIDE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the propane-fired fluid bed dryer(ID No. ES-3) shall not exceed 2.3 pounds per million Btu heat input. 7. VISIBLE EMISSIONS CONTROL REQUIREMENT -As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources not subject to regulation 2D .0524, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein. 8. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" - For the crushers, screens, belt conveyors, surge/storage bins, recycling quartz sand system, screening and magnetic separation system,mica discharge conveyor system, and rod mills (ID Nos. ES-BC-01 through ES-BC-9, ES-BC-19 through ES-BC-25, ES-BC-30, ES-BC- 31, ES-BE-2, through ES-BE-8, ES-BN-02 through ES-BN-6, ES-BN-07A, ES-BN-8 through ES-BN-13, ES-BN-15 through ES-BN-17, ES-BN-19, ES-BN-21, ES-BN-22, ES- CR-01, ES-CR-02, ES-CR-03, ES-VS-03A, ES-VS-04A, ES-VS-01 through ES-VS-16, ES- VS-18 through ES-VS-27, ES-VS-30 through ES-VS-44,ES-VS-50, ES-VS-51, ES-VS-60 through ES-VS-69, ES-RM-1, ES-RM-2, SE-1 and 5E-2),the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and Permit No. 04000R20 Page 8 monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524 "New Source Performance Standards" (NSPS) as promulgated in 40 CFR 60, Subpart 000,including Subpart A "General Provisions." a. NSPS Reporting Requirements - In addition to any other notification requirements to the Environmental Protection Agency (EPA),the Permittee is required to NOTIFY the Regional Supervisor, DAQ, in WRITING, of the actual date of initial start-up of an affected facility,postmarked within 15 days after such date; b. NSPS Emissions Limitations -As required by 15A NCAC 2D .0524, the following permit limits shall not be exceeded: i. For affected facilities that commenced construction, modification, or reconstruction after August 31, 1983 but before April 22, 2008 (wet material processing operations, as defined in 60.671, are not subject to this Subpart): Affected Facility ; Pollutant Emission Limit PM 0.022 Affected facilities with dry capture systems gr/dscf (i.e., bagfilters) Visible Emissions 71X,opacity Visible Crushers 15% o acit p y Emissions Fugitive emissions from conveyor belts, Visible screening operations, and other affected Emissions 10% opacity, facilities If an affected facility is enclosed in a building,the affected facility must comply with the limits listed above OR the building enclosing the affected facilities must comply with a visible emissions limit of seven(7)percent opacity from the building openings(except for vents as defined in 60.671) and a particulate emission limit of 0.022 grains per dry standard cubic foot from the vents. ii. For affected facilities that commenced construction,modification, or reconstruction on or after April 22, 2008 (wet material processing operations, as defined in 60.671, are not subject to this Subpart): Permit No. 04000R20 Page 9 Emission ; Affected Facility Pollutant Limit Affected facilities with dry capture systems 0.014 (i.e., bagfilters) PM gr/dscf Visible Crushers Emissions 12% opacity; . .. -- _-- - Fugitive emissions from conveyor belts, Visible screening operations, and other affected 7% opacity facilities Emissions If an affected facility is enclosed in a building,the affected facility must comply with the limits listed above OR the building enclosing the affected facilities must comply with a visible emissions limit of seven(7) percent opacity from the building openings (except for vents as defined in 60.671) and a particulate emission limit of 0.014 grains per dry standard cubic foot from the vents. C. NSPS Monitoring Requirements - As required by 15A NCAC 2D .0524, the following monitoring shall be conducted: i. For any affected facility that commenced construction, modification, or reconstruction on or after April 22, 2008 that uses wet suppression to control emissions,the Permittee shall: A. Perform monthly periodic inspections to check that water is flowing to discharge spray nozzles in the wet suppression systems. B. Initiate corrective action within 24 hours and complete corrective action as expediently as practical if the Permittee finds that water is not flowing properly during an inspection of the water spray nozzles. ii. For any affected facility that commenced construction, modification, or reconstruction on or after April 22, 2008 that is controlled with a bagfilter system, the Permittee shall: A. Conduct quarterly visible emissions inspections using EPA Method 22 while the bagfilter system is in operation. If any visible emissions are observed,the Permittee must initiate corrective action within 24 hours to return the bagfilter system to normal operation. OR B. Install, operate, and maintain a bag leak detection system according to specifications and requirements listed in 40 CFR 60.674(d)(1). The Permittee must develop and submit for approval a site-specific monitoring plan for each bag leak detection system. The Permittee must operate and maintain the bag leak detection system according to the approved site-specific monitoring plan at all times. The Permittee must initiate procedures to determine the cause of an alarm within l Permit No. 04000R20 Page 10 hour of the alarm. The cause of the alarm must be alleviated within 3 hours of the alarm by taking any corrective action necessary. d. NSPS Recordkeeping_Requirements -As required by 15A NCAC 2D .0524,the following recordkeeping requirements shall be conducted: i. Each inspection of the water spray nozzles, including the date of each inspection and any corrective actions taken, shall be recorded in a logbook (in written or electronic form). ii. Each quarterly Method 22, including the date, results of the observation, and any corrective actions taken, shall be recorded in a logbook(in written or electronic form). iii. For each bag leak detection system,records of the system output, any system adjustments (including the date and time of the adjustment,the initial system settings, and the final system settings), and information pertaining to all system alarms (including the date and time of the alarm,the time that procedures to determine the causes of the alarm were initiated,the cause of the alarm, an explanation of the actions taken, the date and time the cause of the alarm was alleviated, and whether the cause of the alarm was alleviated within 3 hours of the alarm) shall be recorded in a logbook(in written or electronic form). iv. The logbooks (in written or electronic form) shall be maintained on-site and made available to DAQ personnel upon request. e. NSPS Performance Testing-As required by 15A NCAC 2D .0524,the following performance tests shall be conducted: .......... ............... .__............_...---............................. ................ -......................._._......_._.... .............:................... Affected Facility Pollutant Test t Method PM Method 5 Affected facilities with dry capture systems (i.e., bagfilter)'and vents from a buildingthat encloses affected facilities ` Visible Emissions ; Method 9 .... .......... _.......... .. Visible Crushers Emissions ! Method 9 Fugitive emissions from conveyor belts, screening Visible operations, and other affected facilities Emissions ? Method 9 i. All performance tests shall be conducted in accordance with EPA Reference Methods, contained in 40 CFR 60, Appendix A; ii. The EPA Administrator retains the exclusive right to approve equivalent and alternative test methods, continuous monitoring procedures, and reporting requirements; Permit No. 04000R20 Page 1.1 iii. Within 60 days after achieving the maximum production rate at which the affected facility(s) will be operated, but not later than 180 days after the initial start-up of the affected facility(s),the Permittee shall conduct the required performance test(s) and submit two copies of a written report of the test(s)to the Regional Supervisor, DAQ; iv. The Permittee shall be responsible for ensuring, within the limits of practicality, that the equipment or process being tested is operated at or near its maximum normal production rate or at a lesser rate if specified by the Director or his delegate; V. All associated testing costs are the responsibility of the Permittee; vi. At least 45 days prior to performing any required emissions testing,the Permittee must submit two copies of a testing protocol to the Regional Supervisor, DAQ for review and approval. All testing protocols must be approved by the DAQ prior to performing such tests; and vii. To afford the Regional Supervisor, DAQ,the opportunity to have an observer present,the Permittee shall PROVIDE the Regional Office, in WRITING, at least 7 days notice of any required performance test(s)that involve only Method 9. All other tests require a 15 day notice. viii. For any affected facility that commenced construction, modification, or reconstruction on or after April 22, 2008 that does not use wet suppression to control emissions shall conduct the performance tests within five (5) years of the previous test. If an affected facility relies on water carryover from upstream wet suppression to control fugitive emissions,then that affected facility is exempt from the 5-year repeat testing requirement provided that the Permittee conducts periodic inspections of the upstream wet suppression that is responsible for controlling fugitive emissions from the affected facility and designates which upstream wet suppression systems will be periodically inspected at the time of the initial performance test. ix. If a building encloses affected facilities that commenced construction modification, or reconstruction on or after April 22, 2008,the Permittee must conduct an initial Method 9 performance test. X. If a building encloses only affected facilities that commenced construction, modification, or reconstruction before April 22, 2008, and the Permittee has not previously conducted an initial visible emissions performance test,then the Permittee must conduct an initial Method 9 performance test to show compliance with the above limits. f. Like-For-Like-Replacement-As provided in 40 CFR 60.670(d), when an existing facility is replaced by a piece of equipment of equal or smaller size, as defined in 40 CFR 60.671, having the same function as the existing facility, the new facility is exempt from the provisions of 40 CFR 60.672, 60.674, and 60.675 except as Permit No. 04000R20 Page 12 provided for in 60.670(d)(3). The Permittee shall comply with the reporting requirements of 40 CFR 60.676(a). Equipment covered under 40 CFR 60.670 shall comply the requirements of 15A NCAC 2D .0521. 9. NOTIFICATION REQUIREMENT - As required by 15A NCAC 2D .0535, the Permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall: a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence and describe: i. the name and location of the facility, _ ii. the nature and cause of the malfunction or breakdown, iii. the time when the malfunction or breakdown is first observed, iv. the expected duration, and V. an estimated rate of emissions. b. Notify the Director or his designee immediately when the corrective measures have been accomplished. This reporting requirement does not allow the operation of the facility in excess of Environmental Management Commission Regulations. 10. FUGITIVE DUST CONTROL REQUIREMENT -As required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. If substantive complaints or excessive fugitive dust emissions from the facility are observed beyond the property boundaries for six minutes in any one hour (using Reference Method 22 in 40 CFR,Appendix A), the owner or operator may be required to submit a fugitive dust plan as described in 2D .0540(f). "Fugitive dust emissions" means particulate matter that does not pass through a process stack or vent and that is generated within plant property boundaries from activities such as: unloading and loading areas, process areas stockpiles, stock pile working, plant parking lots, and plant roads (including access roads and haul roads). 11. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS - As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions" the Permittee shall not operate the facility without implementing management practices or installing and operating odor control equipment sufficient to prevent odorous emissions from the facility from causing or contributing to objectionable odors beyond the facility's boundary. 12. LIMITATION TO AVOID 15A NCAC 2Q .0501 - Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of Section and Requirement for a Permit," as requested by the Permittee,facility-wide emissions shall be less than the following: Permit No. 04000R20 Page 13 Pollutant Emission Limit (Tons per consecutive 12-month period) PMIo.-.._...� 100 ;Hydrofluoric Acid 10 BAGFILTER REQUIREMENTS - Particulate matter emissions from the emission sources (ID Nos. BC-19, VS-21, and BN-22 (combined); ES-4; ES-06; BS-V; and ES-7) shall be controlled by the bagfilters (ID Nos. DC-03, DC-02, DC-01, DC-04, and DC-05, respectively). a. Inspection and Maintenance Requirements - To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits, the Permittee shall perform, at a minimum, an annual (once every 12 months) internal inspection of each bagfilter system. In addition, the Permittee shall perform periodic inspections and maintenance as recommended by the equipment manufacturer. b. Recordkeeping Requirements - The results of all inspections and any variance from manufacturer's recommendations or from those given in this permit (when applicable) shall be investigated with corrections made and dates of actions recorded in a logbook. Records of all maintenance activities shall be recorded in the logbook. The logbook (in written or electronic form) shall be kept on-site and made available to DAQ personnel upon request. PACKED TOWER GAS ABSORBER REQUIREMENTS - HF emissions from the acid storage tanks (ID Nos. ES-2 and ES-5) shall be controlled by the packed column scrubbers (ID Nos. WS-02 and WS-03, respectively) with polypropylene packing and a water scrubbing medium. a. Inspection and Maintenance Requirements - To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits, the Permittee shall perform periodic inspections and maintenance as recommended by the manufacturer. In addition, the Permittee shall perform an annual (once every 12 months) internal inspection of each scrubber system. As a minimum,the annual internal inspection will include inspection of spray nozzles, packing material, chemical feed system (if so equipped), and the cleaning/calibration of all associated instrumentation annually. b. Recordkeeping Requirements - The results of all inspections and any variance from manufacturer's recommendations or from those given in this permit (when applicable) shall be investigated with corrections made and dates of actions recorded in a logbook. Records of all maintenance and monitoring activities shall be recorded in the logbook. The logbook (in written or electronic form) shall be kept on-site and made available to DAQ personnel upon request. c. Monitoring Requirements - The Permittee shall ensure the proper performance of the scrubber by monitoring the following operational parameters: Permit No. 04000R20 Page 14 i. liquid injection rate; and ii. pressure drop across the scrubber. 13. TOXIC AIR POLLUTANT EMISSIONS LIMITATION REQUIREMENT -Pursuant to 15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," for each of the below listed toxic air pollutants (TAPS),the Permittee has made a demonstration that facility-wide actual emissions do not exceed the Toxic Permit Emission Rates (TPERs) listed in 15A NCAC 2Q .0711. The facility shall be operated and maintained in such a manner that emissions of any listed TAPS from the facility, including fugitive emissions, will not exceed TPERs listed in 15A NCAC 2Q .0711. a. A permit to emit any of the below listed TAPS shall be required for this facility if actual emissions from all sources will become greater than the corresponding TPERs. b. PRIOR to exceeding any of these listed TPERs,the Permittee shall be responsible for obtaining a permit to emit TAPS and for demonstrating compliance with the requirements of 15A NCAC 21) .1100 "Control of Toxic Air Pollutants". c. In accordance with the approved application,the Permittee shall maintain records of operational information demonstrating that the TAP emissions do not exceed the TPERs as listed below: . ...... ........... . . ....... ......__ ......... ... ............. . ..................._.. Acute ( Chronic Acute Carcinogens 1 Systemic Pollutant Toxicants Irritants E (lb/yr) (lb/day) Toxicants (lb/hr) .. . _._............ ... _..... . (lb/hr) I ....._....... ;hydrogen fluoride {(7664-39-3) ! 0.63 0.064 !sulfuric acid ' ( 0.25 0.025 F (7664-93-9)._.............._.... ..... _...... . 14. LIMITATION TO AVOID 40 CFR Part 68 "Accidental Release Prevention Requirements: Risk Management Programs Under the Clean Air Act, Section 112(r)" - The,Permittee may not store any 112(r)Regulated Substances(including> 49%HF)above the threshold quantity, as defined in.40 CFR Part 68,without first following all the requirements of Part 68, including the submittal of a risk management plan. B. GENERAL CONDITIONS AND LIMITATIONS 1. TWO COPIES OF ALL DOCUMENTS, REPORTS, TEST DATA, MONITORING DATA, NOTIFICATIONS,REQUESTS FOR RENEWAL,AND ANY OTHER INFORMATION REQUIRED BY THIS PERMIT shall be submitted to the: Permit No. 04000R20 Page 15 Regional Air Quality Supervisor North Carolina Division of Air Quality Asheville Regional Office 2090 U.S.Highway 70 Swannanoa,NC 28778 (828) 296-4500 2. RECORDS RETENTION REQUIREMENT -Any records required by the conditions of this permit shall be kept on site and made available to DAQ personnel for inspection upon request. These records shall be maintained in a form suitable and readily available for expeditious inspection and review. These records must be kept on site fora minimum of 2 years, unless another time period is otherwise specified. 3. ANNUAL FEE PAYMENT - Pursuant to 15A NCAC 2Q .0203(a),the Permittee shall pay the annual permit fee within 30 days of being billed by the DAQ. Failure to pay the fee in a timely manner will cause the DAQ to initiate action to revoke the permit. 4. EQUIPMENT RELOCATION- A new air permit shall be obtained by the Permittee prior to establishing,building, erecting, using, or operating the emission sources or air cleaning equipment at a site or location not specified in this permit. 5. REPORTING REQUIREMENT - Any of the following that would result in previously unpermitted, new, or increased emissions must be reported to the Regional Supervisor, DAQ: a. changes in the information submitted in the application regarding facility emissions; b. changes that modify equipment or processes of existing permitted facilities; or c. changes in the quantity or quality of materials processed. If appropriate, modifications to the permit may then be made by the DAQ to reflect any necessary changes in the permit conditions. In no case are any new or increased emissions allowed that will cause a violation of the emission limitations specified herein. 6. This permit is subject to revocation or modification by the DAQ upon a determination that information contained in the application or presented in the support thereof is incorrect, conditions under which this permit was granted have changed, or violations of conditions contained in this permit have occurred. The facility shall be properly operated and maintained at all times in a manner that will effect an overall reduction in air pollution. Unless otherwise specified by this permit,no emission source may be operated without the concurrent operation of its associated air cleaning device(s) and appurtenances. 7. This permit is nontransferable by the Permittee. Future owners and operators must obtain a new air permit from the DAQ. Permit No. 04000R20 Page 16 8. This issuance of this permit in no way absolves the Permittee of liability for any potential civil penalties which may be assessed for violations of State law which have occurred prior to the effective date of this permit. 9. This permit does not relieve the Permittee of the responsibility of complying with all applicable requirements of any Federal, State, or Local water quality or land quality control authority. 10. Reports on the operation and maintenance of the facility shall be submitted by the Permittee to the Regional Supervisor, DAQ at such intervals and in such form and detail as may be required by the DAQ. Information required in such reports may include,but is not limited to, process weight rates, firing rates, hours of operation, and preventive maintenance schedules. 11. A violation of any term or condition of this permit shall subject the Permittee to enforcement pursuant to G.S. 143-215.114A, 143-215.11413, and 143-215.114C, including assessment of civil and/or criminal penalties. 12. Pursuant to North Carolina General Statute 143-215.3(a)(2), no person shall refuse entry or access to any authorized representative of the DAQ who requests entry or access for purposes of inspection, and who presents appropriate credentials, nor shall any person obstruct, hamper, or interfere with any such representative while in the process of carrying out his official duties. Refusal of entry or access may constitute grounds for permit revocation and assessment of civil penalties. 13. The Permittee must comply with any applicable Federal, State, or Local requirements governing the handling, disposal, or incineration of hazardous, solid, or medical wastes, including the Resource Conservation and Recovery Act(RCRA) administered by the Division of Waste Management. 14. PERMIT RETENTION REQUIREMENT- The Permittee shall retain a current copy of the air permit at the site. The Permittee must make available to personnel of the DAQ, upon request,the current copy of the air permit for the site. 15. CLEAN AIR ACT SECTION 112(r)REQUIREMENTS - Pursuant to 40 CFR Part 68 "Accidental Release Prevention Requirements: Risk Management Programs Under the Clean Air Act, Section 112(r)," if the Permittee is required to develop and register a risk management plan pursuant to Section 112(r).of the Federal Clean Air Act, then the Permittee is required to register this plan in accordance with 40 CFR Part 68. 16. PREVENTION OF ACCIDENTAL RELEASES - GENERAL DUTY -Pursuant to Title I Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants - Prevention of Accidental Releases -Purpose and General Duty," although a risk management plan may not be required, if the Permittee produces, processes, handles, or stores any amount of a listed hazardous substance, the Permittee has a general duty to take such steps as are necessary to prevent the accidental release of such substance and to minimize the consequences of any release. This condition is federally-enforceable only. Permit No. 04000R20 Page 17 17. GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS - If emissions testing is required by this permit,or the DAQ, or if the Permittee submits emissions testing to the DAQ in support of a,permit application or to demonstrate compliance,the Permittee shall perform such testing in accordance with 1 SA NCAC 2D .2600 and follow all DAQ procedures including protocol approval, regional notification, report submittal, and test results approval. Permit issued this the 14 `of February 2014. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION - Paul K. Muller, P.E. T Regional.Air Quality Supervisor By Authority of the Environmental Management Commission. Air Permit No. 04000R20 ATTACHMENT to Permit No. 04000R20,February 14, 2014 Insignificant/Exempt Activities Exemption Source of Source of Source Title V Regulation TAPS? pollutants? I-Boiler-A- one No.2 fuel oil-fired boiler(5.028 2Q .0102 No Yes miIlion BTU per hour maximum heat input rate) (c)(2)(B)(ii) I-ES-7 - one lime slurry mix tank 2Q .0102 No Yes .... . one amine drum oven E 2Q .0102 No Yes _(c)(2)(E)(lv)_ I-ES-9 --one hot water heater 2Q .0102 (2.2 million Btu per hour maximum heating rate) (c)(2)(E)(i) Yes Yes I-ES-10 - one hot water heater 2Q .0102 (2.2 million Btu per hour maximum heating rate) (c)(2)(E)(i) Yes.. ........................... Yes II-ES-BC-3 I- one 24-inch wide belt conveyor 2Q .0102 No Yes installed on the wastewater treatment facility (c)(1)(F) 1. Because an activity is exempted from being required to have a permit or permit modification does not mean that the activity is exempted from an applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. 2. When applicable, emissions from stationary source activities identified above shall be included in determining compliance with the permit requirements for toxic air pollutants under 15A NCAC 2D .1100 "Control of Toxic Air Pollutants" or 2Q .0711 "Emission Rates Requiring a Permit.