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HomeMy WebLinkAboutAQ_F_1800377_20140227_PRMT_Permit_R12 �j NCDER 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 27, 2014 Mr. Rick Holt Plant Manager Certainteed Vinyl Operations PO Box 760 Claremont,NC 28610 Subject: Air Permit No. 06650R12 Certainteed Vinyl Operations Claremont, Catawba County,North Carolina Permit Class:Synthetic Minor Facility ID# 1800377 Dear Mr. Holt: In accordance with your completed application received February 24, 2014, we are forwarding herewith Permit No. 06650R12 to Certainteed Vinyl Operations, Claremont, Catawba County,North Carolina for the construction and operation of air emissions sources or air cleaning devices and appurtenances. Additionally, any emissions activities determined from your air permit application as meeting the exemption requirements contained in 15A NCAC 2Q .0102 have been listed for information purposes as an "ATTACHMENT" to the enclosed air permit. Please note the records retention requirements are contained in General Condition 2 of the General Conditions and Limitations. If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have the right to request a formal adjudicatory hearing within 30 days following receipt of this permit, identifying the specific issues to be contested. Such a request will stay the effectiveness of the entire permit. This hearing request must be in the form of a written petition, conforming to G.S. 150B-23 of the North Carolina General Statutes, and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh,NC 27699-6714. The form for requesting a formal adjudicatory hearing may be obtained upon request from the Office of Administrative Hearings. Unless a request for a hearing is made pursuant to G.S. 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 Mooresville Regional Office-Division of Air Quality 610 East Center Avenue,Suite 301,Mooresville,North Carolina 28115 Phone:704-663-1699/FAX:704-663-7579 Internet:www.ncair.org An Equal opportunity 1 Affirmative Action Employer-Made in part by Recycled Paper Rick Holt February 27, 2014 Page 2 provisions or issues for which the modification is sought. Please note that the permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Unless exempted by a condition of this permit or the regulations, construction of new air pollution sources or air cleaning devices,or modifications to the sources or air cleaning devices described in this permit must be covered under a permit issued by the Division of Air Quality prior to construction. Failure to do so is a violation of G.S. 143-215.108 and may subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143- 215.114B. This permit shall be effective from February 27, 2014 until June 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): An effective date of thirty days after permit issuance was added to the synthetic minor condition for the inspection and maintenance requirements of the new bagfilter. Should you have any questions concerning this matter,please contact Jennifer Womick at(704) 663-1699. Sincerely, Ronald E. Slack Regional Air Quality Supervisor JAW Enclosures c: Mooresville Regional Office G:\AQ\Shared\WPDATA\COUNTIES\CATAWBA\00377\Rl2—PERMIT.doex NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 06650R12 Issue Date: February 27, 2014 Effective Date: February 27, 2014 Expiration Date: June 30,2014 Replaces Permit: 06650R1 I To construct and operate air emission source(s) and/or air cleaning device(s), and for the discharge of the associated air contaminants into the atmosphere in accordance with the provisions of Article 21B of Chapter 143, General Statutes of North Carolina(NCGS) as amended, and other applicable Laws, Rules and Regulations, Certainteed Vinyl, Operations 2651 Penny Road Claremont, Catawba County,North Carolina Permit Class: Synthetic Minor Facility ID# 1800377 (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-1001 PVC resin vacuum railcar FR-1001 filter receiver(183 square unloading system(25,000 feet of filter area) pounds per hour maximum capacity) ES-1011 PVC storage silo(12,500 BV-1011 bin vent filter(184 square pounds per hour maximum feet of filter area) capacity) r-1012 PVC storage silo(12,500 BV-1012 bin vent filter(184 square pounds per hour maximum feet of filter area) capacity) rS-1O15a calcium carbonate silo(20 FBV-1015a bin vent filter(183 square tons per hour fill rate) feet of filter area) ___.,.IlFS-1015b calcium carbonate pneumaticV-1O15b bin vent filter(226 square conveyor(2 tons per hour feet'of filter area) _._. maximum unloading rate)v H r2001 vacuum resin conveying FR-2001 bagfilter(183 square feet of system(19,500 pounds per filter area) hour maximum capacity) Permit No. 06650R12 Page 2 Emission Emission Source Control Control System Source ID Description System ID Description _._._ ._..__...__.. .__.._.......__........__..-_- __._r.. _....M_..____...__...._-.__..........._.___.__.... _...._...__..___.._....._.___.___.._..._._.... ES-3001 vacuum compound FR-3011,FR-3012,FR- twenty(20)bagfilters(ID conveying system(51,000 3 02 1,FR-3022,FR-3031, Nos.FR-3011,FR-3012, pounds per hour capacity) FR-3032,FR-3041,FR- FR-3021,FR-3022,FR- consisting of seventeen(17) 3042,FR-3051,FR-3052, 3 03 1,FR-3032,FR-3041, vacuum conveying lines FR-3062,FR-3072,FR- FR-3042,FR-3051,FR- 3082,FR-3092,FR-3102, 3052,FR-3062,FR-3072, FR-3061,FR-3071,FR- FR-3082,FR-3092,and FR- 3081,FR-3091,FR-3101 3102,FR-3061,FR-3071, FM081,FR-3091,and FR- 3101; 183.4 square feet of filter area,each)installed in parallel ES-6001 cool mixer(24,000 pound FR-6001 bagfilter(183.4 square feet per hour maximum capacity) of filter area) ES-6002 cool mixer 4,000 pounds FR-6002 rbagfilter(183.4 square feet maximum capacity) filter area) ES-6003 blending heat mixer(24,000 FR-6003 bagfilter(183.4 square feet pounds per hour maximum of filter area) process rate) ES-7001 _ glue application line used in construction of cardboard N/A N/A boxes containing vinyl siding ES-8001 barcode labeling system including fifteen(15)ink jet N/A N/A print heads installed on ten (10)extrusion lines FS-_81-02 PVC grinding operation - FR-8002 bagfilter(1,530 square feet (3,000 pounds per hour 7of filter area) maximum process rate) in accordance with the completed application 1800377.14A received February 24, 2014 including any plans, specifications,previous applications, and other supporting data, all of which are filed with the Department of Environment and Natural Resources, Division of Air Quality(DAQ) and are incorporated as part of this permit. This permit is subject to the following specified conditions and limitations including any TESTING, REPORTING, OR MONITORING REQUIREMENTS: A. SPECIFIC CONDITIONS AND LIMITATIONS 1. Any air emission sources or control devices authorized to construct and operate above must be operated and maintained in accordance with the provisions contained herein. The Permittee shall comply with applicable Environmental Management Commission Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0515, 2D .0521, 2D .0535,2D .0540, 2D .0958, 2Q .0315 and 2Q .0711. Permit No. 06650R12 Page 3 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 (0. 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. 3. PARTICULATE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from PVC resin vacuumrailcar unloading system (ID No. ES-1001), PVC storage silo (ID No. ES-1011),PVC storage silo (ID No. ES-1012), calcium carbonate silo (ID No. ES-1015a), calcium carbonate pneumatic conveyor(ID No. ES-1015b), vacuum resin conveying system (ID No. ES-2001), vacuum compound conveying system(ID No. ES-3001), cool mixer(ID No. ES-6001), cool mixer(ID No. ES-6002), blending heat mixer(ID No. ES-6003) and PVC grinding operation(3,000 pounds per hour maximum process rate) (ID No. ES-8002) shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0515, a function of the process weight rate and shall be determined by the following equation(s), where P is the process throughput rate in tons per hour(tons/hr) and E is the allowable emission rate in pounds per hour(lbs/hr). E=4.10 * (P) 0.67 for P <=30 tons/hr, or E= 55 * (P) 0.11- 40 for P>30 tons/hr 4. VISIBLE EMISSIONS CONTROL REQUIREMENT -As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply.with applicable visible emissions requirements contained therein. 5. NOTIFICATION REQUIREMENT -As required by 15A NCAC 2D .0535,the Permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall: a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence and describe: i. the name and location of the facility, ii. the nature and cause of the malfunction or breakdown, Permit No. 06650R12 Page 4 iii. the time when the malfunction or breakdown is first observed, iv. the expected duration, and V. an estimated rate of emissions. b. Notify the Director or his designee immediately when the corrective measures have been accomplished. This reporting requirement does not allow the operation of the facility in excess of Environmental Management Commission Regulations. 6. FUGITIVE DUST CONTROL REQUIREMENT -As required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. If substantive complaints or excessive fugitive dust emissions from the facility are observed beyond the property boundaries for six minutes in any one hour(using Reference Method 22 in 40 CFR,Appendix A),the owner or operator may be required to submit a fugitive dust plan as described in 2D .0540(f). "Fugitive dust emissions"means particulate matter that does not pass through a process stack or vent and that is generated within plant property,boundaries from activities such as: unloading and loading areas,process areas stockpiles, stock pile working,plant parking lots, and plant roads (including access roads and haul roads). 7. 15A NCAC 2D .0958: WORK PRACTICES FOR SOURCES OF VOLATILE ORGANIC COMPOUNDS a. As required by 15A NCAC 2D .0958(c), for all sources at facilities that use volatile organic compounds (VOC) as solvents, carriers, material processing media, or industrial chemical reactants, or in similar uses that mix, blend, or manufacture volatile organic compounds, or emit volatile organic compounds as a product of chemical reactions; the Permittee shall adhere to the following required work practices: i. The Permittee shall store all VOC-containing material not in use (including waste material) in containers covered with a tightly fitting lid that is free of cracks, holes, or other defects. ii. The Permittee shall clean up spills as soon as possible following proper safety procedures. iii. The Permittee shall store wipe rags in closed containers. iv. The Permittee shall not clean sponges, fabric, wood, paper products, and other absorbent materials. Permit No. 06650R12 Page 5 V. The Permittee shall drain solvents used to clean supply lines and other coating equipment into closable containers and close containers immediately after each use. vi. The Permittee shall clean mixing, blending, and manufacturing vats and containers by adding cleaning solvent, closing the vat or container before agitating the cleaning solvent. vii. The Permittee shall pour spent cleaning solvent into closable containers and close containers immediately after each use. b. As required by 15A NCAC 2D .0958(d), when cleaning parts with a solvent containing a volatile organic compound,the Permittee shall: i. flush parts in the freeboard area, ii. take precautions to reduce the pooling of solvent on and in the parts, iii. tilt or rotate parts to drain solvent and allow a minimum of 15 seconds for drying or until all dripping has stopped, whichever is longer, iv. not fill cleaning machines above the fill line, v. not agitate solvent to the point of causing splashing. 8. LIMITATION TO AVOID 15A NCAC 2Q .0501 - Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of Section and Requirement for a Permit," as requested by the Permittee,facility-wide emissions shall be less than the following: Pollutant Emission Limit Tons per consecutive 12 month eriod) PM10 100 a. Inspection and Maintenance Requirements - i. Bagfilter Requirements - Particulate matter emissions shall be controlled as described in the permitted equipment list. The inspection, maintenance and record keeping requirements shall become effective March 27, 2014 for the bagfilter(ID No. FR-8002). To comply with the provisions of this permit and ensure that emissions do not exceed the regulated limits,the Permittee shall perform periodic inspections and maintenance (I&M) as recommended by the manufacturer. In addition,the Permittee shall perform an annual (for each 12 month period following the initial inspection) internal inspection of each bagfilter system. Permit No. 06650R12 Page 6 b. RecordkeepingiRequirements i. A log book shall be kept on site for each control device and made available to Division of Air Quality personnel upon request. The Permittee shall record all inspection, maintenance and monitoring requirements listed above in the log book. Any variance from the manufacturer's recommendations shall be investigated with corrections made and date of actions recorded in the log book. 9. 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 2D .1100 "Control of Toxic Air Pollutants". c. In accordance with the approved application,the Permittee shall maintain records of operational information demonstrating that the TAP emissions do not exceed the TPERs as listed below: Chronic Acute Acute Pollutant Carcinogens Toxicants Systemic Irritants (lb/yr) (lb/day) Toxicants (lb/hr) (lb/hr) MEK(methyl ethyl ketone, 2- 78 22.4 butanone) (78-93-3) 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: Regional Air Quality Supervisor North Carolina Division of Air Quality Mooresville Regional Office 610 East Center Avenue, Suite 301 Mooresville,NC 28115 704-663-1699 Permit No. 06650R12 Page 7 For identification purposes, each submittal should include the facility name as listed on the permit, the facility identification number, and the permit number. 2. RECORDS RETENTION REQUIREMENT - Any records required by the conditions of this permit shall be kept on site and made available to DAQ personnel for inspection upon request. These records shall be maintained in a form suitable and readily available for expeditious inspection and review. These records must be kept on site for a minimum of 2 years, unless another time period is otherwise specified. 3. ANNUAL FEE PAYMENT -Pursuant to 15A NCAC 2Q .0203(a),the Permittee shall pay the annual permit fee within 30 days of being billed by the DAQ. Failure to pay the fee in a timely manner will cause the DAQ to initiate action to revoke the permit. 4. EQUIPMENT RELOCATION- A new air permit shall be obtained by the Permittee prior to establishing, building, erecting, using, or operating the emission sources or air cleaning equipment at a site or location not specified in this permit. 5. REPORTING REQUIREMENT - Any of the following that would result in previously unpermitted, new, or increased emissions must be reported to the Regional Supervisor, DAQ: a. changes in the information submitted in the application regarding facility emissions; b. changes that modify equipment or processes of existing permitted facilities; or c. changes in the quantity or quality of materials processed. If appropriate,modifications to the permit may then be made by the DAQ to reflect any necessary changes in the permit conditions. In no case are any new or increased emissions allowed that will cause a violation of the emission limitations specified herein. 6. This permit is subject to revocation or modification by the DAQ upon a determination that information contained in the application or presented in the support thereof is incorrect, conditions under which this permit was granted have changed, or violations of conditions contained in this permit have occurred. The facility shall be properly operated and maintained at all times in a manner that will effect an overall reduction in air pollution. Unless otherwise specified by this permit,no emission source may be operated without the concurrent operation of its associated air cleaning device(s) and appurtenances. 7. This permit is nontransferable by the Permittee. Future owners and operators must obtain a new air permit from the DAQ. 8. This issuance of this permit in no way absolves the Permittee of liability for any potential civil penalties which may be assessed for violations of State law which have occurred prior to the effective date of this permit. 9. This permit does not relieve the Permittee of the responsibility of complying with all applicable requirements of any Federal, State, or Local water quality or land quality control authority. Permit No. 06650R12 Page 8 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, 143-215.114B, and 143-215.114C, including assessment of civil and/or criminal penalties. 12. Pursuant to North Carolina General Statute 141215.3(a)(2), no person shall refuse entry or access to any authorized representative of the DAQ who requests entry or access for purposes of inspection, and who presents appropriate credentials, nor shall any person obstruct,-hamper, or interfere with any such representative while in the process of carrying out his official duties. Refusal of entry or access may constitute grounds for permit revocation and assessment of civil penalties. 13. The Permittee must comply with any applicable Federal,State,or Local requirements governing the handling, disposal, or incineration of hazardous, solid, or medical wastes, including the Resource Conservation and Recovery Act(RCRA) administered by the Division of Waste Management. 14. PERMIT RETENTION REQUIREMENT- The Permittee shall retain a current copy of the air permit at the site. The Permittee must make available to personnel of the DAQ,upon request, the current copy of the air permit for the site. 15. CLEAN AIR ACT SECTION 112(r)REQUIREMENTS - Pursuant to 15A NCAC 2D .2100 "Risk Management Program," if the Permittee is required to develop and register a risk management plan pursuant to Section 112(r) of the Federal Clean Air Act,then the Permittee is required to register this plan with the USEPA in accordance with 40 CFR Part 68. 16. PREVENTION OF ACCIDENTAL RELEASES - GENERAL DUTY Pursuant to Title I Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants - Prevention of Accidental Releases - Purpose and General Duty," although a risk management plan may not be required, if the Permittee produces,processes,handles, or stores any amount of a listed hazardous substance, the Permittee has a general duty to take such steps as are necessary to prevent the accidental release of such substance and to minimize the consequences of any release. This condition is federally-enforceable only. 17. GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS If emissions testing is required by this permit, or the DAQ, or if the Permittee submits emissions testing to the DAQ in support of a permit application or to demonstrate compliance, the Permittee shall perform such testing in accordance with 15A NCAC 2D .2600 and follow all DAQ procedures including protocol approval,regional notification, report submittal, and test results approval. Permit No. 06650RI2 Page 9 Permit issued this the 27th.of February, 2014. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Y�onald:, Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 06650RI2 ATTACHMENT to Permit No. 06650R12, February 27, 2014 Insignificant/Exempt Activities Source Exemption. Source of Source of Title V Regulation TAPs? Pollutants? ' ES -5001 extruder process consisting of 2Q .0102 (10) extrusion lines (two extruders per Yes Yes ne) (c)(2)(E)(i) 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."