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HomeMy WebLinkAboutAQ_F_1200180_20130624_PRMT_Permit ATA 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 June 24, 2013 Mr. Koji Kawada President Viscotec Automotive Products, LLC P.O. Box 130 Morganton,NC 28680-0130 Subject: Air Permit No. 09231R12 Viscotec Automotive Products, LLC Morganton, Burke County, North Carolina Permit Class: Synthetic Minor Facility IN 1200180 Dear Mr. Kawada: In accordance with your completed application received April 2, 2013, we are forwarding herewith Permit No. 09231RI2 to Viscotec Automotive Products, LLC, Morganton,Burke 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. t t G.S. 5 - 3 this permit shall e final d Unless a request for a hearing is made pursuant o .S. OB 2 rs air p rt b an binding. Asheville Regional Office-Division of Air Quality 2090 U.S.Highway 70,Swannanoa,North Carolina 28778 Phone:828-296-4500/FAX:828-299-7043 Internet:www.ncair.org An Equal Opportunity 1 Affirmative Action Employer-Made in part by Recycled Paper Mr. Koji Kawada June 24, 2013 Page 2 You may request modification of your air permit through informal means pursuant to G.S. 150B-22. This request must be submitted in writing to the Director and must identify the specific provisions or issues for which the modification is sought. Please note that the permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Unless exempted by a condition of this permit or the regulations, construction of new air pollution sources or air cleaning devices, or modifications to the sources or air cleaning devices described in this permit must be covered under a permit issued by the Division of Air Quality prior to construction. Failure to do so is a violation of G.S. 143-215.108 and may subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143- 215.11413. This permit shall be effective from June 24,2013 until May 31, 2018, 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 emissions inventory for calendar year 2016 is due 90 days prior to the expiration of the permit. Should you have any questions concerning this matter,please contact Harold Brady at(828) 296- 4500. Sincerely, Paul K. Muller, P.E. Regional Air Quality Supervisor PKM:hlb Enclosures c: Asheville Regional Office NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 09231R12 Issue Date: June 24, 2013 Effective Date: June 24, 2013 Expiration Date:May 31, 2018 Replaces Permit: 09231RI 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 21 B of Chapter 143, General Statutes of North Carolina(NCGS)as amended, and other applicable Laws, Rules and Regulations, Viscotec Automotive Products, LLC 1500 E Union Street Morganton,Burke County,North Carolina Permit Class: Synthetic Minor Facility ID# 1200180 (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 Description mmM._. .__...___.._..._... _._......System ID Description _ one indirectly heated tenter frame(964 pounds of ; ES-1 fabric per hour maximum throughput;maximum oil content of fabric 3.0%) _. ......... ... one indirectly heated tenter flame(964 pounds of one condenser-type packed ES-2 !fabric per hour maximum throughput;maximum CD-6 bed mist eliminator(20,000 t oil content of fabric 3.0%) s, acfm gas flow rate) ES-7one indirectly heated tenter frame(840 pounds-s of 3ES 33 fabric per hour maximum throughput;maximum oil content of fabric 3.0%) aw......._..._....._ _............ _ -.,,....._.,. _......_.._.._.. one indirectly heated tenter frame(840 pounds of i one condenser-type packed- ES-4 fabric per hour maximum throughput;maximum ' CD-4 bed mist eliminator(20,000 oil content of fabric 3 0%) acfinw as flow rate g. ...... ,.,. )................ 3 one venturi scrubber in ES-5 !one natural gas-fired flame laminator(3.0 CD-5 `series with a vertical packed 3 mmBtu/hr maximum capacity) ; tower and mist eliminator '(6,000 acfin gas flow rate) Permit No. 09231R12 Page 2 .. .... .................. .. _..__.,......................................_ ,Emission Emission Source Control Control System Source ID 1 Description ! System ID Description Ione indirectly heated tenter frame(2,400 pounds ES-6 of fabric per hour maximum throughput; $ ' maximum oil content of fabric 3 0%) --i-�--�I one indirectly heated tenter frame(2,400 pounds one condenser-type packed- ES-7 !of fabric per hour maximum throughput; CD-4 bed mist eliminator(20,000 maximum oil content of fabric 3.0%) acfin gas flow rate) __ ....__. .. .... .., ..._... . ... ----.._ -- --- one indirectly heated tenter frame(1,200 pounds ES-8 of fabric per hour maximum throughput; maximum oil content of fabric 3 0%) s FES 9 one indirectly heated tenter frame with no presetting capacity N/A ) N/A I _ 7 ES-10 one indirectly heated tenter frame with no 1presettin capacityN/A. ....N/A p ......._ g ..... ........................... in accordance with the completed application 1200180.13A received April 2, 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 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 .0516, 2D .0521, 2D .0535, 2D .0540, 2D .1100, 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 2016 calendar year. 3. PARTICULATE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the emission sources 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 Permit No. 0923IR12 Page 3 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) 0.61 for P <= 30 tons/hr, or E= 55 * (P) 0-"- 40 for P>30 tons/hr 4. SULFUR DIOXIDE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the combustion sources shall not exceed 2.3 pounds per million Btu heat input. 5. VISIBLE EMISSIONS CONTROL REQUIREMENT -As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .I 110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein. 6. NOTIFICATION REQUIREMENT - As required by 15A NCAC 2D .0535, the Permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall: a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence and describe: i. the name and location of the facility, ii. the nature and cause of the malfunction or breakdown, iii. the time when the 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. 7. FUGITIVE DUST CONTROL REQUIREMENT - As required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. If substantive complaints or excessive fugitive dust emissions from the facility are observed beyond the property boundaries for six minutes Permit No. 09231RI2 Page 4 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). 8. TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND REPORTING REQUIREMENT- Pursuant to 15A NCAC 2D .1100 "Control of Toxic Air Pollutants," and in accordance with the approved application for an air toxic compliance demonstration, the following permit limits shall not be exceeded: Emission Affected Source(s) Toxic Air Pollutant Limit j Hydrogen cyanide (as HCN 1 0.042 lb/hr Component of CNC) (74-90-8) 1.00 lb/day j one natural gas-fired flame laminator t Hydrogen chloride (hydrochloric (3.0 mmBtu/hr maximum capacity) 0 418 lb/hr ES-5 acid) (7647 O1 0) m.. _.. ............... Toluene diisocyanate 2 4- and isomers (584-84-9,91-08-7) 0 00071b/day a. Restrictions - To ensure compliance with the above limits, the following restrictions shall apply: i. emissions from the natural gas-fired flame laminator(ID No. ES-5) shall be controlled by the venturi scrubber and packed tower(ID No. CD-5); ii. the venturi scrubber/packed tower stack(ID No. CD-5) shall be located and operated per information provided by the facility on April 2, 2012. 9. LIMITATION TO AVOID 15A NCAC 2Q .0501 - Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of Section and Requirement for a Permit," as requested by the Permittee, facility-wide emissions shall be less than the following: Pollutant Emission Limit (Tons per consecutive 12-month period) PMIO 100 a. Inspection and Maintenance Requirements - i. Condenser/Mist Eliminator Requirements - Emissions shall be controlled as described in the permitted equipment list. 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 (I&M) as recommended by the manufacturer. In addition, the Permittee shall perform Permit No. 09231R12 Page 5 an annual (for each 12 month period following the initial inspection) inspection of each condenser system. As a minimum,the I&M program and each annual inspection should include the following: A. inspection and maintenance of the structural integrity of each condenser, including inspection for leakage of coolant and, if the' system is under positive gauge pressure, leakage of the contaminated gas stream. To determine leakage of the coolant,the condensate shall be inspected for the presence of coolant. B. inspection and maintenance of the structural integrity of duct work and piping leading to and coming from each condenser. ii. PM-Scrubber(Packed Tower) Requirements - Particulate matter emissions shall be controlled as described in the permitted equipment list. 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 (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 scrubber system. As a minimum, the I&M program and each annual inspection should include the following: A. inspection of spray nozzles,packing material, chemical feed system (if so equipped), and the cleaning/calibration of all associated instrumentation annually. B. two weeks following initial start-up and startup following major maintenance of each scrubber, the Permittee shall shut down the system and inspect for nozzle plugging and settling of the packing. b. Recordkeeping Requirements -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. 10. 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. Permit No. 09231R12 Page 6 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: ' Acute Carcinogens Chronic Acute ens ; Pollutant g Toxicants Systemic Irritants (lb/yr) ! (lb/day) Toxicants (lb/hr) i lb/hr 'Acetaldehyde (75-07-0) � 6.8 Dioxane, 1,4- (123-91-1) 12 (� d. Compliance with these emission limitations shall be demonstrated as set forth in Specific Condition No. 9. 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 Asheville Regional Office 2090 U.S. Highway 70 Swannanoa,NC 28778 828-296-4500 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. Permit No. 09231RI2 Page 7 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. 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 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 Permit No. 09231R12 Page 8 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 issued this the 241h of June, 2013. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Paul K. Muller, P.E. Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 09231RI2 ATTACHMENT to Permit No. 09231R12, June 24, 2013 Insignificant/Exempt Activities .......__ _. . _ _....... __.,.._ _ -- ------------- �"�+_ Exemption Source Source of Title; Source Regulation TAPs� V Pollutants? ............. - .. _. .-_ .... ...... - 11ES-1 -Pressurized/closed fabric dyeing operation` 2Q .0102~~ No No (negligible emissions expected) (c)(l)(L)(xii) IES-2 - Six natural gas-fired steam boilers (three rated at 13.2 MMBtu/hr(NSPS affected), two 2Q .0102 yes ? Yes rated at 1.2 MMBtu/hr, and one rated at 8.3 ± (c)(2)(B)(ii) ii MMBtu/hr maximum heat input) IES-3 - Two natural gas-fired hot oil boilers(8.3 2Q .0102 MMBtu/hr maximum heat input, each) (c)(2)(B)(ii) yes ' Yes IES-4 - One Visco Dry process that utilizes acetic 2Q .0102 yes Yes acid and ink :.._(c)(2)(D)(i)..... IES-5 - One cleaning/soap process that utilizes 2Q .0102 y. ...........es Yes ethylene glycol and acetic acid (c)(2)(D)(i) I-ES8 - one 2000 gallon acetic acid storage tank 2Q . _jF 0102 yes ' Yes ��)�1)�L)�xu)....: ....... _.. _......, . ._. __...._ .; 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."