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HomeMy WebLinkAboutAQ_F_0400005_20120308_PRMT_Permit NCDENR North Carolina Department of Environment and Natural Resources Division of Air Quality Beverly Eaves Perdue Sheila C. Holman Dee Freeman Governor Director Secretary March 8, 2012 Mr. Jeff Horne Plant Manager Bonsal American 351 Hailey's Ferry Road Lilesville,NC 28091 Subject: Air Permit No. 01759R20 Bonsai American Lilesville, Anson County,North Carolina Permit Class: Synthetic Minor Facility ID# 0400005 Dear Mr. Horne: In accordance with your completed application received February 9, 2012, we are forwarding herewith Permit No. 01759R20 to Bonsal American, Lilesville, Anson County, North Carolina for the construction and operation of air emissions sources or air cleaning devices and appurtenances. Please note the regOrds retention requirements are contained in General Condition 2 of the General Conditions and Limitations.), If any parts, reqmUents, 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 final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Fayetteville Regional Office-Division of Air Quality One Building,225 Green Street,Suite 714.Fayetteville,North Carolina 28301-5094 OPt�1�ZPO�lI11 Phone:(910)433-33001 FAX:(910)485-7467\Internet:www.ncair,org/ An Equal Opportunity\Affirmative Action Employer AdurallY Jeff Horne March 8, 2012 Page 2 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 March 8, 2012 until February 28, 2017, 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. Should you have any questions concerning this matter, please contact Gregory Reeves at (910) 433-3300. Sincerely, Steven F.Vozzo Regional Air Quality Supervisor GWR Enclosures c: Fayetteville Regional Office NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 01759R20 Issue Date: March 8,2012 Effective Date: March 8, 2012 Expiration Date: February 28, 2017 Replaces Permit: 01759R19 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, Bonsai American 351 Hailey's Ferry Road Lilesville, Anson County, North Carolina Permit Class: Synthetic Minor Facility ID# 0400005 (the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenancesdescribed below: J A , 'b{ �, ,� i� ( rr RY 1U ''^1ti a fi b gar ,- m 3 E .�sston � I mission ourcc �ontroi Cpn MEN stcm SOUr00 t F ' D083CrIGFt9 a _i ,}{St0II1 ID i. ti;; �gs9IPIMI a 1� (Drying Operation, consishng of: Natural gas/No 2 fuel fired(15 mml3tu max heat input)sand and gravel i ES30 dryer(50 tons per hour maximum BH1A Bagfilter(3,825 square feet of filter area) capacity) Production Line 1, consisting of; SF22 ( Portland cement silo, Line 1 ( 131-122 Bagfilter(156 square feet of filter area) ----- ---- ----- - -- -- ----- --- -- -- It - SF23 Recycled cement ssilo-, Line 1 BH23 Bagfilter(156 square feet off-filter area) SF24 Fly ash silo, Line I BH24 I Bagfilter(]56 square feet of filter area) -- - -- — ---- - - - --- ------ -----_ -- - SF25 Nomix cement silo Line 1 BH25 Bagfilter(156 square feet of filter area) -- -- --- --- - -- _ . .. -- - ----- ---- — — - — - - Rock and sand bucket conveyor ES03 operation including a rock silo and a 13H1A Bagfilter(3,825 square feet of filter area) sand silo weighing, mixing), Line I ES01 Cement handling operation(bagging, 131-101 Bagfilter(3,840 square feet of filter area) Permit No. 01759R20 Page 2 �>Inrss�o►i��`, r,�t„7� �` �r�it�$r�11�Sonrce I��Ctiotlthol{,� 1 ' �{ Cbnfrb�S�'stern : ; ` O�IICtt`' i act. p , %.� t 7 ss,}` telY��;I De,�erlptlon„ ,� r., f Deaer► tion .z 11'ro-duction Line 2, consisting of SF40 Portland cement silo Line 2 BH40 I Bagfilter(156 square feet of filter area) SF41 Rock silo, Line 2 BH41 ' Bagfilter(156 square feet of filter area) SF42 Sand silo split,Iine 2 ( BI142 Bagfilter(156 square fee[of filter area) SF43 Fly ash silo,Line 2 I BH43 I -Bag filter(156 square feet of filter area) — --- -- ---— .. _. SF44 Type S cement silo Lme 2 r B1I44 Bagfilter (156 square feet of filter area) SF52 Recycled cement silo,Lme 2 BH52 Bag filter(156 square feet of filter area) ES18 I Rock screen from sand, Line 2 BH13 Bagfilter(1,200 square feet of filter area) Cement handling operation(bagging, ES02 B1402 Bagfilter(1,900 square feet of filter are) � weighing, mixing), Li e 2 in accordance with the completed application 0400005.12A received February 9, 2012 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 and 2D .0611. 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 2015 calendar year. Permit No. 01759R20 Page 3 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 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) 1.61 for P <= 30 tons/hr, or E= 55 * (P) o"" - 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. Permit No. 01759R20 Page 4 7. FUGITIVE DUST CONTROL REQUIREMENT - As required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. If substantive complaints or excessive fugitive dust emissions from the facility are observed beyond the property boundaries for six minutes in any one hour (using Reference Method 22 in 40 CFR, Appendix A), the owner or operator may be required to submit a fugitive dust plan as described in 2D .0540(I). "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). 8. FABRIC FILTER REQUIREMENTS includingc artridge filters, baghouses, and other dry filter particulate collection devices - As required by 15A NCAC 2D .0611, particulate matter emissions shall be controlled as described in the permitted equipment list. 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 (for each 12 month period following the initial inspection) 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 format) shall be kept on-site and made available to DAQ personnel upon request. Permit No. 01759R20 Page 5 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 Fayetteville Regional Office Systel Building 225 Green Street, Suite 714 Fayetteville,NC 28301-5094 (910) 433-3300 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. Permit No. 01759R20 Page 6 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, 143-215.11413, 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. Permit No. 0 175 9R20 Page 7 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 I I2(r)(1) of the Clean Air Act "Hazardous Air Pollutants - Prevention of Accidental Releases - Purpose and General Duty," although a risk management plan may not be required, if the Permittee produces, processes, handles, or stores any amount of a listed hazardous substance, the Permittee has a general duty to take such steps as are necessary to prevent the accidental release of such substance and to minimize the consequences of any release. This condition is federally-enforceable only. 17. GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS - If emissions testing is required by this permit, or the DAQ, or if the Permittee submits emissions testing to the DAQ in support of a permit application or to demonstrate compliance, the Permittee shall perform such testing in accordance with 15A NCAC 21) .2600 and follow all DAQ procedures including protocol approval, regional notification, report submittal, and test results approval. Permit issued this the 8`" of March, 2012. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION yu, lC, Steven F. Vozzo Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 01759R20 _._,)�t�'�. � r'�� _. � (.)�