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HomeMy WebLinkAboutAQ_F_1400188_20130401_PRMT_Permit NCDEN North Carolina Department of Environment and Natural Resources Division of Air Quality Pat McCrory Sheila C. Holman John E. Skvarla, III Governor Director Secretary April 1, 2013 Mr. B. K. Mount President Maymead Materials, Inc. Post Office Box 911 1995 Roan Creek Road Mountain City, TN 37683 Subject: Air Permit No. 08589R04 Maymead Materials, Inc. -North 321 Stone Yard Lenoir, Caldwell County, North Carolina Permit Class: Small Facility ID# 1400188 Dear Mr. Mount: In accordance with your completed application received January 30, 2013, we are forwarding herewith Permit No. 08589R04 to Maymead Materials, Inc. -North 321 Stone Yard, Lenoir, Caldwell County,North Carolina for the construction and operation of air emissions sources or air cleaning devices and appurtenances. 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:828-296-4500/FAX:828-299-7043 Internet:www.ncair.org An Equal Opportunity 1 Affirmative Action Employer-Made in part by Recycled Paper Mr. B. K. Mount April 1, 2013 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 April 1, 2013 until March 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): • This Permit contains an emission inventory requirement for the 2016 calendar year as part of the next renewal in 2018. Should you have any questions concerning this matter,please contact Christopher Scott at(828) 296-4500. Sincerely, Paul K. Muller, P.E. Regional Air Quality Supervisor PKM:ces Enclosures c: Asheville Regional Office NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 08589R04 Issue Date: April 1, 2013 Effective Date: April 1, 2013 Expiration Date: March 31, 2018 Replaces Permit: 08589R03 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, Maymead Materials, Inc. -North 321 Stone Yard 3540 Blowing Rock Road Lenoir, Caldwell County,North Carolina Permit Class: Small Facility ID# 1400188 (the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenances described below: ........... -... ........------_._....u.._._. _____._........_._._......................___..._..._ _.._.._ Emission Emission Source Control Control System j Source ID Description System ID Description i {Non-Metallic Mineral Processing Plant,200 tons per hour rating, equipped with water suppression,with no other control devices, including: ES Crush(NSPS) Crushing Operations , N/A N/A ' �ES-Screen(NSPS) Screening Operations , N/A N/A _.............................. ......... ..... _. _.............. ._.........._........ ....._._.._. ES-Convey(NSPS)~Conveying^Operations j N/A N/A _,._........ ........ .. ._..... _. in accordance with the completed application 1400188.13A received January 30, 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: Permit No. 08589R04 Page 2 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 .0501, 2D .0510, 2D .0521, 2D .0524 (40 CFR 60, Subpart 000), 2D .0535 and 2D .0540. 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. EQUIPMENT REPORTING - To demonstrate compliance with 15A NCAC 2D .0501(c), the Permittee shall maintain on-site an equipment list and a plant(or flow) diagram of all equipment covered under this permit. a. The equipment list shall include the total rated crushing capacity of all primary crushers at the facility and the following information for each piece of equipment: i. A description of equipment including applicability of New Source Performance Standards, and: A. Width of belt conveyors, B. Dimensions and configuration(e.g., triple deck) of screens, C. Rated capacity (tons/hr) of each crusher, and D. Rated capacity(tons or tons/hr) of all equipment not exempt from permit requirements under 15 A NCAC 2Q.0IO2(c), ii. A unique ID number. iii. The date the equipment was manufactured, and iv. The dates any required performance testing was conducted and submitted to the Regional Supervisor, Division of Air Quality. b. The equipment list and plant diagram shall bear the date when the current list and diagrams were revised. Permit No. 08589R04 Page 3 c. The Permittee shall provide documentation to the Regional Supervisor, Division of Air Quality, for any required performance testing within seven days of a written request. d. Notwithstanding General Condition and Limitation titled 'Equipment Relocation," the Permittee may install new non-primary crushing nonmetallic mineral processing equipment so long as such equipment does not change the primary crushing rated capacity of the facility and the equipment does not utilize any mechanical collection device(s). The Permittee shall provide written notification to the Regional Supervisor, Division of Air Quality, including a revised equipment list and a plant layout or flow diagram, each time non-primary crushing nonmetallic mineral processing equipment is installed at a facility. This notification shall be submitted at least 15 days before the equipment is installed at the facility unless otherwise approved by the Director. Non-primary crushing nonmetallic mineral processing equipment includes all non-primary crushers, screen, conveyors and loadout bins. e. Notwithstanding General Condition and Limitation titled 'Equipment Relocation," the Permittee may relocate existing non-primary crushing nonmetallic mineral processing equipment so long as such equipment does not change the primary crushing rated capacity of the facility. The Permittee shall provide written notification to the Regional Supervisor, Division of Air Quality, including a revised equipment list and a plant layout or flow diagram, each time non-primary crushing nonmetallic mineral processing equipment is relocated at a facility. This notification shall be submitted within 15 days of the relocation made at the facility, unless otherwise approved by the Director. 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, recycled asphalt pavement(RAP), 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, RAP, or crushed stone operations shall be controlled by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources." c. The Permittee of any sand, gravel, RAP, or crushed stone operation shall control process-generated emissions: i. From crushers with wet suppression(excluding RAP crushers); and I From conveyors, screens, and transfer points Permit No. 08589R04 Page 4 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. This primary crusher is a 42-inch x 48-inch jaw crusher rated at 200 tons per hour at a jaw setting of 6 inches, with no grizzly by-pass,per the manufacturer's specifications as submitted. Any change from this crusher definition, other than like-for-like, will require a - permit application to be submitted. The purpose of this stipulation is to characterize the primary crusher and not limit production. 6. 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. 7. VISIBLE EMISSIONS CONTROL REQUIREMENT - As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources, manufactured as of July 1, 1971, shall not be more than 40 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 90 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 nonmetallic mineral processing equipment (wet material processing operations, as defined in 60.671, are not subject to this Subpart) including Conveying Operations (ID No. ES- Convey), Crushing Operations (ID No. ES-Crush) and Screening Operations (ID No. ES- Screen), the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and 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 following: i. The date construction(40 CFR 60.7) or reconstruction(40 CFR 60.15) of an affected source(s) is commenced,postmarked no later than 30 days after such date. This requirement shall not apply in the case of mass-produced facilities which are purchased in completed form; and ii. The actual date of initial start-up of an affected facility,postmarked within 15 days after such date. Permit No. 08589R04 Page 5 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 1 Limit V�sle Crushers j Emissions ons 15% opacity I a Fugitive emissions from conveyor belts, Visible {Fscreenin erations and other affected facilities€ Emissionsg op 10% opacity _ 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): Affected Facility ' Pollutant a Emission Limit Visible 12% opacity Crushers Emissions ................ Fugitive emissions from conveyor belts, Visible o j ! screening operations, and other affected facilities ` Emissions 7/o opacity _ _g p � c. NSPS Monitoring Requirements - As required by 15A NCAC 2D .0524, 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: i. Perform monthly periodic inspections to check that water is flowing to discharge spray nozzles in the wet suppression systems. ii. 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. 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. The logbooks (in written or electronic form) shall be maintained on-site and made available to DAQ personnel upon request. Permit No. 08589R04 Page 6 e. NSPS Performance Testing- As required by 15A NCAC 2D .0524, the following performance tests shall be conducted: Affected Facility Pollutant ' Test Method ...................................... Visible Crushers ` Method 9 Emissions Fugitive emissions from conveyor belts, screening Visible Method g Y g d9 I operations, and other affected facilities : Emissions 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; 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, 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. When determining compliance with the visible emissions limit from fugitive emissions from crushers, conveyor belts, screening operations, and other affected facilities (as described in 60.672(b) or 60.672(e)(1)), the duration of the Method 9 test must be 30 minutes (five 6-minute averages). Compliance with the fugitive visible emissions limits must be based on the average of the five 6-minute averages. Permit No. 08589R04 Page 7 ix. 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,the Permittee shall repeat 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. 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, and there is no increase in the amount of emissions,the new facility is exempt from the provisions of 40 CFR 60.672, 60.674, and 60.675 except as 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 with 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). Permit No. 08589R04 Page 8 "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). 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. 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. 08589R04 Page 9 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 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 = Permit No. 08589R04 Page 10 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 1 sc of April, 2013. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Paul K. Muller, Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 08589R04