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HomeMy WebLinkAboutAQ_F_0000075_20130117_PRMT_Permit DN North Carolina Department of Environment and Natural Resources Division of Air Quality Pat McCrory Sheila C. Holman John E. Skvarla III Governor Director Secretary January 17, 2013 Mr. Van Medlock Environmental Manager Ralph Rogers and Company P.O. Box 25250 Nashville, TN 37202 Subject: Air Permit No. 09935R04 Ralph Rogers and Company - Burnsville Plant Burnsville, Yancey County,North Carolina Permit Class: Synthetic Minor Facility ID# 0000075 Dear Mr. Medlock: In accordance with an Administrative Amendment dated January 17, 2013, we are forwarding herewith Permit No. 09935R04 to Ralph Rogers and Company's Burnsville Plant in Yancey 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. Asheville Regional Office-Division of Air Quality 2090 U.S.Highway 70,Swannanoa,North Carolina 28778 Phone:(828)296-45001 FAX:(828)299-7043 Internet:www.ncair.org An Equal Opportunity 1 Affirmative Action Employer—Made in part by Recycled Paper Mr. Van Medlock January 17, 2013 Page 2 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. 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 January 17, 2013 until August 31, 2013, 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): • A condition regarding Post-consumer Reclaimed Asphalt Shingles (PRAS)has been added to the permit. The condition was erroneously omitted from the previous permit. 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. 09935R04 Issue Date: January 17, 2013 Effective Date: January 17, 2013 Expiration Date: August 31, 2013 Replaces Permit: 09935R03 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, Ralph Rogers and Company - Burnsville Plant 421 OMC Drive Burnsville, Yancey County, North Carolina Permit Class: Synthetic Minor Facility ID# 0000075 (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 one drum-mix asphalt plant(300 tons per hour maximum capacity), consisting of: ....._. ... ES-01 one natural gas/virgin No. CD-1 !one bagfilter NSPS 1 2/recycled No. 2/virgin No. 1(10,374 square feet of filter area) j 4/recycled No. 4 fuel oil-fired drum I mix asphalt plant(105 million Btu per hour maximum heat input rate) ES-02,ES-03 three 150-ton asphalt storage silos and ES-04 i N/A N/A NSPS I FUG1 one silo filling operation and one { NSPS iltruck loadout operation N/A N/A ES-10 j one fines silo CD-2 one bagfilter NSPS (176 square feet of filter area), - CD-1 in series with one bagfilter (10,374 square feet of filter area) Permit No. 09935R04 Page 2 Emission Emission Source Control Control System Source ID Description System ID Description Recycled Asphalt Product(RAP) and Post-consumer Reclaimed Asphalt Shingles (PRAS) processing system consisting of: ES-05 one RAP breaker (250 ton per hour NSPS maximum process rate) N/A N/A ES-06 one RAP loading bin N/A N/A (20-ton capacity) F7 ES-07 !one RAP conveyor(250 ton per NSPS 'hour maximum process rate) N/A N/A ES-08 ;one PRAS loading bin N/A N/A (20-ton capacity) ES-09 ilone PRAS conveyor (250 ton per N/A N/A hour maximum process rate) in accordance with an administrative amendment dated January 17, 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 .0506, 2D .0510, 2D .0516, 2D .0521, 2D .0524 (40 CFR 60, Subpart I, Subpart 000), 2D .0535, 2D .0540, 2D .0611, 2D .1100, 2D .1806, 2Q .0315, 2Q .0317 (Avoidance) 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 2012 calendar year. Permit No. 09935R04 Page 3 3. PARTICULATE CONTROL REQUIREMENT -As required by 15A NCAC 2D .0506 "Particulates from Hot Mix Asphalt Plants," a. Particulate matter emissions resulting from the operation of a hot mix asphalt plant shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0506, a function of the process weight rate and shall be determined by the following equation (calculated to three significant figures), 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=4.9445 * (p) 11.4376 for P <300 tons/hr, or E= 60 lbs/hr for P >=300 tons/hr b. Visible emissions from stacks or vents at a hot mix asphalt plant shall be less than 20 percent opacity when averaged over a six-minute period. c. Fugitive dust emissions shall be controlled as required by 15A NCAC 2D .0540 "Particulates From Fugitive Dust Emission Sources." d. Fugitive emissions for sources at a hot mix asphalt plant not covered elsewhere under this Rule shall not exceed 20 percent opacity averaged over six minutes. 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 ii. From conveyors, screens, and transfer points such that the applicable opacity standards in 15A NCAC 2D .0521 Control of Visible Emissions," or 15A NCAC 2D .0524 "New Source Performance standards" are not exceeded. Permit No. 09935R04 Page 4 5. SULFUR DIOXIDE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the drum mix asphalt plant(ID No. ES-01) shall not exceed 2.3 pounds per million Btu heat input. 6. VISIBLE EMISSIONS CONTROL REQUIREMENT -As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the RAP loading bin(ID No. ES-06),the PRAS loading bin(ID No. ES-08) and the PRAS conveyor (ID No.ES-09), 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. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" - For the drum mix asphalt plant(ID No. ES-1), three storage silos (ID Nos. ES-2, ES-3 and ES-4), the fines silo (ID No. ES-10) and the silo filling and truck loadout operation(ID No. FUG1), 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 I, including Subpart A "General Provisions." a. NSPS Emissions Limitations - As required by 15A NCAC 2D .0524, the Permittee shall not discharge or cause the discharge into the atmosphere from any affected source any gases which: i. Contain particulate matter in excess of 90 mg/dscm (0.04 gr/dscf); or ii. Exhibit 20 percent opacity, or greater. 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 the RAP breaker (ID No. ES-05) and the RAP conveyor(ID No. ES-07), 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 actual date of initial start-up of an affected facility,postmarked within 15 days after such date; b. NSPS Emissions Limitations -As required by 15A NCAC 2D .0524,the following permit limits shall not be exceeded: Permit No. 09935R04 Page 5 i. 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 ' Emission Limit Visible Crushers 12%opacity y Emissions: ............ .......... .......... ...... Fugitive emissions from conveyor belts, Visible 1 7%opacity screening operations, and other affected facilities Emissions L ............- c. NSPS Monitoring Requirements - As required by 15A NCAC 2D .0524, the following monitoring shall be conducted: i. For any affected facility that commenced construction, modification, or reconstruction on or after April 22, 2008 that uses wet suppression to control emissions,the Permittee shall: A. Perform monthly periodic inspections to check that water is flowing to discharge spray nozzles in the wet suppression systems. B. Initiate corrective action within 24 hours and complete corrective action as expediently as practical if the Pen-nittee 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. e. NSPS Performance TestingAs required by 15A NCAC 2D .0524,the following performance tests shall be conducted: ... . ...... ... ................ Test Affected Facility Pollutant Method Crushers VisibleMethod 9 Emissions .................................. ............... Me thod 9 iF Fugitive emissions from conveyor belts, screening Visible operations, and other affected facilitiesEmissions thod .............. ............... Permit No. 09935R04 Page 6 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,the opportunity to have an observer present, the Permittee shall PROVIDE the Regional Office, in WRITING, at least 7 days notice of any required performance test(s)that involve only Method 9. All other tests require a 15 day notice. viii. 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. 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. Permit No. 09935R04 Page 7 £ 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). "Fugitive dust emissions" means particulate matter that does not pass through a process stack or vent and that is generated within plant property boundaries from activities such as: unloading and loading areas,process areas stockpiles, stock pile working,plant parking lots, and plant roads (including access roads and haul roads). 11. FABRIC FILTER REQUIREMENTS including cartridge 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 Permit No. 09935R04 Page 8 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. 12. 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: Affected Source(s) Toxic Air Pollutant Emission Limit; Arsenic & Compounds 1 0.0161b/yr (ASC (7778394)) `Benzene (71-43-2) 11.191b/yr/yr _ _ one drum mix asphalt plant aggregate `Formaldehyde (50-00-0) 0.930 lb/hr dryer(ID No. ES-1) Mercury,vapor 0.0191b/day (Component of HGC) (7439 97-6) Nickel metal - -�� 0.451b/day (Component of NIC) (7440-02-0) three 150-ton asphalt storage silos Benzene (71 43-2) 0.11 lb/yr (ID Nos. ES-2, ES-3, and ES-4) Formaldehyde (50-00-0) [ 0.02521b/hr Benzene 71-43-2 0.0621b/ r one silo filling operation and one truck ; ( ) _Y loadout operation(ID No. FUG1) Formaldehyde (50-00-0) T 0.0011 lb/hr a. Restrictions - To ensure compliance with the above limits, the following restrictions shall apply: i. the production of hot mix asphalt may not exceed 275,000 tons per 12-month period or 300 tons per hour ii. particulate matter emissions shall be controlled by the two bagfilters (ID No. CD-1 and CD-2) iii. the facility equipment shall be constructed and operated according to the parameters set forth in the submitted modeling result approved by DAQ on July 29, 2008 such that: Permit No. 09935R04 Page 9 A. the height of the main dryer stack(ID No. ES-1) shall not be less than 30 feet(9.14 meters)high; B. the main dryer stack (ID No. ES-1) shall not be closer than 519 feet (158 meters) from the nearest property boundary; C. the silo vent (ID No. ES-2) shall not be closer than 594 feet(181 meters)from the nearest property boundary; D. the silo loadout (ID No. ES-3) shall not be closer than 594 feet (181 meters) from the nearest property boundary; and E. only one truck shall be loaded with asphalt at any one time. b. Reporting Requirements - Compliance with this limit shall be established by compliance with the Synthetic Minor limit, recordkeeping, and reporting requirements outlined in Specific Condition and Limitation No. 14. 13. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS - As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions" the Permittee shall not operate the facility without implementing management practices or installing and operating odor control equipment sufficient to prevent odorous emissions from the facility from causing or contributing to objectionable odors beyond the facility's boundary. 14. 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: ollutant Emission Limit (Tons per consecutive 12-month period) S02 J 100 CO 1, 100 a. Operations Restrictions - To ensure emissions do not exceed the limitations above, the following restrictions shall apply: i. The amount of asphalt produced shall be less than 275,000 tons per consecutive 12-month period. ii. The sulfur content of the No. 2 fuel oil, including recycled No. 2 fuel oil shall be limited to 0.5% sulfur by weight. iii. the sulfur content of No. 4 fuel oil, including recycled No. 4 fuel oil, shall be limited to 2.0% sulfur by weight iv. If multiple fuels are used, emissions should be determined using the sum of the individual emissions rates. Permit No. 09935R04 Page 10 b. Fuel Certification Requirement- Fuel supplier certification shall be kept on-site and made available to DAQ personnel upon request. The Permittee shall keep each record on file for a minimum of three years. c. Reporting Requirements - Within 30 days after each calendar year, regardless of the actual emissions, the Permittee shall submit the following to the Regional Supervisor, DAQ,in writing: i. the monthly amount of asphalt produced for each fuel type, and the total annual amount of asphalt produced for each fuel type, for the previous 12- month period; and ii. a copy of the fuel certification for the shipment of each fuel oil type with the highest sulfur content by weight delivered during the 12-month period. The fuel supplier certification shall include the following information: A. the name of the oil supplier; and B. a certified statement signed by the owner or operator of the facility that the records of fuel supplier certification submitted represent all of the fuel combusted during the reporting period. i 15. LIMITATION TO AVOID 15A NCAC 2D .0530 'PREVENTION OF SIGNIFICANT DETERIORATION" - In accordance with 15A NCAC 2Q .0317, to comply with this permit and avoid the applicability of 15A NCAC 2D .0530 "Prevention of Significant Deterioration," as requested by the Permittee, emissions shall be limited as follows: _ ................ ..... Emission Limit Affected Source(s) s Pollutanta Tons Per Consecutive 12-month Period) one drum mix asphalt plants (ID No. ES-1) SO2 250 Compliance with this limit shall be established by compliance with the Synthetic Minor limit,recordkeeping, and reporting requirements outlined in Specific Condition and Limitation No. 14, above. 16. RECYCLED ASPHALT SHINGLE REQUIREMENTS - In accordance with Rule 2Q .0317, the Permittee is avoiding the applicability of Rule 2Q .0700 and 2D .1100 for asbestos, and 40 CFR 61, Subpart M, National Emission Standard for Asbestos by using post-consumer reclaimed asphalt roofing shingles (also known as PRAS and herein denoted as recycled shingles) which are equivalent to their virgin or unadulterated counterparts. The Permittee is allowed to use the recycled shingles and associated asphalt roofing materials provided the following conditions are met: Specifications - The recycled shingles shall be considered equivalent to unadulterated asphalt and aggregate for use in manufacturing of asphalt concrete by meeting the following criteria: Permit No. 09935R04 Page 11 The recycled shingles and roofing materials are certified to be free of asbestos containing material (ACM). This certification shall be provided by demonstration that the materials sampled are representative of the recycled asphalt roofing materials and are certified to be free of ACM as measured by the method specified in appendix E, 40 CFR 763, Section 1, polarized light microscopy (PLM). Certification shall be provided by NC-accredited Asbestos Inspectors or Roofing Supervisors to sample the PRAS to meet the above criteria. Accreditation shall be obtained through the Division of Public Health's Health Hazards Control Unit. a. The Permittee is responsible for ensuring that the recycled shingles and roofing materials, as used at the site, meet the approved criteria for unadulterated materials including meeting minimum sampling criteria as specified by best practices. These practices shall include visual inspection of each load for suspect ACM and a sampling of at least one sample event per 100 tons of recycled shingles received for processing. i. Each load or batch of recycled asphalt roofing materials purchased from or provided by an outside vendor shall include a certification that the material does not contain ACM and that it was tested in accordance with the best practices specified above, or ii. If certification of the incoming recycled shingle material is not provided at delivery by an outside vendor, the Permittee shall arrange for testing and certification of the material as not being ACM, meeting the specifications outlined above,prior to use in the process. The Permittee shall arrange for the results of such sampling and testing to be provided in a manner and form consistent with meeting the recordkeeping requirements cited below. b. The Permittee is held responsible for any discrepancies discovered by DAQ as a result of any sampling and analysis of the recycled shingles and asphalt roofing materials. c. Recordkeeping Requirements - The Permittee shall maintain certifications that the materials received and used are not ACM. These certifications shall be maintained at the facility for a minimum of three years, and shall be made available to representatives of the DAQ upon request. In addition, accurate records of the following shall be maintained: i. The actual amount of recycled shingles delivered to and used at the facility in the production of asphalt concrete pavement. ii. Each load or batch of recycled shingles shall include the following: A. A delivery manifest document clearly showing the shipment content and amount, its place and date of loading, and place and date of = destination. B. A batch specific analytical report that contains an analysis for all - constituents/properties listed above in the specification. Analytical Permit No. 09935R04 Page 12 results of the samples representative of the recycled shingles/roofing materials shipment from the vendor shall be no more than one year old when received. C. Batch signature information consisting of the following: a batch number, batch weight or volume of recycled shingles/roofing materials delivered. D. A certification statement indicating that the recycled shingles were sampled in accordance with best practices and tested according to appendix E, 40 CFR 763, Section 1 and do not contain ACM or are otherwise asbestos-free as determined by PLM prior to grinding. d. The Permittee shall be obligated to comply with any additional regulations or obtain any additional permits associated with the receipt and/or storage of the recycled asphalt roofing materials. This permit condition to use these materials in the asphalt concrete manufacturing process creates no waiver from other applicable laws and regulations. e. The DAQ reserves the right to require additional testing and/or monitoring of the recycled shingles/roofing materials in accordance with Rule 2Q. 0317. 17. VENDOR SUPPLIED RECYCLED No(s). 2 and 4 FUEL OIL REQUIREMENTS - In accordance with Rule 2Q .0317,the Permittee is avoiding the applicability of Rule 2Q .0700 by using recycled fuels which are equivalent to their virgin counterparts. The Permittee is allowed to use the recycled fuel oil(s) supplied by a DAQ-approved vendor as follows: a. Specifications - The recycled fuel oil(s) shall be equivalent to unadulterated fossil fuel by meeting the following criteria: ......................... .._................__........................._................_......... ..........__.._.......-.....__....................... Constituent/Property, Level Arsenic 1.0 ppm maximum Cadmium 2.0 ppm maximum Chromium 5.0 ppm maximum ............. .... Lead 100 ppm maximum Total Halogens 1000 ppm maximum Flash Point No. 2 100°F minimum No. 4 130°F minimum Sulfur.. .. ..... . No. 2 10.5%maximum(by weight) No. 4 2.0%maximum(by weight) Ash 11.0%maximum b. The Permittee is responsible for ensuring that the recycled fuel oil(s), as received at the site,meet(s)the approved criteria for unadulterated fuel. The Permittee is held Permit No. 09935R04 Page 13 responsible for any discrepancies discovered by DAQ as a result of any sampling and analysis of the fuel oil(s). c. Recordkeeping Requirements - The Permittee shall maintain at the facility for a minimum of three years, and shall make available to representatives of the DAQ upon request, accurate records of the following: i. The actual amount of recycled fuel oil(s) delivered to, and combusted at the facility on an annual basis. ii. Each load of recycled fuel oil received shall include the following: A. A delivery manifest document clearly showing the shipment content and amount, its place and date of loading, and place and date of destination. B. A batch specific analytical report that contains an analysis for all constituents/properties listed above. Analytical results of the samples representative of the recycled oil shipment from the vendor shall be no more than one year old when received. C. Batch signature information consisting of the following: a batch number,tank identification with batch volume of recycled oil, date and time the batch completed treatment, and volume(s) delivered. D. A certification indicating that the recycled fuel oil does not contain detectable PCBs (<2ppm). d. Reporting Requirements - Within 30 days after each calendar year, regardless of the amount received or combusted,the Permittee shall submit in writing to the Regional Supervisor, DAQ,the following: i. A summary of the results of the analytical testing for the previous 12 months. ii. The total gallons of recycled fuel oil(s) from each approved vendor combusted at the facility for the previous 12 months. e. The DAQ reserves the right to require additional testing and/or monitoring of the recycled fuel oil(s) on an annual basis or without notice. 18. 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. 09935R04 Page 14 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: ........ ._.......... _. j Acute Chronic Acute i Carcinogens ` Systemic Pollutant (lb/yr) Toxicants Irritants I ( Toxicants lb/day) ! (lb/hr) ..... .._ (lb/hr).__. 3 ....... ._._.._ j Acetaldehyde j 6.8 I(75-07-0) j Acrolein 0.02 Benzo(a)pyrene (Component of 83329/POMTV & 56553/7PAH) 2.2 ?(50-32-8) E Beryllium metal (unreacted) 3 ` { 4 I(Component of BEC) 0.28 (7440-41-7) CFC-11 (Trichlorofluoromethane) r 140 (75-69-4) Cadmium Metal (elemental i unreacted, Component of CDC) 0.37 �( ............7440 43 9) i ?. Carbon Disuffide ' 3.9 (75-15-0 Chromium(VI) Soluble Chromate F Compounds (Component of CRC) 3 0.013 If(So1CR6) Hexachlorodibenzo-p-dioxin 1,2,3,6,7,8 (Component of CLDC) 0.0051 (57653._85-7).- n-Hexane 23 (110-54-3) I i ..... Manganese& Compounds ; (MNC) 0.63 Permit No. 09935R04 Page 15 Chronic Acute Acute Pollutant Carcinogens Toxicants Systemic Irritants (lb/yr) (lb/day) Toxicants (lb/hr) f. (lb/hr) _ .. r Chloroform 250 64 6) .................._...... _.......... _. ..... _ Methyl Ethyl Ketone --—--j 78 22.4 iF 78 93-3 Methylene Chloride 1600 ( 0.39 (75-09-2) ..... .. ............... .___. ...... ..._.._ .... ...........f.. ..-.. -..........-.. i A Perchloroethylene 1 �[ (Tetrachloroethylene) (127-18 4) 13000 E ......... .... ................_........._.-. Phenol 0.24 f(108-95-2) !'F Il ! Styrene IF, f(100-42-5) i Tetrachlorodibenzo-p-dioxin, i 3 2,3,7,8- (Component of CLDC & ; 0.0002 83329/POMTV) (1746-01-6) j 14 Toluene 98 .4 j 11(108-88-3) Trichloroethylene i E 4000 3 Xylene i 57 16.4 (1330-20-7) d. To ensure compliance with the above limits,the following restrictions shall apply: i. production of hot mix asphalt may not exceed 275,000 tons per 12-month period or 300 tons per hour; ii. particulate matter emissions shall be controlled by the two bagfilters bagfilters (ID Nos. CD-1 and CD-2); and iii. Compliance with this limit shall be established by compliance with the Synthetic Minor limit,recordkeeping, and reporting requirements outlined in Specific Condition and Limitation No. 14 above. Permit No. 09935R04 Page 16 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. 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. Permit No. 09935R04 Page 17 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 40 CFR Part 68 "Accidental Release Prevention Requirements: Risk Management Programs Under the Clean Air Act, Section 112(r)," if the Permittee is required to develop and register a risk management plan pursuant to Section 112(r) of the Federal Clean Air Act, then the Permittee is required to register this plan in accordance with 40 CFR Part 68. 16. PREVENTION OF ACCIDENTAL RELEASES - GENERAL DUTY - Pursuant to Title I Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants - Prevention of Accidental Releases -Purpose and General Duty," although a risk management plan may not Permit No. 09935R04 Page 18 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 171h of January, 2013. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION 1w, 0 Paul K. Muller,VIF, Regional Air Quality Supervisor By Authority of the Environmental Management Commission I Air Permit No. 09935R04 ATTACHMENT to Permit No. 09935R04, January 17, 2013 Insignificant/Exempt Activities Title V ' Source 3 Exemption Source of Source of Regulation TAPs? ? pollutants? 2Q 0102 :IES ES1 - fuel oil storage tanks Yes Yes IES-2 - asphalt cement storage tank(s) E . ... ._ . . ....., ._ _ _._. ..... 2Q .0102 (30000 gallon capacity) .. Y _. Yes(c)(1)(L)(xii e � IES-3 - one natural gas/propane fired asphalt heater 1.6 million Btu per hour maximum heat 2Q .0102 yes Yes ( input rate) IES-4 -one aggregate handling system(consisting' 2Q .0102 No Y of cold feed bins and assorted conveyors) (c)(2)(E)(i) E Yes I 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."