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HomeMy WebLinkAboutAQ_F_0800109_20130214_PRMT_Permit (3) ALIT NCDENR North Carolina Department of Environment and Natural Resources Division of Air Quality Pat McCrory Sheila C. Holman John E. Skvarla, III Governor Director Secretary February 14;-2013 Mr. Wayne Black Environmental Director Perdue Agribusiness, LLC Post Office Box 460 Lewiston Woodville,NC 27849 Subject: Air Permit No. 10265ROI Perdue Foods LLC - Lewiston Lewiston, Bertie County,North Carolina Permit Class: Synthetic Minor Facility ID#0800109 Dear Mr. Black: In accordance with your completed application received January 14, 2013,we are forwarding herewith Permit No. 10265ROI to Perdue Foods LLC - Lewiston, Lewiston, Bertie 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. 150B-23,this air permit shall be final and binding. You may request modification of your air permit through informal means pursuant to G.S. 150B-22. This request must be submitted in writing to the Director and must identify the specific Washington Regional Office-Division of Air Quality 943 Washington Square Mail,Washington,North Carolina 27889 Phone:252-946-6481/FAX:252-975-3716 Internet:www.ncair.oro An Equal Opportunity\Affirmative Action Employer-Made in part by Recycled Paper Wayne Black February 14, 2013 Page 2 provisions or issues for which the modification is sought. Please note that the permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Unless exempted by a condition of this permit or the regulations, construction of new air pollution sources or air cleaning devices, or modifications to the sources or air cleaning devices described in this permit must be covered under a permit issued by the Division of Air Quality prior to construction. Failure to do so is a violation of G.S. 143-215.108 and may subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143- 215.114B. This permit shall be effective from February 14, 2013 until September 30, 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. 1. The two boilers are combined in the source table 2. The two boiler descriptions have "capacity" added to the description 3. NESHAP designation is added to generators in the source table 4. Specific Condition 9: The fabric filter condition has added language to include types of filter material 5. General Condition 15 wording has been updated. 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 conceming this matter, please contact me at(252) 948-3834. Sincerely, Robert P. Fisher Regional Air Quality Supervisor RPF Enclosures c: Washington Regional Office K:\Bertie08\00109\08BO0109SMR01.docx NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF AIR QUALITY AIR PERMIT NO. 10265ROI Issue Date: February 14, 2013 Effective Date: February 14, 2013 Expiration Date: September 30, 2017 Replaces Permit: 10265R00 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 2 1 B of Chapter 143, General Statutes of North Carolina(NCGS) as amended, and other applicable Laws, Rules and Regulations, Perdue Foods LLC - Lewiston 3569 Governors Road Lewiston,Bertie County,North Carolina Permit Class: Synthetic Minor Facility ID# 0800109 (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 System Source ID I Description DescriptionID I , ...._.....:.---____._.__........ __ _ ............. ES-1 !Three(3)live poultry receiving and handling systems CD-1 bagfilters(2,800 square feet of i ES-2 , CD-2 filter area,each) ES-3 CD-3 ..... ES4 jTwo(2)natural gas/No.6 fuel oil-fired boilers........... (20.3 N/A N/A ES-5 jmillion Btu per hour maximum heat input capacity) _F ES-22A Two(2)diesel-fired emergency/peak shaving generators ES-22B (2628 horsepower engine output) N/A N/A (NESHAP) !.. in accordance with the completed application 0800109.13A received January 14, 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. 10265ROI 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 Commiss ion Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0503,2D .0515,2D .0516, 2D .0521, 2D .0535, 2D .0540, 2D .0611, 2D .1111 (40 CFR 63, Subparts JJJJJJ and ZZZZ),2D .1806, 2Q .0315, and 2Q .0317 (Avoidance) . 2. PERMIT RENEWAL AND EMISSION INVENTORY REQUIREMENT-The Permittee, at least 90 days prior to the expiration date of this permit, shall request permit renewal by letter in accordance with 15A NCAC 2Q .0304(d) and(f). Pursuant to 15A NCAC 2Q .0203(i), no permit application fee is required for renewal of an existing air permit(without a modification request). The renewal request(with AA application form) should be submitted to the Regional Supervisor, DAQ. Also, at least 90 days prior to the expiration date of this permit,the Permittee shall submit the air pollution emission inventory report (with Certification Sheet) in accordance with 15A NCAC 2D .0202,pursuant to N.C. General Statute 143 215.65. The report shall be submitted to the Regional Supervisor, DAQ and shall document air pollutants emitted for the.2016 calendar year. 3. PARTICULATE CONTROL REQUIREMENT- As required by 15A NCAC 2D .0503 "Particulates from Fuel Burning Indirect Heat Exchangers," particulate matter emissions from the fuel burning indirect heat exchangers shall not exceed the allowable emission rates listed below: Emission Limit Source (Ibs/million Btu) _ _ Natural gas/No. 6 fuel oil-fired boilers ID Nos. ES-4 and ES-5 J (20.3 million Btu per hour maximum heat input capacity) 0.42 (each) 4. PARTICULATE CONTROL REQUIREMENT- As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the poultry receiving and handling systems shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0515, a function of the process weight rate and shall be determined by the following equation(s), where P is the process throughput rate in tons per hour(tons/hr) and E is the allowable emission rate in pounds per hour(lbs/hr). E=4.10 * (P)0.61 for P <=30 tons/hr, or E= 55 * (P)0-"-40 for P>30 tons/hr 5. SULFUR DIOXIDE CONTROL REQUIREMENT-As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the boilers and generators shall not exceed 2.3 pounds per million Btu heat input. Permit No. 10265R0I Page 3 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. 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, ill. 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 P g Environmental Management Commission Regulations. 8. 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). 9. FABRIC FILTER REQUIREMENTS including_cartridge filters, baghouses, and other dry filter particulate collection devices - As required by 15A NCAC 2D .0611, particulate matter I Permit No. 10265R0l Page 4 emissions from the poultry receiving and handling systems shall be controlled by bagfilters (ID Nos. CD-1, CD-2 and CD-3). 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. 10. GENERALLY AVAILABLE CONTROL TECHNOLOGY- For the natural gas/No. 6 fuel oil-fired boilers (ID Nos. ES-4 and ES-5) (20.3 million Btu per hour maximum heat input capacity), the Permittee shall comply with all applicable provisions, including the notification, testing, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .1111, as promulgated in 40 CFR 63, Subpart JJJJJJ, " National Emission Standards for Hazardous Air Pollutants for Area Sources: Industrial, Commercial, and Institutional Boilers", including Subpart A "General Provisions." a. Compliance Dates (40 CFR 63.11196)-The owner or operator of an existing source subject to a work practice or management practice standard of a tune-up was required to comply with this final rule no later than March 21,2012. The owner or operator of an existing source subject to an energy assessment requirement is required to comply with this final rule no later than March 21, 2014. b. Compliance Requirements-As required by 15A NCAC 213 .1111, the Permittee shall comply with the following requirements: i. General Duty Clause(40 CFR 63.11205(a)) - At all times the Permittee shall operate and maintain any affected source, including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control practices for minimizing emissions. ii. Boiler Tune-up (40 CFR 63.11223) An initial boiler tune-up was required by March 21, 2012. A biennial tune-up is also required and shall be conducted no more than 25 months after the previous tune-up. If the unit is not operating on the required date for a tune-up,the tune-up must be conducted within one week of startup. The tune-up shall include the following: A. As applicable, inspect the burner, and clean or replace any components of the burner as necessary (the Permittee may delay the Permit No. 10265ROI Page 5 burner inspection until the next scheduled unit shutdown,but must inspect each burner at least once every 36 months). B. Inspect the flame pattern, as applicable, and adjust the burner as necessary to optimize the flame pattern. The adjustment should be consistent with the manufacturer's specifications, if available. C. Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly. D. Optimize total emissions of carbon monoxide. This optimization should be consistent with the manufacturer's specifications, if available. E. Measure the concentrations in the effluent stream of carbon monoxide in parts per million,by volume, and oxygen in volume percent,before and after the adjustments are made (measurements may be either on a dry or wet basis, as long as it is the same basis before and after the adjustments are made). F. Maintain onsite a biennial report(see item c. below) containing: I. The concentrations of CO in the effluent stream in parts per million,by volume, and oxygen in volume percent, measured before and after the tune-up of the boiler. II. A description of any corrective actions taken as a part of the tune-up of the boiler. III. The type and amount of fuel used over the 12 months prior to the biennial tune-up of the boiler. iii. Energy Assessment(40 CFR 63.11214(c)) -A one-time initial energy assessment is required by March 21, 2014. The energy assessment must be performed by a qualified energy assessor. An energy assessment completed on or after January 1,2008,that meets or is amended to meet the energy assessment requirements in this section satisfies the energy assessment requirement. The energy assessment must include: A. A visual inspection of the boiler system. B. An evaluation of operating characteristics of the facility, specifications of energy using systems, operating and maintenance procedures, and unusual operating constraints. C. Inventory of major systems consuming energy from affected boilers. D. A review of available architectural and engineering plans, facility operation and maintenance procedures and logs, and fuel usage. Permit No. 10265ROl Page 6 E. A list of major energy conservation measures. F. A comprehensive report detailing the ways to improve efficiency,the cost of specific improvements, benefits, and the time frame for recouping those investments. c. Notification and Reporting Requirements -In addition to the notification and reporting requirements of the Environmental Protection Agency(EPA),the Permittee is required to NOTIFY the Regional Supervisor, DAQ, in WRITING,of the following: i. Initial Notification(per 40 CFR 63.9(b) and 40 CFR 63.11225(a)(2))was required by September 17, 2011. ii. Notification of Compliance Status (40 CFR 63.11225(a)(4)) was required by July 19, 2012. If the compliance status notification for the energy assessment is not included in the July 19,-2012 notification, a separate notification for this requirement is required by July 19, 2014. iii. Biennial Compliance Report must be prepared by March 1 of every other year starting March 1,2015 and submitted upon request. If the source experiences any deviations from the applicable requirements, then a report must be submitted by March 15. The report must meet the requirements of 40 CFR 63.11225(b)(1-4). d. Recordkeeping Requirements - In addition to any other recordkeeping requirements of the EPA, the Permittee shall maintain the following records as defined under 40 CFR 63.11225(c): i. Copies of all required notifications. ii. Maintain records to document conformance with the work practices, emission reduction measures, and management practices: A. Tune-up records -records must identify each boiler,the date of tune- up,the procedures followed for tune-up, and the manufacturer's specifications to which the boiler was tuned. B. A copy the Energy Assessment required by 40 CFR 63.11214(c). C. Records documenting the fuel type(s) used monthly by each boiler, including, but not limited to, a description of the fuel, including whether the fuel has received a nonwaste determination by the Permittee or EPA, and the total fuel usage amount with units of measure. If the Permittee combusts nonhazardous secondary materials that have been determined not to be solid waste pursuant to 40 CFR 241.3(b)(1),the Permittee must keep a record which documents how the secondary material meets each of the legitimacy criteria. The Permit No. 10265ROI Page 7 records may be annual,monthly,or periodic, depending on fuel delivery frequencies. iii. Malfunction Records-Records of the occurrence and duration of each malfunction of the boiler, or of the associated air pollution control and monitoring equipment. Records of actions taken during periods of malfunction to minimize emissions in accordance with the general duty to minimize emissions in 40 CFR 63.11205(a), including corrective actions to restore the malfunctioning boiler, air pollution control, or monitoring equipment to its normal or usual manner of operation. iv. Record Retention- You must keep each record for 5 years following the date of each recorded action. 11. 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. 12. LIMITATION TO AVOID 15A NCAC 20 .0501 -Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of Section and Requirement for a Permit," as requested by the Permittee, facility-wide emissions shall be less than the following: Pollutant' Emission Limit i {Tons per consecutive 12-_month period) S02 100 NOx �� 100 a. Recordkeeping Requirements i. The Permittee shall record monthly: I A. the amounts of No. 6 fuel oil, diesel fuel, and natural gas combusted for the month, B. the rolling 12-month totals of fuel combusted, and C. the rolling 12-month facility-wide S02 and NOx emissions. ii. The sulfur content in fuel oil shall not exceed 2.1 percent sulfur by weight. Fuel supplier sulfur certifications shall be kept on-site and made available to DAQ personnel upon request. iii. The Permittee shall keep each record on file for a minimum of three years. b. Reporting Requirements - Within 30 days after each calendar year, regardless of the actual emissions,the Permittee shall submit the following: Permit No. 10265R0I Page 8 i. for each calendar month, the rolling 12-month totals of each fuel combusted, and ii. for each calendar month,the rolling 12-month facility-wide SO2 and NOx emissions. 13. 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, facility-wide SO2 and NOx emissions shall be less than 250 tons per consecutive 12-month period. a. Recordkeeping and Reporting Requirements -The Permittee shall comply with the recordkeeping and reporting requirements listed in Specific Conditions 12.a. and 12.b. of this Permit. 14. 15A NCAC 2D .I 111 "MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY", for the generators(ID Nos. ES-22A and ES-22B),which are considered existing,non-emergency, non-black start, compression ignition(CI) reciprocating internal combustion engines (RICE) greater than 500 brake horsepower,the Permittee shall comply with all applicable provisions, including the notification, testing, recordkeeping, reporting and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .1111, "Maximum Achievable Control Technology" as promulgated in 40 CFR 63, Subpart ZZZZ, "National Emissions Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines", including Subpart A "General Provisions." a. Compliance Date-Pursuant to 40 CFR 63.6595(a)(1), the source(s)must be in compliance with 40 CFR 63, Subpart ZZZZ by May 3, 2013. b. Emission Limits - Pursuant to 40 CFR 63.6603(a); the affected source must comply with the following emission limits, except during periods of startup: i. The concentration of carbon monoxide (CO) in the exhaust cannot exceed 23 ppmvd at 15 percent oxygen; Or ii. Reduce CO emissions by 70 percent or more. c. Testing -Pursuant to 40 CFR 63.6612(a), 63.6615, 63.6620, 63.6630, 63.6640, and 63.6645 the Permittee must: i. Conduct an emission test per 40 CFR 63.6620 and Table 4 of 40 CFR 63 Subpart ZZZZ within 180 days after the compliance date. ii. Per 40 CFR 63.6630(b), during the initial performance test, the Permittee must establish each operating limitation identified in Table 2b of 40 CFR 63 Subpart ZZZZ (summarized below): Permit No. 10265R01 Page 9 For each CI RICE complying with The Permittee must establish and record during initial the requirement to . . . performance testing the following operating limitations . . ._.--.-..___-----......._..........._.-._....._.................._ !Reduce CO emissions and using an The pressure drop across the catalyst and the temperature at oxidation catalyst; the catalyst inlet. 30RThe temperature for the catalyst inlet must be greater than or ;equal to 450 °F and less than or equal to 1350 'F. The Limit the concentration of CO in the Vermittee may petition the director of DAQ pursuant to the !RICE exhaust by using an oxidation equirements of 40 CFR 63.8(g) for a different temperature catalyst ange. k Reduce CO emissions and not using an oxidation catalyst; i Or Comply with any operating limitations approved by the Limit the concentration of CO in the DAQ Regional Supervisor. RICE exhaust and not using an oxidation catalyst { k I i t i Per 40 CFR 63.6620(f), if complying with the emission limitation to reduce CO in the exhaust without using an oxidation catalyst the Permittee must petition the DAQ Regional Supervisor for operating limitations to be established during the initial performance test and continuously monitored thereafter, or for approval of no operating limitation. The Permittee must not conduct the initial performance test until after the petition has been approved by the Regional Supervisor. The petition must include the information described in 40 CFR 63.6620(g) or(h). iii. Per 40 CFR 63.6620(i), the engine percent load during a performance test must be determined by documenting the calculations, assumptions, and measurement devices used to measure or estimate the percent load in a specific application. A written report of the average percent load determination must be included in the notification of compliance status. The following information must be included in the written report: the engine model number, the engine manufacturer,the year of purchase, the manufacturer's site-rated brake horsepower, the ambient temperature, pressure, and humidity during the performance test, and all assumptions that were made to estimate or calculate percent load during the performance test must be clearly explained. If measurement devices such as flow meters, kilowatt meters, beta analyzers, stain gauges, etc. are used, the model number of the measurement device, and an estimate of its accuracy in percentage of true value must be provided. Permit No. 10265R0I Page 10 iv. The Permittee shall perform such testing in accordance with 40 CFR 63.6645 and 15A NCAC 2D .2600 (see GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS in Section B. of this Air Permit). The procedures are outlined below: A. The Permittee must notify DAQ in writing of their intent to conduct the performance test at least 60 days before the scheduled performance test in accordance with 40 CFR 63.6645(g)and 40 CFR 63.7(b)(1). B. The Permittee shall submit a completed Protocol Submittal Form to the DAQ Regional Supervisor at least 45 days prior to the scheduled test date. A copy of the Protocol Submittal Form may be obtained from the Regional Supervisor. C. The Permittee shall notify the Regional Supervisor of the specific test dates at least 15 days prior to testing in order to afford the DAQ the opportunity to have an observer on-site during the sampling program. If a specific test date cannot be identified due to the operational requirements of the RICE,then the Permittee shall notify the Regional Supervisor of the approximate test date. If a specific test date is identified within the 15 day notification timeframe identified above, then the Permittee must notify the Regional Supervisor as soon as the test date is determined. D. The Permittee shall submit two copies of the test report to the DAQ. The test report shall be submitted to the Regional Supervisor-DAQ not later than 60 days after completion of testing. The Permittee may request an extension to submit the final test report. The DAQ Regional Supervisor will approve an extension request if it is determined that the extension request is a result of actions beyond the control of the Permittee. The test report shall contain at a minimum the following information: I. a description of the training and air testing experience of the person directing the test; II. a certification of the test results by the sampling team leader and facility representative; III. a summary of emissions results and text detailing the objectives of the testing program,the applicable state and federal regulations, and conclusions about the testing and compliance status of the emission source(s); IV. a detailed description of the tested emission source(s), process flow diagrams, engineering drawings, and sampling location schematics should be included as necessary; Permit No. 10265R01 Page 11 V. all field, analytical, and calibration data necessary to verify that the testing was performed as specified in the applicable test methods; VI. example calculations for at least one test run using equations in the applicable test methods and all test results including intermediate parameter calculations. E. The testing requirement(s) shall be considered satisfied only upon written approval of the test results by the DAQ. F. The DAQ will review emission test results with respect exclusively to the specified testing objectives as proposed by the Permittee and approved by the DAQ. d. Initial Compliance Demonstration -Pursuant to 40 CFR 63.6630(a), initial compliance for each existing,non-emergency,non-black start, compression ignition reciprocating internal combustion engine greater than 500 brake horsepower is provided in Table 5 of 40 CFR 63 Subpart ZZZZ and shall be demonstrated as follows: For each CI RICE complying , _ I � The Permittee will demonstrate initial compliance if. with the requirement to . . . Reduce CO emissions and using i. The average reduction of emissions of CO determined from the an oxidation catalyst, and using initial performance test achieves the required CO percent a continuous parameter eduction; and monitoring system (CPMS) H. The Permittee has installed a CPMS to continuously monitor atalyst inlet temperature according to the requirements in §63.6625(b); and 'ii. The Permittee has recorded the catalyst pressure drop and ' atalyst inlet temperature during the initial performance test. _ Limit the concentration of CO, i. The average CO concentration determined from the initial _I using an oxidation catalyst, and performance test is less than or equal to the CO emission using a CPMS imitation; and 'i. The Permittee has installed a CPMS to continuously monitor atalyst inlet temperature according to the requirements in §63.6625(b); and 'ii. The Permittee has recorded the catalyst pressure drop and atalyst inlet temperature during the initial performance test. Reduce CO emissions and not The average reduction of emissions of CO determined from the using an oxidation catalyst initial performance test achieves the required CO percent eduction; and I 'i. The Permittee has installed a CPMS to continuous) monitor ......................-_. _...._...:_ . ._...a: __._ .w.�::_._ _._.-.__ _._m.__ _ _.._.__:_ �.__M:.._._...... _ .._.._._y.. ._....­_..............._...__.1 Permit No. 10265R01 Page 12 For each CI RICE complying with the requirement to . . . The Permittee will demonstrate initial compliance if. .. operating parameters approved by the Administrator(if any) according to the requirements in §63.6625(b); and 'ii. The Permittee has recorded the approved operating parameters _ if any)during the initial performance test. Limit the concentration of CO i. The average CO concentration determined from the initial and not using an oxidation performance test is less than or equal to the CO emission catalyst imitation; and E 'i. The Permittee has installed a CPMS to continuously monitor operating parameters approved by the Administrator(if any) according to the requirements in §63.6625(b); and I E 'ii. The Permittee has recorded the approved operating parameters if any)during the initial performance test. Reduce CO emissions and using The Permittee has installed a CEMS to continuously monitor a CEMS 0 and either 02 or CO2 at both the inlet and outlet of the pxidation catalyst according to the requirements in §63.6625(a); and 'i. The Permittee has conducted a performance evaluation of the EMS using PS 3 and 4A of 40 CFR part 60, appendix B; and 1 'ii. The average reduction of CO calculated using §63.6620 equals r exceeds the required percent reduction. The initial test comprises the first 4-hour period after successful validation of the ECEMS. Compliance is based on the average percent reduction t chieved during the 4-hour period. Limit the concentration of CO-� . The Permittee has installed a CEMS to continuously monitor and using a CEMS !CO and either 02 or CO2 at the outlet of the oxidation catalyst according to the requirements in §63.6625(a); and i. The Permittee has conducted a performance evaluation of the EMS using PS 3 and 4A of 40 CFR part 60, appendix B; and 'ii. The average concentration of CO calculated using §63.6620 is # less than or equal to the CO emission limitation. The initial test ! omprises the first 4-hour period after successful validation of the EMS. Compliance is based on the average concentration measured during the 4-hour period. _$ e. Operating Requirements - Pursuant to 40 CFR 63.6603(a), 63.6604, and 63.6625(b), (g), and(h),the Permittee must: Permit No. 10265R01 Page 13 i. Minimize the engine's time spent at idle during startup and minimize the engine's startup time to a period needed for appropriate and safe loading of the engine,not to exceed 30 minutes, after which time the non-startup emission limitations apply. ii. If the engine is not equipped with a closed crankcase ventilation system the Permittee must: A. Install a closed crankcase ventilation system that prevents crankcase emissions from being emitted. OR B. Install an open crankcase filtration emission control system that reduces emissions from the crankcase by filtering the exhaust stream to remove oil mist,particulates, and metals. iii. Follow the manufacturer's maintenance requirements for operating and maintaining the open or closed crankcase ventilations system and replacing crankcase filters. iv. If the engine displacement is less than 30 liters per cylinder then the Permittee must use diesel fuel that meets the requirements in 40 CFR 80.510(b) for nonroad diesel fuel. .. :Sulfur content 15 ppm maximum. jetane index A minimum cetane index of 40; OR OR ;Aromatic content 1A maximum aromatic content of 35 volume percent. i f. Monitoring Requirements - i. Per 40 CFR 63.6603(a),the Permittee must meet each operating limitation as follows: For each CI RICE The Permittee must meet the following operatingv complying with the requirement to . . . _ limitation . Reduce CO emissions and �oes maintain the catalyst so that the pressure drop across the catalyst using an oxidation catalyst; not change by more than 2 inches of water at 100 percent load Permit No. 10265ROI Page 14 For each CI RICE complying with The Permittee must meet the following operating the requirement to . . . limitation . . . _ plus or minus 10 percent from the pressure drop across the catalyst OR ithat was measured during the initial performance test; and Limit the concentration of I b. maintain the temperature of the RICE exhaust so that the catalyst CO in the RICE exhaust and imlet temperature is greater than or equal to 450 °F and less than or using an oxidation catalyst qual to 1350'F. The Permittee may petition the director of DAQ pursuant to the requirements of 40 CFR 63.8(g) for a different _ emperature range. Reduce CO emissions and not using an oxidation acatalyst; OR Comply with any operating limitations approved by the Regional Limit the concentration of Supervisor- DAQ. CO in the RICE exhaust and not using an oxidation catalyst ii. If the Permittee is required to install a continuous parameter monitoring system(CPMS)as specified in the table in Section d. "Initial Compliance Demonstration" above,the Permittee must install, operate, and maintain each CPMS according to the following requirements: A. The Permittee must prepare a site-specific monitoring plan that addresses the monitoring system design, data collection, and the quality assurance and quality control elements outlined below and in §63.8(d). As specified in §63.8(f)(4),the Permittee may request approval of monitoring system quality assurance and quality control procedures alternative to those specified below in the site-specific monitoring plan. I. The performance criteria and design specifications for the monitoring system equipment, including the sample interface, detector signal analyzer, and data acquisition and calculations; II. Sampling interface (e.g., thermocouple) location such that the monitoring system will provide representative measurements; III. Equipment performance evaluations, system accuracy audits, or other audit procedures; Permit No. 10265R01 Page 15 IV. Ongoing operation and maintenance procedures in accordance with provisions in 40 CFR 63.8(c)(1) and(c)(3); and V. Ongoing reporting and recordkeeping procedures in accordance with provisions in 40 CFR 63.10(c), (e)(1), and (e)(2)(i)• B. The Permittee must install, operate, and maintain each CPMS in continuous operation according to the procedures in the site-specific monitoring plan. C. The CPMS must collect data at least once every 15 minutes. D. A CPMS for measuring temperature range,the temperature sensor must have a minimum tolerance of 2.8 degrees Celsius(5 degrees Fahrenheit)or 1 percent of the measurement range,whichever is larger. E. The Permittee must conduct the CPMS equipment performance evaluation, system accuracy audits, or other audit procedures specified in the site-specific monitoring plan at least annually. F. The Permittee must conduct a performance evaluation of each CPMS in accordance with the site-specific monitoring plan. iii. If the Permittee is required to install a continuous emissions monitor(CEMS) as specified in the table in Section d. " Initial Compliance Demonstrations" above,the Permittee must install, operate, and maintain a CEMS to monitor CO and either oxygen or CO2 at both the inlet and the outlet of the control device according to the following requirements: A. Each CEMS must be installed, operated, and maintained according to the applicable performance specifications of 40 CFR part 60, appendix B. B. The Permittee must conduct an initial performance evaluation and an annual relative accuracy test audit (RATA)of each CEMS according to the requirements in 40 CFR 63.8 and according to the applicable performance specifications of 40 CFR part 60, appendix B as well as daily and periodic data quality checks in accordance with 40 CFR part 60, appendix F,procedure 1. C. As specified in 40 CFR 63.8(c)(4)(ii), each CEMS must complete a minimum of one cycle of operation(sampling, analyzing, and data recording) for each successive 15-minute period. The Permittee must have at least two data points, with each representing a different 15- minute period,to have a valid hour of data. Permit No. 10265R01 Page 16 D. The CEMS data must be reduced as specified in 40 CFR 63.8(g)(2) and recorded in parts per million or parts per billion(as appropriate for the applicable limitation) at 15 percent oxygen or the equivalent CO2 concentration. g. Continuous Compliance Demonstration - Pursuant to 40 CFR 63.6640(a), and Table 6 of 40 CFR 63 Subpart ZZZZ, continuous compliance for each existing, non- emergency, non-black start,compression ignition reciprocating internal combustion engine greater than 500 brake horsepower shall be demonstrated as follows: Complying with the The Permittee must demonstrate continuous compliance by. . . requirement to . . . _ Reduce CO emissions, or limiti.Conducting performance tests every 8,760 hours or 3 years, the concentration of CO in the whichever comes first, for CO to demonstrate that the required CO RICE exhaust, and using an percent reduction is achieved or that the emissions remain at or oxidation catalyst ;below the CO concentration limit(') ; and i. Collecting the catalyst inlet temperature data according to §63.6625(b);and Rii. Reducing these data to 4-hour rolling averages; and I iv. Maintaining the 4-hour rolling averages within the operating .imitations for the catalyst inlet temperature; and v. Measuring the pressure drop across the catalyst once per month And demonstrating that the pressure drop across the catalyst is within 6e operating limitation established during the performance test. If the reciprocating internal combustion engine is limited use (ie, perates less than 100 hours per year), then demonstrate compliance y conducting the same performance testing as item "i"above every �d,760 hours or S^years, whichever comes first. A limited use engine must also comply with items "ii"through "v"above. Reduce CO emissions or limit Collecting the monitoring data according to §63.6625(a),reducing ;the concentration of CO in the 11the measurements to 1-hour averages, calculating the percent RICE exhaust, and using a reduction or concentration of CO emissions according to §63.6620; CEMS ;and ii. Demonstrating that the catalyst achieves the required percent reduction of CO emissions over the 4-hour averaging period, or that he emission remain at or below the CO concentration limit; and 'ii. Conducting an annual RATA of the CEMS using PS 3 and 4A of I40 CFR part 60, appendix B, as well as daily and periodic data jquality checks in accordance with 40 CFR part 60, appendix F, procedure 1. Permit No. 10265R01 Page 17 Complying with the ! The Permittee must demonstrate continuous compliance by. . . 1 requirement to . . .__. . .__------ _._ ....... Reduce CO emissions, or limit'i. Conducting performance tests every 8,760 hours or 3 years, the concentration of CO in the ;whichever comes first, for CO to demonstrate that the required CO RICE exhaust, and not using percent reduction is achieved or that the emissions remain at or I n oxidation catalyst ;below the CO concentration limit(2) ; and iii. Collecting the approved operating parameter (if any) data according to §63.6625(b); and iii. Reducing these data to 4-hour rolling averages; and Div. Maintaining the 4-hour rolling averages within the operating ;limitations for the operating parameters established during the ;performance test. a)If the reciprocating internal combustion engine is limited use (ie, operates less than 100 hours per year) then demonstrate compliance by conducting the same performance testing as item i above every 1 8,760 hours or S^years whichever comes first. A limited use engine :F Must also comply with items "ii"through "iv"above. h. Recordkeeping Requirements - Pursuant to 40 CFR 63.6655, the Permittee must keep the following records (in written or electronic format). The records must be maintained for five (5) years. i. A copy of each notification and report submitted to comply with 40 CFR 63 Subpart ZZZZ. ii. Occurrence and duration of each malfunction of operation (i.e., process equipment) or the air pollution control and monitoring equipment. iii. Performance tests and performance evaluations as required in 40 CFR 63.1 0(b)(2)(viii). iv. All required maintenance performed on the air pollution control and monitoring equipment. V. Actions taken during periods of malfunction to minimize emissions in accordance with 40 CFR 63.6605(b), including corrective actions to restore malfunctioning process and air pollution control and monitoring equipment to its normal or usual manner of operation. vi. All records compliance required to show continuous with each emission or q operating limitations listed in Section g. above. {40 CFR 63.6655(d)). Permit No. 10265ROl Page 18 vii. If the Permittee uses CEMs or CPMS the following records shall be maintained: A. Records described in 40 CFR 63.1 0(b)(2)(vi)through(xi). B. Previous(i.e., superseded)versions of the site-specific monitoring plan as required in 40 CFR 63.8(d)(3). C. Requests for alternatives to the relative accuracy test for CEMS or CPMS as required in 40 CFR 63.8(f)(6)(i), if applicable. i. Reportine Requirements - i. Pursuant to 40 CFR 63.6645(h), for each initial performance test required in Section d. above,the Permittee is required to submit a Notification of Compliance Status before the close of business on the 60`h day following the initial performance test according to 40 CFR 63.9(h)(2)(ii). For each subsequent performance test conducted according to the requirements of Section g above, the Permittee must submit the Notification of Compliance Status, including the performance test results,before the close of business on the 60`h day following the completion of the performance test according to 40 CFR 63.10(d)(2). ii. Pursuant to 40 CFR 63.6650,the Permittee shall submit a semi-annual report by January 31 of each calendar year for the preceding six-month period between July and December and by July 31 of each calendar year for the preceding six-month period between January and June. If the RICE is classified as "limited use" (operation limited to less than 100 hours per year) and there is no deviation,then the report shall be submitted annually by January 31 of each calendar year. The report shall contain the following: A. Company name and address. B. Statement by a responsible official, with that official's name,title, and signature, certifying the accuracy of the content of the report. C. Date of report and beginning and ending dates of the reporting period. D. If a malfunction occurred during the reporting period,the compliance report must include the number, duration, and a brief description for each time of malfunction which occurred during the reporting period and which caused or may have caused any applicable emission limitation to be exceeded. The report must also include a description of actions taken during a malfunction of an affected source to minimize emissions in accordance with 63.6650(b), including actions taken to correct a malfunction. E. If there is no deviation(s), then provide a statement indicating that no deviation(s)occurred during the reporting period. Permit No. 10265R01 Page 19 F. If there is a deviation(s) during the reporting period, then provide information in 40 CFR 63.6650(d) as follows: 1. total operating time of the RICE at which the deviation occurred during the reporting period. I1. the number, duration, and cause of deviation (including unknown cause, if applicable), as applicable, and the corrective action taken. iii. If there are no periods during which the Continuous Monitoring System (CMS - including CEMS and CPMS) was out of control, then a statement that there were no periods during which the CMS was out of control during the reporting period. iv. If there were periods during which the CMS (including CEMS and CPMS) was out-of-control: A. The date and time that each malfunction started and stopped. B. The date, time, and duration that each CMS was inoperative, except for zero (low-level) and high-level checks. C. The date, time, and duration that each CMS was out-of-control, including the information in §63.8(c)(8). D. The date and time that each deviation started and stopped, and whether each deviation occurred during a period of malfunction or during another period. E. A summary of the total duration of the deviation during the reporting period, and the total duration as a percent of the total source operating time during that reporting period. F. A breakdown of the total duration of the deviations during the reporting period into those that are due to control equipment problems, process problems, other known causes, and other unknown causes. G. A summary of the total duration of CMS downtime during the reporting period, and the total duration of CMS downtime as a percent of the total operating time of the RICE at which the CMS downtime occurred during that reporting period. H. An identification of each parameter and pollutant (CO or formaldehyde) that was monitored at the RICE. 1. A brief description of the RICE. J. A brief description of the CMS. Permit No. 10265R01 Page 20 I� K. The date of the latest CMS certification or audit. L. A description of any changes in CMS,processes, or controls since the last reporting period. 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 Washington Regional Office 943 Washington Square Mall Washington,NC 27889 252-946-6481 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. S. 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. 10265R01 Page 21 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 j 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," 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. 10265ROI Page 22 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 14'' of February, 2013. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Robert P. Fisher Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 10265ROI ATTACHMENT to Permit No. 10265R01, February 14,2013 Insignificant/Exempt Activities Exemption So ceru o [Sourc_eofTit1eV_1 f Source Regulation TAPs? Pollutants? IES-6 -refrigeration system 2Q .0102 Yes No IES-7-propane-fired singers for poultry I feathers (4.4 million Btu per hour maximum 2Q .0102 No heat input) Yes (c)(2)(E)(i) 1. Because an activity is exempted from being required to have a permit or permit modification does not mean that the activity is exempted from an applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. 2. When applicable, emissions from stationary source activities identified above shall be included in determining compliance with the permit requirements for toxic air pollutants under 15A NCAC 2D .1100 "Control of Toxic Air Pollutants" or 2Q .0711 "Emission Rates Requiring a Permit." i