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HomeMy WebLinkAboutAQ_F_1900015_20181121_PRMT_Permit { x STAGE ROY COOPER Governor MICHAEL S.REGAN ' Secretary MICHAEL.A13RACZINSKAS Director NORTH CAROLINA Environmental Quality November 21,2018 Henry Scheller MDF Plant Manager Arauco Panels USA,LLC 985 Corinth Rd. Moncure,North Carolina 27559 SUBJECT: Air Quality Permit No. 03449T50 Facility 1D: 1900015 Arauco Panels USA, LLC Moncure,North Carolina Chatham County Fee Class: Title V PSD Status: Major Dear Mr. Scheller: In accordance with your completed air quality permit application for a PS❑ modification, in accordance with 15A NCAC 02Q .0501(b)(2), of your Title V permit, received June 13, 2018, we are forwarding herewith Air Quality Permit No. 03449T50 to Arauco Panels USA, LLC, 985 Corinth Road, Moncure,North Carolina authorizing the construction and operation,of the emission source(s)and associated air pollution control device(s)specified herein. Additionally,any emissions activities determined from your Air Quality Permit Application as being insignificant per 15A North Carolina Administrative Code 02Q .0503(8)have been listed for informational purposes as an"ATTACHMENT." Please note the requirements for the annual compliance certification are contained in General Condition P in Section 3.The current owner is responsible for submitting a compliance certification for the entire year regardless of who owned the facility during the year. As the designated responsible official it is your responsibility to review,understand,and abide by all of the terms and conditions of the attached permit. It is also your responsibility to ensure that any person who operates any emission source and associated air pollution control device subject to any term or condition of the attached permit reviews, understands, and abides by the condition(s) of the attached permit that are applicable to that particular emission source_ If any parts,requirements,or 1 imitations contained in this Air Quality 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. This hearing request must be in the form of a written petition, conforming to NCGS (North Carolina General Statutes) 150B-23, and filed with both the Office of Administrative Hearings,6714 Mail Service Center,Raleigh,North Carolina 27699-6714 and the Division of Air Quality, Permitting Section, 1641 Mail Service Center,Raleigh,North Carolina 27699-1641. The form for requesting a formal adjudicatary hearing may be obtained upon request from the Office of Administrative Hearings. Please note that this permit will be stayed in its entirety upon receipt of the request for a hearing. Unless a request for a hearing is made pursuant to NCGS 15013-23,this Air Quality Permit shall be final and binding 30 days after issuance. �,_ North Carolina Department of Environmental Quality I Division of Air Quaffty 1'� 'fit[ 217 West]ones Street f 1641 Mat[service Canter I Raleigh,North Carolina 27699-1641 o.n.w�usiuwm 919,707.8400 Mr. Scheller: November 21,2018 Page 2 You may request modification of your Air Quality Permit through informal means pursuant to NCGS 150B-22. This request must be submitted in writing to the Director and must identify the specific provisions or issues for which the modification is sought. Please note that this Air Quality Permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under NCGS 150E-23. The construction of new air pollution emission source(s} and associated air pollution control device(s), or modifications to the emission source(s) and air pollution control device(s) described in this permit must be covered under an Air Quality Permit issued by the Division of Air Quality prior to construction unless the Permitne has fulfilled the requirements of NCGS 143-215.108A(b)and received written approval from the Director of the Division of Air Quality to commence construction.Failure to receive an Air Quality Permit or written approval prior to commencing construction is a violation of NCGS 143-215.108A and may subject the Permttee to civil or criminal penalties as described in NCGS 143-215.114A and 143-215.11413. Chatham County has triggered increment tracking under PSD for PMrn, SOa and NO,.. This modification may result in an increase of 0.19 tblhr(pound per hour)of PM o,0.02 lblhr of SOa and 0.36 lb/hr of NOx. This Air Quality Permit shall be effective from November 21, 2018 until June 30, 2021, is nontransferable to future owners and operators, and shall be subject to the conditions and limitations as specified therein. Should you have any questions concerning this matter,please contact Joseph Voelker,P.E. at(919)707-8730. Q 4 ncereiy you—, i '9 /JV, �Cc'" William D.Willets,P.E.,Chief,Permitting Section, Division of Air Quality,NCDEQ Enclosure cc: Heather Ceron,EPA Region 4 Connie Home(cover letter only) Raleigh Regional Office Central Files ATTACHMENT to cover letter to Permit No. 03449T50 Insignificant Activities per 15A NCAC 02Q .4543(8) Emission Source ID No. Emission Source Description I-VENTS Roof ventilators I-GAS One 500 gallons above ground+gasoline stora re tank I-TANKl,I-TANIC2,I-TANKS,I- Four above ground propane storage tanks, 1000 gallons each TANK4 I-LPA Log Processing Area I-MDFR-1,I-MDFR-2,I-MDFR-3, I-MDFR-4 Four M DF Resin Storage Tanks MACT DDDD I-DFP-1 Diesel fuel-fired Fire Pump Engine(347 Brake Horsepower output) MALT ZZZZ,NSPS IIII { I-ODG Diesel-fuel Fired Emergency Generator(465 horsepower,3,026 million Btu MACT ZZZZ per hour heat input I I-Irri anon fugitive Spray rah•Irrigation Field Fugitives I-Wastewater onds FuLitives from wastewater lagoons I-5 rar paints MACT DI3i3D Paints and stri ing for Markin wood anels 1. Because an activity is insignificant 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 02D.1100"Control of Toxic Air Pollutants"or 02Q.0711 "Emission Rates Requiring a Permit". 3. For additional information regarding the applicability of MALT see the DAQ page titled"The Regulatory Guide for Insignificant Activities/Permits Exempt Activities".The link to this site is as follows: h_. )://dace.state.ne.us/permits/insit,/ ATTACHMENT to cover letter to Air Quality Permit No. 43449T50 Table of Changes Existing New Condition Condition Changes No. No. Cover Same ■ Updated permit revision numbers,issue and effective dates,etc. Letter permit, Same ■ Revised dates,permit numbers,etc. age 1 For hot oil heaters(ID Nos.ES-18,-19 and-20) Section 1, • Revised heat inputs from 26 to 30.4 MMBtu/hr each) Permitted Same ■ Removed reference to Case by Case MACT equipment List ■ Added reference to MACT DDDDD ■ Added 02(l.0504 footnote 2.1 C ■ Fixed a typographical error.The descriptor for ES-06-B appeared in the Table two different ways.The incorrect descriptor was removed. Table 2.LC Same • Removed reference to all venturi scrubber exhaust points.Now that the biofilter is installed the emission point is that of the biofilter,identified as emission point EP 18. • Removed reference to testing the venturi scrubber's emission points and C.I.c Same added reference to testin=the biofilter emission point EP 18) ■ Removed reference to all venturi scrubber exhaust points.The Permittee C.2.c Same shall reestablish normal VEs within 30 days after the modifications addressed in the application are completed. ■ Revised condition to reflect the project addressed in the current application CA a same ■ Clarified that the project addressed in application no. .17D was not designed to increase the overall desiari capacity of the MDF Mill. ■ Removed reference to VOC C.6 c same • Clarified the duration of time for which records should he kept ■ Revised recordkeeping to a duration of 10 years since the project involves an increase in design capacity of the MDF Mill • Removed reference to VOC C.6 d same ■ Revised projected actual emission estimates for the MDF Mill to include the impact of the current prqiect 2.1 D emission ■ Revised heat inputs from 26 to 30.4 MMBtwbr each) source table same ■ • For 02D.1111 applicable Removed compliance date of May 20,2019 regulation same table Removed reference to one-time energy assessment ■ Removed reference to 02D .1109 D.l.a same ■ Revised emission limitation from 0.35 to 0.25 lb/MMBtu D.4.b same ■ Revised recordkeeping requirements to current DAQ standards.A two-year recordkeeping maintenance requirement pursuant to 60.48c(i)was added. NA DA.c ■ Added actual startup notification requirements for these sources. D.5 NA ■ Removed Case by Case MACT requirements • Removed MACT 5D requirements with a compliance date of May 20,2019 D.6 D.5 for existing sources and replaced them with MACT 5D requirements for new sources with a com liance date u on start-u . 2.2 B.2 (02D.0530)PSD condition Existing New Condition Condition Changes No. No. ■ Revised BACT limits for sources controlled by the biofilter to 50%DRE of Table 2.2 WPP1 VOC B 2 Same ■ Corrected description for the MDF dryers and backup burners ■ Corrected descriptors for ES-06-B and ES-15 • Revised testing conditioo to test for VOCs . Streamline testing requirements to be consistent with MACT 4Dtesting requirements * Testing shall be completed within 180 days after the issuance of permit no. C. same 03449T50 unless an alternate date is approved by the DAQ. This alternate dated may include any testing occurring after September 28,2018.See review for discussion. ■ Added a permit application submittal requirement to revise the permit to incorporate the bioflter bed temperatures based on the required testing. + Removed reference to 1120)requirements. Corrected reference to MALT 5D e. same requirements • Streamlined requirements as possible to reference the MALT 4D condition (Section 2.2 A.1). f same . Added a.specific condition to incorporate the biofilter bed temperatures. This condition was not streamlines as the bed temperatures here may be different than those found in the MALT 4D condition NA 2.2 B.3 • Added a TV a .lication submittal requirement pursuant to 02Q .0504. . Revised General conditions from version 5.2,08/03/2017 to version 5.3, 08/21/2018.Changes consist of: • Condition K was revised to be consistent with the rule 02Q.0513 which was revised effective April 1,2018. It was revised from: ...unless a complete 15A NCAC 02Q.0500 renewal Section 2.4 Same application is submitted at least nine months before the date of permit expiration... to ...unless a complete 15A NCAC 02Q.0500 renewal application is submitted at least six months before the date of permit expiration... State of North Carolina L t, Department of Environmental Quality NDRTH CAROLINA UEQ Deparumn of a at®l Waft Division of Air Quality AIR QUALITY PERMIT Permit No. Replaces Permit No. Effective Date Expiration Date 03449T50 03449T49 November 21,2018 .Tune 30, 2021 Until such time as this permit expires or is modified or revoked,the below named Permittee is permitted to construct and operate the emission source(s)and associated air pollution control device(s)specified herein, in accordance with the terms,conditions, and limitations within this permit. This permit is issued under the provisions of Article 21B of Chapter 143,General Statutes of North Carolina as amended,and Title 15A North Carolina Administrative Codes(15A NCAC), Subchapters 02D and 02Q,and other applicable Laws. Pursuant w Title 15A NCAC,Subchapter 02Q,the Permittee shall not construct operate,or modify any emission source(s)or air pollution control device(s)without having first submitted a complete Air Quality Permit Application to the permitting authority and received an Air Quality Permit,except as provided in this permit. Permittee: Arauco Panels USA, LLC Facility ID: 1900015 Facility Site Location: 985 Corinth Road City, County, State, Zip: Moncure, Chatham County,North Carolina 27559 Mailing Address: 985 Corinth Road City, County, State,Zip: Moncure,Chatham County,North Carolina 27559 Application Number: 1900015.18A Complete Application Date: June 13,2018 Primary SIC Codes: 2493 Division of Air Quality, Raleigh Regional Office Regional Office Address: 3800 Barrett Drive,Suite 101 Raleigh, North Carolina 27509 Permit issued this the 2 1'day of November,2018 fir 44— k7o,-11- \�-'illiarn D. Willets,P.E.. Chief, Permitting Section S Authority of the Environmental Management Commission Y Y g Table of Contents SECTION 1: PERMITTED EMISSION SOURCE(S)AND ASSOCIATED AIR POLLUTION CONTROL DEVICE(S)AND APPURTENANCES SECTION 2: SPECIFIC LIMITATIONS AND CONDITIONS 2.1 - Emission Sources Specific Limitations and Conditions (Including specific requirements) 2.2 - Multiple Emission Source(s) Specific Limitations and Conditions 2.3 - Permit Shield for Non-Applicable Requirements SECTION 3: GENERAL PERMIT CONDITIONS ATTACHMENT List of Acronyms Air Permit 03449T50 Page 3 SECTION 1 - PERMITTED EMISSION SOURCE(S) AND ASSOCIATED AIR POLLUTION CONTROL DEVICES) AND APPURTENANCES The following table contains a summary of all permitted emission sources and associated air pollution control devices and appurtenances: Emission Source Emission Source Description Control Device ID Control Device Description ID No. I No. Material Han ling Sources 7001 or SP-1 TrucklRail Chip Handling System, NIA NIA MACT DDDD Enclosed 7004 or SP-2 Truck/Rail Sawdust Handling System, NIA NIA MACT DDDD Enclosed 7010 Particle Board Mill Truck Dump NIA NIA MACT DDDD 7012,7014, Dump bunkers and CL dryer dump NIA NIA 7015,7029 MACT DDDD 7052,7054, Wood residue bunkers NIA NIA 7055,7056 MACT DDDD 6001,7002-A, Wood chip piles-Medium Density NIA NIA 7002-B,7002-C, Fiberboard Mill 7002-D MACT DDDD 6003,7006, Wood Fuel Pad and Boiler Transfers NIA NIA 7007,7022 MACT DDDD 7005-D,7005-E, Sawdust transport to A-frame NIA NIA 7005-F,7005-G MACT DDDD 7025 Scale transfer conveyors NIA NIA MACT DDDD 7019,7026 Fiber dump and reject filter bins NIA NIA MACT DDDD 7027 Hog fuel hopper NIA NIA MACT DDDD 7040,7044,7046, Particleboard Mill chip transfer NIA NIA 7048,7050 MACT DDDD SP Fuel Sawdust and Chip Storage Piles NIA NIA MACT DDDD 7024 Particleboard Mill feed bins NIA NIA MACT DDDD Medium Density Fiberboard (MD Facilities** ES-01 Refiner CD01 Refiner Abort Cyclone(66 inches in PSD diameter)l MACT DDDD CD02 Venturi scrubber in series with CD 1 S Biofilter CD14 Venturi scrubber In series r"rith CD 1 S Biofilter 1 For operation during startup,shutdown and malfunction only, Air Permit 03449T50 Page 4 Emission Source Emission Source Description Control Device ID Control Device Description ID Ni . No. ES-19,ES-19,and Three natural gas-fired hot oil heaters NIA NIA ES-20 (30.4 mullion Btu per hour maximum PSD heat input each) NSPS De MACT DDDDD ES-02-A Energy System consisting of one CD02-A Uwa/water injection system PSD dry/wet wood/woodwaste-fired burner CD02 Venturi scrubber MACT DDDD (205 mullion Btu per hour heat input) In series with CD18 Biofilter CD14 Venturi scrubber In series with CD18 Biofilter ES-02-B Two Stage Dryer System CD02 Venturi scrubber and and In series with ES-02-C-1 and ES- Three backup natural gas-fined dryer CD18 Biofilter 02-C-2, ES-02-D burners(35,35,and 17 million Btu per CD14 Venturi scrubber PSD hour heat input respectively) In series with MACT DDDD CD18 Biofilter ES-16 MDF Press and Press Hall CD02 Venturi scrubber PSD In series with MACT DDD❑ CD18 Biofilter CD14 Venturi scrubber In series with CD18 Biofilter ES-06-B MDF Board Cooler CD02 Venturi scrubber PSD In series with MACT DDDD CD18 Biofilter CD14 Venturi scrubber In series with CD18 Biofilter ES-03 Fiber Sifter System CD03 Fabric Filter(12,290 square feet of PSD filter area) MACT DDDD ES-04 Forming Line Clean-Up System CD04 Fabric Filter(9,346 square feet of PSD filter area) MACT DDDD ES-05 Mat Reject System CD05 Fabric Filter(9,346 square feet of PSD filter area) MACT DDDD ES-07 Saw System CD07 Fabric Filter(6,793 square feet of PSD filter area) MACT DDDD ES-08 Sander System No.l CD08 Fabric Filter(12,290 square feet of PSD filter area) MACT DDDD ES-09 Recycled Fiber Silo No.1 CD09 Bin Vent Filter(226 square feet of PSD filter area) MACT DDDD ES-10 Sander System No.2 CD10 Fabric Filter(12,290 square feet of PSD filter area) MACT DDD❑ ES-12 Sander Dust Silo No, 1 CD12 Bin Vent Filter(226 square feet of PSD filter area) MACT DDDD Air Permit 03449T50 Page 5 Emission Source Emission Source Description Control Device ID Control Device Description ID No. No. ES-13 Dry Sawdust Silo CD13 Bin Vent Filter(226 square feet of PSD filter area) MALT DDDD ES-15 Recycled Fiber Silo No.2 CD15 Bin Vent Filter(226 square feet of PSI] filter area) MACT DDDD ES-17 Sander Dust Silo No.2 CD17 Bin Vent Filter(226 square feet of PSD filter area) MALT DDDD ES-21 Diesel Fuel-fired Emergency NIA NIA PSD Generator(1592 brake Horsepower MACT ZZZZ out uo Particleboard Mill 3501 Sawdust Rock and Metal Separator CD-SC High efficiency cyclone-72 inches in PSD diameter MALT DDDD CD-3501 Reverse flow bag filter with 2,410 square feet of surface area 1430 Surface layer triple pass,rotary drum CD-1431 High efficiency multi-cyclone with 2 PSD (0)dryer with one wood suspension tubes,each 132 inches in diameter MACT DDDD dust/natural gas-feed burner(60 mullion Btu per hour maximum rated CD-PB-WESP Wet electrostatic precipitator heat input) 1420 Core layer single pass,rotary drum CD-1421 High efficiency multi-cyclone with 4 PSD (#1)dryer with one wood suspension tubes,each 80 inches in diameter MACT DDDD dust/natural gas-fired burner(50 million B to per hour maximum rated CD-PB-WESP Wet electrostatic precipitator heat input) 3201 One"Wellons"unit operating as a CD-1431 High efficiency multi-cyclone with 2 PSD natural gas-fired burner(21.8 million tubes,each 132 inches in diameter MACT DDDD Btu per hour maximum rated heat input); AND/OR exhausting to either CD-1421 High efficiency multi-cyclone with 4 tubes,each 80 inches in diameter surface layer triple pass,rotary drum AND (0)dryer[ID No. 1430] and/or CD-PB-WESP Wet electrostatic precipitator core layer single pass,rotary drum(91) d er ID No. 1420 3201 One"Wellons"unit operating as a NIA NIA MACT DDDDD natural gas-bred indirect heat exchanger(21.8 million Btu per hour maximum rated heat input) 3515 Surface Material Transport CD-3500, Simple cyclone-72 inches in PSD (SL fines from screening operation) diameter MACT DDDD CD-3525 Reverse flow fabric filter with 6,918 s uare feet of surface area CD-3512B Simple cyclone-72 inches in diameter CD-3515 Reverse flow fabric filter with 5,767 s uare feet of surface area Air Permit 03449T50 Page 6 Emission Source Emission Source Description Control Device ID Control Device Description ID No. No. 3525 Surface Formers and Mat Dumps CD-3520A, Three(3)simple cyclones-each 96 PSD CD-3520B, inches in diameter MACT DDDD CD-3521 CD-3525 Reverse flow fabric filter with 6,918 square feet of surface area 3535 Flying Cut Of Saw,Pretrim Saws,& CD-3530 Simple cyclone-84 inches in PSD Production Collection diameter MACT DDDD CD-3531 Simple cyclone- 108 inches in diameter CD-3533 Simple cyclone- 108 inches in diameter CD-3535 Reverse flow fabric filter with 6,918 square feet of filter area 3545 Particleboard Mill Steinemann CD-2006 Reverse flow bag filter with 6,918 PSD Finishing Sander square feet of surface area MACT DDDD CD-3570 High efficiency cyclone- 144 inches in diameter CD-3575 Reverse flow bag filter with 1,159 _ square feet of surface area DEF-2010 Particleboard Press NIA NIA PSD MACT DDDD PB-BC Particleboard Cooler NIA NIA PSD MACT DDDD 3565 Particleboard Mill Steinmann CD-5001 Reverse flow fabric filter with 6,918 PSD Calibrating Sander square feet of surface area MACT DDDD CD-3570 High efficiency cyclone- 144 inches in diameter CD-3575 Reverse flow bag filter with 1,159 square feet of surface area 3555 Schelling Saw Board Trim CD-3522 High efficiency cyclone-120 inches PSD in diameter MACT DDDD CD-4005 Reverse flow bag filter with 6,918 sc uarc feet of surface area 3575 Sander Filter Transport for Filters CD-3570 High efficiency cyclone- 144 inches PSD 3545&3565 in diameter MACT DDDD CD-3575 Reverse flow hag filter with 1,159 square feet of surface area 3585 PZKR Green Chip Makers CD-3585 Reverse flow bag filter with 4,880 PSD square feet of surface area MACT DDDD 3595 Oversize Material Pallmann Mill CD-3595 Reverse flow bagfilter(Maximum MACT DDDD air-to-cloth ratio of 3.0 ACFMltotal filter surface area). Air Permit 03449T50 Page 7 Emission Source Emission Source Description Control Device ID Control Device Description m No. No. 3577 Dry waste transport system CD-3532 Simple cyclone-60 inches in PSD diameter MACT DDDD CD-3577 Reverse flow bag filter with 4,068 sc uare feet of surface area Laminator Mill 3593 and 3594 Two(2)Short Cycle Laminating CD-3593 Reverse flow bagfilter(Maximum Presses air-to-cloth ratio of 4.1 ACFMAotal filter surface area). Pr-Heatl Natural gas or No.2 fuel oil-fired hot NIA N/A Case-by-Case oil heater(4.7 million Btu per hour MACT heat input)used with short cycle laminatin:. presses Miscellaneous EVAP-1 Wastewater evaporator* N1A �NIA MACT DDDD *This ernission source(lD No.EVAP-1)is listed as a 15A NCAC 02Q.0501(c)(2)modification. The Permittee shall file a Title V Air Quality Permit Application on or before 12 months after commencing operation in accordance with General Condition NN.1, The permit shield described in GencraI Condition R does not apply and eomplian=certification as described in General Condition P is not required. *'These emission sources and/or control devices(MDF Facilities)are listed as a 15A NCAC 02Q .0501(b)(2)modification. The Pcrmittee shall fHe a Title V Air Quality Permit Application on or before 12 months after commencing operation in accordance with General Condition NN.1. The permit shield described in General Condition R does not apply and compliance certification as described in General Condition P is not required, Air Permit 03449T50 Page 8 SECTION 2 - SPECIFIC LIMITATIONS AND CONDITIONS 2.1 - Emission Source(s) and Control Devices(s) Specific Limitations and Conditions The emission source(s)and associated air pollution control device(%)and appurtenances listed below are subject to the following specific terms,conditions,and limitations,including the testing,monitoring,record keeping,and reporting requirements as specified herein; A. The following Material Handling Sources: Table 2.1.A. Emission Source ID Control Control No. Emission Source Description Device ID Device No. Description 7001 or SPA Truck/Rail Chip Handling System,Enclosed NIA NIA 7004 or SP-2 Truck4tail Sawdust Handling System,Enclosed NIA NIA 7010 Particle Board Mill Truck Dwn NIA NIA 7012,7014 7015,7029 Dume bunkers and CL dryer dump NIA NIA 7052 7054,7055 7056 Wood residue bunkers NIA NIA 6001,7002-A,7002-B, Wood chip piles-Medium Density Fiberboard NIA NIA 7002-C,7002-D Mill 6003,7006,7007,7022 Wood Fuel Pad and Boiler Transfers N/A NIA 7005-D,7005-E,7005- Sawdust transport to A-frame NIA NIA F, 7005-G 7025 Scale transfer convevors NIA NIA 7019,7026 Fiber dum i and re1ect filter bins NIA NIA 7027 I-log fuel hopper NIA NIA 7040,7044,7046,7048, Particleboard Mill chip transfer NIA NIA 7050 SP Fuel Sawdust and Chip StoraLe Piles NIA NIA 7024 Particleboard Mill feed bins NIA NIA The following table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant Limits/Standards Applicable Regulation Visible emissions 20 percent opacity 15A NCAC 02D.0521 HAPs No applicable requirements 15A NCAC 02D.1111 Odors State Enforceable Only 15A NCAC 02D.1806 Odorous emissions must be controlled-See Section 2.2.A.2 1. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from these sources shall not be more than 20 percent opacity when averaged over a six- minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition 7r, If the results of the test performed exceed the limits given in Section 2.1.A.1.a.(above)for visible emissions, the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitoring/Recordkeepin2/Repordn2 [15A NCAC 02Q.0508(f)] c. No monitoring,record keeping,or reporting is required for visible emissions from these emission sources. Air Permit 03449T50 Page 9 B. Medium Density Fiberboard Facilities woodworking operations as presented in Table 2.1.8. Table 2A.B. Emission Control Source ID Emission Source Description Device TD Control Device Description No. No. ES-03 Fiber Sifter System CD03 Fabric Filter(12,290 square feet of filter area) ES-04 Forming Line Clean-Up System CD04 Fabric Filter(9,346 square feet of filter area) ES-05 Mat Reject System CDO5 Fabric Filter(9,346 square feet of filter area) ES-07 Saw System CD07 Fabric Filter(6,793 square feet of filter area) E Snder System Na. 1 CD08 Fabric Filter(12.290 square feet of filter area) Fiber Silo No. 1 C1709 Bin Vent Filter(226 square feet of filter areal ES-10 Sander System No.2 CDIO Fabric Filter(12,290 square feet of filter area) ES-12 Sander Dust Silo No. 1 CD12 Bin Vent Filter(226 square feet of filter area) ES-13 Dry Sawdust Silo CD13 Bin Vent Filter(226 square feet of filter area) ES-15 Recycled Fiber Silo No.2 CD 15 Bin Vent Filter(226 square feet of filter areal ES-17 Sander Dust Silo No.2 CD17 Bin Vent Filter(226 square feet of filter areal The following table provides a summary of limits and/or standards for the woodworking operations in Table 2.1.B. Regulated Pollutant Limits/Standards Applicable Regulation PM adequate duct work and properly desiEed collectors 15A NCAC 02D.0512 Visible emissions 20 percent opacity 15A NCAC 02D.0521 National Emission Standards for Hazardous Air HAPs Pollutants:Plywood and Composite Wood Products NCAC 63 ,1 i 11 See Section 2.2 A.i {40 CFA Part Subpart 17DDD) Odors State Enforceable OnIN 15A NCAC 02D.1806 See Section 2.2 A.2 NOx,PMx.s,PMlo See Section 2.2 H.1. 15A NCAC 02Q.0317 i PSD Avoidance) VOCs Best Available Control Technology 15A NCAC 02D .0530 See Section 2.2 B.2. 1. 15A NCAC 02D.0512: PARTICULATES FROM WOOD PRODUCTS FINISHING PLANTS a. The Permittee shall not cause,allow,or permit particulate matter caused by the working,sanding,or finishing of wood to be discharged from any stack,vent,or building into the atmosphere without providing,as a minimum for its collection,adequate duct work and properly designed collectors. In no case shall the ambient air quality standards be exceeded beyond the property line. Air Permit 03449T50 Page 10 Monitorine[15A NCAC 02Q.0508(f)] b. Particulate matter emissions from the MDF wood working operations shall be controlled as presented in Table 2.1.B. To ensure compliance,the Permittee shall perform inspections and maintenance as recommended by the manufacturer,if any. As a minimum,the inspection and maintenance program shall include: i. monthly external inspection of the ductwork,cyclones,and bagfilters noting the structural integrity;and ii. annual(for each 12 month period following the initial inspection)internal inspection of the bagfilters noting the structural integrity and the condition of the filters. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0512 if the ductwork,cyclones and/or bagfilters are not inspected and maintained. Recordkeenin [15A NCAC 02Q.0508(f)] c. The results of inspection and maintenance for the cyclones and bagfilters shall be maintained in a logbook (written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;and iii. the results of maintenance performed on any control device. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0512 if these records are not maintained. Renortin¢[15A NCAC 02Q.0508(f)] d. The Pennittee shall submit the results of any maintenance performed on the control devices within 30 days of a written rcqucst by the DAQ. e. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 2. 15A NCAC 02D.0521: CONTROL OF VISIBLE E1IIISSIONS a. Visible emissions from the MDF wood working operations listed in Table 2.1.B.shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[15A NCAC 02Q,0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 B.2.a.above, the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitoring[15A NCAC 02Q.0508(f)] c. To ensure compliance,once a week the Permittee shall ohserve the emission points of these sources for any visible emissions above normal.The weekly observations must he made for each week of the calendar year period to ensure compliance with this requirement. If visible emissions from this source are observed to he above normal,the Permittee shall either: i. take appropriate action to correct the abovo-normal emissions as soon as practicahle and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 02D.2610(Method 9)for 12 minutes is below the limit given in Section 2.1 B.2.a. shove. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii) above cannot he made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 02D.0521. Air Permit 03449T50 Page 11 Recordkeenin [15A NCAC 02Q.0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions__and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521 if these records are not maintained. R_euorting[15ANCAC 02Q.0508(f)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. Air Permit 03449T50 Page 12 C. Medium Density Fiberboard Facilities Operations as presented in Table 2.1.C. Table 2.1.C. Emission Control Emission Emission Source Source Description Device ID Control Device Description Point ID No. No. CD01 Refiner Abort Cyclone(66 inches EP01 in diameter)2 CD02 Venturi scrubber ES-0 Refiner in series with EP18 CD18 Biofilter CD14 Venturi scrubber In series with EP18 CD18 Biofilter CD02-A Urea/water injection system EP18 Energy System consisting CD02 Venturi scrubber of a dry/wet In series with EPI 8 ES-02-A woodlwoodwaste-Fired CD18 Biofilter burner(205 million Btu per CD14 Venturi scrubber hour heat input) In series with EP18 CD18 Biofilter ES-02-B Two Stage Dryer System CD02 Venturi scrubber In series with EP18 ES-02-C- Three backup natural gas- CD18 Biofilter 1,ES-02- fired dryer burners(35,35 CD14 Venturi scrubber C-2 and and 17 mullion Btu per hour In series with ES-02-D heat input respectively) CD18 Biofilter EP18 ES-06-B MDF Board Cooler CD02 Venturi scrubber In series with EP18 CD18 Biofilter CD14 Venturi scrubber In series with EP18 CD18 Biofilter CD02 Venturi scrubber In series with EP18 ES-16 MDF Press and Press Hall CD18 Biofilter CD14 Venturi scrubber In series with EP18 CD18 Biofilter s For operation during startup,shutdown and malfunction only. Air Permit 03449T50 Page 13 The following table provides a summary of limits and/or standards for the operations in Table 2.1.C. Regulated Pollutant Limits/Standards Applicable Regulation E=4.1 OP 1.67 or E=55.0(P)o.11-40 PM where;E=allowable emission rate in pounds per hour 15A NCAC 02D.0515 P=Ivocess weight in tons per hour Sulfur dioxide 2.3 pounds per million Btu heat input 15A NCAC 02D.0516 Visible emissions 24 percent v.acit 15A NCAC 02D.0521 PM Compliance Assurance Monitoring 15A NCAC 02D.06I4: VOCs 40 CFR 64 National Emission Standards for Hazardous Air 15A NCAC 02D.1111 HAPs Pollutants:Plywood and Composite Wood Products (40 CFR Part 63 Subpart DDDD) See Section 2.2 A.1 Odors State Enforceable Onl► 15A NCAC 02D .1806 See Section 2.2 A.2 NOx,PM2 s,PM10 See Section 2.2 B.1. 15A NCAC 02Q.0317 (PSD Avoidance) VOCs Best Available Control Technology 15A NCAC 02D .0530 See Section 2.2 B.2. HAPs 15A NCAC 02D.I 111 Schedule of Compliance Vacs See Section 2.3 (40 CFR Part 63 Subpart DDDD) 15A NCAC 02D.0530 1. 15A NCAC d2D.051S; PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the emission sources in Table 2.1.C. shall not exceed an allowable emission rate as calculated by the following equation(s): Process Rate Allowable Emission Rate Equation Less than or equLd to 30 tons per hour E=4.10 x P 1,61 Greater than 30 tons per hour E=55.0(P)v.i i-40 Where E=allowable emission rate in pounds per hour P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing[15A NCAC 02Q.0508(t}] h. TF emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 C.La above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515. c. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limit above on an annual basis by testing the emission point EP 18 in accordance with General Condition JJ. If the results of this test are less than 80 percent of the emission limit above,the Permittee shall be required to stack test only once every five years following the previous stack test.If the results of this test are above the limit given in Section 2.1 C.La .above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0515. Air Permit 03449T50 Page 14 Monitorine[15A NCAC 02Q.0508(f)] d. Particulate matter emissions from these sources shall be controlled by the venturi scrubbers as described in Table 2.1.C. e. The Permittee shall perform inspections and maintenance as recommended by the manufacturer. f. The Permittee shall install,operate,and maintain instrumentation on the scrubbers identified in Table 2A.C.to continuously monitor the parameters in Table 2.1 C.11and maintain the parameters in the associated operating ranges. These ranges are not required during performance testing. Table 2.1 C.11 F, Parameter Control Device ID No. Minimum operating range, per control device Pressure drop(inches of water CD02 6.5 gauge,3-hour block average) CD14 6.5 Recirculating liquid flow rate CD02 378 (gallons per minute,3-hour block CDI4 416 avera�e) The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if the monitoring requirements in Sections 2.1 C.Ld through f are not met. Recordkeenin [15A NCAC 02Q.0508(f)] g. The results of any monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed on the control devices; iv. any variance from manufacturer's recommendations,if any,and corrections made;and v. pressure drop,and recirculating flow rate,(3—hour block averages)for each venturi scrubber. The Pernttee shall be deemed in noncompliance with 15A NCAC 02D .0515 if these recordkeeping requirements are not met. Reuortin¢[15A NCAC 02Q.0508(f)] h. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 2. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the emission sources in Table 2.I.C.shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-bour period. In no event shall the six-minute average exceed 87 percent opacity. Test[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 C.2.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitorins[15ANCAC 02Q.0508(f)] c. To ensure compliance,once a week the Permittee shall observe the emission point(EP18)for any visible emissions above normal. The weekly observation must be made for each week of the calendar year period to ensure compliance with this requirement.The Permittee shall re-establish"normal"within 30 days after the initial operation of the biofilter(ID No.CD18)after the modifications undertaken in application no. 1900015.I8A are completed.If visible emissions from this source are observed to he above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or Air Permit 03449T50 Page 15 ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 02D.2610(Method 9)for 12 minutes is below the limit given in condition a. above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made, the Permittee shall be deemed to be in noncompliance with 15A NCAC 02D.0521. Reeordkeeping It 5A NCAC 02Q.0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following; i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with I5A NCAC 0213.0521 if these records are not maintained. Reporting[15A NCAC 02Q.0508(t)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified, 3. 15A NCAC 02D.051G:SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from the Energy System(ID No.ES-02-A)and the two-stage dryer system(ID No.ES-02-B)with two backup natural gas-fired burners(ID Nos.ES-02-C-1 and-2 and ES-02-D)shall not exceed 2.3 pounds per mullion Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels, wastes,ores,and other substances shall be included when determining compliance with this standard. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required, the testing shall be performed in accordance with General Condition JJ.If the results of this test are above the limit given in Section 2.1 C.3.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0516. Monitoring/fteeordkeepinJReportine[15A NCAC 02Q.0508(f)] c. No monitoring,recordkeeping or reporting is required for sulfur dioxide emissions from wood combustion for these sources. Air Permit 03449T50 Page 16 4. I5A NCAC 02D.0614:COMPLIANCE ASSURANCE MONITORING[40 CFR 641 a. Pursuant to 40 CFR 64 and 15A NCAC 02D.0614,the Permittee shall comply with the conditions below for the Pollutant Specific Emission Unit(s)controlled by the venturi scrubbers(II)Nos.CD02 and CD14). Emission Limitations/Standards b. The following table presents the regulated pollutants and the associated emission limitations/standards: Regulated Pollutant Linilts/Standards Applicable Regulation PM See Section 2.1 C.l 15A NCAC 02D.0515 Monitoring Approach [15A NCAC 02Q.0508(f),40 CFR 64.6] c. The key elements of the monitoring approach for PM,including parameters to be monitored,parameter ranges and performance criteria are presented in the following table. [Monitoring Indicator No. 1 Indicator No.2 Elements Measurement Injection rate measurements are made every Pressure drop measurements are made every Approach 15 minutes 15 minutes 64.6(c)(1)(i ii Indicator Range An excursion is defined as a one-hour block An excursion is defined as a one-hour block [64.6(c)(2)] average injection rate reading lower than the average pressure drop reading lower than the respective 3-hour block average reading listed respective 3-hour block average reading listed in Table 2.1 C.1.f of this permit.Excursions in Table 2.1 C.Lf of this permit.Excursions trio per an inspection and corrective action. i trigger an inspection and corrective action. QIP threshold The QIP threshold is six excursions in a six- The QIP threshold is six excursions in a six- [64.81 month reporting period. month reporting eriod. Data Measurements are made once every 15 Measurements are made once every 15 Representativeness minutes and complied into the appropriate minutes and complied into the appropriate [64.6(c)(1)(iii), averaging periods. averaging periods. 64.3(b)(1) Verification of Monitoring shall be required upon issuance of permit no. 03449T45 Operational Status 64.3(b)2 QAIQC Practices Flowmeter calibration shall be performed Pressure transducer calibration shall be and Criteria according to manufacturer recommendations. performed according to manufacturer 64.3(b)(3) recommendations. Monitoring Measurements are made by a computerized data acquisition and handling system once every 15 frequency minutes and complied into the appropriate averaging periods. 64.3 b 4 _ Data collection Non-SSM periods when flowrate or pressure drop falls below the acceptable ranges for more procedure than one-hour will be documented.An electronic or written logbook will he kept of all control 64.3(b)(4)1 device inspections and corrective actions Recordkeeping Requirements[15A NCAC 02Q.0508(f),40 CFR 64.9] d. The owner or operator shall maintain records of the following: L Date and time and results of all monitoring activities; ii. Information on the number,duration and cause(including unknown cause,if applicable)of excursions or exceedances,as applicable,and the corrective actions taken; iii. Maintenance records of the differential pressure gauge;and iv. Written QIP required pursuant to 40 CFR 64.8 and any activities undertaken to implement a quality improvement plan. Reportine Requirements[I5A NCAC 02Q.0508(f),40 CFR 64.9] e. The Permittee shall submit a summary report of all monitoring activities postmarked on or before January 30 Air Permit 03449T50 Page 17 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations for the requirements of this permit must be clearly identified, At a minimum,the report shall include the following elements: i. Summary information on the number,duration and cause(including unknown cause,if applicable)of excursions or exceedances,as applicable,and the corrective actions taken; ii. Summary information on the number,duration and cause(including unknown cause,if applicable)for monitor downtime incidents(other than downtime associated with zero and span or other daily calibration checks,if applicable);and iii. A description of the actions taken to implement a QIP during the reporting period as specified in 40 CFR 64,8.Upon completion of a QIP,the owner or operator shall include in the next summary report documentation that the implementation of the plan has been completed and reduced the likelihood of similar levels of excursions or exceedances occurring. 5. 15A NCAC 02D.0614: COMPLIANCE ASSURANCE MONITORING[40 CFR 641 a. Pursuant to 40 CFR 64 and 15A NCAC 2D.0614,the Permittee shall comply with the conditions below for the Pollutant Specific Emission Unit(s)controlled by the biofilter(ID No.CD-18). Emission Limitations/Standards b. The following table presents the regulated pollutants and the associated emission limitations/standards: Regulated Pollutant Limits/Standards Applicable Regulation VOCs Best Available Control Technology 15A NCAC 02D.0530 See Section 2.2 B.2, Monitoring Approach[15A NCAC 02Q.0508(f),40 CFR 64.6] c. The Permittee has elected to satisfy the presumptively acceptable monitoring requirements under MACT DDDD for the biofilter as allowed at 40 CFR 64.4(b)(4).The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if the biofilter bed minimum and maximum temperatures are outside the indicator range found at Section 2.2 A.l.h. Recordkeepina and Reporting Rerluirements[15A NCAC 02Q.0508(t),40 CFR 64.91 d. The Permittee shall meet the recordkeeping and reporting requirements found in Section 2.2 A Laa through ii, as applicable.The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these requirements are not met. 6. 15A NCAC 02D.0530(u): USE OF PROJECTED ACTUAL EMISSIONS TO AVOID APPLICABILITY OF PREVENTION OF SIGNIFICANT DETERIORATION REQUIREMENTS a. i. The Permittee has used projected actual emissions to avoid applicability of Prevention of Significant Deterioration requirements for a project consisting of modifications to the MDF dryer involving natural gas burner replacement to achieve increases in throughput,reliability and safety when firing natural gas. This project does not result in an increase in overall design capacity of the MDF Mill.This project is fully described in application no. 1900015.17D. ii. The Permittee has used projected actual emissions to avoid applicability of Prevention of Significant Deterioration requirements for a project consisting of modifications to the NIDF Mill to achieve increases in throughput.This project is expected to result in an increase in overall design capacity of the MDF Mill. This project is fully described in application no, 1900015.18A. In order to verify the assumptions used in the projected actual emissions calculatians,the Permittee shall comply with the testing,record keeping and reporting requirements in Sections 2.1 C.6.b through a below. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance General Condition JJ. Recordkee ing[15ANCAC 02D.0530(u)] c. The Permittee shall maintain records of the actual emissions of PMio,PM2.5,NO,and CO from the sources indicated in the permitted equipment list in Section 1 as the Medium Density Fiberboard(MDF)Facilities Air Permit 03449T50 Page 18 (MDF Facilities)in tons per year.Records shall start following the resumption of regular operations after the modifications described in application no. 1900015.17D and shall continue for ten years after the resumption of regular operations after the modifications described in application no. 1900015.18A.The first year shall start on the first day of the first full calendar month after commencing regular operations after the modification described in application no. 1900015.17D.Each subsequent year shall include the same 12-month period. d. The reported actual emissions(post-construction emissions)of the MDF Facilities for each of the years will be compared to the projected actual emissions(pre-construction projection)for the dryer as included belowi Pollutant Projected Actual Emissions* tons per year i PMto 92 _ PM2.5 92 NOx 144 CO 251 * These projections are not enforceable limitations. If projected emissions are exceeded,consistent with 15A NCAC 02D.0530,the permittee shall include in its annual report an explanation as to why the actual rates exceeded the projection. The Permittee shall make the information,documented and maintained in this condition available to the Director or the general public pursuant to the requirements in 40 CFR 70.4(b)(3)(viii). Reporting[15A NCAC 02D.0530(u)] e. The Permittee shall submit a report of the actual emissions of the pollutants identified in Section 2.1 C.6.c from the MDF Facilities to the Director within 60 days after the end of each year(as defined in Section 2.1 C.6.c) during which the records in Section 2.1 C.6.c must be generated. The report shall contain the items listed in 40 CFR 51.166(r)(6)(v)(a)through(c). D. The following sources for the Medium Density Fiberboard Facilities Emission Source ID Nv. Emission Source Description Control Control Device Device ID No. Description ES-18,ES-19,and ES-20 Three natural gas-fired hot oil heaters NSPS Dc (30.4 million Btu per hour maximum NA NA MACT DDDDD heat input each) The following table provides a summary of limits and/or standards for the emission sources above: Regulated Pollutant Limits/Standards Applicable Regulation PM 0.25 pounds per million Btu heat input 15A NCAC 02D.0503 Sulfur dioxide 2.3 pounds per million B to heat input 15A NCAC 02D .0516 Visible emissions 20 percent opacity 15A NCAC 02D.0521 NA Notification and Recordkeeping 15A NCAC 02D.0524(NSPS Subpart Do) HAPs Annual tune ups 15A NCAC 02D.1111 Odors State-Enforceable Only 15A NCAC 02D.1806 See Section 2.2 A.2 NOx,PM2.5,PMio See Section 2.2 B.1. ((PS NCAC 02Q.0317 PSD Avoidance VOCs Best Available Control Technology 15A NCAC 02D.0530 See Section 2.2 B.2. 1. 15A NCAC 02D.0503: PARTICULATES FROM FUEL BURNIINIG INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of natural gas that are discharged from these sources into the atmosphere shall not exceed 0.25 pounds per million Btu heat input. Air Permit 03449T50 Page 19 Testing f 15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance General Condition JJ.If the results of this test are above the limit given in condition a. above, the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0503. Monitorin ecordkee in a ortin [I5ANCAC 02Q.0508(f)] c. No monitoringlrecordkeeping/reporting is required for particulate emissions from the firing of natural gas in these sources. 2. 15A NCAC 02D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from these sources shall not exceed 2.3 pounds per million Btu beat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testing [15A NCAC 02Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0516. Monitoring Recordkee in [I5ANCAC 02Q.0508(f)] c. No monitoring/recordkeeping is required for sulfur dioxide emissions from natural gas combustion for these sources. 3. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from these sources shall not be more than 20 percent opacity when averaged over a six- minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity, Testine[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition J.T. If the results of this test are above the limit given in condition a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0521. Monitorin2/Recordkee in IRe ortina [15A NCAC 02Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of natural gas in these sources. 4. 15A NCAC 02D.0524:NEW SOURCE PERFORMANCE STANDARDS a. For these sources,the Permittee shall comply with all applicable provisions,including the notification,testing, recordkeeping,and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 02D.0524"New Source Performance Standards(NSPS)as promulgated in 40 CFR Part 60 Subpart Dc,"Standards of Performance for Small Industrial-Commercial-Institutional Steam Generating Units"including Subpart A"General Provisions." Recordkeeping Re uirements[15A NCAC 02Q.0508(f)] b. The Permittee shall record and maintain records of the amounts of each fuel fired during each month, [40 CFR 60.48c(g)(2)]These records shall be maintained by the Permittee for a period of two years following the date of such record. [40 CFR 60.48c(i)]The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0524 if these recordkeeping requirements are not met, Notification Requirements[15A NCAC 02Q.0508(f)] c. The Permittee shall submit notification of the actual startup for each source within 15 days after such date. [40 CFR 60.7(a)(3),60.48c(a)] 5. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY AAPRlicability[40 CFR 63.7485,63.7490,63.7499(1)] Air Permit 03449T50 Page 20 a. For these sources the Permittee shall comply with all applicable provisions,including the monitoring, recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .1111 "Maximum Achievable Control Technology"(MACT)as promulgated in 40 CFR 63,Subpart DDDDD "National Emission Standards for Hazardous Air Pollutants for Major Sources:Industrial,Commercial,and Institutional Boilers and Process Heaters"and Subpart A"General Provisions." Definitions and Nomenclature[40 CFR 63.7575] b. For the purpose of this permit condition,the definitions and nomenclature contained in 40 CFR 63.7575 shall apply. 40 CFR Part 63 Subpart A General Provisions[40 CFR 63.7565] c. The Permittee shall comply with the requirements of 40 CFR 63 Subpart A General Provisions according to the applicability of Subpart A to such sources as identified in Table 10 to 40 CFR Part 63,Subpart DDDDD. Compliance Date 140 CFR 63.7495(a)] d. The Permittee shall comply with the applicable requirements upon startup of these sources. Notifications j40 CFR 63.7545] e. As specified in 40 CFR 639(b)(4)and(5),the Permittee shall submit an Initial Notification to the DAQ not later than 15 days after the acrual date of startup of each affected source.L40 CFR 63.7545(c)] Work Practice Standards[15A NCAC 02Q,0508(f)] f The Permittee shall conduct a tune-up annually for each source as specified below: i. As applicable,inspect the burner,and clean or replace any components of the burner as necessary. The Permittee may perform the burner inspection any time prior to the tune-up or delay the burner inspection until the next scheduled or unscheduled shutdown. ii. Inspect the flame pattern,as applicable,and adjust the burner as necessary to optimize the flame patter. The adjustment should be consistent with the manufacturer's specifications,if available; iii. Inspect the system controlling the air-to-fuel ratio,as applicable,and ensure that it is correctly calibrated and functioning properly(you may delay the inspection until the next scheduled unit shutdown). iv. Optimize total emissions of CO.This optimization should be consistent with the manufacturer's specifications,if available,and with any NOx requirement to which the unit is subject. v. Measure the concentrations in the effluent stream of CO 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).Measurements may be taken using a portable CO analyzer. [40 CFR 63.7500(a),63.7540(a)(10)] g. For these sources,each annual tune-up shall be conducted no more than 13 months after the previous tune-up. The initial tune-up shall be conducted no later than 13 months after the initial startup of the source. [40 CFR 63.7515(d)] h. if the unit is not operating on the required date for a tune-up,the tune-up must be conducted within 30 calendar days of startup. [40 CFR 63.7540(a)(13),63.7515(g)] i. At all times,you must 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.Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator that may include,but is not limited to, monitoring results,review of operation and maintenance procedures,review of operation and maintenance records,and inspection of the source. [40 CFR 63.7500(a)(3)] j. The Permittee shall he deemed in noncompliance with 15A NCAC 02D.1111 if the requirements in Section 2.1 D.5.e through i are not met. Recordkeepina Requirements[15A NCAC 02Q.0508(f)] k. The Permittee must keep the following: i. A copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,or 5-year compliance report that has been submitted,according to the requirements in 40 CFR 63.10(b)(2)(xiv).[40 CFR 63.7555(a)(1)] ii. Maintain on-site and submit,if requested by the Administrator,a report containing the information in paragraphs(A)through(C)below: Air Permit 03449T50 Page 21 (A) The concentrations of CO in the effluent stream in parts per million by volume,and oxygen in volume percent,measured at high fire or typical operating load,before and after the tune-up of the boiler or process heater; (B) A description of any corrective actions taken as a part of the tune-up;and (C) The type and amount of fuel used over the 12 months prior to the tune-up,but only if the unit was physically and legally capable of using more than one type of fuel during that period.Units sharing a fuel meter may estimate the fuel use by each unit. [40 CFR 63.7540(a)(10)(vi)] iii. The associated records for Section 2.1 D.5.e through i. 1. The Pennittee shall: i. maintain records in a form suitable and readily available for expeditious review; ii. keep each record for 5 years following the date of each occurrence,measurement,maintenance,corrective action,report,or record;and iii. keep each record on site for at least 2 years after the date of each occurrence,measurement,maintenance, corrective action,report,or record.The Permittee can keep the records offsite for the remaining 3 years. [40 CFR 63.7560,63.10(b)(1)] m. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .1111 if records are not maintained pursuant to Section 2.1 D.51 through 1. Reporting Reg uirements[15ANCAC 02Q.0508(f)] n. The Permittee shall submit compliance reports to the DAQ on an annual basis.The fast report shall cover the period beginning on the compliance date specified in Section 2.1 D.5 d(i.e.,start-up)and ending on the earliest December 3151 less than one year from the compliance date. Subsequent annual reports shall cover the periods from January 1 to December 31.The Permittee shall submit the compliance reports postmarked on or before January 30. [40 CFR 63.7550(a),(b),63.10(a)(4),(5)] o. The compliance report must also be submitted electronically via the Compliance and Emissions Data Reporting Interface(CEDRI).CEDRI can be accessed through the EPA's Central Data Exchange(CDX) (https://cdx.epa.gov/).)You must use the appropriate electronic report in CEDRI for this subpart.Instead of using the electronic report in CEDRI for this subpart,you may submit an alternate electronic file consistent with the XML schema listed on the CEDRI Web site(http://www.epa.gov/ttn/chief/cedrUindex.htail),once the XML schema is available. If the reporting form specific to this subpart is not available in CEDRI at the time that the report is due,you must submit the report to the Administrator at the appropriate address listed in §63.13.You must begin submitting reports via CEDRI no later than 90 days after the form becomes available in CEDRI. [40 CFR 63.7550(h)(3)] p. The compliance report must contain the following information: i. Company name and address; ii. Process unit information,emissions limitations,and operating parameter limitations; iii. Date of report and beginning and ending dates of the reporting period; iv. Include the date of the most recent tune-up for each unit required according to Section 2.1 D.51.Include the date of the most recent hurner inspection if it was not done on a 5-year basis and was delayed until the next scheduled or unscheduled unit shutdown. v. Statement by a responsible official with that official's name,title,and signature,certifying the truth, accuracy,and completeness of the content of the report. [40 CFR 63.7550(a)and(c),Table 91 q. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .11 I I if the reporting requirements in Section 2.1 D.5.n through p are not met. Air Permit 03444T50 Page 22 E. The following Particleboard Mill operations: Table 2.1 E.1 Emission Control Source Emission Source Description Device Control Device Description ID No. I ID No. Particleboard Mill Combustion Sources and Drvers Surface layer triple pass,rotary drum CD-1431 High efficiency multi-cyclone with 2 tubes, (#3)dryer with one wood suspension each 132 inches in diameter 1430 dust/natural gas-fired burner(60 CD-PB- Wet electrostatic precipitator million Btu per hour maximum rated WESP heat input) Core layer single pass,rotary drum CD-1421 High efficiency multi-cyclone with 4 tubes, (#1)dryer with one wood suspension each 80 inches in diameter 1420 dust/natural gas-fired burner(50 CD-PB- Wet electrostatic precipitator million Btu per hour maximum rated WESP heat input) Operating Scenario 1 CD-1431 High efficiency multi-cyclone with 2 tubes, One"Wellons"unit operating as a each 132 inches in diameter natural gas-fired burner(21.8 million AND/OR Btu per hour maximum rated heat input); CD-1421 High efficiency multi-cyclone with 4 tubes, each 80 inches in diameter 3201 exhausting to either AND surface layer triple pass,rotary drum (#3)dryer[ID No. 1430]and/or CD-PB- Wet electrostatic precipitator WESP core layer single pass,rotary drum(#1 dryer JD No. 1420 Operating Scenario 2 3201 One"Wellons"unit operating as a NA NA natural gas-fired indirect heat exchanger(21.8 million Btu per hour maximum rated heat input) Air Permit 03449T50 Page 23 Table 2.1 E.2 Emission Emission Source Control Device Source Description ID No. Control Device Description ID No. Particleboard Mill Other Operations Sawdust Rock CD-SC High efficiency cyclone-72 inches in diameter 3501 and Metal CD-3501 Reverse flow bag filter with 2,410 square feet of surface Separator area CD-3500, Simple cyclone-72 inches in diameter Surface Material CD-3525 Reverse flow fabric filter with 6,918 square feet of surface Transport area 3515 (SL fines from in parallel with screening CD-3512B, Simple cyclone-72 inches in diameter operation) CD-3515 Reverse flow fabric filter with 5,767 square feet of surface area CD-3520A, Three(3)simple cyclones-each 96 inches in diameter Surface Formers CD-3520B, 3525 and Mat Dumps CD-3521 Reverse flow fabric filter with 6,918 square feet of surface CD-3525 area Flying Cut Off Saw, CD-3530 Simple cyclone-84 inches in diameter 3535 Pretrim Saws,& CD-3531 Simple cyclone- 108 inches in diameter Production CD-3533 Simple cyclone- 108 inches in diameter Collection CD-3535 Reverse flow fabric filter with 6,918 square feet of filter are: CD-2006, Reverse flow bag filter with 6,918 square feet of surface area Particleboard Mill CD-3570, in series with 3545 Steinmann CD-3575 High efficiency cyclone- 144 inches in diameter Finishing Sander in series with Reverse flow bag filter with 1,159 square feet of surface area DEF-20101 Particleboard Press NIA NIA PB-BC Particleboard NIA NIA Cooler CD-5001, Reverse flow fabric filter with 6,918 square feet of surface area Particleboard Mill CD-3570, in series with 3565 Steinemann CD-3575 High efficiency cyclone- 144 inches in diameter Calibrating Sander in series with Reverse flow bag filter with 1,159 square feet of surface area Schelling Saw CD-3522, High efficiency cyclone- 120 inches in diameter 3555 Board Trim CD-4005 Reverse flow bag filter with 6,918 square feet of surface area Sander Filter CD-3570, High efficiency cyclone-144 inches in diameter 3575 Transport for Filters CD-3575 Reverse flow bag filter with 1,159 square feet of surface 3545&3565 area 3585 PZKR Green Chip CD-3585 Reverse flow bag filter with 4,880 square feet of surface Flakers area 3595 Oversize Material CD-3595 Reverse flow bagfilter(Maximum air-to-cloth ratio of 3.0 Pallmann Mill ACFMltotal filter surface area). CD-3532, Simple cyclone-60 inches in diameter 3577 Dry waste transport system CD-3577 Reverse flow bag filter with 4,068 square feet of surface area Air Permit 03449T50 Page 24 The following table provides a summary of limits and/or standards for the particleboard null. Regulated Pollutant Limits/Standards Applicable Regulation PM 0.30 lb/million Btu ID No.3201 OS-2 only) 15A NCAC 02D.0503 PM adequate duct work and properly designed collectors 15A NCAC 02D .0512 Affected facilities: Sources listed in Table 2.1 E.2 PM E=4.l OP 0 fi7 when PE30 tons per hour 15A NCAC 02D.0515 Or E=55.0P°1 when P>30 tons per hour where E=allowable emission rate in pounds per hour P=process weight in tons per hour Affected facilities: Sources listed in Table 2.1 F.l except(ED No.3201) during OS-2 Sulfur dioxide 2.3 pounds per million Btu heat input 15A NCAC 02D.0516 Affected facilities: Sources listed in Table 2.1 E.1 Visible emissions 20 ercent opacity 15A NCAC 02D.0521 PM10 15A NCAC 02D.0530 Carhon monoxide VOCs See Section 2.1 E.6. Nitrogen dioxide Visible emissions PM,PM]0,VOC Compliance Assurance Monitoring 15A NCAC 02D.0614 40 CFR 64 HAPs National Emission Standards for Hazardous Air 15A NCAC 02D.1111 Pollutants for Major Sources: Industrial,Commercial, (40 CFR Part 63 Subpart and Institutional Boilers and Process Heaters DDDDD) (11D No.3201) (OS-2 only) HAPs National Emission Standards for Hazardous Air 15A NCAC 02D.1111 Pollutants:Plywood and Composite Wood Preducts (40 CFR Part 63 Subpart DDDD) See Section 2.2 A.1 Odors State Enforceable Onlr 15A NCAC 02D.1806 See Section 2.2 A.2 Air Permit 03449T50 Page 25 I. 15A NCAC 02D.0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from.the Wellons(ID No 3201,when operating in OS-2 only)that are discharged from this source into the atmosphere shall not exceed 0.33 pounds per million Btu heat input. Ted[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ.If the results of this test are above the limit given in Section 2.1 E.La above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0503. M_onitorinz(Reeordkeepine/Revortini„[15ANCAC 02Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for particulate emissions from the firing of natural gas in this source. 2. 15A NCAC 02D.0512: PARTICULATES FROM WOOD PRODUCTS FINISHING PLANTS a. The Permittee shall not cause,allow,or permit particulate matter caused by the working,sanding,or finishing of wood to be discharged from any stack,vent,or building into the atmosphere without providing,as a minimum for its collection,adequate duct work and properly designed collectors. In no case"I the ambient air quality standards be exceeded beyond the property line. Monitoring ecordkee in [15A NCAC 02Q.0508(f)] b. Particulate matter emissions from the sources in Table 2.1 E.2 shall be controlled as presented in Table 2.1 E.2. i. No monitoring,recordkeeping or reporting shall be required for the particulate matter emissions from the particleboard press(ID No.DEF-2010)and particleboard cooler(ID No.PB-BC), c. To ensure compliance,the Permittee shall perform inspections and as follows: i. monthly external inspection of the duct work and cyclones,noting the structural integrity;and ii. internal inspection of the bag filters,every 12 months,noting the structural integrity and the condition of the filters. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0512 if the ductwork,cyclones,and bag filters are not inspected and maintained. d. The results of inspection and maintenance for the cyclones,and hag filters shall be maintained in a logbook (written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection;and iii. the results of maintenance performed on any control device. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0512 if these records are not maintained. Renortin¢[15A NCAC 02Q.0508(t)] e. The Permittee shall submit the results of any maintenance performed on the control devices in Table E.2 within 30 days of a written request by the DAQ. f. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. Air Permit 03449T50 Page 26 3. 15A NCAC 02D.0515:PARTICULATE EMISSIONS FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the emission sources in Table 2.1 E.1 that are discharged into the atmosphere shall not exceed an allowable emission rate as calculated by the following equations: Process Rate Allowable Emission Rate Equation Less than orequal to 30 tons per hour E=4.10 x P"1 Greater than 30 tons per hour E=55.0(P)O,'i-40 Where E=allowable emission rate in pounds per hour P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. TestinE[15ANCAC 02Q.0508(f)] b. If emissions testing is required, the testing shall be performed in accordance with General Condition JJ. If the results of the test performed exceed the limits given in Section 2.1 E.3.a above for particulate matter,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.05I5. Monitoringiltecordkee ing[I5A NCAC 02Q.0508(f)] c. Particulate matter emissions from the emission sources in Table 2.1 E.I.shall be controlled as presented in Table 2.1 E.I d. The monitoring,recordkeeping,and reporting requirements required in Sections 2.1 E.6.d.ii,e,f,i,m,and n shall be followed in order to demonstrate compliance with 15A NCAC 02D.0515. 4. 15A NCAC 02D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Sulfur dioxide from the emission sources in Table 2.1 E.I shall not exceed 23 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testim [I5A NCAC 02Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2,1 E.4.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0516. Monitorin IRecordkee in r Re ortin [I5A NCAC 02Q .0508(f)] c. No monitoring,record keeping,or reporting is required for sulfur dioxide emissions from then sources in Table 2.1 E.I. Air Permit 03449T50 Page 27 5. ISA NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the emission sources in Table 2.1 E.1 and 2.1 E.2 shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[I5A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of the test performed exceed the limits given in Section 2.1 E.5a above for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitorin^/Recordkeenine [15A NCAC 02Q.0508(f)] c. To ensure compliance, the Permittee shall observe,on a weekly basis, the following emission points in the Particleboard mill for any visible emissions above normal: Emission Source Description and ID No. Emission Point ID No. Sawdust Rock�Drver etal 5e aratar lI1 No.3501 CD-3501 Surface LaverID No.1430 Core Layer°er D er#1 ID V. 1420 CD-PB-ESP "Wellons"Burner No.3201 OS-1 only)* Particleboard Press ID No.DEF-20I0 DEF-2010 Surface Material Transport(ID No.3515) CD-3515 and CD-3525 Surface Formers and Mat Dumps(ID No.3525) CD-3525 Flying Cut Off Saw Pretrim Saws,and Production Collection ID No.3535 CD-3535 Board Cooler(ID No.PB-BC} PB-BC Particleboard Mill Steinemann Calibrating Sander ID No.3565 CD-3575 Particleboard Mill Steinemann Finishing Sander(ID No.3545) CD-3575 and CD-2006 Schellin.,Saw Board Trim ID No.3555 CD-4005 Sander Filter Transport for Filters 3545 and 3565 ID No.3575 CD-3575 PZKR Green Chip Flakers[ID No.3585) CD-3585 Oversized Material Pallmann Mill ID No.3595 CD-3595 Lpry Waste Transport System{M No.3577) CD-3577 * No observations are required for the Wellons burner(ID No.3201)when operating in 08-2. The weekly observation must be made for each week of the calendar year period to ensure compliance with this requirement. If visible emissions from these sources are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 02D .2610(Method 9)for 12 minutes is below the limit given in condition a. above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 02D .0521. d. The results of the monitoring for visible emissions shall be maintained in a logbook(written or electronic forinat)on-site and made available to an authorized representative upon request.To ensure quality,entries in the logbook should he signed by personnel responsible for the effective operation of the units in the particleboard mill and their air pollution control devices.The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Permittee shall be deemed in.noncompliance with 15A NCAC 02D.0521 if these records are not maintained. Air Permit 03449T50 Page 28 Reportine[15A NCAC 02Q.0508(f)] e. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 6. 15A NCAC 02D.0530: PREVENTION OF SIGNIFICANT DETERIORATION a. For PSD purposes,the following"Best Available Control Technology" (BACT)permit limitations shall not be exceeded for units in the particleboard mill(ID No.PB): Emission Source Pollutants Emission Limits"`• Control Technology Sawdust Rock and Metal PM10 0.02 lbs/hr cyclone and baahouse Separator(ID No.3501) V❑C 5.56 lbs/hr,as C none ❑ acity 20 percent cyclone and baahouse PM,o 28.3 lbs/hr k' good combustion control with existing Surface Layer Dryer(ID No.1430) multiclones and wet ESP *k Core Layer Dryer # 1(ID VOC 163.3 lbslhr,as C No. good combustion control with existing wet 1420) ESP CO 329.4 lbs/hr"` r ood combustion control NOx 94.7 lbs/hr" good combustion control Surface Material Transport(ID PM10 0.02 lbs/hr cyclones and bayllouse No.3515) VOC 46.5 lbs/hr,as C none opacity 20 percent cyclones and ba=house Surface Formers and Mat Dumps PM10 0.06 lbs/lhr _cyclones and ba house (JD No.3525) VOC 1.95 lbs/hr,as C none Opacity 20 percent cyclones and baghouse Flying Cut Off Saw,Pretrim PM10 0.005 lbslhr cyclones and ba*house Saws,and Production Collection VOC 1.77 lbs/hr,as C none (ID No.3535) Opacity 20 percent cyclones and ba house Particleboard Press(ID No.DEF- PM10 3.29 lbs/hour none 2010)and Board Cooler(ID No. VOC 32.1 lbs/hour as C none PB-BC) Opacity 20 percent none Particleboard Steinmann PM10 0.02 lbs/hour cyclone and ba houses Calibrating Sander(ID No.3565} VOC 1.08 lbs/hour as C none O cit 'M ercent cvclone and baahouses Particleboard Steinmann PM10 12 lbs/hour cyclone and baahouses Finishing Sander(ID No.3545) VOC 0.35 lbs/hour as C none O acity 20 percent cyclone and ba ghouses Schelling Saw Board Trim(ID PM10 0.01 lbs/hour cyclone and ba gliouse No.3522) VOC 0.72 lbs/hour as C none ❑ achy 20 percent cyclone and ba ouse Sander Filter Transport for Filters PM10 4.0 lbs/hour ❑ clone and baahouse 3545 and 3565 QD No.3575) VOC 1.77 lbs/hour as C none Opacity 20 percent cyclone and bap-house PZKR Green Chip Flakers(ID PM10 1.0 lbs/hour ba house No.3585) VOC 0.641bslhour as C none Opacity 20 percent ba house Oversized Material Pallmann Mill PM10 0.005 lbs/hour bap-house (ID No.3595) VOC 1.77 lbs/hour as C none Opacity 20 percent ba house Dry Waste Transport System(ID PM10 0.005 lbs/hour cyclone and bag-house No.3577] VOC 1.77 lbs/hour as C none O.acit� 20 percent cyclone and ba cruse * BACT limits shall apply at all times.However,emissions resulting from startup,shutdown or malfunction as Air Permit 03449T50 Page 29 defined under 15A NCAC 02D.0535,exceeding the limits in condition a. above are permitted,provided that the Permittee,to the extent practicable,maintains and operates each emission source including any associated air pollution control equipment listed in this Table,in a manner consistent with good air pollution control practice for minimizing emissions. ** BACT emission limits are a total for the two remaining particleboard dryers(ID Nos. 1420,and 1430). Testing[PMio,VOC.CO.NOx] [15A NCAC 02Q.0508(t)] b. If emissions testing is required for visible emissions,PMlo,VOC,CO and NOx,the testing shall be performed in accordance with General Condition JJ. If the results of this test exceed the limits given in Section 2.1 E.6.a. above, the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530. c. For the dryers(ID No. 1420 and 1430), the Permittee shall conduct a source test for VOC within 180 days following the initial introduction of the low moisture furnish.If the results of this test exceed the limits given in Section 2.1 E.6.a.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530. Monitorine(PM10[15A NCAC 02Q.0508(f)] d. PM o emissions from the units in the particleboard mill[ID No.PB]shall be controlled as follows: i. In the sawdust rock and metal separator(ID No.3501),raw materials shall be sorted to remove unusable material and transported through a high efficiency cyclone(lD No.SC),which is 72 inches in diameter. Emissions from the cyclone shall be exhausted to a fabric filter(ID No.CD-3501)with 2,410 square feet of filter surface area. ii. Emissions from the sources in in Table 2.1.E.1.shall be controlled as presented in Table 2.I.E.1 iii. Emissions from the sources in in Table 2.1.E.2.shall be controlled as presented in Table 2.1.E.2 Cyclones,multievelones and fabric filters in Tables 2.1.E.1 and 2.1.E.2 e. To ensure compliance and effective operation,the Permittee shall perform inspections and maintenance,as recommended by the manufacturer, In addition to the manufacturer's inspection and maintenance recommendations,or if there is no manufacturer's inspection and maintenance recommendations,as a minimum, the inspection and maintenance requirement shall include the following: i, a monthly visual external inspection of the control devices,system ductwork,and the material collection units for leaks. ii. for each bagfilter,an annual(for each 12 month period following the initial inspection)internal inspection of the bagfilter's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if the requirements in condition e.are not met. Wet electrostatic precipitator OID No.CD-PB-NVESP f. To ensure compliance and the effective operation of the wet electrostatic precipitator(ID No.CD-PB-WESP), the Permittee shall: L operate the wet electrostatic precipitator with a minimum of two of the possible three fields,excluding periods when one of the two fields is in a wash cycle; ii. monitor and record the secondary voltage and current through the precipitator.The lower limits(3-hour block averages)are given below: Table 2.1 E.6.17 Field No. Minimum Secondary Voltage, Minimum Current,n lliamps kilovolts _ 1 23 48 2 25 75 3 1 27 127 iii. shall meet the requirements for a dry rotary dryer at Sections 2.2 AAJ in lieu of monitoring the water injection rate to assure compliance with the VOC BACT limit in Section 2.1 E.6.a. iv. The parameter ranges in Table 2.1 E.6.f are not required during performance testing. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if; i. the voltage or current readings are not monitored or recorded,excluding periods of start-up,shut-down., malfunction,and monitor downtime;and as provided in i.and ii.above; Air Permit 03449T50 Page 30 Li. the voltage or current fall below the lower limits as established above in condition Ed.;or iii, the requirements in f iii are not met. Monitoring CO VOC and NOx [I5A NCAC 02Q.0508(f)] g. i. To ensure compliance and effective operation,the Permittee sball perfonn inspections and maintenance of the particleboard dryers(ID Nos. 1420,and 1430). At a minimum,the inspection and maintenance requirement shall include the following: (A).a weekly inspection of bumers,fans,blowers,and associated process control equipment. (B) an annual(for each 12-month period following the initial inspection)internal inspection of the particleboard.dryers(ID Nos.1420,and I430)for structural integrity. ii. For VOCs from the particleboard dryers(ID Nos.1420,and 1430),the Permittee shall meet the inlet temperature and moisture monitoring requirements at Section 2.2 A.I.w through y. If these monitoring requirements are not met,the Permittee shall be deemed to be in noncompliance with 15A NCAC 02D.0530. Monitorine/Recordkeeping(VE)[I5A NCAC 02Q.0508(f)] h. The monitoringlrecordkeeping requirements in Section 2.1 E.5.c and d shall be sufficient to ensure compliance with 15A NCAC 02D.0530. If the requirements of Section 2.1 E.5.c and d are not met,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530. Recordkee vines PMi [I5A NCAC 02Q.0508(f)] For the cyclones.multicvclones and fabric filters and WESP in Tables 2.1.E.1 and 2.1.E.2 i. The results of inspection and maintenance activities shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative ofDAQ upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each inspection; iii. the results of any maintenance performed;and iv. any variance from manufacturer's recommendations,if any,and corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these records are not maintained. Recordkee in g CO VOC and NOx [15A NCAC 02Q.0508(f)] j. i. The results of inspection and maintenance of the particleboard dryers(ID Nos.1420,and 1430)shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative of DAQ upon request. The logbook shall record the following: (A) the date and time of each recorded action; (B) the results of each inspection; (C) the results of any maintenance performed on the particleboard dryers;and (D) any variance from manufacturer's recommendations,if any,and corrections made. ii. For VOCs from the particleboard dryers(ID Nos. 1420 and 1430),the Permittee shall meet the inlet temperature and moisture recordkeeping requirements at Section 2.2 A.1.aa and bb. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these records are not maintained. MenitoringfRecordkeepinp_(Mg,g,CO.VOC,NO.,and VE) [15A NCAC 02Q.0508(t)] k. The total particleboard production at the Particleboard Mill(ID No.PB)during any consecutive 12-month period shall not exceed 180,000,000 square feet on a %-inch basis. The Permittee shall maintain monthly records of the total amount of particleboard produced in a logbook(written or in electronic format). Such records shall indicate the amount of particleboard produced during the preceding month and the total amount of particleboard produced over the preceding 12-month period. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these requirements are not met. 1. The operating hours for particleboard dryers(ID Nos. 1420 and 1430)shall not exceed 8,500 hours each during any consecutive 12-month period. The Permittee shall keep monthly records of the hours of operation for each particleboard dryer. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these requirements.are not met. Air Permit 03449T50 Page 31 Reporting{ Mia.CO,VOC,and NOxI[15ANCAC 02Q.0508(f)] PMia,CO,VOC,and NOx m. The Permittee shall submit the results of any maintenance performed on the control devices in Tables 2.1.E,1 and 2.1.E.2 and/or particleboard dryers(ID Nos.1420,and 1430)within 30 days of a written request by the DAQ. n. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. i. For VOCs from the particleboard.dryers(ID Nos. 1420 and 1430),the Permittee shall meet the reporting requirements at Section 2.2 A.Ldd through gg. VE o. Reporting requirements in Section 2.1 E.5.e shall be sufficient to ensure compliance with 15A NCAC 02D .0530. I'Mie,CO VOC NO.,VE p. By January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June,the following shall be reported to the Regional Supervisor,Division of Air Quality: i. the annual production rate at the Particleboard Mill(113 No.PB)in square feet on a %-inch basis.The annual production rate must be calculated for each of the six twelve-month periods over the previous seventeen months. ii, the hours of operation for each particleboard dryer(ID Nos.m1420 and 1430)for each of the six twelve- month periods over the previous seventeen months. All instances of deviations from the requirements of this permit must be clearly identified. 7. 15A NCAC 02D.0614: COMPLIANCE ASSURANCE MONITORING[40 CFR 641 a. Pursuant to 40 CFR 64 and 15A NCAC 02D.0614,the Permittee shall comply with the conditions below for the Pollutant Specific Emission Unit(s)controlled by the wet electrostatic precipitator JD No.CD-PB-WESP). Emission Limitations/Standards b. The following table presents the regulated pollutants and the associated emission limitations/standards: Regulated Pollutant Limits/Standards Applicable Regulation PM See condition 2.1 E.1 15A NCAC 02D.0515 PMI0 See condition 2.1 E.6 15A NCAC 02D.0530 VOCs See condition 2.1 E.6 15ANCAC 02D.0530 Monitoring Approach[15A NCAC 02Q.0508(f),40 CFR 64.61 c. The key elements of the monitoring approach for PM and PMlo,including parameters to be monitored, parameter ranges and performance criteria are presented in the following table. Air Permit 03449T50 Page 32 Monitoring Indicator No. 1 Indicator No.2 Elements Measurement Secondary voltage readings on each of the Current readings on each of the three fields Approach three fields are made on each field of the wet are made on each field of the wet ESP every 64.6(c)(1){i} (ii) ESP eve 15 minutes 15 minutes Indicator Range An excursion is defined as a one-hour block An excursion is defined as a one-hour block [64.6(c)(2)] average voltage reading in any field lower average current reading in any field lower than the respective 3-hour block average than the respective 3-hour block average reading listed in Table 2.1.E.6.f.of this reading listed in Table 2.1.E.61 of this permit.Excursions trigger an inspection and permit. Excursions trigger an inspection and corrective action. corrective action. kQEPthr7e—shold The QIP threshold is six excursions in a six- The QIP thresbold is six excursions in a six- 64.8 month reporting od, month reporting period. Data Measurements are made once every 15 Measurements are made once every 15 Representativeness minutes and complied into the appropriate minutes and complied into the appropriate [64.6(c)(1)(iii), averaging periods. averaging periods. 64.3(b)(1) Verification of Monitoring shall be required upon issuance of permit no.03449T47 Operational Status 64,3(b)f2} QAIQC Practices Voltmeter calibration shall be performed Ammeter calibration shall be performed and Criteria according to manufacturer recommendations. according to manufacturer recommendations. [64.3(b)(3)] _ Monitoring Measurements are made by a computerized data acquisition and handling system once every 15 frequency minutes and complied into the appropriate averaging periods. 64.3(b)(4) Data collection Non-SSM periods when voltage and current falls below the acceptable ranges for more than procedure one-hour will be documented.An electronic or written logbook will be kept of all control 164.3(b)(4)1 I device ins ections and corrective actions Monitoring,Approach [l 5A NCAC 02Q.0508(f),40 CFR 64.6] d. For VOC, the Permittee has elected to satisfy the presumptively acceptable monitoring requirements under MACT DDDD for the dry rotary dryer as allowed at 40 CFR 64.4(b)(4).The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if the moisture and temperature values are outside the indicator ranges found at Section 2.2 A.l.j. Recordkeepina Remirements[15ANCAC 02Q.0508(f),40 CFR 64,9] e. The owner or operator shall maintain records of the following: L Date and time and results of all monitoring activities; U. Information on the number,duration and cause(including unknown cause,if applicable)of excursions or exceedances,as applicable,and the corrective actions taken; iii. Maintenance records of the differential pressure gauge;and iv, Written QIP required pursuant to 40 CFR 64.8 and any activities undertaken to implement a quality improvement plan. v. For VOC,the Permittee shall meet the recordkeeping and reporting requirements found in Section 2.2 A.l.aa through ii,as applicable.The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if these requirements are not met. Reporting Requirements[15A NCAC 02Q.0508(f),40 CFR 64.9] f The Permittee shall submit a summary report of all monitoring activities postmarked on or before January 30 of eacb calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations for the requirements of this permit must be clearly identified. At a minimum,the report shall include the following elements; L Summary information on the number,duration and cause(including unknown cause,if applicable)of excursions or exceedances,as applicable,and the corrective actions taken; ii. Summary information on the number,duration and cause(including unknown cause,if applicable)for Air Permit 03449T50 Page 33 monitor downtime incidents(other than downtime associated with zero and span or other daily calibration checks,if applicable);and iii. A description of the actions taken to implement a QIP during the reporting period as specified in 40 CFR 64.8.Upon completion of a QIP,the owner or operator shall include in the next summary report documentation that the implementation of the plan has been completed and reduced the likelihood of similar levels of excursions or exceedances occurring. iv. For VOC,the Permittee shall meet the recordkeeping and reporting requirements found in Section 2.2 A.l.aa through ii,as applicable.The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if these requirements are not met. 8. 15A NCAC 02D.1111: MARTMUINI ACHIEVABLE CONTROL TECHNOLOGY Applicability[40 CFR 63.7485] a. For this existing process heater designed to bum gas 1 fuels(1D No.3201),the Permittee shall comply with all applicable provisions,including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 021).1111 "Maximum Achievable Control Technology" (MACT) as promulgated in 40 CFR Part 63 Subpart DDDDD."National Emission Standards for Hazardous Air Pollutants for Major Sources:Industrial,Commercial,and Institutional Boilers and Process Heaters"and Subpart A"General Provisions." i. Condition 2.1.E.8 applies only when the Permittee operates the Wellons(ID No.3201)in operating scenario 2 (OS-2). Definitions and Nomenclature[40 CFR 63,7575] b. For the purpose of this permit condition,the definitions and nomenclature contained in 40 CFR 63.7575 shall apply, 40 CFR Part 63 Subpart A General Provisions [40 CFR 63.7565] c. The Permittee shall comply with the requirements of 40 CFR Part 63 Subpart A General Provisions according to the applicability of Subpart A to such sources as identified in Table 10 to 40 CFR Part 63 Subpart DDDDD. Compliance Date J40 CFR 63.7495(b)] d. The Permittee shall complete the initial tune up and the one-time energy assessment no later than January 31,2016. J40 CFR 63.7495(b),63.7510(e)] i. If the Wellons(11)No.3201)is not operated in OS-2 prior to January 1,2016,the Permittee shall complete the initial tune up no later than 30 days after startup. [40 CFR 63.75100)] Notifications J40 CFR 63.7545,63.7530(d),(e),(t)] e. The Permittee shall submit a Notification of Compliance Status. The notification shall contain the following: i. A description of the affected unit(s)including identification of which subcategories the unit is in,the design heat input capacity of the unit,and description of the fuel(s)burned. ii. the Following certification(s)of compliance,as applicable: i.-"This facility complies with the required initial tune-up according to the procedures in condition g.i. through g.v.and in.ii.' (40 CFR 63.7540(a)(10)(i)through(vi));and ii.-"This facility has had an energy assessment performed according to condition k.(40 CFR 63.7530(e))." The notification must be signed by a responsible official and sent before the close of business on the 60th day following the completion of the initial tune up and one time energy assessment(whichever is later). General Compliance Reg uiirements 140 CFR 63.7505(a),63.7500(f)] f. The Permittee shall be in compliance with the work practice standards in this subpart.These standards apply at all times the affected unit is operating. Air Permit 03449T50 Page 34 Work Practice Standards[15ANCAC 02Q.0508(f)] g. The Permittee shall conduct a tune-up of the process heater annually as specified below. i. As applicable,inspect the burner,and clean or replace any components of the burner as necessary(the Permittee may delay the burner inspection until the next scheduled unscheduled unit shutdown; ii. 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; iii. Inspect the system controlling the air-to-fuel ratio,as applicable,and ensure that it is correctly calibrated and functioning properly(the Permittee may delay the inspection until the next scheduled unit shutdown)' iv. Optimize total emissions of carbon monoxide.This optimization should be consistent with the manufacturer's specifications,if available,and with any NOX requirement to which the unit is subject. v. 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 he either on a dry or wet basis,as long as it is the same basis before and after the adjustments are made).Measurements may be taken using a portable CO analyzer. [40CFR 63.7500(a),63.7540(a)(10)] h. Each annual tune-up shall he conducted no more than 13 months after the previous tune-up. [40CFR 63.7515(d)] i. If the unit is not operating on the required date for a tune-up, the tune-up must he conducted within 30 calendar days of startup. [40 CFR 63.7540(a)(13),63.7515(g)] j. At all times,the Permittee must 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.Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator that may include,but is not limited to,monitoring results,review of operation and maintenance procedures,review of operation and maintenance records,and inspection ofthe source. [40 CFR 63.7500(a)(3)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D .1111 if the requirements in F throggh i.are not met. EneraF Assessment Requirements[15A NCAC 02Q.0508(b)] k. The Permittee shall have a one-time energy assessment performed by a qualified energy assessor.The energy assessment must include the following items: i. A visual inspection of the boiler system; ii. An evaluation of operating characteristics of the affected boiler systems,specifications of energy use systems, operating and maintenance procedures,and unusual operating constraints; iii. An inventory of major energy use systems consuming energy from affected hoiler(s)and which are under control of the boiler owner or operator; iv. A review of available architectural and engineering plans,facility operation and maintenance procedures and logs,and fuel usage; v. A list of major energy conservation measures that are within the facility's control; vi. A list of the energy savings potential of the energy conservation measures identified;and vii. A comprehensive report detailing the ways to improve efficiency,the cost of specific improvements,benefits, and the time frame for recouping those investments. 1. The energy assessment will he 8 on-site technical labor hours in length maximum,but may be longer at the discretion of the owner or operator of the affected source.The boiler system(s)and any on-site(excluding MDF plant)energy use systems)accounting for at least 50 percent of the affected boiler(s)energy(e.g.,steam,hot water,process heat,or electricity)production,as applicable,will be evaluated to identify energy savings opportunities,within the limit of performing an 8-hour on-site energy assessment. [40 CFR 63.7500(a)(1),Table 3] The Pennittee shall he deemed in noncompliance with 15A NCAC 02D.I I l 1 if the requirements in k. through 1.are not met. Recordkeepin*Requirements[15A NCAC 02Q.0508(f),40 CFR 63.7555] m. The Permittee shall keep the following: i. A copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,or semiannual compliance report that Air Permit 03449T50 Page 35 has been submitted,according to the requirements in 40 CFR 63.10(b)(2)(xiv). [40 CFR 63.7555(a)(1)] ii. Maintain on-site and submit,if requested by the Administrator,an annual report containing the information in paragraphs(A)through(C)below: (A) The concentrations of carbon monoxide in the effluent stream in parts per million by volume,and oxygen in volume percent,measured before and after the adjustments of the source; (B) A description of any corrective actions taken as apart of the combustion adjustment;and (C) The type and amount of fuel used over the 12 months prior to the annual adjustment,but only if the unit was physically and legally capable of using more than one type of fuel during that period.Units sharing a fuel meter may estimate the fuel use by each unit. [40 CFR 63.7540(a)(10)(vi)] iii. The associated records for conditions f.through 1. including the occurrence and duration of each malfunction of operation(i.e.,process equipment)or the required air pollution control and monitoring equipment. [40 CFR 63.1 0(b)(2)(ii)] iv. maintain records of the calendar date,time,occurrence and duration of each startup and shutdown. [40 CFR 63.7555(i)] v. maintain records of the type(s)and amount(s)of fuels used during each startup and shutdown. 140 CFR 63.75556)] n. The Permittee shall: i. maintain records in a form suitable and readily available for expeditious review; ii. keep each record for 5 years following the date of each occurrence,measurement,maintenance,corrective action,report,or record;and id. keep each record on site for at least 2 years after the date of each occurrence,measurement,maintenance, corrective action,report,or record.The Permittee can keep the records offsite for the remaining 3 years. [40 CFR 63.7560,63.10(h)(1)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if records are not maintained per conditions m.through n. Reporting Requirements[15ANCAC 02Q ,0508(f)] o. In lieu of a 1-year reporting requirement pursuant to 40 CFR 63.7550(b),the Permittee has elected to submit compliance reports to the DAQ on a semi-annual basis.The Permittee shall submit the compliance report postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. i. The first report shall cover the period beginning on January 31,2016 and shall be postmarked on or before July 30,2016. ii. These reports must also be submitted electronically through the EPMs Central Data Exchange(CDX) (www.epa.gov/cdx).However,if the reporting form specific to this subpart is not available in CEDRI at the time that the report is due the report the Permittee submit the report to the at the appropriate address listed in 40 CFR 63.13.[40 CFR 63.7550(h)(3)] A. The Permittee may submit the CDX report in condition o.ii. above on a 1-year basis as allowed pursuant to 40 CFR 63.7550(b). p. The compliance report must contain the following information: i. Company name and address; d. Process unit information,emissions limitations,and operating parameter limitations; iii. Date of report and beginning and ending dates of the reporting period; iv. The total operating time during the reporting period; iv. If there are no deviations from the requirements of the work practice requirements in condition g.above,a statement that there were no deviations from the work practice standards during the reporting period;and v. Include the date of the most recent tune-up for each unit required to conduct an annual tune-up according to condition g.Include the date of the most recent burner inspection if it was not done annually and was delayed until the next scheduled or unscheduled unit shutdown. [40 CFR 63.7550(a)and(c),Table 9] q. If there is a deviation from a work practice standard during the reporting period,the report must contain the following information: Air Permit 03449T50 Page 36 i. A description of the deviation and which emission limit or operating limit from which the Permittee deviated; and ii. Information oo the number,duration,and cause of deviations(including unknown cause), as applicable,and the corrective action taken. [40 CFR 63.7550(a)and(d),63.7540(b),Table 9] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if the reporting requirements in o. through q. are not met. F. Laminating Mill: Table 2.1.F Emission Emission Source Description Control Device Control Device Description Source ID No. I ID No. Two(2)Short Cycle Laminating Reverse flow bagfikter(Maximum 3593 and 3594 Presses CD-3593 air-to-cloth ratio of4.1 ACFM/total filter surface area]. Natural gas-fired hot oil heater(4.7 Pr-Heatl million Btu per hour heat input)used NIA NA with short cycle laminating presses The followki!table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant Limits/Standards Applicable Regulation Affected source: {ID No.Pr-H cat 1 r 15A NCAC 02D.0503 0.60 pounds Cer million Btu heat input PM Affected source: (ID Nos.3593 and 3594) E=4.10P 0.67 where;E=allowable emission rate in pounds per hour 15A NCAC D2D.D515 P=process weight in tons per hour Sulfur dioxide Affected source: RD No.Pr-Heatl) 15A NCAC 02D.0516 2.3 pounds per mullion Btu heat input Visible emissions 20 percent opacity 15A NCAC 02D.D521 HAPs Affected source.(ID No.Pr-Heatl) 15A NCAC 02D.1109 Best Combustion Practices [o7d 0- rs State-Enforceable Only See Section 2.2 A.2 15A NCAC 02D.1806 I. 15A NCAC 02D.0503:PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of natural gas from the hot oil heater(ID No.Pr-Heatl) into the atmosphere shall not exceed 0.60 pounds per million Btu heat input. Testing[15A NCAC 02D.0508(f)j b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test exceed the limit given in condition a.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0503. Monitorin./RecordkeeninaiRepnrtin [15A NCAC D2Q.0508(f)] c. No monitoring,record keeping,or reporting is required for particulate emissions from the firing of No.2 fuel oil and natural gas in the hot oil heater(ID No.Pr-Heatl). 2. 15A NCAC 02D.0515;PARTICULATE EMISSIONS FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the units in the short cycle laminating presses(ID Nos.3593 and 3594) that are discharged into the atmosphere shall not exceed an allowable emission rate as calculated by the following equations: Air Permit 03449T50 Page 37 Process Rate Allowable Emission Rate Equation Less than or equal to 30 tons per hour E=4.10 x P 0.67 Greater than 30 tons per hour E=55.0(P)0•11-40 Where E=allowable emission rate in pounds per hour P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing[15ANCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of the test performed exceed the limits given in condition a. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515. MonitoringLkecordkeeainglEeporting[15A NCAC 02Q .0508(f)] c. Particulate matter emissions from the short cycle laminating presses(ID Nos.3593 and 3594)shall be controlled using the reverse flow bagfilter(11)No.CD-3593). To ensure compliance,the Permittee shall perform inspections and maintenance as recommended by the manufacturer. In addition to the manufacturer's inspection and maintenance recommendations,or if there are no manufacturer's inspection and maintenance recommendations,as a minimum,the inspection and maintenance requirement shall include the following: i. a monthly visual inspection of the system ductwork and material collection unit for leaks;and ii. an annual(fox each 12 month period following the initial inspection)internal inspection of the hagfiltees structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if the ductwork and bagfilters are not inspected and maintained. d. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on- site and made available to an authorized representative upon request. The logbook shall record the followiog: i. the date and time of each recorded action; ii. the results of each inspection;and iii. the results of maintenance performed on any control device. The Permittee shall he deemed in noncompliance with 15A NCAC 02D.0515 if these records are not maintained. Reporting[15ANCAC 02Q.0508(f)] e. The Permittee shall submit the results of any maintenance performed on the bagfilter(ID No.CD-3593)within 30 days of a written request by the DAQ. f. The Permittee shall submit a summary report of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preeeding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 3. 15A NCAC 02D.051G:SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Sulfur dioxide emissions from the hot oil beater(ID No.Pr-Heat1)shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall he included when determining compliance with this standard. Testing[15ANCAC 02Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .0516. MonitoringlRecordkeening[15A NCAC 02Q.0508(f)] c. No monitoring,record keeping,or reporting is required for sulfur dioxide emissions from the firing of natural gas in the hot oil heater(ID No.Pr-Heat1). Air Permit 03449T50 Page 38 4. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the sources listed in Table 2.1.F.shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. if the results of the test performed exceed the limits given in condition a.(above)for visible emissions,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitoring/Recordkee ing[I5ANCAC 02Q.0508(f)] c. To ensure compliance, the Permittee shall observe,on a weekly basis,the following emission points in the Particleboard mill for any visible emissions above normal: Emission Source Emission Point ID No. short cycle laminating presses(ID Nos.3593 and 3594) CD-3593 The weekly observation must be wade for each of the calendar year period to ensure compliance with this requirement. If visible emissions from the short cycle laminating presses are observed to be above normal,the Permittee shall either: i. take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below,or ii. demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 02D.2610(Method 9)for 12 minutes is below the limit given in condition a.above. If the above-normal emissions are not corrected per(i)above or if the demonstration in(ii)above cannot be made,the Permittee shall be deemed to be in noncompliance with 15A NCAC 02D.0521. d. The results of the monitoring for visible emissions shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request.To ensure quality,entries in the logbook should be signed by personnel responsible for the effective operation of the units in the particleboard mill and their air pollution control devices.The logbook shall record the following: i. The date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Penn ittee shall be deemed in noncompliance with 15A NCAC 02D.0521 if these records are not maintained. Reporting[15A NCAC 02Q.0508(f)] e. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 5. 15A NCAC b2D.1109: Case-by-Case MACT a. The Permittee shall use best combustion practices when operating the affected heater(11D No.Pr-Heat1). The initial compliance date for this work practice standard and the associated monitoring,recordkeeping,and reporting requirements is October 18,2013. These conditions need not be included on the annual compliance certification until after the initial compliance date. i. The Permittee shall comply with this CAA§1126)standard until May 19,2019.The initial compliance date for the applicable CAA§112(d)standard for"National Emission Standards for Hazardous Air Pollutants for Industrial,Commercial,and Institutional Boilers and Process Heaters"is May 20,2019,as specified in Section 2.LF.6.below. Air Permit 03449T50 Page 39 Monitorin s!IRecordkee p ins b. To ensure compliance,the Permttee shall perform an annual boiler inspection and maintenance as recommended by the manufacturer,or as a minimum,the inspection and maintenance requirement shall include the following: i. Inspect the burner,and clean or replace any components of the burner as necessary; ii. Inspect the flame pattern and make any adjustments to the burner necessary to optimize the flame pattern; and, iii. Inspect the system controlling the air-to-fuel ratio,and ensure that it is correctly calibrated and functioning properly. The Permittee shall conduct at least one tune-up per calendar year to demonstrate compliance with this requirement. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1109 if the affected heater is not inspected and maintained as required above. c. The results of inspection and maintenance shall be maintained in a logbook(written or electronic format)on- site and made available to an authorized representative upon request. The loghook shall record the following: i. The date of each recorded action; ii. The results of each inspection;and, iii. The results of any maintenance perfornned on the heater. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1109 if these records are not maintained. Reportine[15A NCAC 02Q.0508(f)] d. No reporting is required. 6. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY Applicability[40 CFR 63.7485,.7490(d),.7499(1)] a. For the heater(ID No.Pr-Heatl)(an existing source designed to burn gas i fuels with a heat input capacity of less than or equal to 5 million Btu per hour),the Permittee shall comply with all applicable provisions, including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .1111 "Maximum Achievable Control Technology"(MACT)as proinulgated in 40 CFR Part 63 Subpart DDDDD,"National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial,Commercial,and Institutional Boilers and Process Heaters"and Subpart A"General Provisions." i. The Permittee shall comply with the CAA§1120)standard in Section 2.1.F.5. through May 19,2019. The Permittee shall be subject to the requirements of this standard starting May 20,2019.Note that the requirements of this standard inay require action on behalf of the Permittee prior to May 20,2019. Definitions and Nomenclature[40 CFR 63.7575] b. For the purpose of this permit condition,the definitions and nomenclature contained an 40 CFR 63.7575 sball apply. 40 CFR Part 63 Subpart A General Provisions[40 CFR 63.7565] c. The Permittee shall comply with the requirements of 40 CFR Part 63 Subpart A General Provisions according to the applicability of Subpart A to such sources as identified in Table 10 to 40 CFR Part 63 Subpart DDDDD. Compliance Date L40 CFR 63.7510(e),63.56(b)] d. The Permittee shall complete the initial rune up and the one-timc energy assessment no later than May 20, 2019. Notifications L40 CFR 63.7545(e)(8),63.7530(e),(f)] e. The Permittee shall submit a Notification of Compliance Status. The notification must be signed by a responsible official and sent before the close of business on the 60th day following the completion of the initial tune up and one time energy assessment(whichever is later).The notification shall contain the following: i. A description of the affected unit(s)including identification of which subcategories the unit is in,the design heat input capacity of the unit,and description of the fuel(s)burned, ii. the following certification(s)of compliance,as applicable: Air Permit 03449T50 Page 40 A.-"This facility completed the required initial tune-up for all of the boilers and process heaters covered by 40 CFR Part 63 Subpart DDDDD at the site according to the procedures in.40 CFR 63.7540(a)(10)(i)through(vi)' [i.e.,conditions g.i.through g.v.and 1. ii.];and B.-"This facility has had an energy assessment performed according to 40 CFR 63.7530(e)"[i.e., condition k.]and is an accurate depiction of the facility at the time of the assessment. General Compliance Requirements j40 CFR 63.7505(a),63.7500(f)] f. The Permittee shall be in compliance with the work practice standards in this subpart.These standards apply at all times the affected unit is operating. Work Practice Standards[15A NCAC 02Q.0508(f)] g. The Permittee shall conduct a tune-up of the process heater every five years as specified helow. i. As applicable,inspect the burner,and clean or replace any components of the burner as necessary(the Permittee may delay the burner inspection until the next scheduled or unscheduled unit shutdown,but the burner must be inspected at least once every 72 months ii. Inspect the flame pattern,as applicahle,and adjust the hurner as necessary to optimize the flame pattern. The adjustment should be consistent with the manufacturer's specifications,if available; iii. Inspect the system controlling the air-to-fuel ratio,as applicahle,and ensure that it is correctly calibrated and functioning properly(the Permittee may delay the inspection until the next scheduled unit shutdown)' iv. Optimize total emissions of carbon monoxide.This optimization should be consistent with the manufacturer's specifications,if available,and with any NOx requirement to which the unit is subject. v. Measure the concentrations in the effluent stream of carbon monoxide in parts per mullion,by volume,and oxygen in volume percent,before and after the adjustments are made(measurements may he either on a dry or wet basis,as long as it is the same basis before and after the adjustments are made).Measurements may he taken using a portable CO analyzer. [40CFR 63.7500(a),(e),63.7540(a)(10),(a)(12)] h. Each 5-year tune-up shall he conducted no more than 61 months after the previous tune-up. [40CFR 63.7515(d)] i. If the unit is not operating on the required date for a tune-up,the tune-up must be conducted within 30 calendar days of startup. [40 CFR 63.7540(a)(13),63.7515(g)] j. At all times,the Permittee must 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.Determination of whether such operation and maintenance procedures are being used will be hased on information available to the Administrator that may include,but is not limited to, monitoring results,review of operation and maintenance procedures,review of operation and maintenance records,and inspection of the source. [40 CFR 63.7500(a)(3)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if the requirements in f throu r j.are not met. Enerz-Assessment Requirements[15A NCAC 02Q.0508(f)] k. The Permittee shall have a one-time energy assessment performed by a qualified energy assessor.The energy assessment must address the requirements in 40 CFR Part 63 Subpart DDDDD,Tahle 3,with the extent of the evaluation for items(a)to(e)in Table 3 appropriate for the on-site technical hours listed in§63.7575: [§63.7500(a)(1),Table 3] The Permittee shall he deemed in noncompliance with 15A NCAC 02D.1111 if the requirements in condition k. are not met. Recordkeepinp-Requirements[15A NCAC 02Q.0508(f),40 CFR 63.7555] 1. The Permittee shall keep the following: i. A copy of each notification and report suhmitted to comply with this suhpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,or semiannual compliance report that has been submitted,according to the requirements in 40 CFR 63.10(b)(2)(xiv). [40 CFR 63,7555(a)(1)] ii. Maintain on-site and suhmit,if requested by the Administrator,an annual report containing the information in paragraphs(A)through(C)below: A- The concentrations of carbon monoxide in the effluent stream in parts per million by volume,and Air Permit 03449T50 Page 41 oxygen in volume percent,measured before and after the adjustments of the source; B. A description of any corrective actions taken as a part of the combustion adjustment_and C. The type and amount of fuel used over the 12 months prior to the annual adjustment,but only if the unit was physically and legally capable of using more than one type of fuel during that period.Units sharing a fuel meter may estimate the fuel use by each unit. [40 CFR 63.7540(a)(10)(vi)] iii. The associated records for conditions f. through 1.including: A. the occurrence and duration of each malfunction of operation(i.e.,process equipment)or the required air pollution control and monitoring equipment. [40 CFR 63.10(b)(2)(ii)] iv. maintain records of the calendar date,time,occurrence and duration of each startup and shutdown. [40 CFR 63.7555(i)] v. maintain records of the type(s)and amount(s)of fuels used during each startup and shutdown. [40 CFR 63.75556)] m. The Permittee shall; i. maintain records in a form suitable and readily available for expeditious review; ii. keep each record for 5 years following the date of each occurrence,measurement,maintenance,corrective action,report,or record;and iii. keep each record on site for at least 2 years after the date of each occurrence,measurement,maintenance, corrective action,report,or record,The Permittee can keep the records offsite for the remaining 3 years. [40 CFR 63.7560,63.10(b)(1)] The Permittee shall be deemed in noncompliance with 15A NCAC 02D A 111 if records are not maintained as described in conditions 1. through m. Reporting Requirements[15A NCAC 02Q.0508(f)] n. The Permittee shall submit compliance reports to the DAQ on a 5-year basis.The first report shall cover the period beginning on the compliance date specified in condition d.and ending on the earliest December 31 st following a complete 5-year period.5uhsequent 5-year reports shall cover the periods from January 1 to December 31.The Permittee shall submit the compliance reports postmarked on or before January 31. [40 CFR 63.7550(a),(b)] i. This report must also be submitted electronically through the EPNs Central Data Exchange(CDX) (www.epa.govlcdx).However,if the reporting form specific to this subpart is not available in CEDRI at the time that the report is due the report the Permittee submit the report to the at the appropriate address listed in 40 CFR 63.13. [40 CFR 63.7550(h)(3)] o. The compliance report must contain the following information: i. Company name and address; ii. Process unit information,emissions limitations,and operating parameter limitations; iii. Date of report and beginning and ending dates of the reporting period; iv. The total operating time during the reporting period; iv. If there are no deviations from the requirements of the work practice requirements in condition g. above,a statement that there were no deviations from the work practice standards during the reporting period;and v. Include the date of the most recent tune-up for each unit required according to condition g.Include the date of the most recent burner inspection if it was not done as scheduled and was delayed until the next scheduled or unscheduled unit shutdown. [40 CFR 63.7550(a)and(c),Table 9] p. If the Permittee has a deviation from a work practice standard during the reporting period,the report must contain the following information: i. A description of the deviation and which emission limit or operating limit from which the Permittee deviated;and ii. Information on the number,duration,and cause of deviations(including unknown cause),as applicable, and the corrective action taken. [40 CFR 63.7550(a)and(d),63.7540(b),Table g] The Permittee shall he deemed in noncompliance with 15A NCAC 02D.1111 if the reporting requirements in n.through p.are not met. Air Permit 03449T50 Page 42 G. The following source: Emission Emission Source Description Control Device Control Device Description Source ID No. ID No. EVAP-1 Wastewater evaporator NIA NA The following table provides a summary of limits and/or standards for the material handling sources. Regulated Pollutant ts/Standards Applicable Regulation E=4.10P 0,67 or E=55.0(P)0.11-40 PM where;E=allowable emission rate in pounds per hour 15A NCAC 0213.0515 P=E2cess weight in tons per hour Visible emissions 20 percent opacity 15A NCAC 02D.0521 PM10/PM2.5 limit PM2.5/PM10 emissions to less than 10/15 tons per year 15A NCAC 02Q.0317 See Section 2.1 G.3 (PSD Avoidance) Odors STATE ENFORCEABLE ONLY 15A NCAC 02D.180d Odorous emissions must be controlled-See Section 2.2.A.2 HAPs National Emission Standards for Hazardous Air Pollutants: 15A NCAC 02D.1111 Plywood and Composite Wood Products (40 CFR 63 Subpart. No a i ,licable requirements DDDD) 1. 15A NCAC 02D.0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from this source shall not exceed an allowable emission rate as calculated by the following equation(s): Process Rate Allowable Emission Rate Equation Less than or a qual to 30 tons per hour E=4.10 x P 0-11 Greater than 30 tons per hour E=55.0(P)1.11-40 Where E=allowable emission rate in pounds per hour P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition 77. If the results of this test are above the limit given in Section 2.1 G.La above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515. Monitoring[15A NCAC 02Q.05 08(f)] c. The Permittee shall: i. install,operate,and maintain a liquid flowmeter on the wastewater evaporator; ii. limit the liquid flowrate of the wastewater evaporator to 200 gallons per minute.An instantaneous flowrate reading shall be made at the beginning of the operating day and at the end of the operating day;and iii. meet the total dissolved solids content requirement in Section 2.1 G.3.c.iii. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if these monitoring requirements are not met. Recordkeepin [15A NCAC 02Q .0508(f)] d. The results of any monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the date,time and result of each flowrate measurement.The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0515 if these recordkeeping requirements are not met. Air Permit 03449T50 Page 43 Reporting[15A NCAC 02Q.0508(f)] e. The Permittee shall submit a summary report of monitoring and recordkeeping activities in Sections 2.1 G.1.c and d postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 2. 15A NCAC 02D.4521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this emission source. shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[15A NCAC 02Q.0508(0] b. If emissions testing is required, the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the Limit given in Section 2.1 G.2.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D .052 L Monitoring[15A NCAC 02Q.0508(f)] c. i. To ensure compliance,once a week the Permittee shall observe the emission point of this source for any visible emissions above normal. The weekly observation must be made for each week of the calendar year period in which the source is in operation to ensure compliance with this requirement. The Permittee shall establish"normal"for this source in the First 30 days following the effective date of the permit or of beginning operation. If visible emissions from this source are observed to be above normal,the Permittee shall either: (A) take appropriate action to correct the above-normal emissions as soon as practicable and within the monitoring period and record the action taken as provided in the recordkeeping requirements below, or (B) demonstrate that the percent opacity from the emission points of the emission source in accordance with 15A NCAC 02D.2610(Method 9)for 12 minutes is below the limit given in Section 2.1 G.2.a above. ii. The Permittee shall be deemed to be in noncompliance with 15A NCAC 02D.0521 if- (A) the above-normal emissions are not corrected per c.i.(A)above; (B) the demonstration in c.i.(B)above cannot be made; (C) the weekly observations are not conducted per c.i above;or (D) "normal"is not established for this source in the first 30 days following the effective date of this permit/of beginning operation per c.i above. Recordkeeuin [15A NCAC 02Q.0508(f)] d. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the date and time of each recorded action; ii. the results of each observation and/or test noting those sources with emissions that were observed to be in noncompliance along with any corrective actions taken to reduce visible emissions;and iii. the results of any corrective actions performed. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521 if these records are not maintained. Reporting[15A NCAC 02Q.0508(f)] e. The Permittee shall submit a summary report of the monitoring and recordkeeping activities given in Sections 2.1 G.2.c and d above postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must he clearly identified. Air Permit 03449T50 Page 44 3. 15A NCAC 02Q.0317:AVOIDANCE CONDITIONS for 15A NCAC 02D.0530:PREVENTION OF SIGNIFICANT DETERIORATION a. In order to the avoid the applicability of 15A NCAC 02D.0530,the emissions from the source shall not exceed the following limits: i. PM2.5 emissions shall not exceed 10 tons per consecutive 12-month period. ii. PM10 emissions shall not exceed 15 tons per consecutive 12-month period. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitorim/Recordkee in 15A NCAC 02Q.0508(f)] c. The Permittee shall: i. shall install,operate,and maintain a liquid flow totalizer on the wastewater evaporator; ii. limit the liquid flowrate of the wastewater evaporator to 5,580,000 gallons per consecutive 12-month period;and iii. limit the total dissolved solids content of the wastewater to 3,900 milligrams per liter. d. The Permittee shall calculate and record on a monthly basis. i. the total dissolved solids content of the wastewater in pond 5C during each calendar month evaporator is operated; ii. the monthly and rolling 12-month total gallons of wastewater pumped;and iii. the monthly and roiling 12-month total PM10 and PM2.5 emissions from the source. e. The Permittee shall be deemed in noncompliance with 15A NCAC 02Q.0530 if the requirements in Sections 2.1 G.3.c and d are not met. Reportine[15A NCAC 02Q.0508(f)] f. The Permittee shall submit a summary report of the monitoring and recordkeeping activities given in Sections 2.1 G.3.c and d above postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 4. 15A NCAC 02Q.0504: OPTION FOR OBTAINING CONSTRUCTION AND OPERATION PERMIT Permitting[15A NCAC 02Q .0504(d)] a. For completion of the two-step significant modification process pursuant to 15A NCAC 02Q.0501(c)(2)or (d)(2),the Permittee shall file an amended application following the procedures of Section 15A NCAC 02Q .0500 within one year from the date of beginning operation of this source. _Reporting[15A NCAC 02Q.0508(f)] b. The Permittee shall notify the Regional Office in writing of the date of beginning operation of this source, postmarked no later than 30 days after such date. H. Reserved 1. The following combustion source: Table 2.I.I. Emission Source ID Emission Source Description Control Device ID No. Control Device No. -Description ES-21 Diesel Fuel-fired Emergency MALT ZZZZ Generator(1592 Brake Horsepower NA NA output)ut) Air Permit 03449T50 Page 45 The following table provides a summary of limits and/or standards for the emission sources above: Regulated Pollutant Limits/Standards Applicable Regulation Sulfur dioxide 2.3 pounds per million Btu beat input 15A NCAC 0213.0516 Visible emissions 20 percent opacity 15A NCAC 02D.0521 HAPs Maximum Achievable Control Technology 15A NCAC 02D.I 111 (40 CFR Part 63 Subpart ZZZZ) Odors State Enforceable Onh, 15A NCAC 02D.1806 See Section 2.2 A.2. NOx,PM15,PMIa See Section 2.2 B.1. 15A NCAC 02Q.0317 i PSD Avoidance) VOCs Best Available Control Technology 15A NCAC 02D.0530 See Section 2.2 B.2. 1. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this source shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing[15A NCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test are above the limit given in condition a,above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0521. Monitorin2/Recordkee ina/Ne ortin [15A NCAC 02Q.0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of diesel Fuel in this source. 2. 15A NCAC 02D.0516:SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide From this source shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide Formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testing[I 5A NCAC 02Q .0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ found in Section 3. If the results of this test are above the limit given in condition a.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0516. Monitoring/Recordkeepina[15A NCAC 02Q .0508(f)] c. No monitoring/recordkeeping is required for sulfur dioxide emissions from the firing of diesel fuel in this source. 3. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY Applicability[40 CFR 63.6585,63.6590(a)(1)(i)] a. For this emission source(existing stationary RICE with a site rating of more than 500 brake HP located at a major source of HAP emissions),the Pernnttee shall comply with all applicable provisions,including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D.I I I 1 "Maximuur Achievable Control Technology" (MACT)as promulgated in 40 CFR Part 63 Subpart ZZZZ"National Emissions Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines"and Subpart A"General Provisions." Stationary RICE subject to limited requirements[40 CFR 63.6590(b)] Air Permit 03449T50 Page 46 b. Pursuant to 40 CFR 63.6590(b)(3)(iii),these sources do not have to meet the requirements of 40 CFR Part 63 Subpart ZZZZ and Subpart A,including initial notification requirements. 2.2 - Multiple Emission Source(s) Specific Limitations and Conditions A. Facility-wide affected emission sources The following table provides a summary of limits and standards applicable facility wide.- Regulated Pollutant Limits/Standards Applicable Regulation HAPs National Emission Standards for Hazardous 15A NCAC 02D.1111 Air Pollutants:Plywood and Composite Wood (40 CFR Part 63 Subpart Products DDDD) Odors State Enforceable Only 15A NCAC 02D.1806 Odorous emissions must be controlled 1. 15A NCAC 2D.1111: NIAh'IMUM ACHIEVABLE CONTROL TECHNOLOGY Auulicability[§63.2231] a. For the emission sources subject to"MACT Subpart DDDD"as indicated in the permitted equipment list,the Permittee shall comply with all applicable provisions,including the monitoring,recordkeeping,and reporting contained in Environmental Management Commission Standard 15A NCAC 02D.1111 "Maximum Achievable Control Technology"(MACT)as promulgated in 40 CFR 63, Subpart DDDD."National Emission Standards for Hazardous Air Pollutants:Plywood and Composite Wood Products"and Subpart A"General Provisions." Definitions and Nomenclature[§63.2292] b. For the purposes of this permit condition,the definitions and nomenclature contained in§63.2292 shall apply_ 40 CFR Part 63 Subpart A General Provisions[§63.2290] c. The Permittee shall comply with the requirements of 40 CFR 63 Subpart A General Provisions according to the applicability of Subpart A to such sources,as identified in Table 10 to 40 CFR Part 63,Subpart DDDD. Affected Sources Not Subject to Operating.Requirements[§63.2252) d. For process units not subject to the operating requirements in Sections 2.2 A.l.e through 1,The Permittee is not required to comply with the compliance options,work practice requirements,performance testing,monitoring, SSM plans,and recordkeeping or reporting requirements of this 40 CFR 63 Subpart DDDD,or any other requirements in 40 CFR 63 Subpart A except for the initial notification requirements in§63.9(b). Daerating Requirements[15A NCAC 02Q.0508(f), §63.2240(b)] Group I Coating Operations e. The Permittee shall use non-HAP coatings(as defined§63.2292)in its Group 1 miscellaneous coating operations (including H)No.I-Spray paints). [Table 3,40 CFR 63 Subpart DDDD] MDFPlant f. The emissions from the MDF process units in Table 2.2 A.1 shall be controlled by the biofilter(ID No.CD18): Air Permit 03449T50 Page 47 Table 2.2 A.1 Emission Source 11D No. Emission Source Description ES-01 Refiner ES-02-A Energy System consisting of a dry/wet woodlwoodwaste-fired burner(205 million Btu per hour heat input) l ES-02-B Two Sta e Dryer System ES-02-C and ES-02-D Two backup natural gas-fired dryer burners(78.5 and 17 million Btu per hour heat input respectively) I ES-16 MDF Press and Press Hall g. The HAP emissions from the sources in Table 2.2 A I above shall be controlled to meet one of the following compliance options: [§63.2240] i. Reduce emissions of total HAP,measured as THC(as carbon)a,by 90 percent;or ii. Limit emissions of total HAP,measured as THE(as carbon)a,to 20 ppmvd;or iii. Reduce methanol emissions by 90 percent;or iv. Limit methanol emissions to less than or equal to 1 ppmvd if uncontrolled methanol emissions entering the control device are greater than or equal to 10 ppmvd;or v. Reduce formaldehyde emissions by 90 percent;or vi. Limit formaldehyde emissions to less than or equal to 1 ppmvd if uncontrolled formaldehyde emissions entering the control device are greater than or equal to 10 ppmvd. h. The Permittee shall maintain the 24-hour block hiofilter bed temperature within the following range as established according to condition n. [§63.2240] i. minimum hiofilter bed temperature: TBD IF ii. maximum biofilter bed temperature:TBD OF i. The Permittee shall operate the IVIDF Press(ID No.ES 16)in an enclosure that meets the definition of a wood products enclosure in 40 CFR 63.2292. [§63,2240(b)] PB Plant j. The dryers(ID Nos. 1420,and 1430)shall be operated such that: i. the process furnish will have a 24-hour block average inlet moisture content of less than or equal to 30 percent (by weight dry basis); and ii. the 24-hour block average inlet dryer temperature is less than or equal to 600'F. [§63.2241] k. The press(ID No.DEF-2010)shall meet the production-based compliance option by emitting less than 0.30 lb of total HAP per thousand square feet of board,3/4'basis. [§63.2240] 1. For the press(ID No.DEF-2010),the Permittee has chosen the methanol and formaldehyde content in the resin as the process unit controlling parameter.The Permittee shall maintain the methanol and formaldehyde content of the resins used to levels below those used during the initial compliance demonstration as shown below.The Permittee shall determine the methanol and formaldehyde resin levels based on vendor supplied data on a per shipment basis. These values do not apply during subsequent performance testing. [§63.2262(n)] HAP Resin content limit %b wei ht] Sum of Methanol and Formaldehyde TBD Ted[15A NCAC 02Q,0508(f)] rn. If emissions(performance)testing is required,the testing shall be performed in accordance General Condition 7I.If the results of this test are above the limit given in condition g. above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111. n. All initial performance tests shall be conducted pursuant to§63.2260. o. Any subsequent performance tests shall be conducted pursuant to§63.2262. Air Permit 03449T50 Page 48 MDF Plant Biof lter p. For the biofilter(ID No.CD 18),the Permittee.- i. shall conduct the initial performance tests within 180 days following initial startup of the biofilter[§63.2261]; ii. shall establish the biofilter bed temperature range during the initial performance tests;and iii. may expand the biofilter bed temperature operating range; according to§63.2262 and§63.2267. q. For the biofilter(ID No.CD18),the Permittee shall conduct a repeat performance test using the applicable method(s)specified in Table 4 to 40 CFR 63 Subpart DDDD two years following the previous performance test and within 180 days after each replacement of any portion of the biofilter bed media with a different type of media or each replacement of more than 50 percent(by volume)of the biofilter bed media with the same type of media. [Table 4,40 CFR 63 Subpart DDDD] PB Plant Dry Rotary Dryer r. For the dryers(11)No. 1420 and 1430),the Permittee shall conduct the initial performance tests to meet the definition of a dry rotary dryer(as defined in§63.2292)within 180 days after the issuance of permit no.T49, according to§63.2263. PB Plant Press s. For the press(ID No.DEF-2010),the Permittee shall conduct the initial performance tests to meet the production- based compliance option in Section 2.2 A.Lk within 180 days within 180 days after the issuance of permit no.T49, according to§63.2267. t. If these tests are not conducted pursuant to and do not meet the requirements of Sections 2.2 A.l.m through s,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.1 l 11. GeneralReguirements[15ANCAC 02Q .0508(f),63.2250] u. i. The Permittee must be in compliance with the compliance options,operating requirements,and the work practice requirements in 40 CFR 63 Subpart DDDD at all times,except during periods of process unit or control device startup,shutdown,and malfunction;prior to process unit initial startup;and during the routine control device maintenance exemption specified in condition t.The compliance options,operating requirements,and work practice requirements do not apply during times when the process unit(s)subject to the compliance options,operating requirements,and work practice requirements are not operating,or during periods of startup,shutdown,and malfunction. Startup and shutdown periods must not exceed the minimum amount of time necessary for these events. ii. The Permittee must always operate and maintain the affected source,including air pollution control and monitoring equipment,according to the provisions in§63.6(e)(1)(i). iii. The Permittee must develop a written Startup,Shutdown,and Malfunction Plan(SSMP)according to the provisions in§63.6(e)(3). iv. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if these requirements are not met. Routine Control Device Maintenance Exemption[15A NCAC 02Q.0508(f)] v. RESERVED Monitorina Requirements [15A NCAC 02Q.0508(f)] Temperature Monitoring w. i. The Permittee shall monitor and record the MDF Plant Biofilter(IL)No. CD 18)bed temperature and the PB Plant dryers(ID Nos. 1420 and 1430)average inlet temperature with continuous parameter monitoring systems (CPMS). ii. The Permittee shall install,operate,and maintain each temperature CPMS according to§63.2269(a)and(b). Moisture Monitoring x. The Permittee shall install,operate,and maintain a moisture CPMS on the PB plant dryers(ID Nos. 1420 and 1430) according to §63.2269(a)and(c). All CPMS Air Permit 03449T50 Page 49 Y. i. For the biofilter(ID No.CD18),and dryers(ID No. 1420 and 1430).the Permittee shall determine the 24-hour block average of all recorded readings,calculated after every 24 hours of operation as the average of the evenly spaced recorded readings in the previous 24 operating hours(excluding periods described in paragraphs ii and iii below. [§63.2270(e)] ii. Except for,as appropriate,monitor malfunctions,associated repairs,required quality assurance or control activities(including,as applicable,calibration checks and required zero and span adjustments)the Permittee shall conduct all monitoring in continuous operation at all times that the process unit is operating.For purposes of calculating data averages,the Permittee must not use data recorded during monitoring malfunctions, associated repairs,out-of-control periods,or required quality assurance or control activities.The Permittee must use all the data collected during all other periods in assessing compliance.A monitoring malfunction is any sudden,infrequent,not reasonably preventable failure of the monitoring to provide valid data.Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions.Any period for which the monitoring system is out-of-control and data are not available for required calculations constitute an instance of noncompliance with the monitoring requirements. [§63.2270(b)] iii. The Permittee may not use data recorded during monitoring malfunctions,associated repairs,and required quality assurance or control activities;data recorded during periods of startup,shutdown,and malfunction;or data recorded during periods of control device downtime covered in any approved routine control device maintenance exemption in data averages and calculations used to report emission or operating levels,nor may such data be used in fulfilling a minimum data availability requirement,if applicable.The Permittee must use all the data collected during all other periods in assessing the operation of the control system. [§63.2270(c)] iv. To calculate the data averages for each 24-hour averaging period,the Permittee must have at least 75 percent of the required recorded readings for that period using only recorded readings that are based on valid data(i.e., not from periods described in paragraphs ii and iii above0. [§63.2270(f)] z. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if the monitoring requirements in Section 2.2 A-l.v through y are not met. Reeordkeeain Requirements[15A NCAC 02Q .0508(f),§63.2282 and.2283] aa. The Permittee shall keep the following: i. a copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,according to the requirements in §63.10(b)(2)(xiv); ii. the records in§63.6(e)(3)(iii)through(v)related to startup,shutdown,and malfunction; iii. documentation of the approved routine control device maintenance exemption,requested under§63.2251; iv. records of performance tests and performance evaluations as required in§63.10(b)(2)(viii); v. the associated records for sections 2.2 A Lu through w;and vi. records showing that non-HAP coatings are being used. bb. The Permittee shall: i. maintain records in a form suitable and readily available for expeditious review as specified in§63.1 0(b)(1). ii. as specified in§63.1 0(b)(1),keep each record for 5 years following the date of each occurrence,measurement, maintenance,corrective action,report,or record. iii. keep each record on site for at least 2 years after the date of each occurrence,measurement,maintenance, corrective action,report,or record according to §63.10(b)(1).The Permittee can keep the records offsite for the remaining 3 years. [§63.2283] cc. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if records are not maintained pursuant to Sections 2.2 A.1.aa through cc. Reportiue Requirements[15A NCAC 02Q.0508(f),40 CFR 63.2281] dd. The permittee shall submit a compliance report semiannually postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June.All instances of noncompliance with the requirements of this permit must be clearly identified. [§63.22 8 1(b)(5)and§63.2281(g)] The compliance report must contain the information in paragraphs(1)through(8)of this section. (1) Company name and address. Air Permit 03449T50 Page 50 (2) Statement by a responsible official with that official's name, title,and signature,certifying the truth,accuracy, and completeness of the content of the report. (3) Date of report and beginning and ending dates of the reporting period. (4) If you had a startup,shutdown,or malfunction during the reporting period and you took actions consistent with your SSMP,the compliance report must include the information specified in§63.10(d)(5)(i). (5) A description of control device maintenance performed while the control device was offline and one or more of the process units controlled by the control device was operating,including the information specified in paragraphs(5)(i)through(iii)of this section. (i) The date and time when the control device was shut down and restarted. (ii) Identification of the process units that were operating and the number of hours that each process unit operated while the control device was offline. (iii)A statement of whether or not the control device maintenance was included in your approved routine control device maintenance exemption developed pursuant to§63.2251.If the control device maintenance was included in your approved routine control device maintenance exemption, then you must report the information in paragraphs(5)(iii)(A)through(C)of this section. (A) The total amount of time that each process unit controlled by the control device operated during the semiannual compliance period and during the previous semiannual compliance period. (B) The amount of time that each process unit controlled by the control device operated while the control device was down for maintenance covered under the routine control device maintenance exemption during the semiannual compliance period and during the previous semiannual compliance period. (C) Based on the information recorded under paragraphs(y)(5)(iii)(A)and(B)of this section for each process unit,compute the annual percent of process unit operating uptime during which the control device was offline for routine maintenance using Equation 1 of this section. D T + DT PUN +PUC Where: RM=Annual percentage of process unit uptime during which control device is down for routine control device maintenance; PUp Process unit uptime for the previous semiannual compliance period; PU,=Process unit uptime for the current semiannual compliance period; DTp=Control device downtime claimed under the routine control device maintenance exemption for the previous semiannual compliance period; DT,=Control device downtime claimed under the routine control device maintenance exemption for the current semiannual compliance period. (6) The results of any performance tests conducted during the semiannual reporting period. (7) If there are no instances of noncompliance with any applicable compliance option or operating requirement,a statement that there were no instances of noncompliance with the compliance options or operating requirements during the reporting period. (8) If there were no periods during which the continuous monitoring system(CMS),including CPMS,was out-of- control as specified in§63.8(c)(7),a statement that there were no periods during which the CMS was out-of- control during the reporting period. 1§63.2281(c)] ee. The compliance report must also include the following information for each instance of noncompliance from a compliance option or operating requirement where►°ou are using a CMS to comply with the compliance options and operating requirements.This includes periods of startup,shutdown,and malfunction and routine control device maintenance. (1) The date and time that each malfunction started and stopped. (2) The date and time that each CMS was inoperative,except for zero(low-level)and high-level checks. (3) The date, time,and duration that each CMS was out-of-control,including the information in§63.8(c)(8). (4) The date and time that each instance of noncompliance started and stopped,and whether each instance of noncompliance occurred during a period of startup,shutdown,or malfunction;during a period of control device maintenance covered in your approved routine control device maintenance exemption;or during another period. (5) A summary of the total duration of the instance of noncompliance during the reporting period and the total duration as a percent of the total source operating time during that reporting period. Air Permit 03449T50 Page 51 (6) A breakdown of the total duration of the instances of noncompliance during the reporting period into those that are due to startup,shutdown,control system problems,control device maintenance,process problems,other known causes,and other unknown causes. (7) 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 source operating time during that reporting period. (8) A brief description of the process units. (9) A brief description of the CMS. (10)The date of the latest CMS certification or audit. (11)A description of any changes in CMS,processes,or controls since the last reporting period. [§63.2271, §63.2281(e)] ff. The compliance report must also contain the following in formation for each instance of noncompliance with a compliance option or operating requirement and for each instance of noncompliance with the work practice requirements that occurs where You are not using a CMS to comply with the compliance options,operating requirements,or work practice requirements.This includes periods of startup,shutdown,and malfunction and routine control device maintenance. (1) The total operating time of each affected source during the reporting period. (2) Information on the number,duration,and cause of instances of noncompliance(including unknown cause,if applicable),as applicable,and the corrective action taken. [§63.2271, §63.2281(d)] gg. The permittee shall submit a report if a startup,shutdown,or malfunction during the reporting period occurred that is not consistent with the SSW.The report must contain the following: i. Actions taken for the event and must be submitted by fax or telephone within two working days after starting actions inconsistent with the plan. ii. The information in 40 CFR63.10(d)(5)(ii)and must he submitted by letter within seven working days after the end of the event unless alternative arrangements have been made with the permitting authority. [Table 9,40 CFR 63 Subpart DDDD] hh. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.1111 if the reporting requirements in Sections 2.2 A.1.dd through gg are not met. Notification Reuuirements[§63.2280] ii. The Permittee shall: i. submit all of the notifications in§63.7(b) [Notification of Performance Test]and(c) [Quality Assurance Program],63.8(e)[Performance evaluation of CMS'],(1)(4)[alternative monitoring method]and(1)(6) [alternative RATA],63.9(b)through(e)[initial notifications],and(g) [CMS notifications] and(h)[Notification of compliance status]by the dates specified. [§63.2280(a)] ii. submit a written notification of intent to conduct a performance test at least 60 calendar days before the performance test is scheduled to begin as specified in§ 63.7(b)(1). iii. for the biofilter(ID No.CD 18),submit a Notification of Compliance Status(NOCS)containing the results of the initial compliance demonstration,including the performance test results and documentation that the wood products enclosure on press(1D No.ES-16)meet the press enclosure design criteria in§ 63.2292.The NOCS shall be submitted before the close of business on the 60th calendar day following the completion of the performance test. [§§63.9(h)(2),63.10(d)(2),63.2260c),63.2280(d)] iv. for the press(ID No.DEF-2010),submit a Notification of Compliance Status containing the results of the initial compliance demonstration.The NOCS shall be submitted before the close of business on the 60th calendar day following the completion of the performance test,not to exceed 180 days after issuance of permit no.T49.[§§63.9(h)(2),63.10(d)(2),63.2260c),63.2280(d)] v. for the dryers(ID Nos. 1420 and 1430),submit a Notification of Compliance Status a signed statement by a responsible official that certifies with truth,accuracy,and completeness that the dryers each meet the criteria of a"dry rotary dryer"and will dry furnish with a maximum inlet moisture content less than or equal to 30 percent by weight,dry basis and will operate with a maximum inlet temperature of less than or equal to 600'F in the future.The notification shall be submitted before the close of business on the 30th calendar day following the completion of the initial compliance demonstration,not to exceed 180 days after issuance of permit no.T49. [§§63.9(h)(2),63.10(d)(2),63.2263] vi. submit permit application(s)with the appropriate Notification of Compliance Status to revise the permit to include monitoring parameters for the biofilter(ID No.CD18)and press(ID No.DEF-2010). Air Permit 03449T50 Page 52 vii. be deemed in noncompliance with 15A NCAC 02D.I 111 if these notification requirements are not met. STATE ENFORCEABLE ONLY 2. 15A NCAC 02D.1806:CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Penmittee 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. B. Medium Density Fiberboard Facilities The following table provides a summary of the limits and/or standards for the MDF facilities: Regulated Pollutant Limits/Standards Al2pHcable Re,,elation NOx,PM2.5,PM10 See Section 2.2 B.Z. 15A NCAC 02Q.0317 (PSD Avoidance) VOC Best Available Control Tecbnola v 15A NCAC 02D.0530 1. 15A NCAC 02Q.0317:AVOIDANCE CONDITIONS for 15A NCAC 02D.0530:PREVENTION OF SIGNIFICANT DETERIORATION a. In order to the avoid the applicability of 15A NCAC 02D.0530,the combined emissions from the sources indicated in the permitted equipment list in Section 1 as the Medium Density Fiberboard Facilities(MDF sources)shall not exceed the following limits: i. Nitrogen oxide emissions shall not exceed 177.8 tons per consecutive 12-month. ii. PM-2.5 emissions shall not exceed 111.9 tons per consecutive 12-month period. ii. PM-10 emissions shall not exceed 116.9 tons per consecutive 12-month period. Testing[15ANCAC 02Q.0508(f)] b. If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. If the results of this test exceed the limits given in Section 2.2 B.La.above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530. c. Under the provisions of NCGS 143-215.108,the Permittee shall test the biofitter(ID No CD18)to establish emission factors to be used for purposes of Section 2.2 B,Le and f below.Testing shall be completed within 180 days after the start-up of the biofilter(ID No.CD18). Testing shall be conducted in scenarios that represent worst-case emissions.The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these requirements are not met. Monitorina15A NCAC 02Q .0508(f)] d. The Permittee shall maintain a minimum urea/water solution(45%urea concentration by volume)injection rate of 0.24 gpm(3-hour block average)(ID No.CD02-A). This injection rate does not apply during performance testing. e. The Permittee shall calculate on a monthly basis the monthly and rolling 12-month total for each of the nitrogen oxides,PM10 and PM2.5 emissions from the MDF sources. f. For purposes of condition e.the Permittee shall utilize the following emission factors in Table 2.2.13.1 below. If the Permittee conducts source testing that results in any emission factors greater than those in Table 2.2.13.1, the Permittee shall,submit a permit application to revise the permit with the test report required in Section 2.2 B.lc. g. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if the requirements in Sections 2.2 B.Ld through f are not met. Recordkeenin 15A NCAC 02Q.0508(f)] h. The Pen,ittee shall keep the following records in a logbook(written or electronic format): i. the 3-hour block averages of the urea/water injection rate(ID No.CD02-A); ii. the monthly and rolling 12-month total for each of the nitrogen oxides,PM10 and PM2.5 emissions from the MDF sources;and iii. the process rates of the dryers in ODMT/hr, the process rates of the press in MSF/hr;and the heat inputs for the combustion sources in MMBtu/hr.These values may he calculated on a monthly average basis. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these requirements are not met. Air Permit 03449T50 Page 53 Table 2.2.B.1 Emission Description PM-10 - PM-2.5 NOx Point E,F Units EF Units EF Units EP-01 Refiner Abort Cyclone 3.52 lb/hr 3.52 lb/hr EP-Q3 Fiber Sifter System Filter 0.58 lb/hr 0.58 lb/hr EP-04 Forming Line Clean-Up Filter 0.55 lb/hr 0.55 lblhr EP-05 Mat reject system Filter 0.48 lb/hr 0.48 lb/hr EP-07 Saw System Filter 0.84 lb/hr 0.84 lb/hr EP-08 Sander System No.I Exhaust Filter 0.90 lblhr 0.9 lb/hr EP-09 Recvcled Fiber Silo No.I Filter 0.02 lb/hr 0.02 1 lb/hr EP-10 Sander System No.2 Exhaust Filter 0.45 lb/hr 0.45 lb/hr EP-12 Sander Dust Silo No.I Filter 0.02 lb/hr 0.02 lb/hr EP-13 Dry Sawdust Silo Filter 0.02 lb/hr 0.02 lb/hr EP-15 Recycled Fiber Silo No.2 Filter 0.02 lb/hr 0.02 lb/hr EP-17 Sander Dust Silo No.2 Filter 0.02 lb/hr 0.02 lb/hr EP-18/19/20 N.G.Combustion 7.45E-03 IbIMMBtu 7.45E-03 lb/MMBtu 0.098 lbIMMBtu ES-02-A Energy System Abort(50150 dry/wet fuel) 0.5 1bIMMBtu 0.43 lbIM ffltu 0.33 lbIMMBtu ES-02-A Energy System Abort(dry fuel) 0.36 Ib1MMBtu 0.31 lb/MMBtu 0.33 lbIMMBtu EP-16 Press Scrubber 0.088 lbfMSF 0.088 lbfMSF EP-02114 Dryer scrubber(SW) 0.51 1b1ODMT 0.51 lb1ODMT 0.33 lbfMMBtu EP-02114 Dryer scrubber(SWIHW) 0.51 lb1ODMT 0.51 ib1ODMT 0.33 lbIMMBtu EP-16 Press Scrubber(CDMDT) 0.088 lb1MSF 0.088 lbIMSF EP-021I4 Dry�scrubber {SW){CDMDT} 0.51 1b1QDMT Q.51 IbIQDMT 0.33 1bIMM8tu Dryber(S_WII3W)(CDMDT} 0.51 1b1ODMT 0.51 1b1pDMT 0.33 1hIMIVIBtu SW-softwood only processing ... - S W/H W-softwood and hardwood processing CDMDT-Control Device Maintenance Downtime,MACT Subpart DDDD,CD02-2,CD14-2,CD16-2 Air Permit 03449T50 Page 54 Reporting_[I 5A NCAC 02Q .0508(1)] i. The Permittee shall submit a semi-annual summary report,acceptable to the Regional Air Quality Supervisor,of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December,and July 30 of each calendar year for the preceding six-month period between January and June. The report shall contain the following: i. a summary of the 3-hour block averages of the urea/water injection rate(ID No CD02-A);and ii. the monthly and rolling 12-month total for each of the nitrogen oxides,PM10 and PM2.5 emissions from the MDF sources.The 12 month rolling totals shall be calculated for each of the previous 17 months. 2. 15A NCAC 02D.0530:PREVENTION OF SIGNIFICANT DETERIORATION a. For PSD purposes,the following"Best Available Control Technology"(BACT)permit limitations shall not be exceeded for units at the MDF Facilities: _ Table 2.2.11.2 Equipment/Process D No. Emission Limits* Control Technology► MDF Facilities Operations Two Stage Dryer System ES-02-B with backup natural gas ES-02-C-1,C-2 burners ES-02-D 50%DRE of WPP1 VOC Biofilter(ID No.CD18) MDF Board Cooler ES-06-B NIDF Press and Press Hall ES-16 MDF Woodworldng Operations Fiber Sifter Svsteim ES-03 0.082 th WPP1 VOCIODMT Forming Line Clean-Up ES-04 0.082 lb WPPI VOCIODMT System Mat Reiect System ES-05 0.082 lb WPP1 VOCIODMT Saw System ES-07 0.01 lb WPPI VOCIMSF Sander System No. 1 ES-08 0.01 Ib WPP1 VOCIMSF (Primary sander) Sander System No.2 None (Finishing Sanded ES-10 0.01 lb WPPI VOCIIVISF Recvcled Fiber Silo No. 1 ES-09 0.082 lb WPP1 VOCIODMT Reeveled Fiber Silo No.2 ES-15 0.082 lb WPP 1 VOCIODMT Sander Dust Silo No. 1 ES-12 0.268 lb WPP 1 VOCIODMT Sander Dust Silo No.2 ES-17 0.268 lb WPP1 VOC/ODMT Dry Sawdust Silo Filter ES-13 0.268 lb WPP1 VOCIODMT Other Emission Sources in the MDF Plant Work practice standards and Diesel Fuel-fired Emergency ES-21 maintenance as required by 40 CFR None Generators I-DFP 40 Part 63 Subpart ZZZZ and CFR 40 Part 60 Subpart IIII as applicable Natural gas-fired hot oil ES-18,ES-19, Proper design,maintenance,and None heaters ES-20 o eratinm practices Gasoline storage tank I-Gas Proper design,maintenance,and _Diesel stora-e tanks Not emitted o erating ractices None * BACT limits shall apply at all times.However,emissions resulting from startup,shutdown or malfunction as defined under 15A NCAC 02D.0535,exceeding the limits in condition a.above are permitted,provided that the Permittee,to the extent practicable,maintains and operates each emission source including any associated air pollution control equipment listed in this Table,in a manner consistent with good air pollution control practice for minimizing emissions. ** Wood Products Protocol 1 (WPP1)as provided in U.S.EPA,document entitled,"Interim VOC Measurement Protocol for the Wood Products Industry,"July 2007. Air Permit 03449T50 Page 55 Teshnff[I5ANCAC 02Q.0508(f)] b. If emissions testing is required, the testing shall be performed in accordance with General Condition 77. If the results of this test exceed the limits given in Section 2.2 B.2.a above,the Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530. c. Under the provisions of NCGS 143-215.108,the Permittee shall demonstrate compliance with the emission limits in Table 2.2 B.2.for the MDF facilities controlled by the biofilter(ID No.CD18).Testing shall be conducted in accordance with the following: i. The Permittee shall perform testing and establish a minimum and maximum biofilter bed temperature during testing,using procedures specified in Section 2.2 A.l.m through p,excepting p.i. ii. The energy system(ID No.ES-02-A),the two-stage dryer system(11)No.ES-02-B),and the MDF Press(ID No.ES-16)shall be in operation during source testing, The Permittee shall be responsible for ensuring,within the limits of practicality,that the equipment or processes being tested are operated at or near their maximum normal production rate or at a lesser rate if specified by the Director or his delegate. iii. Testing shall be completed within 180 days after the issuance of permit no.03449T50 unless an alternate date is approved by the DAQ.This alternate date may include any testing occurring after September 28,2018. iv. The Permittee shall submit a written report of the test(s)results to the Regional Supervisor,DAQ within 60 days of completion of the initial test and include a permit application to revise the permit to include monitoring parameters for the biofilter(ID No.CD18)at Section 2.2 B.21. V. Subsequent testing shall be required concurrent with the testing requirements of Section 2.2 A.l.q. After the establishment of the initial biofilter bed temperature range in Section 2.2 1B.2.h,revisions to the bed temperature range may occur only as the result of retesting to determine compliance with the emission limits in Table 2.2 B.2.for the MDF facilities controlled by the biofilter. If the results of the tests are above any of the limits in Section 2.2 B.2.a above or if the testing is not conducted in accordance with Section 2.2 B.2.c,the Pernuttee shall be deemed in noncompliance with 15A NCAC 02D.0530. Monitorin lReeordkee ing.Re uirements[15A NCAC 02Q.0508(f)] d. The Permittee shall perform inspections and maintenance as recommended by the manufacturer,if any,for the MDF woodworking operations cited in Table 2.2.B.2. The results of inspection and maintenance activities for the MDF woodworking operations shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The logbook shall record the following: i. the monthly throughput for each emission source in either ODMT or MSF,as appropriate. ii. the results of any maintenance activities performed on the emission sources,including corrective actions. The Permiltee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these monitoring and recordkeeping activities are met. e. The monitoring and recordkeeping requirements in Section 2.1 D.5.f through 1,as applicable,shall be sufficient to ensure compliance with 15AN CAC 02D.0530 for the natural gas-fired hot oil heaters(m Nos.ES-18,ES-19,and ES-20). The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these monitoring and recordkeeping requirements are not met. f. The Permittee shall comply with the work practice standards and maintenance requirements and associated recordkeeping and reporting as required by 40 CFR 40 Part 63 Subpart ZZZZ and CFR 40 Part 60 Subpart IM,as applicable,for the emergency diesel fuel-fired engines(ID Nos.ES-21 and I-DFP). The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if these monitoring and recordkeeping requirements are not met. g. No monitoring or recordkeeping is required for VOC emissions from the MDF storage tanks cited in Table 2.23.2. above. It. The Permittee shall conduct the following monitoring and recordkeeping activities for the MDF facilities operations in Table 2.2 B.2 above. L The Permittee shall record the monthly throughput for each emission source in either ODMT or MSF,as appropriate. ii. The Permittee shall install and operate and maintain continuous temperature monitoring system on the biofilter (ID No.CD18)according to section 2.2 A.l.w.ii, iii. The Permittee shall maintain the 24-hour block biofilter bed temperature within the following range as established according to Section 2.2 B.2.c. (A) minimum biofilter bed temperature: TBD OF (B) maximum biofilter bed temperature: TBD°F iv. For biofilter bed temperature monitoring,the Pennittee shall monitor and collect data according to Section 2.2 A.I.y. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if the biofilter bed temperature range is not maintained or if the monitoring and recordkeeping requirements are not met. Air Permit 03449T50 Page 56 Reporting Requirements[15A NCAC 02Q .0508(1)] i. The Permittee shall submit the results of any maintenance performed on the biofilter(ID No.CD18)within 30 days of a written request by the DAQ. j. The Permittee shall submit a summary report of monitoring and record keeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. All instances of deviations from the requirements of this permit must be clearly identified. 3. 15A NCAC 02Q.0504: OPTION FOR OBTAINING CONSTRUCTION AND OPERATION PERMIT Permitting[15A NCAC 02Q .0504(d)] a. Pursuant to 15A NCAC 02Q .0501(b)(2),for completion of the two-step significant modification process initiated by application no. 1900015.1$A, the Permittee shall file an amended application following the procedures of Section 15A NCAC 02Q.0500 no later than 12 months after issuance of permit no.03449T50. 2.3 Permit Shield for Non-Applicable Requirements The Permittee is shielded from the following non-applicable requirements[15A NCAC 02Q.0512(a)(1)(A)and(B)]. A. New Source Performance Standard(NSPS)Subpart Db is not applicable to the bio-mass fired Energy System(ID No.ES- 02A)because the system is considered a process heater and the primary purpose is to produce a final product. Air Permit 03449T50 Page 57 SECTION 3 - GENERAL CONDITIONS (version 5.3, 08/2I/201.8) This section describes terms and conditions applicable to this Title V facility. A. General Provisions[NCGS 143-215 and 15A NCAC 02Q.0508(i)(16)] 1. Terms not otherwise defined in this permit shall have the meaning assigned to such terms as defined in 15A NCAC 02D and 02Q. 2. The terms,conditions,requirements,limitations,and restrictions set forth in this permit are binding and enforceable pursuant to NCGS 143-215.114A and 143-215.114B,including assessment of civil and/or criminal penalties.Any unauthorized deviation from the conditions of this permit may constitute grounds for revocation and/or enforcement action by the DAQ. 3. This permit is not a waiver of or approval of any other Department permits that may be required for other aspects of the facility which are not addressed in this permit. 4. This permit does not relieve the Permittee from liab llity for harm or injury to human health or welfare,animal or plant life,or property caused by the construction or operation of this permitted facility,or from penalties therefore,nor does it allow the Permittee to cause pollution in contravention of state laws or rules,unless specifically authorized by an order from the North Carolina Environmental Management Commission. 5. Except as identified as state-only requirements in this permit,all terms and conditions contained herein shall be enforceahle by the DAQ,the EPA,and citizens of the United States as defined in the Federal Clean Air Act. 6. Any stationary source of air pollution shall not be operated,maintained,or modified without the appropriate and valid permits issued by the DAQ,unless the source is exempted by rule. The DAQ may issue a permit only after it receives reasonable assurance that the installation will not cause air pollution in violation of any of the applicable requirements. A permitted installation may only be operated,maintained,constructed,expanded,or modified in a manner that is consistent with the terms of this permit. B. Permit Availability[15A NCAC 02Q.0507(k)and.0508(i)(9)(B)] The Permittee shall have available at the facility a copy of this permit and shall retain for the duration of the permit term one complete copy of the application and any information submitted in support of the application package. The permit and application shall be made available to an authorized representative of Department of Environmental Quality upon request. C. Severabifty Clause[15A NCAC 02Q.0508(i)(2)] In the event of an administrative challenge to a final and binding permit in which a condition is held to be invalid,the provisions in this permit are severable so that all requirements contained in the permit,except those held to be invalid,shall remain valid and must be complied with. D. Submissions[15ANCAC 02Q.0507(e)and 02Q.0508(i)(16)] Except as otherwise specified herein,two copies of all documents,reports,test data,monitoring data,notifications,request for renewal,and any other information required by this permit shall be submitted to the appropriate Regional Office. Refer to the Regional Office address on the cover page of this permit. For continuous emissions monitoring systems(CEMS) reports,continuous opacity monitoring systems(COMS)reports,quality assurance(QA)/quality control(QC)reports,acid rain CEM certification reports,and NOx budget CEM certification reports,one copy shall be sent to the appropriate Regional Office and one copy shall be sent to: Supervisor,Stationary Source Compliance North Carolina Division of Air Quality 1641 Mail Service Center Raleigh,NC 27699-1641 All submittals shall include the facility name and Facility ID number(refer to the cover page of this permit). E. Duty to Comply[15A NCAC 02Q.0508(i)(3)] The Permittee shall comply with all terms,conditions,requirements,limitations and restrictions set forth in this permit. Noncompliance with any permit condition except conditions identified as state-only requirements constitutes a violation of the Federal Clean Air Act. Noncompliance with any permit condition is grounds for enforcement action,forpermit termination,revocation and reissuance,or modification,or for denial of a permit renewal application. Air Permit 03449T50 Page 58 F. Circumvention-STATE ENFORCEABLE ONLY 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 pollution control device(s)and appurtenances. G. Permit Modifications 1. Administrative Permit Amendments[15A NCAC 02Q,0514] The Permittee shall submit an application for an administrative permit amendment in accordance with 15A NCAC 02Q .0514. 2. Transfer in Ownership or Operation and Application Submittal Content[15A NCAC 02Q.0524 and 02Q.05051 The Permittee shall submit an application for an ownership change in accordance with 15A NCAC 02Q.0524 and 02Q .0505. 3. Minor Permit Modifications[15A NCAC 02Q.0515] The Permittee shall submit an application for a minor permit modification in accordance with 15A NCAC 02Q,0515. 4. Significant Permit Modifications[I 5A NCAC 02Q.0516] The Permittee shall submit an application for a significant permit modification in accordance with 15A NCAC 02Q .051 b, 5. Reopening for Cause[15A NCAC 02Q.0517] The Permittee shall submit an application for reopening for cause in accordance with 15A NCAC 02Q.0517. H. Chan=es Not Re uirin Permit Modifications 1. Reporting Requirements Any of the following that would result in new or increased emissions from the emission source(s)listed in Section 1 must be reported to the Regional Supervisor,DAQ: a. changes in the information submitted in the application; b. changes that modify equipment or processes;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. 2. Section 502(b)(I0)Changes[15A NCAC 02Q.0523(a)] a. "Section 502(b)(10)changes"ineans changes that contravene an express permit term or condition Such changes do not include changes that would violate applicable requirements or contravene federally enforceable permit terms and conditions that are monitoring(including test methods),recordkeeping,reporting,or compliance certification requirements. b. The Permittee may make Section 502(b)(10)changes without having the permit revised if i. the changes are not a modification under Title I of the Federal Clean Air Act; ii. the changes do not cause the allowable emissions under the permit to be exceeded; iii. the Permittee notifies the Director and EPA with written notification at least seven days before the change is made;and iv. the Permittee shall attach the notice to the relevant permit. c. The written notification shall include: i. a description of the change; ii. the date on which the change will occur; iii. any change in emissions;and iv, any permit term or condition that is no longer applicable as a result of the change. d. Section 502(b)(I0)changes shall be made in the permit the next time that the permit is revised or renewed, whichever comes first. 3. Off Permit Changes[15A NCAC 02Q.0523(b)] The Permittee may make changes in the operation or emissions without revising the permit if. a. the change affects only insignificant activities and the activities remain insignificant after the change;or b. the change is not covered under any applicable requirement. 4. Emissions Trading[15A NCAC 02Q.0523(c)] To the extent that emissions trading is allowed under 15A NCAC 02D,including subsequently adopted maximum achievable control technology standards,emissions trading shall be allowed without permit revision pursuant to 15A NCAC 02Q.0523(c). Air Permit 03449T50 Page 59 LA Revorting Re uirements for Excess Emissions and Permit Deviations(15A NCAC 02D.0535(t)and 02Q.0508(f)(2)] "Excess Emissions"-means an emission rate that exceeds any applicable emission limitation or standard allowed by any Wile in Sections.0500,.0900,.1200,or.1400 of Subchapter 0213;or by a permit condition;or that exceeds an emission limit established in a permit issued under 15A NCAC 02Q.0700. (Note:Definitions of excess emissions under 02D.1110 and 02D.1111 shall apply where defined by nde) "Deviations"-for the purposes of this condition,any action or condition not in accordance with the terms and conditions of this permit including those attributable to upset conditions as well as excess emissions as defined above lasting less than four hours. Excess Emissions 1. If a source is required to report excess emissions under NSPS(15A NCAC 02D.0524),NESHAPS(15A NCAC 02D .1110 or.1111),or the operating permit provides for periodic(e.g.,quarterly)reporting of excess emissions,reporting shall be performed as prescribed.therein. 2. If the source is not subject to NSPS(15A NCAC 02D.0524),NESHAPS(15A NCAC 02D.1110 or.1111),or these rules do NOT define"excess emissions,"the Permittee shall report excess emissions in accordance r%rith 15A NCAC 02D.0535 as follows; a. Pursuant to 15A NCAC 02D.0535,if excess emissions last for more than four hours resulting from a malfunction, a breakdown of process or control equipment,or any other abnormal condition,the owner or operator shall: i. notify the Regional Supervisor or Director 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.provide: • name and location of the facility; • nature and cause of the malfunction or breakdown; • time when the malfunction or breakdown is first observed; • expected duration;and • estimated rate of emissions; ii. notify the Regional Supervisor or Director immediately when corrective measures have been accomplished; and iii. submit to the Regional Supervisor or Director within 15 days a written report as described in 15A NCAC 02D A535(f)(3). Permit Deviations 3. Pursuant to 15A NCAC 02Q.0508(f)(2),the Permitter shall report deviations from permit requirements(terms and conditions)as follows: a. Notify the Regional Supervisor or Director of all other deviations from permit requirements not covered under 15A NCAC 02D.0535 quarterly. A written report to the Regional Supervisor shall include the prohahle cause of such deviation and any corrective actions or preventative actions taken, The responsible official shall certify all deviations from permit requirements. 1.13 Other Requirements under 15A NCAC 02D.0535 The Permittee shall comply with all other applicable requirements contained in 15A NCAC 02D.0535,including 15A NCAC 02D.0535(c)as follows: 1. Any excess emissions that do not occur during start-up and shut-down shall be considered a violation of the appropriate Wile unless the owner or operator of the sources demonstrates to the Director,that the excess emissions are a result of a malfunction. The Director shall consider,along with any other pertinent information,the criteria contained in 15A NCAC 02D,0535(c)(1)through(7). 2. 15A NCAC 02D.0535(g). Excess emissions during start-up and shut-down shall be considered a violation of the appropriate rule if the owner or operator cannot demonstrate that excess emissions are unavoidable. J. Emergencv Provisions[40 CFR 70.5(g)] The Permittee shall be subject to the following provisions with respect to emergencies: 1. An emergency means any situation arising from sudden and reasonably unforeseeable events beyond the control of the facility,including acts of God,which situation requires immediate corrective action to restore normal operation,and that causes the facility to exceed a technology-based emission limitation under the permit,due to unavoidable increases in emissions attributable to the emergency. An emergency shall not include noncompliance to the extent caused by improperly designed equipment,lack of preventive maintenance,careless or improper operation,or operator error. Air Permit 03449T50 Page 60 2. An emergency constitutes an affirmative defense to an action brought for noncompliance with such technology-based emission limitations if the conditions specified in 3.below are met. 3. The affirmative defense of emergency shall be demonstrated through properly signed contemporaneous operating logs or other relevant evidence that include information as follows: a. an emergency occurred and the Permittee can identify the cause(s)of the emergency; b. the permitted facility was at the time being properly operated; c. during the period of the emergency the Permittee took all reasonable steps to minimize levels of emissions that exceeded the standards or other requirements in the permit;and d. the Permittee submitted notice of the emergency to the DAQ within two working days of the time when emission limitations were exceeded due to the emergency. This notice must contain a description of the emergency,steps taken to mitigate emissions,and corrective actions taken. 4. In any enforcement proceeding,the Permittee seeking to establish the occurrence of an emergency has the burden of proof. 5. This provision is in addition to any emergency or upset provision contained in any applicable requirement specified elsewhere herein. K. Permit Renewal[15A NCAC 02Q.0508(e)and 02Q.0513(b)] This 15A NCAC 02Q.0500 permit is issued for a fixed term not to exceed five years and shalt expire at the cud of its term. Permit expiration terminates the facitit}/s right to operate unless a complete 15A NCAC 02Q.0500 renewal application is suhmitted at least six months before the date of permit expiration. If the Permittee or applicant has complied with 15A NCAC 02Q.0512(b)(1),this 15A NCAC 02Q.0500 permit shall not expire until the renewal permit has been issued or denied. Permit expiration under 15A NCAC 02Q.0400 terminates the facility's right to operate unless a complete 15A NCAC 02Q.0400 renewal application is submitted at least six months before the date of permit expiration for facilities subject to 15A NCAC 02Q.0400 requirements. In either of these events,all terms and conditions of these permits shall remain in effect until the renewal permits have been issued or denied. L. Need to Halt or Reduce Activih,Not a Defense[15A NCAC 02Q,0508(i)(4)] It shall not be a defense for a Permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity in order to maintain compliance with The conditions of this permit. M. Duh_-to Provide Information(submittal of information)[15A NCAC 02Q.0508(i)(9)] 1. The Permittee sball furnish to the DAQ,in a timely manner,any reasonable information that the Director may request in writing to determine whether cause exists for modifying,revoking and reissuing,or terminating the permit or to determine compliance with the permit. 2. The Permittee shall furnish the DAQ copies of records required to be kept by the permit when such copies are requested by the Director.For information claimed to be confidential,the Permittee may furnish such records directly to the EPA upon request along with a claim of confidentiality. N. Duo,to Supplement[15A NCAC 02Q.0507(f)] The Pern ittee,upon becoming aware that any relevant facts were omitted or incorrect information was submitted in the permit application,shall promptly submit such supplementary facts or corrected information to the DAQ. The Permittee shall also provide additional information as necessary to address any requirement that becomes applicable to the facility after the date a complete permit application was submitted but prior to the release of the draft permit. d. Retention of Records[15A NCAC 02Q.0508(f)and 02Q.0508(1)] The Permittee shalt retain records of all required monitoring data and supporting information for a period of at least five years from the date of the monitoring sample,measurement,report,or application. Supporting information includes all calibration and maintenance records and all original strip-chart recordings for continuous monitoring information,and copies of all reports required by the permit. These records shall be maintained in a form suitable and readily available for expeditious inspection and review. Any records required by the conditions of this permit shall be kept on site and made available to DAQ personnel for inspection upon request. P. Compliance Certification[I5ANCAC 02Q.0508(n)] The Permittee shall submit to the DAQ and the EPA(Air and EPCRA Enforcement Branch,EPA,Region 4,61 Forsyth Street SW,Atlanta,GA 30303)postmarked on or before March 1 a compliance certification(for the preceding calendar year)by a responsible official Kith all federally-enforceable terms and conditions in the permit,including emissions limitations,standards,or work practices. It shall be the responsibility of the current owner to submit a compliance certification for the entire year regardless of who owned the facility during the year. The compliance certification shall Air Permit 03449T50 Page 51 comply with additional requirements as may be specified under Sections 114(a)(3)or 504(b)of the Federal Clean Air Act. The compliance certification shall specify: 1, the identification of each term or condition of the permit that is the basis of the certification; 2, the compliance status(with the terms and conditions of the permit for the period covered by the certification); 3. whether compliance was continuous or intermittent;and 4. the method(s)used for determining the compliance status of the source during the certification period. Q. Certification by Responsible Official[15A NCAC 02Q.0520] A responsible official shall certify the truth,accuracy,and completeness of any application form,report,or compliance certification required by this permit. All certifications shall state that based on information and belief formed after reasonable inquiry,the statements and information in the document are true,accurate,and complete. R. Permit Shield for Applicable Requirements[15A NCAC 02Q.0512] l. Compliance with the terms and conditions of this permit shall be deemed compliance with applicable requirements, where such applicable requirements are included and specifically identified in the permit as of the date of permit issuance. 2. A permit shield shall not alter or affect: a, the power of the Commission,Secretary of the Department,or Governor under NCGS 143-215.3(a)(12),or EPA under Section 303 of the Federal Clean Air Act; b, the liability of an owner or operator of a facility for any violation of applicable requirements prior to the effective date of the permit or at the time ofpermit issuance; c. the applicable requirements under Title IV;or d. the ability of the Director or the EPA under Section 114 of the Federal Clean Air Act to obtain information to determine compliance of the facility with its permit. 3. A permit shield does not apply to any change made at a facility that does not require a permit or permit revision made under 15A NCAC 02Q.0523. 4. A permit shield does not extend to minor permit modifications made under 15A NCAC 02Q.0515. S. Termination,Modification.and Revocation of the Permit[15A NCAC 02Q.0519] The Director may terminate,modify,or revoke and reissue this permit if- 1. the information contained in the application or presented in support thereof is determined to be incorrect; 2. the conditions under which the permit or permit renewal was granted have changed; 3, violations of conditions contained in the permit have occurred; 4. the EPA requests that the permit be revoked under 40 CFR 70.7(g)or 70.8(d);or 5. the Director finds that termination,modification,or revocation and reissuance of the permit is necessary to carry out the purpose of NCGS Chapter 143,Article 21B. T. Insignificant Activities[15A NCAC 02Q.0503] Because an emission source or activity is insignificant does not mean that the emission source or activity is exempted from any applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. The Pemnittee shall have available at the facility at all tiros and made available to an authorized representative upon request,documentation,including calculations,if necessary,to demonstrate that an emission source or activity is insignificant. U, Property Rights[I5A NCAC 02Q.0508(i)(8)] This permit does not convey any property rights in either real or personal property or any exclusive privileges. V. Inspection and Entry[15A NCAC 02Q,05080)and NCGS 143-215.3(a)(2)] 1. Upon presentation of credentials and other documents as may be required by law,the Permnittee shall allow the DAQ, or an authorized representative,to perform the following: a. enter the Permittee's premises where the permitted facility is located or emissions-related activity is conducted,or where records are kept under the conditions of the permit; b, have access to and copy,at reasonable times,any records that are required to be kept under the conditions of the permit; c. inspect at reasonable limes and using reasonable safety practices any source,equipment(including monitoring and air pollution control equipment),practices,or operations regulated or required under the permit;and d. sample or monitor substances or parameters,using reasonable safety practices,for the purpose of assuring compliance with the permit or applicable requirements at reasonable times. Air Permit 03449T50 Page 62 Nothing in this condition shall limit the ability of the EPA to inspect or enter the premises of the Pernu.ttee under Section 114 or other provisions of the Federal Clean Air Act. 2. No person shall refuse entry or access to any authorized representative of the DAQ who requests entry for purposes of inspection,and who presents appropriate credentials,nor shall any person obstruct,hamper,or interfere with any such authorized 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. W. Annual Fee Payment[15A NCAC 02Q ,0508(i)(10)] 1. The Permittee shall pay all fees in accordance with 15A NCAC 02Q.0200. 2. Payment of fees may be by check or money order made payable to the N.C.Department of Environmental Quality. Annual permit fee payments shall refer to the permit number. 3. If,within 30 days after being billed,the Permittee fails to pay an annual fee,the Director may initiate action to terminate the permit under 15A NCAC 02Q.0519. X. Annual_Emission Inventory Requirements[15A NCAC 02Q.0207] The Permittee shall report by June 30 of each year the actual emissions of each air pollutant lasted in 15A NCAC 02Q .0207(a)from each emission source within the facility during the previous calendar year. The report shall be in or on such form as may be established by the Director. The accuracy of the report shall be certified by a responsible official of the facility. Y. Confidential Information[15A NCAC 02Q.0107 and 02Q.0508(i)(9)] Whenever the Permittee submits information under a claim of umnfmdentiality pursuant to 15A NCAC 02Q.0107,the Permittee may also submit a copy of all such information and claim directly to the EPA upon request. All requests for confidentiality must be in accordance with 15A NCAC 02Q.0107. Z. Construction and Operation Permits[I5A NCAC 02Q.0100 and.0300] A construction and operating permit shall be obtained by the Permittee for any proposed new or modified facility or emission source which is not exempted from having a permit prior to the beginning of construction or modification,in accordance with all applicable provisions of 15A NCAC 02Q.0100 and.0300. AA. Standard Ati plication Form and Required Information[I5A NCAC 02Q.0505 and.0507] The Permittee shall submit applications and required information in accordance with the provisions of 15A NCAC 02Q .0505 and.0507. BB. Financial Responsibilih'and Compliance History 115A NCAC 02Q,0507(d)(4)] The DAQ may require an applicant to submit a statement of financial qualifications and/or a statement of substantial compliance history. CC. Refrigerant Requirements IStratospheric Ozone and Climate Protection)[I5A NCAC 02Q.050I(e)] 1. If the Permittee has appliances or refrigeration equipment,including air conditioning equipment,which use Class I or H ozone-depleting substances such as chlorofluorocarbons and hydrochlorofluorocarbous listed as refrigerants in 40 CFR Part 82 Subpart A Appendices A and B,the Permittee shall service,repair,and maintain such equipment according to the work practices,personnel certification requirements,and certified recycling and recovery equipment specified in 40 CFR Part 82 Subpart F. 2. The Permittee shall not knowingly vent or otherwise release any Class I or 11 substance into the environment during the repair,servicing,maintenance,or disposal of any such device except as provided in 40 CFR Part 82 Subpart F. 3. The Permittee shall comply with all reporting and recordkeeping requirements of 40 CFR 82.166. Reports shall be submitted to the EPA or its designee as required. DD. Prevention of Accidental Releases-Section 112(r) [15A NCAC 02Q.0508(h)] If the Permittee is required to develop and register a Risk Management Plan with EPA pursuant to Section 112(r)of the Clean Air Act,then the Permittee is required to register this plan in accordance with 40 CFR Part 68. EE. Prevention of Accidental Releases General Duty Clause-Section 112 r 1 —FEDERALLY-ENFORCEABLE ONLY 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 Permitter 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. Air Permit 03449T50 Page 63 FF. Title IV Allowances[15A NCAC 02Q.0508(i)(1)] This permit does not limit the number of Title IV allowances held by the Permittee,but the Permittee may not use allowances as a defense to noncompliance with any other applicable requirement. The Permittee's emissions may not exceed any allowances that the facility lawfully holds under Title IV of the Federal Clean Air Act_ GG. Air Pollution Emergenc►-Episode[15A NCAC 02D.0300] Should the Director of the DAQ declare an Air Pollution Emergency Episode,the Permittee will be required to operate in accordance with the Pemuttee's previously approved Emission Reduction Plan or,in the absence of an approved plan,with the appropriate requirements specified in 15A NCAC 02D.0300. 1414. Realstration of Air Pollution Sources[15A NCAC 02D.0202] The Director of the DAQ may require the Permittee to register a source of air pollution. If the Permittee is required to register a source of air pollution,this registration and required information will be in accordance with 15A NCAC 02D .0202(b). II. Ambient Air Quality Standards[15A NCAC 02D.0501(c)] In addition to any control or manner of operation necessary to meet emission standards specified in this permit,any source of air pollution shall be operated with such control or in such manner that the source shall not cause the ambient air quality standards in 15A NCAC 02D.0400 to be exceeded at any point beyond the premises on which the source is located. When controls more stringent than named in the applicable emission standards in this permit are required to prevent violation of the ambient air quality standards or are required to create an offset,the permit shall contain a condition requiring these controls. 7J. General Emissions Testing and Reporting Requirements[I5A NCAC 02Q 0508(i)(16)] Emission compliance testing shall be by the procedures of Section.2600,except as may be otherwise required in Rules .0524, .0912,.l 110,.111 I,or.1415 of Subchapter 02D.If emissions testing is required by this permit or the DAQ or if the Permittee submits emissions testing to the DAQ to demonstrate compliance,the Permittee shall perform such testing in accordance with 15A NCAC 02D.2600 and follow the procedures outlined below: 1. The owner or operator of the source shall arrange for air emission testing protocols to be provided to the Director prior to air pollution testing.Testing protocols are not required to be pre-approved by the Director prior to air pollution testing.The Director shall review air emission testing protocols for pre-approval prior to testing if requested by the owner or operator at least 45 days before conducting the test. 2. Any person proposing to conduct an emissions test to demonstrate compliance with an applicable standard shall notify the Director at least 15 days before beginning the test so that the Director may at his option observe the test. 3. The owner or operator of the source shall arrange for controlling and measuring the production rates during the period of air testing.The owner or operator of the source shall ensure that the equipment or process being tested is operated at the production rate that best fulfills the purpose of the test.The individual conducting the emission test shall describe the procedures used to obtain accurate process data and include in the test report the average production rates determined during each testing period. 4. Two copies of the final air emission test report shall be submitted to the Director not later than 30 days after sample collection unless otherwise specified in the specific conditions. The owner or operator may request an extension to submit the final test report.The Director shall approve an extension request if he finds that the extension request is a result of actions beyond the control of the owner or operator. a.. The Director shall make the final determination regarding any testing procedure deviation and the validity of the compliance test.The Director may: i. Allow deviations from a method specified under a rule in this Section if the owner or operator of the source being tested demonstrates to the satisfaction of the Director that the specified method is inappropriate for the source being tested. h. Prescribe alternate test procedures on an individual basis when he finds that the alternative method is necessary to secure more reliable test data.. iii. Prescribe or approve methods on an individual basis for sources or pollutants for which no test method is specified in this Section if the methods can be demonstrated to determine compliance of permitted emission sources or pollutants. b. The Director may authorize the Division of Air Quality to conduct independent tests of any source subject to a rule in this Subchapter to determine the compliance status of that source or to verify any test data submitted relating to that source.Any test conducted by the Division of Air Quality using the appropriate testing procedures described in Section 02D.2600 has precedence over all other tests. Air Permit 03449T50 Page 64 KK. Reopening for Cause[15A NCAC 02Q.0517] 1. A permit shall be reopened and revised under the following circumstances: a, additional applicable requirements become applicable to a facility with remaining permit term of three or more yew; b. additional requirements(including excess emission requirements)become applicable to a source covered by Tide IV; c. the Director or EPA finds that the permit contains a material mistake or that inaccurate statements were made in establishing the emissions standards or other terms or conditions of the permit;or d. the Director or EPA determines that the permit must be revised or revoked to assure compliance with the applicable requirements. 2. Any permit reopening shall be completed or a revised permit issued within 18 months after the applicable requirement is promulgated. No reopening is required if the effective date of the requirement is after the expiration of the permit term unless the term of the permit was extended pursuant to 15A NCAC 02Q.0513(c). 3. Except for the state-enforceable only portion of the permit,the procedures set out in 15A NCAC 02Q.0507,.0521,or .0522 shall be followed to reissue the permit. If the State-enforceable only portion of the permit is reopened,the procedures in 15A NCAC 02Q.0300 shall be followed. The proceedings shall affect only those parts of the permit for which came to reopen exists. 4. The Director shall notify the Permittee at least 60 days in advance of the date that the permit is to be reopened,except in cases of imminent threat to public health or safety the notification period may be less than 60 days. 5. Within 90 days,or 180 days if the EPA extends the response period,after receiving notification from the EPA that a permit needs to be terminated,modified,or revoked and reissued,the Director shall send to the EPA a proposed determination of termination,modification,or revocation and reissuance,as appropriate. LL. Reporting Requirements for Non-Operating,Equipment[15A NCAC 02Q.0508(i)(16)] The Permittee shall maintain a record of operation for permitted equipment noting whenever the equipment is taken from and placed into operation. When permitted equipment is not in operation,the requirements for testing,monitoring,and recordkeeping are suspended until operation resumes. MM.Fugitive Dust Control Requirement[15A NCAC 02D.0540] As required by 15A NCAC 02D.0540"Particulates from Fugitive Dust Emission Sources," the Permitree 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 02D.0540(f). "Fugitive dust emissions"means particulate matter from process operations that does not pass through a process stack or vent and that is generated within plant property boundaries from activities such as:unloading and loading areas,process areas,stockpiles,stock:pile working,plant parking lots,and plant roads(including access roads and haul roads). NN.Specific Permit Modifications[15A NCAC 02Q.0501 and.0523] 1. For modifications made pursuant to 15A NCAC 02Q.0501(c)(2),the Permittee shall file a Title V Air Quality Permit Application for the air emission source(s)and associated air pollution control device(s)on or before 12 months after commencing operation. 2. For modifications made pursuant to 15A NCAC 02Q.0501(d)(2),the Permittee shall not begin operation of the air emission source(s)and associated air pollution control device(s)until a Title V Air Quality Permit Application is filed and a construction and operation permit following the procedures of Section.0500(except for Rule.0504 of this Section)is obtained. 3. For modifications made pursuant to 502(b)(10),in accordance with 15A NCAC 02Q.0523(a)(1)(C),the Pennittee shall notify the Director and FPA(EPA-Air Planning Branch,61 Forsyth Street SW,Atlanta,GA 30303)in writing at least seven days before the change is made. The written notification shall include: a. a description of the change at the facility; b. the date on which the change will occur; C. any change in emissions;and d. any permit term or condition that is no longer applicable as a result of the change. In addition to this notification requirement,with the next significant modification or Air Quality Permit renewal,the Permittee shall submit a page"E5" of the application forms signed by the responsible official verifying that the Air Permit 03449T50 Page 65 application for the 502(b)(10)change/modification,is true,accurate,and complete. Further note that modifications made pursuant to 502(b)(10)do not relieve the Permittee from satisfying preconstruction requirements. 00. Third Party Participation and EPA Review[15A NCAC 02Q.0521,.0522 and.0525(7)] For permits modifications subject to 45-day review by the federal Environmental Protection Agency (EPA),EPA's decision to not object to the proposed permit is considered final and binding on the EPA and absent a third party petition, the failure to object is the end of EPA's decision-making process with respect to the revisions to the permit.The time period available to submit a public petition pursuant to 15A NCAC 02Q.0518 begins at the end of the 45-day EPA review period. Air Permit 03449T50 Page bb ATTACHMENT List of Acronyms AGS Alternative Operating Scenario BACT Best Available Control Technology Btu British thermal Unit CAA Clean Air Act CAIR Clean Air Interstate Rule CEM Continuous Emission Monitor CFR Code of Federal Regulations DAQ Division of Air Quality DEQ Department of Environmental Quality EMC Environmental Management Commission EPA Environmental Protection Agency FR Federal Register GACT Generally Available Control Technology HAP Hazardous Air Pollutant MALT Maximum Achievable Control Technology NAA Non-Attainment Area NCAC North Carolina Administrative Code NCGS North Carolina General Statutes NESHAP National Emission Standards for Hazardous Air Pollutants NGx Nitrogen Oxides NSPS New Source Performance Standard GAH Office of Administrative Hearings PM Particulate Matter PM10 Particulate Matter with Nominal Aerodynamic Diameter of 10 Micrometers or Less POS Primary Operating Scenario PSD Prevention of Significant Deterioration RACT Reasonably Available Control Technology SIC Standard Industrial Classification SIP State Implementation Plan S02 Sulfur Dioxide tpy Tons Per Year VGC Volatile Organic Compound