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HomeMy WebLinkAboutAQ_F_0900009_20190221_CMPL_InspRpt fn NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY Chemours Company-Fayetteville Works NC Facility ID 0900009 Inspection Report County/FIPS:Bladen/017 Date: 02/25/2019 Facility Data Permit Data Chemours Company-Fayetteville Works Permit 03735/T43 22828 NC Highway 87 West Issued 12/14/2016 Fayetteville,NC 28306 Expires 3/31/2021 Lat: 34d 50.6700m Long: 78d 49.8750m Class/Status Title V SIC: 2869/Industrial Organic Chemicals,nec Permit Status Active NAICS: 32512/Industrial Gas Manufacturing Current Permit Application(s)TV-Sign-50I(b)(2) Part I,TV-Sign-501(b)(2)Part I,TV-Sign- Contact Data 501(b)(2)Part II Facility Contact Authorized Contact Technical Contact Program Applicability Christel Compton Brian Long Christel Compton SIP/Title V/112r Program Manager Plant Manager Program Manager (910)678-1213 (910)678-1415 (910)678-1213 MACT Part 63: Subpart Boiler-112j,Subpart FFFF, Subpart ZZZZ NSPS: Subpart Dc Compliance Data r1nsp ents: Inspection Date 02/21/2011 Inspector's Name Gregory Reeves tor's Signature:40W Operating Status Operating Compliance Code Compliance-inspection Action Code FCE Date of Signature: pl/j� 'f On-Site Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP SO2 NOX VOC CO PM10 *HAP 2017 3.97 0.2000 61.63 239.09 33.86 3.97 34586.00 2016 4.16 0.2100 65.19 237.76 36.45 4.16 36881.00 2015 8.94 0.2030 55.45 290.39 42.10 8.94 34123.00 *Highest HAP Emitted(in ounds) Five Year Violation History:None Date Letter Type Rule Violated Violation Resolution Date Performed Stack Tests since last FCE: None Date Test Results Test Method(s) Source(s)Tested Chemours Company—Fayetteville Works Compliance Inspection Report Page 2 of 12 1. DIRECTIONS TO SITE: Chemours Company-Fayetteville Works is located on NC Highway 87 in Bladen County. From FRO,take Highway 87 south. The entrance to the facility is approximately 18 miles from FRO on the left side of Highway 87 just before the Cumberland/Bladen County line. 2. SAFETY CONSIDERATIONS:The usual FRO safety gear is required(hardhat,safety glasses,safety shoes, hearing protection). Entry into several areas of the plant requires specialized safety gear. In the HFPO reactor and MMF process areas,personnel are not allowed to enter unless the process is not operating due to the possibility of explosion hazards of the chemical reaction process. 3. FACILITY DESCRIPTION: Chemours Company-Fayetteville Works is a chemical manufacturing facility located in Bladen County. The facility was formerly owned by DuPont. The facility employs approximately 500 employees and 250 full-time contractors on a 24 hr,7 day per week basis. The facility consists of four individual manufacturing plants,a boiler house and a waste treatment operation. Several processes have PSD avoidance conditions. The facility has two permanent boilers onsite,one permanent boiler which is permitted but not yet constructed,and one permitted temporary boiler. 4. INSPECTION SUMMARY: On Thursday,February 21,2019,I,Greg Reeves,of the DAQ Fayetteville Regional Office,met with Christel Compton,Program Manager,and Justin Spencer,Site Environmental Consultant,for a full compliance inspection. Ms.Compton reviewed the FacFinder sheet and noted that all information is correct. Facility records were reviewed for emissions calculations and control device inspections. There are extensive electronic records for the facility operations available on the local computer area network. Ms.Compton confirmed that there have been no changes in permitted emission sources** since the previous inspection/permit modification and that the emissions sources listed on the permit had not changed. PSD records and most all other records are accessible on the facility computer LAN in Ms. Compton's office. For the operating areas,flow rates and pressure drops in scrubbers are available in the control rooms of the respective areas. Only one boiler(PS-A)was operating, firing natural gas. The second boiler(PS-B)was not operating,and the third permitted boiler(PS-C)is not yet constructed. The permitted temporary boiler(PSC-Temp)is not currently on site,and was not on site during 2018. The HFPO product container decontamination process(ID No.NS-N),Vinyl Ethers North product container decontamination process(ID No.NS-0),and the Vinyl Ethers South product container decontamination process(ID No.NS-P)were not operating during the inspection. All other processes were in operation during the inspection. I observed zero visible emissions from each of the operating source emission points. **Note that the facility has installed two carbon bed adsorbers at the Vinyl Ethers North Division exhaust stack and the PPA plant exhaust stack,and have added a second stage on the Division Waste Gas scrubber at Vinyl Ethers North in accordance with the pending Consent Order for the facility. 5. PERMITTED EMISSION SOURCES: At the time of the inspection,Chemours Company—Fayetteville Works was operating under Permit No.03735T43 which includes the following emission sources: Emission Emission Source Description Control Device Control Device Description Source ID No. ID No. PS-A Natural Gas/No. 2 fuel oil-fired boiler N/A N/A Case-by-case (139.4 million Btu per hour maximum MACT heat input) OPERATING PS-B Natural Gas/No. 2 fuel oil-fired boiler N/A N/A Case-by-case (88.4 million Btu per hour maximum heat MACT input) OPERATING PS-C Natural Gas/No.2 fuel oil-fired boiler N/A N/A NSPS De (97 million Btu per hour maximum heat Case-by-case input)equipped with a low-NOx burner MACT NOT YET CONSTRUCTED Chemours Company—Fayetteville Works Compliance Inspection Report Page 3 of 12 Emission Emission Source Description Control Device Control Device Description Source ED No. ID No. PS-Temp Natural Gas/No.2 fuel oil-fired boiler N/A N/A (less than 100.0 million Btu per hour maximum heat input) NOT ON SITE AT THIS TIME NS-A Hexfluoropropylene epoxide(BFPO) NCI)-Hdrl Baffle-plate scrubber(7,000 MACT FFFF process kilogram/hour liquid injection rate OPERATING -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-B Vinyl Ethers North process NCD-Hdrl Baffle-plate scrubber(7,000 MACT FFFF OPERATING kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-C Vinyl Ethers South process NCI)-Hdrl Baffle-plate scrubber(7,000 MACT FFFF OPERATING kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-D RSU Process NCD-Hdrl Baffle-plate scrubber(7,000 OPERATING kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-E FPS Liquid waste stabilization NCD-Hdrl Baffle-plate scrubber(7,000 OPERATING kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-F MMF process NCD-Hdrl Baffle-plate scrubber(7,000 OPERATING kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle-plate scrubber(7,000 kilogram/hour liquid injection rate averaged over a 3-hourperiod) NS-G LXM Resins process NCD-G Venturi vacuum jet caustic scrubber MACT FFFF OPERATING NS-H LXM membrane process N/A N/A OPERATING NS-I LXM membrane coating N/A N/A OPERATING Chemours Company—Fayetteville Works Compliance Inspection Report Page 4 of 12 Emission Emission Source Description Control Device Control Device Description Source ID No. ED No. NS-K E-2 Process N/A N/A OPERATING NS-M TFE/CO2 separation process N/A N/A OPERATING NS-N BFPO product container decontamination N/A N/A process OPERATING NS-0 Vinyl Ethers North product container N/A N/A decontamination process OPERATING NS-P Vinyl Ethers South product container N/A N/A decontamination process OPERATING SW-1 Semiworks polymerization operation N/A N/A OPERATING SW-2 Semiworks laboratory hood N/A N/A OPERATING AS-A Polymer Processing Aid Process ACD-AI Wet scrubber(30 gallons per minute OPERATING water injection rate averaged over a 3- hourperiod)State-enforceable only WTS-A Extended aeration biological wastewater N/A N/A treatment facility OPERATING WTS-B, Two(2)Indirect steam-heated,rotary WTCD-1 Wet scrubber with mist eliminator WTS-C sludge dryers State-enforceable only OPERATING 6. APPLICABLE AIR QUALITY REGULATIONS: Regulations will be discussed for each of the various manufacturing processes as listed on the current air permit. ■Powerhouse Boilers PS-A,PS-B,and PS-C)t The facility is permitted to operate one Natural Gas/No.2 fuel oil-fired boiler(139.4 mmBw/hr maximum heat input,PS-A),one Natural Gas/No.2 fuel oil-fired boiler(88.4 mmBtu/hr maximum heat input,PS-B),and one Natural Gas/No.2 fuel oil-fired boiler with low-NOx burner(97 mmBtu/hr maximum heat input,PS-C). The third boiler(PS-C)has not yet been constructed. According to Ms.Compton,this boiler will not be constructed anytime soon,as there is no current need for additional steam capacity. Both of the existing boilers are currently combusting natural gas. The larger boiler(PS-A)has a steam capacity of 113,000 pounds of steam per hour(139.4 rmnBtu maximum heat input)and was manufactured in 1969. The smaller boiler(PS-B)was manufactured in 1982 with a steam capacity of 72,000 pounds per hour(88.4 mmBtu/hr maximum heat input). They are both pre-NSPS boilers; however,Boiler PS-B has a PSD avoidance condition for NO.and SO2. Boiler PS-C will be subject to NSPS Subpart Dc when constructed. All three of the boilers are now subject to the 2D.1109 Case-by-case MACT condition through May 2019,in lieu of the NESHAP Subpart DDDDD Boiler MACT. Therefore,they are not currently subject to any of the requirements of the Boiler MACT. Boiler MACT requirements will become effective in May 2019. Chemours has a facility-wide PSD SO2 emissions limitation of 702.5 tons per consecutive 12-month period. Chemours Company—Fayetteville Works Compliance Inspection Report Page 5 of 12 15A NCAC 2D.0503 PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS— Particulate emissions from boilers PS-A and PS-B shall not exceed 0.2667 lbs/mmBtu. Particulate emissions from PS-C shall not exceed 0.22681bs/mmBtu. No monitoring/recordkeeping/reporting is required. APPEARS IN COMPLIANCE—The AP-42 emissions factor for Natural Gas is 0.007 lbs/mmBtu and for No. 2 fuel oil is 0.024 lbs/mmBtu. As long as the facility only combusts these fuels,they should not exceed the emission limits. The facility is currently combusting natural gas. The last#2 fuel oil was combusted in January 2018 during a short natural gas curtailment(28,350 gallons of No.2 fuel oil combusted). The#2 fuel oil used is ultra-low sulfur content(< 15 ppm sulfur by weight.) 15A NCAC 2D.0516 SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES—The sulfur dioxide emissions from boilers PS-A and PS-B shall not exceed 2.3 pounds per million Btu heat input while firing natural gas or No.2 fuel oil,and the sulfur dioxide emissions from boiler PS-C shall not exceed 2.3 pounds per million Btu heat input while firing natural gas only. No monitoring/recordkeeping/reporting is required. APPEARS INCOMPLIANCE—The AP-42 emissions factor for Natural Gas is 0.001 lbs/mmBtu and for No. 2 fuel oil(with 0.5%sulfur content by weight)is 0.507 lbs/mmBtu. All No.2 fuel oil is ultra-low sulfur fuel oil (< 15 ppm sulfur content by weight.)The facility should never exceed the S02 emission limit while combusting either natural gas or#2 fuel oil. Ms.Compton produced a bill of lading for the latest fuel oil shipment which indicated the sulfur content to be< 15 ppm. 15A NCAC 2D.0521 CONTROL OF VISIBLE EMISSIONS—Visible emissions from Boiler PS-A shall not exceed 40%opacity. Visible emissions from PS-B and PS-C shall not exceed 20%opacity. No monitoring/recordkeeping/reporting is required. APPEARS IN COMPLIANCE—When operating,the boilers are currently combusting natural gas and I observed 0%opacity from the boiler stack. Boiler PS-C has not yet been constructed. Boiler PS-B was not operating. 15A NCAC 2D.0524 NEW SOURCE PERFORMANCE STANDARDS—SUBPART De(for PS-C only)— The sulfur content of fuel combusted in the new boiler(PS-C)shall not exceed 0.5%by weight and visible emissions are limited to 20%opacity. Written notifications are required for construction commencement and startup within 30 days after these events. The facility must conduct Method 9 testing after boiler start-up if using No.2 fuel oil. The facility must maintain records of fuel usage and fuel oil certifications. Records of startup,shutdown, and malfunctions must also be maintained. A semi-annual summary report is required. APPEARS IN COMPLIANCE—Boiler PS-C has not yet commenced construction,and there are no current plans to install this unit. Therefore,none of the above requirements have been triggered. The last semi-annual report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS(PS-B only)—Emissions from Boiler PS-B shall not exceed the following: 40 TPY NO.,and 40 TPY S02. The Permittee shall keep monthly records of fuel usage,fuel sulfur content,and maintain fuel certifications. A semi-annual report is required,listing monthly emissions(I 7-monthperiod),fuel usage,and sulfur content. The Permittee must also list all deviations from the requirements in the report. APPEARS IN COMPLIANCE—All records show that the facility is well below these emissions limits. The highest 12-month total NOx emissions during 2018 were 3.9 tons and S02 emissions were 0.0 tons. The last semi-annual report was received at FRO on 01/30/19,which noted no deviations. Chemours Company—Fayetteville Works Compliance Inspection Report Page 6 of 12 15A NCAC 2D.1109 CASE-BY-CASE MACT—This condition includes requirements for boilers PS-A,PS- B,and PS-C that were instituted as a result of the vacating of the Boiler MACT. Requirements include an annual inspection and tune-up of each boiler each calendar year. Records of inspections and tune-ups are required. A semi-annual report is required,starting January 30,2014. APPEARS IN COMPLIANCE—The last inspection and tune-up o£PS-A was conducted on 10/22/18,and the last inspection and tune-up of PS-B was conducted on 10/22/18. The last semi-annual report was received on 01/30/19 and appeared complete. 15A NCAC 2D.1111 MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY—Requires that the Permittee comply with the requirements of NESHAP Subpart DDDDD beginning as of May 20,2019. Includes the requirement for a one-time energy assessment,which must be conducted prior to May 20,2019. APPEARS IN COMPLIANCE—These requirements are not yet applicable. The facility contacts were reminded of the due date of the energy assessment. They stated that the energy assessment is currently in progress. k FPS/IXM Process Area* The operation produces a variety of relatively uncommon monomer and polymer chemicals. Some of the monomers are shipped offsite,while others are used onsite in the production of various polymers. The polymers are shipped offsite or used onsite to produce Nafion®membrane material. A principal use of this membrane is in the electrolysis cells for production of chlorine and sodium hydroxide at chloro-alkali plants. The two waste gas scrubbers located at the FPS/IXM process area are used to control the emissions of various pollutants including hydrogen fluoride and other acid fluorides. The HFPO,Vinyl Ethers North and South,and the IXM Resins processes(ID Nos.NS-A,NS- B,NS-C,and NS-G)are subject to the Miscellaneous Organic NESHAP, Subpart FFFF and are classified as existing sources under this regulation. 15A NCAC 2D.0515 PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES— Particulate matter emissions from the membrane coating process NS-I shall not exceed E=4.10*P067. The Permittee shall maintain production records. A semi-annual summary report is required. APPEARS IN COMPLIANCE—The initial permit application indicated that compliance would be achieved based on the process description as permitted. No changes to the process have been made since that application, and therefore compliance is indicated. Production records are available at each manufacturing facility. The last semi-annual summary report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2D.0521 CONTROL OF VISIBLE EMISSIONS—Visible emissions from the membrane coating process NS-I shall not exceed 20%opacity. No monitoring,recordkeeping,or reporting is required. APPEARS IN COMPLIANCE—I observed no visible emissions from any of the sources during this inspection. 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS—VOC emissions from the Vinyl Ethers North process,NS-B,shall not exceed 68.9 TPY VOC. The Permittee shall keep monthly records of VOC emissions. A semi-annual report is required. APPEARS IN COMPLIANCE—VOC emissions are calculated using stack test results,material balances,and flow rates/concentrations on a monthly basis. These records are submitted to Ms.Compton within 30 days of the end of the previous month. Records indicate that the highest 12-month VOC emissions during 2018 were 17.12 tons. The last semi-annual report was received at FRO on 01/30/19 and appeared complete. Chemours Company—Fayetteville Works Compliance Inspection Report Page 7 of 12 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS—Emissions from the resin process NS-G shall not exceed 40 TPY VOC. The Permittee shall keep monthly records of VOC emissions. A semi-annual summary report is required. APPEARS IN COMPLIANCE—Records indicate that the highest 12-month VOC emissions during 2018 were 31.98 tons. The last semi-annual summary report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS—Emissions from the resin process NS-A shall not exceed 85.3 TPY VOC. The Permittee shall keep monthly records of VOC emissions. A semi-annual summary report is required. APPEARS IN COMPLIANCE—Records indicate that the highest 12-month VOC emissions during 2018 were 41.04 tons. The last semi-annual summary report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS—Emissions from the HFPO Product Container Decontamination Process(NS-N)shall not exceed 40 TPY VOC. The Permittee shall keep monthly records of VOC emissions. The Permittee shall also maintain records of dates each container is decontaminated and total mass of VOC removed from each container. A semi-annual summary report is required. APPEARS IN COMPLIANCE—Records indicate that the highest 12-month VOC emissions during 2018 were 14.06 tons. The last semi-annual report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2D.0530(u)USE OF PROJECTED ACTUAL EMISSIONS TO AVOID APPLICABILITY OF REQUIREMENTS OF PSD—Requires the facility to maintain records of annual VOC emissions from the IXM Membrane Coating Process(ID No.NS-I)for 10 years following the startup of the modified process. An annual report is required within 60 days after the end of the calendar year. If the projected actual emissions of 67.27 tons per year,as stated in the permit application,are exceeded,an explanation as to why the actual rates exceeded the projection must be included in the annual report. APPEARS IN COMPLIANCE—The IXM Membrane Coating process modification started operation on May 1,2017. The Actual VOC emissions in 2018 were 44.1 tons. The startup notification was received at FRO on 05/08/17. The latest annual report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2D.1111 MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY(MALT)40 CFR Part 60 Subpart FFFF: MISCELLANEOUS ORGANIC NESHAP(MON)—The HFPO,Vinyl Ethers North and South, and the DCvI Resins processes(ID Nos.NS-A,NS-B,NS-C,and NS-G)must comply with all provisions of this MACT. The MON requires 99%control efficiency for some Group 1 sources;however, Chemours determined that their sources are not subject to the stricter requirements of a control device. The Permittee shall monitor and inspect all the valves,pumps,compressors,agitators,and connectors for leaks using the instrument monitoring methods described in 40 CFR 63.1023(b)-(c). All equipment affected by the leak requirements shall be identified. The Permittee shall create and retain a record of the monitoring schedule for each process unit. If a leak is identified,it shall be repaired as provided in the repair provisions of this section. After a leak has been repaired,the valve shall be monitored at least once within the first 3 months after its repair. This requirement is in addition to the monitoring required to satisfy the definition of repaired and first attempt at repair. The required periodic monitoring may be used if it satisfies the timing requirement of this condition. The Permittee shall repair each leak detected as soon as practical,but not later than 15 calendar days after it is detected. The facility operates two process heat exchangers that are subject to the MON. Monitoring for presence of a leak in a heat exchanger system requires that three samples of both the cooling water entrance to and exit from the heat exchanger be monitored for the presence of hazardous air pollutants monthly for the first six months of operation and quarterly thereafter. A semi-annual summary report is required. APPEARS IN COMPLIANCE—The scrubbers currently controlling the HFPO,Vinyl Ethers North and South, and the IXM Resins processes(ID Nos.NS-A,NS-B,NS-C,and NS-G)(NCD-Hdrl and Hdr2)meet the Chemours Company—Fayetteville Works Compliance Inspection Report Page 8 of 12 control efficiency requirement. The scrubbers were tested at 99.6%efficiency in August 2003 (further data indicates that the efficiency was only 99.1%). Initial notification was received on 2 March 2004. However,no controls are required for this facility based on HAP content,THE values,and other various parameters. The facility has an extensive LDAR program,and inspects all the valves,pumps,compressors,agitators,and connectors for leaks on a monthly basis.Records are available at the site. Each affected unit has a physical tag for equipment identification. Three samples of both the cooling entrance and exit are taken at the heat exchangers to analyze for leaks on a monthly basis. The facility also submits a semi-annual report for MACT Subpart FFFF. There were no deviations from the emission limits,operating limits,or work practice standards during 2018. The last semi-annual summary report was received at FRO on 01/30/19. A more extensive MACT FFFF report is submitted to EPA and FRO also,which includes several items not required in the Title V permit,but are required by the MACT. The facility has a"zero leak"policy. If a leak is discovered,it is fixed ASAP,even if the process must be shut down. No delay of repair scenarios are normally permitted by the facility's LDAR policy,but they are allowed under the MACT regulation. According to the facility records,no delays of repair occurred in any of the facility processes during 2018. +Polymer Processing Aid(PPA)Process fall sources labeled with AS-and ACD-)* The polymer processing aid process,formerly the ammonium perfluorooctanoate(APFO)process,began operation in December of 2002. Formerly,the Polymer Processing Aid reaction process used perfluorooctanoic acid(PFOA- brought in by truck in its iodide/salt form)reacted with sodium hydroxide(stored in totes)to form the acid fluoride. The acid fluoride was then reacted with ammonia to produce the ammonium salt. Fuming sulfuric acid(oleum)is received by truck and used as a solvent in the process. Currently,APFO and the associated(PFOA),also known as C8,are not regulated as toxic or hazardous air pollutants. However,the EPA has been reviewing the chemical with the possibility of its designation in the future as a regulated pollutant. Due to historical pollution and health effects concerns and recent controversy regarding the DuPont facility in West Virginia,and the recent activities by the U.S. EPA to develop and review toxicity data for this chemical,the DAQ file includes several documents and articles related to APFO,PFOA,or C8. The APFO process was subject to the 112(r)chemical accident prevention program for oleum. DuPont made a decision to eliminate APFO by 2015,and therefore the PPA process at the Fayetteville Works was modified,and no longer produces APFO and is no longer subject to 112(r)written risk management plan requirements. The replacement for APFO is HFPO Dimer Acid,which is currently also under scrutiny. 15A NCAC 2D.1100 CONTROL OF TOXIC AIR POLLUTANTS(State Enforceable Only)—Emissions from the PPA facility shall be controlled by a wet scrubber. The liquid flow rate in the packed bed section shall be a minimum of 30 gallons per minute and the differential pressure across the bed shall be a maximum of 12 inches of water,based on three-hour averages. An alarm is required for the pressure monitoring. Records of all inspections shall be kept in a logbook. No reporting is required. APPEARS IN COMPLIANCE—The scrubber is interlocked so that the system will shut down,almost instantaneously,if the parameters are exceeded. The facility will go into shutdown mode if the three-hour average is less than 30 gpm or pressure is 5 inches of water. The system is set up such that upon startup after an extended shutdown,the scrubber must be operated for three hours to establish the minimum 3-hour average prior to allowing the startup of the remaining equipment. The polymer processing aid chemical is a surfactant; therefore,the AP increases occasionally due to `suds' in the scrubber. The liquid flowrate during the inspection was 50 gpm,and the pressure drop across the scrubber bed was-0.3"H2O. The last internal inspection of the scrubber was performed on 10/19/18. Inspections are on an annual basis. ChemoursCompany—Fayetteville Works Compliance Inspection Report Page 9 of 12 *Wastewater Treatment Area(all sources labeled with WTS-and WTCD-)* For the wastewater treatment operations,the Title V permit specifies two rotary sludge dryers controlled by an impingement-type wet scrubber with mist eliminator. The Miscellaneous Organic NESHAP(MON)also addresses emissions from wastewater. With respect to quantity of emissions,methanol is the most significant air pollutant from the wastewater treatment operation. 15A NCAC 2D.1806 CONTROL AND PROHIBITION OF ODOROUS EMISSIONS—The wastewater treatment facility shall not operate 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 property boundary. The sludge dryers shall be controlled by a caustic injection scrubber. An I&M logbook is also required for the scrubber. No reporting is required. APPEARS INCOMPLIANCE—Odorous emissions from the sludge dryers are controlled by a scrubber utilizing potassium hydroxide solution. Inspections of this scrubber are on a 5-year cycle. Wastewater treatment odors were not noted at boundary lines. The sludge dryers are located inside a building. The facility keeps maintenance records for the scrubber in their electronic maintenance program. Ms.Compton stated that no odor complaints have been received by the facility. The most recent 5-year inspection was 06/29/16. * Temporary Boiler(PS-Temp)* This boiler is permitted to combust Natural Gas/No.2 fuel oil and is brought on-site on an `as needed'basis. There is currently no temporary boiler on site. The temporary boiler was last on site during the period 11/19/12 through 01/09/13 and utilized natural gas for fuel. 15A NCAC 2D.0503 PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS— Particulate emissions from the temporary boiler shall not exceed 0.2426 lbs/mmBtu. No monitoring/recordkeeping/reporting is required. APPEARS IN COMPLIANCE—The AP42 emissions factor for Natural Gas is 0.007 lbs/mmBtu and for No. 2 fuel oil is 0.024 lbs/mmBTU. The boiler was not on site during this inspection. 15A NCAC 213.0516 SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES—Sulfur Dioxide emissions from the temporary boiler shall not exceed 2.3 lb/mmBtu heat input. No monitoring/recordkeeping/reporting is required. The boiler was not on site during this inspection. APPEARS IN COMPLIANCE—The AP42 emission factor for Natural Gas is 0.001 lb/mmBtu and for No.2 fuel oil burning ultra-low sulfur content oil(< 15 ppm Sulfur by weight)is 0.002 Ib/mmBtu. Therefore,the source will not exceed the limits while combusting either of these permitted fuels. The boiler was not on site during this inspection. 15A NCAC 2D.0521 CONTROL OF VISIBLE EMISSIONS—Visible emissions shall be no more than 20% opacity. No monitoring/recordkeeping/reporting is required. APPEARS IN COMPLIANCE—The source was not on site during the inspection. While combusting either natural gas or#2 fuel oil, it is expected that there will be no visible emissions from this source(VE=0% opacity). 15A NCAC 2Q.0317 AVOIDANCE OF 15A NCAC 2D.0530 PREVENTION OF SIGNIFICANT DETERIORATION—The temporary boiler PS-Temp shall discharge into the atmosphere less than 40 tons of S02 per consecutive 12-month period. Monthly records of fuel usage are required. Monthly calculation of S02 emissions and rolling 12-month S02 emissions are required. A semi-annual report is required. APPEARS IN COMPLIANCE—The boiler was not onsite during this inspection. The last semi-annual report was received at FRO on 01/30/19 and appeared complete. Chemours Company—Fayetteville Works Compliance Inspection Report Page 10 of 12 15A NCAC 2Q.0317 AVOIDANCE OF 15A NCAC 2D.1109 CASE-BY-CASE MACT FOR BOILERS AND PROCESS HEATERS AND OF 40 CFR 63 SUBPART DDDDD MACT FOR BOILERS AND PROCESS HEATERS—The temporary boiler shall remain onsite for no longer than 180 consecutive days. If it is onsite for more than 180 consecutive days,the facility must notify the regional office within 10 days of exceeding the 180-day period. A startup notification is required within 15 days after startup of the boiler. APPEARS IN COMPLLANCE—The boiler was not onsite during 2018. No notifications have been required. *Multiple Emission Source(s)Specific Limitations and Conditions* *Boilers* 15A NCAC 2Q.0317 PREVENTION OF SIGNIFICANT DETERIORATION AVOIDANCE CONDITIONS—Emissions from the boilers(PS-A,PS-B,PS-C,and PS-Temp)shall not exceed 702.5 tons of S02 per consecutive 12-month period. Records must be maintained for the quantities of fuels used monthly. Fuel supplier certification must be maintained for fuel oil shipments. A semi-annual report is required. APPEARS IN COMPLIANCE—The highest 12-month rolling total S02 emissions during the past 15 months from the 4 boilers was 0.2 tons. Current fuel is natural gas. Fuel oil certifications are available in the company records on site. #2 fuel oil used is ultra-low sulfur content(< 15 ppm sulfur by weight.) Some No.2 fuel oil was combusted in January 2018(28,350 gallons)during a short natural gas curtailment. The last semi-annual report was received at FRO on 01/30/19 and appeared complete. *Facility-Wide* 15A NCAC 2D.1100 CONTROL OF TOXIC AIR POLLUTANTS(State Enforceable Only)—The Permittee shall maintain records of production rates,throughputs,material usage,excess emissions,and control equipment failures. A quarterly summary report is required APPEARS IN COMPLIANCE—Production rates,material usages,emissions,and equipment failure records are available on the company electronic data system. TAP reports are submitted quarterly and show emissions well below the 213.1100 limits. The last quarterly report was received at FRO on 01/30/19 and appeared complete. 15A NCAC 2D.1100 CONTROL OF TOXIC AIR POLLUTANTS(State Enforceable Only)—The Permittee shall emit less than the limits listed in the permit for BF from high dispersion stacks and from all other sources. The Permittee shall also report quarterly all TPER exceedances,the maximum 1-hour emission rate and the maximum 24-hour emissions rate. The liquid flow rate in the Baffle Plate-Type Scrubbers(NCD-Hdr-1 and NCD-Hdr-2)shall be a minimum 7,000 kg/hr each. The Permittee shall maintain a logbook of all inspection and maintenance activities on the applicable scrubber. A quarterly report is required. APPEARS IN COMPLIANCE—The liquid flow rates during the inspection were 15,000 kg/hr for Hdr-1 and 18,543 kg/hr for Hdr-2. The scrubber utilizes a potassium hydroxide solution in the scrubber and is interlocked to shut the systems down when flowrate drops below 7,000 kg/hr and to alarm at 9,000 kg/hr. The electronic I&M logbook appeared to be complete. TAP reports are submitted quarterly and show emissions well below the 2D.1100 limits. Hdr-1 and Hdr-2 are inspected every 4 years. The last inspection of Hdr-1 was performed on 10/19/18 and the last inspection of Hdr-2 was performed on 10/12/18. The last quarterly report was received at FRO on 01/30/19 and appeared complete. Chemours Company—Fayetteville Works Compliance Inspection Report Page 11 of 12 40 CFR Part 68 CHEMICAL ACCIDENT PREVENTION AND CLEAN AIR ACT<SECTION 112(r): The S03 process is subject to 112(r)for sulfur trioxide. The TFE process is subject to 112(r)for Tetrafluoroethylene. APPEARS IN COMPLIANCE- The facility submitted the written Risk Management Plan to the U.S. EPA in June 1999. The facility was issued a facility identifier number 1000 0022 9647. In addition,the facility is subject to the OSHA Process Safety Management(PSM)Standard. The latest update of the RMP was submitted by the facility to EPA on 06/09/15. The last full 112(r)compliance inspection was conducted by Greg Reeves DAQ on 06/21/17. The facility appeared to be in compliance during that inspection. The facility has the following processes subject to 112(r): Process Program Level Covered Chemical in Process Maximum Intended Inventory of Chemical TFE Process 1 TFE(Tetrafluoroeth lene) 59,400 S03 Process 3 Sulfur Trioxide 61,000 15A NCAC 2D.0541 CONTROL OF EMISSIONS FROM ABRASIVE BLASTING—Abrasive blasting shall take place inside a building unless the item exceeds eight feet in length or is permanently situated at an outside location. Fugitive emissions shall not migrate beyond the property boundaries. APPEARS IN COMPLIANCE—The facility has an abrasive blasting building in which the sand blasting occurs. Outside blasting of tanks and equipment is accomplished using shrouds to contain the blasting materials. 15A NCAC 2D.1806 CONTROL AND PROHIBITION OF ODOROUS EMISSIONS—The facility shall not operate 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. APPEARS IN COMPLIANCE—No objectionable odors were detected during the inspection. Ms. Compton stated that no odor complaints have been received by the facility. 15A NCAC 2Q.0504 OPTION FOR OBTAINING CONSTRUCTION AND OPERATION PERMIT —The facility is required to submit an amended Title V permit application within 1 year from the date of beginning normal operation of the IXM Membrane Coating Process(ID No.NS-I). The facility is also required to submit a notification of startup of this process within 15 days after the beginning of normal operation. APPEARS IN COMPLIANCE—The process commenced operation on May 1,2017. Startup notification was received at FRO on 05/08/17. The required permit application was submitted on 04/23/18. PERMIT SHIELD FOR NONAPPLICABLE REQUIREMENTS—This permit condition states that the boiler(ID No.PS-TEMP)has been declared a temporary boiler,as is thus not subject to NESHAP Subpart DDDDD. The facility must keep records documenting that the boiler meets the criteria of a temporary boiler. The facility must also submit a startup notification within 15 days of startup of the boiler. APPEARS IN COMPLIANCE—The boiler has not been brought onsite as yet,so no notification or records have been required. Chemours Company—Fayetteville Works Compliance Inspection Report Page 12 of 12 GENERAL CONDITION 3.I REPORTING REQUIREMENTS FOR EXCESS EMISSIONS AND PERMIT DEVIATIONS—Requires the facility to report incidents of excess emissions or deviations from permit conditions. APPEARS IN COMPLIANCE—Ms.Compton stated that no excess emission events occurred during 2018 and no deviations from permit conditions occurred during 2018. Therefore,no reporting was required. GENERAL CONDITION 3.K.PERMIT RENEWAL—If the permit renewal application is received at least 6 months prior to the expiration of the permit,then the permit shall not expire until the renewal permit has been issued or denied. The renewal application was received more than 6 months prior to the permit expiration date. This application is currently in process. GENERAL CONDITION 3.P COMPLIANCE CERTIFICATION[15A NCAC 2Q.0509(n)]: The facility is required to submit an annual compliance certification to DAQ and EPA by March 1 of each year for the previous calendar year. APPEARS IN COMPLLANCE—The 2017 compliance certification was received at FRO on 03/O1/18. The 2018 certification is due no later than 03/01/19. GENERAL CONDITION 3.X ANNUAL EMISSION INVENTORY REQUIREMENTS—The facility must submit an annual emission inventory by June 30 of each year. APPEARS IN COMPLIANCE—The 2017 emission inventory was received at FRO on 06/29/18 and appeared complete. GENERAL CONDITION 3.MM FUGITIVE DUST CONTROL REQUIREMENT—The facility shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. APPEARS IN COMPLIANCE—I did not observe any dust accumulations nor observe any excess visible emissions beyond the property boundary. Ms.Compton stated that no dust complaints have been received by the facility. 7. NON-COMPLIANCE HISTORY SINCE 2010: There have been no air permit non-compliance instances at this facility since 2010. 8. CONCLUSIONS AND RECOMMENDATIONS: Based on the observations made during the 02/21/19 inspection,Chemours Company—Fayetteville Works APPEARS IN COMPLIANCE with the requirements outlined in their current air permit,03735T43. PINK SHEET: N/A GWR