DEQ-CFW_00088555

SECTION A
FACILITY (General Information) Al
REVISED: 04/15/94 AIR QUALITY SECTION - APPLICATION FOR AIR PERMIT TO CONSTRUCT/OPERATE
FACILITY NAME: DuPont Company - Fayetteville Works
MAILING ADDRESS: P.O. Drawer Z I SITE ADDRESS: Highway 87 South
Bladen
STATE:
NC
ZIP CODE: 28302-177
0 ZIP ODE.
28302-17 70
CONTACT PERSON Michael E. Johnson TITLE: Environmental Coordinator
TELEPHONE [phone] FAX: [phone] <::::::::::::::::::::
OWNER OF FACILITY: E.I. du Pont de Nemours & Co., Inc.
MAILING ADDRESS: 1007 Market Street
n�
CITY: Wilmington STATE: Delaware ZIP CODE: 19898
CONTACT PERSON Michael E. Johnson TITLE: Environmental Coo
TELFPHONF [phone] FAX: [phone]_...............................................................
TYPE OF OPERATION Chemical
IC DES 3081 3083 2821 2869 DESCRIPTION OF PRIMARY SIC R P: Unsupported Plastic Sheeting
FACILITY UTM EAST: OR LATITUDE: 340 50" 00'
COORDINATES QIM N RTH: L N IT DE: 78050" 00'
HAVE YOU INCLUDED (X ) CONSISTENCY DETERMINATION (X) SOURCE REDUCTION & RECYCLING FORM 133-3 AND (X) APPLICATION FEE ?
FACILITY IS: (X) TITLE V FACILITY ( ) NON -TITLE V FACILITY SYNTHETIC MINOR
IF TITLE V INDICATE APPLICABILITY 1 2 3 4 5 (CIRCLE ALL THAT ARE APPLICABLE)
PPLICATION IS BEING MADE FOR (CHECK ALL THAT APPLY, NOTE. (TV) INDICATES APPLICABILITY TO TITLE V FACILITIES ONLY):
) NEW FACILITY INITIAL TITLE V PERMIT (TV) ) RENEWAL (TV)
X) MODIFICATION v; NEW FACILITY (TV) PSD (TV)
EXISTING EMISSION SOURCE(S) MINOR MODIFICATION (TV) NON -ATTAINMENT (TV)
SIGNIFICANT MODIFICATION (TV) 112(g) CM
IF APPLICATION IS BEING MADE FOR ANY OF THE FOLLOWING, FORM A2 MUST BE ATTACHED TO THIS FORM.•
ADMINISTRATIVE AMENDMENT CHANGE OF OWNERSHIP RELOCATION (WITHIN FACILITY) (TV)
ADMINISTRATIVE AMENDMENT (TV) ) CHANGE OF OWNERSHIP (TV) LIKE -FOR -LIKE REPLACEMENT
( RENEWAL RELOCATION (WITHIN FACILITY) LIKE -FOR -LIKE REPLACEMENT;. jTV)
502(b)(10) NOTIFICATION (TV)s;ryj
IHAVE YOU INCLUDED: (X) FLOW CHART(S) (X) ROOF DIAGRAM (X) PLANT LAYOUT (X) PLOT PLAN (X) AREA DIAGRAM
DO YOU CLAIM CONFIDENTIALITY OF DATA YES
NO SEE INSTRUCTIONS
( )
>::>:>_:>:>::>:3'
*::>::>:»:>::
SIGNA4F,�IESE S N OR CO NY OFFICIAL:
X
TITLE: Plant Manager
DATE:
CO
rry
(TYPED) Michrry
DEPARTMENT USE ONLY:
RECEIVED:
ASSIGNED TO:
PREMISE NUMBER:
--i
APPLICATION NUMBER:
RETURNED:
COMPLETE:
REVIEW DATE:
PERMIT NUMBER:
U
DATE ISSUED:
...................
.... ..........
3
DEQ-CFW 00088555

SECTION A
EMISSION SOURCE LISTING (EXISTING FACILITY) A3
(New, Modified, Previously Unpermitted, Replaced, Deleted)
OSED: 04/15/94 AIR QUALITY
SECTION
MISSION
DURCE
1 NO.
EMISSION
SOURCE
DESCRIPTION
CONTROL
DEVICE
ID NO.
CONTROL
DEVICE
DESCRIPTION
EMISSION
POINT ID NO.
or "FUGITIVE"
EQUIPMENT TO BE MODIFIED BY THIS APPLICATION
EQUIPMENT TO BE ADDED BY THIS APPLICATION
New, Previously unpermitted, or Re lacement
i-D
Butacite® Tinting
BCD-D
Tinting Scrubber
BEP-D
(existing source
new control device
EQUIPMENT TO BE DELETED BY THIS APPLICATION
.M'
0
c-) . a
EQUIPMENT BEING REPLACED BY THIS APPLICATION
Co
DEQ-CFW 00088556

SECTION D
EMISSION POINT SUMMARY D4
L'ISED: 04/15/94 AIR QUALITY SECTION
LIST ALL INFORMATION ASSOCIATED WITH EACH EMISSION POINT
_MISSION POINT
ID NO.
EMISSION POINT
HEIGHT (FT)
EQUIV. DIAM.
(FT)
TEMP.
(F)
VELOCITY
(FTISEC)
FLOW RATE
(ACFM)
EMISSION POINT
DIRECTION
RAIN CAP?
(Y OR N)
BEP-D
35
1.94
Amb.
70
12500
Vertical
N
Aa
Y>
)MMENTS: .�.�
co
19
DEQ-CFW 00088557

SECTION D
FACILITY EMISSIONS SUMMARY D5
AIR QUALITY SECTION
' REVISED: 04/15/94 TOTAL FROM SPECIFIC EMISSION SOURCE SUMMARIES
POLLUTANT
CAS NO.
ANNUAL EMISSIONS IN LBSNR
ACTUAL
POTENTIAL
PM
.....................................
.....................................
.....................................
78,082
317,939
2 SO
1,061,362
4,697,878
NOx
219,326
829 385
>
CO
17,690
66,618
VOC
296,116
>
778 401
>
LEAD
--
--
Dimeth I Formamide
68122
2,210
12,905
1
-a
_>
OTAL FACILITY FIRING RATE FOR FOSSIL AND WOOD -FIRED BURNERS: 227.8 MILLION BTU/HR
OTAL REACTIVE VOC's FROM THE FACILITY: N/A LBS/DAY or % Total Control or OTHER (specify) rn
COMMENTS:
Co n
ft
20
DEQ-CFW 00088558

REVISED: 04/15/94
SECTION B
EMISSION SOURCE (PRINTING) B6
AIR QUALITY SECTION
EMISSION SOURCE DESCRIPTION: Butacite® Tinting
EMISSION SOURCE ID NO: BS-D
CONTROL DEVICE ID NO : BCD-1
1EMISSION POINT ID NO : BEP-D
INDICATE WHETHER THIS SOURCE IS SUBJECT TO NSPS OR NESHAP REGULATIONS. See Comment
TERNATIVE OPERATING SCENARIO A N NA
...................................................................................................................................................
..................................................................................................................................................
DESCRIBE PROCESS: Tinting is applied to Butacite® sheeting and dried in a steam heated oven.
Tinting process is carried out in a permanent total enclosure.
OPERATING SCHEDULE ACTUAL PERATION DATE: 1986
HRS/DAY: 24
DAYSNVK: 7
...........................................................................................................
..........................................................................................................
WEEKS/YR: 52
SEASONAL VARIATION %
JAN-MAR: 25
APR-JUN: 25
UL-SEP: 25
OCT-DEC: 25
[TYPE OF PRINTINGOPERATION: Rotogravure
HAT IS BEING PRINTED? Butacite® sheetin
CONTINUOUS PRINTING
I NUMBER OF PRINT STATIONS: 2
WEIGHT OF MATERIAL BEING PRINTED LB/FT2 : 0.233
MAXIMUM WIDTH I IN 12 dMAXIMUM
PE T IN Confid. ACTUAL: Conf.
NON -CONTINUOUS PRINTING
I NUMBER OF PRINT STATIONS:
WEIGHT OF MATERIAL LB/100 ITEMS):
MAXIMUM DIMENSION INCHES
LENGTH:
WIDTH:
MAXIM M PRINTED/MINUTE:
COATING USE
ACTUAL USAGE
MAXIMUM DESIGN CAPACITY
PRINT STATION
COATINGS APPLIED AT THIS STATION LIST ID
GAUHR
GAL/YR
GAUHR
GAUYR
II
V0000
Confid.
Confid.
Confid.
Confid.
NO.OF BAKE OVENS: 1 METHOD OF HEATING: (XX) STEAM ( ) DIRECT FIRED
ELECTRIC)OTHER:
UEL USED: NA
TOTAL MAXIMUM FIRING RATE MILLION BTU/HR :
MAXIMUM ANNUAL FUEL USE:
MAXIMUM HOURLY FUEL USE:
CTUAL ANNUAL FUEL USE:
71,
ACTUAL HOURLY FUEL USE: 01
DESCRIBE ANY MONITORING DEVICES, GAUGES, OR TEST PORTS: Operation of the permanent total enclosure (PTE)
fans is monitored to assure that the fans remain on and the PTE is maintained. o
t—)
INDICATE ALL REQUESTED STATE AND FEDERALLY ENFORCEABLE PERMIT LIMITS (e.g., hours of operation, material input rates,
fission rates, etc.) AND DESCRIBE HOW THESE LIMITS ARE MONITORED AND WITH WHAT FREQUENCY. y
—=1
COMMENTS: This process is subject to the Printing and Publishing MACT Standard, 40 CFR Part 63
Subpart KK. The applicability date of this standard is May 30, 1999
DEQ-CFW 00088559

SECTION C
CONTROL DEVICE (GASEOUS ABSORBER) C7
SED: 04/15/94 AIR QUALITY SECTION
IF
INTROL DEVICE ID NO: BCD-1
ICONTROLS EMISSIONS FROM WHICH EMISSION SOURCE ID NOS : BS-D
IISSION POINT ID NOS : BEP-D
POSITION /N SERIES OF CONTROLS NO 1 OF 1
UNITS
NUFACTURER: Turbosonic
MODEL NO:
FERNAT NE OPERATING SCENARIO AOS NO:
SCRIBE CONTROL SYSTEM: High efficiency multi -stage spray chamber water scrubber. Compressed air
d water are injected through patented spray nozzles to form highly atomized water droplets.
LLUTANT(S) COLLECTED: VOCIDMF
RRESPONDING EFFICIENCY: >96 % % % %
=1CIENCY DETERMINATION CODE: 2,3
=ORE CONTROL EMISSION RATE (LB/HR): 29.5
FER CONTROL EMISSION RATE (LB/HR): < 1.473
ESSURE DROP IN. H20: MIN -1.0 MAX -3.0 WARNING ALARM? YES: NO: XX
ET TEMPERATURE MIN Ambient MAX -200
OUTLET TEMPERATURE : MIN -50 MAX -100
12,500 ET AI LOW RATE C A
RF FM
AL GAS PRESSURE (PSIG): 14.7
GAS DEW POINT NA
GAS VELOCITY (FT/SEC): 16.6
FE OF SYSTEM: Spray Chamber
EKED COLUMN
TYPE OF PACKING:
COLUMN LENGTH (FT):
COLUMN DIAMETER (FT):
ITE COLUMN
PLATE SPACING (INCHES):
COLUMN LENGTH (FT):
COLUMN DIAMETER (FT):
)ITIVE LIQUID SCRUBBING MEDIUM: Water
PERCENT RECIRCULATED 67%
TAL LIQUID INJECTION RATE GAL/MIN : See Note
MAKE UP RATE IN : See Note FOR ADDITNE (GAL/MIN):
SCRIBE MAINTENANCE PROCEDURES: At a minimum, the manufacturers guidelines for maintenance will
followed.
r'*1
SCRIBE ANY MONITORING DEVICES, GAUGES, TEST PORTS, ETC: Liquid injection make up rate and compresRd
y
c7
pressure. I
Cb
cn
-;r
)W BY DIAGRAM THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S): See attached flowchart
�E: The minimum total liquid injection rate and the corresponding make-up rate will be determined
ring the scrubber performance test.
DEQ-CFW 00088560

KEY
------ Vapor Line
Liquid or
Product Line
To
Atmosphere
(BEP-D)
DMF Water Scrubber
------ Compressed Air
;
-------------------------------------,
r----------r-----------------+-----------------
Room
Exhausts
Butacite®Tinting
Permanent I
Area Permanent
Localized
Total Enclosure
Total Enclosure
Hood -__-
Header
(Equipment and 1
I Exhausts
Rooms Within
IA
Dotted Line) 1
Press
i
Hood
1
Exhausts
1
I Butacite®
Butacite Sheeting I
Tinting
Sheeting
Press
Dryer
with Tinted 4pnc 1
to ShippiM I
i
1
Ink in DMF
CO n 1
,
----------------------------------------------
Solvent
0KJ1-1 Environmental Services DuPont Fayetteville Works Butacit ® Tinting
Charlotte, North Carolina Fayetteville, North Carolina IBEP-D
0
DEQ-CFW 00088561

SECTION D
SPECIFIC EMISSION SOURCE (EMISSION INFORMATION) rD-3 P - I
(*see, note in instructions concerning state air to)dcs regulations)
REVISED: 04/15194 AIR QUALITY SECTION
EMISSION SOURCE DESCRIPTION: Butacite@ Tinting
EMISSION SOURCE ID NO: BS-D IS THIS SOURCE A FUGITIVE SOURCE? YES (X) NO
..........
.................... ...........
.... .................... ........ ..............
.................. ..............
............... .............
.........
...... . ... ........
.............. .................
kTERNATIVE OPERATING SCENARIO (AOS) NO: N/A
::: ...... 1.11 .... :.--, - ... ..... .........
........ . ............. ......... .:.,. .. .:., I.' ... ............. .......... .......... .......... .......... .......... .......... .......... ..........
........... . .......... .......... . .
. . . . . . . . . .
EMISSION RATE IN EMISSION RATE IN
EMISSION FACTOR LBS/HR LBS/YR
- T-
POLLUTANT TYPE POTENTIAL ACTUAL POTENTIAL ACTUAL
VOC/DMF 1,2 1.47 0." 12,905 2,210
1COMMENTS: r-i
C-1
13
Co
11
DEQ-CFW-00088562

SECTION E
SPECIFIC EMISSION SOURCE (REGULATORY ANALYSIS) D3-2
LASED: 04/15M AIR QUALITY SECTION
ISSION SOURCE DESCRIPTION: Butacite® Tinting
MISSION SOURCE ID NO: BS-D
IALTERNATIVE OPERATING SCENARIO AOS NO: NA
REGULATED
POLLUTANT
EMISSION AND OPERATING LIMITS
APPLICABLE
REGULATION
?active VOC
Emissions <40 Ibiday or 85% control
15A NCAC 2D.0518 d
MF
Achieve Greater than 95% Overall Control
40 CFR Part 63 Subpart KK
63.825(b)(7)
:OMMENTS: '.T}
,3
v
rri 7
C-1) ._.,.,.�
� ra
to
12
DEQ-CFW 00088563

i
SECTION D
SPECIFIC EMISSION SOURCE (REDUCTION AND RECYCLING ACTIVITIES) D3-3
! A• • / ArATA■
KtVIStU: U4/i5i94 AIR 41UAL1 I i ,CV 1 IVIY
EMISSION SOURCE DESCRIPTION: Butacite® Tinting
EMISSION SOURCE ID NO BS-D
REGULATED ONGOING SOURCE QTY. EMITTED QTY. EMITTED PLANNED SOURCE
POLLUTANT REDUCTION BEFORE REDUCTION AFTER REDUCTION REDUCTION
ACTIVITIES (LBSNR) (LBSNR) ACTIVITIES
ENTER CODES ENTER CODES
OC W99 441194 2,210
COMMENTS: Installation of a water scrubber will result in a greater than 95% reduction in emissions.
rj
FTi :`J
�Iw
13
DEQ-CFW 00088564

SECTION D - FORM D6
ENGINEERING ANALYSIS TO SUPPORT PERMIT APPLICATION
Emission Unit ID: BS-E
Emission Source Desc. Butacite® Tinting
A. Emission Estimation Approach:
Emissions from Butacite® Tinting are estimated using a mass balance approach. DMF can either be collected
as waste, remain in Butacite® sheeting, or emitted to the air. All tinting operations are performed in the tinting
rooms which are maintained under negative pressure (i.e. permanent total enclosure with 100% capture efficiency).
Exhaust from the tinting process dryer and from the tinting rooms isrouted to the DMF scrubber which achieves
>95% control.
Emission Calculations
Actual Hourly
Potential Hourly
Actual Annual Potential Annual
(gal/hr) (lb/hr)
(gal/hr) (lb/hr)
(gal/yr) (lb/yr) (gal/yr) (lb/yr)
DMF Usage
DMF Waste*
CONFIDENTIAL
CONFIDENTIAL
DMF in Sheeting**
DMF Uncontrolled Emis.
1.12 8.84
3.72 29.46
5,580 44,194 32,587 258,091
DMF Controlled Emis.***
0.44
1.47
2,210 12,905
DMF Density = 7.92 lb/gal
*Approximately Conf. of DMF Used is collected as waste
**Approximately Conf. of DMF Used remains in sheeting
*** Based on a conservative estimate of 95% control.
14
%n
Co
DEQ-CFW 00088565

` SECTION D - FORM D6
ENGINEERING ANALYSIS TO SUPPORT PERMIT APPLICATION
Emission Unit ID: BS-D
Emission Unit Description: Butacite® Tinting
B. Regulatory Information:
This emission unit is subject to the following regulations:
15A NCAC 2D .0518 requires that facility -wide emissions of photochemically reactive
VOCs (as defined in the rule) be less than 40 pounds per day or be controlled 85% or
greater.
40 CFR Part 63 Subpart KK in general requires each facility that is a major source of
hazardous air pollutants (HAP) at which product rotogravure printing presses are
operated, to limit emissions from the presses to no more than 5 percent of organic HAP
applied for the month, or to demonstrate that materials used contain no more that 4%
by weight organic HAP.
C. Control Device Information:
This emission unit will be equipped with a water scrubber. The scrubber will utilize
patented spray nozzles that spray a highly atomized mist for efficient removal of DMF.
D. Compliance Information:
15A NCAC 2D .0518 - Only non -reactive inks are used at DuPont Fayetteville
Butacite® facility, and therefore, compliance with the facility -wide limit of 40 lb/day of
photochemically reactive VOC will be achieved.
40 CFR 63 Subpart KK - Compliance with this standard is required by May 1999.
Compliance will be achieved by maintaining a permanent total enclosure (PTE) that
achieves 100% capture and installing a water spray scrubber that achieves greater
than 95% control. The Butacite tinting area meets the criteria for a PTE as defined in
40 CFR §52.741 Appendix B (Procedure T) by virtue of the fact that there are no
natural draft openings (NDOs) and all access doors and windows are closed during
routine operation. As long as the tinting area fans are in operation, a negative C-)
pressure will be maintained and 100% capture will be achieved. Thus, the operatin6,
state of the fans (i.e. on or off) will be monitored to assure that the PTE is maintaingg.
Proper operation of the scrubber will be assured by monitoring the make up waterff6W
rate and the pressure of compressed air injected into the scrubber. Minimum values of
these two parameters necessary for proper scrubber operation will be determined =�
during the initial performance test.
15
DEQ-CFW 00088566

' E. Engineering Certification
The proposed water scrubber for controlling emissions from the DMF tinting process
has been manufactured and designed by an outside vendor. A pilot test was
conducted and demonstrated that the scrubber will efficiently control DMF emissions.
The scrubber is based on proven and accepted technologies that are applicable and
appropriate for the DMF tinting process.
SEAL.
02M
'KJH Environmental Services
PO Box 13190
Charlotte, NC 28226
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.,
C
.,,,
k COCD
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DEQ-CFW 00088567