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HomeMy WebLinkAboutDEQ-CFW_00085794State of North Carolina, Department of Environment, and Natural Resources Division of Air Quality AIR QUALITY PERMIT Permit No. Replaces Permit No. Effective Date Expiration Date 03735T34 03735T33 January 15, 2009 January 31, 2009 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 21) and 2Q, and other applicable Laws. Pursuant to Title 15A NCAC, Subchapter 2Q, 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: E.I. du Pont de Nemours & Co., LLC DBA, DuPont Company — Fayetteville Works Facility ID: 0900009 Facility Site Location: 22828 NC Highway 87 W City, County, State, Zip: Duart Township, Bladen County, NC, 28306-7332 Mailing Address: 22828 NC Highway 87 W City, State, Zip: Fayetteville, NC, 28306-7332 Application Number: 0900009.08AD Complete Application Date: December 9, 2008 Primary SIC Code: 2821, 3081, 3083 Division of Air Quality, Fayetteville Regional Office Regional Office Address: 225 Green Street, Suite 714 Fayetteville, NC 28301 Pe issued this the 5th day of January, 2009 MR —der Vaart, Ph.D., P.E., Cfiief, Air Permits Section ty of the Environmental Management Commission DEQ-CFW 00085794 Permit 03735T34 Page 4 Emission Emission Source Description Control Device Control Device Description Source ID No. ID No. BS-D Butacite®Polyvinyl butyral sheeting BCD -DI Multi -stage horizontal spray scrubber (6 MALT KK rotogravure printing operation gallons per minute of water flow to each nozzle averaged over a 3-hour-period) NS-A Nafion0 Hexfluoropropylene epoxide NCD-Hdrl Baffle -plate scrubber (7,000 MACT FFFF process (HFPO) kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle -plate scrubber (7,000 kilogram/hour liquid injection rate avera ed over a 3-hourperiod) NS-B Naflon0 Vinyl Ethers North process NCD-Hdrl Baffle -plate scrubber (7,000 MACT FFFF 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 NaflonO Vinyl Ethers South process NCD-Hdrl Baffle -plate scrubber (7,000 MALT FFFF 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 NafionO RSU Process NCD-Hdrl Baffle -plate scrubber (7,000 MACT FFFF kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle -plate scrubber (7,000 kilogram/hour liquid injection rate avera ed over a 3-hourperiod) NS-E NaflonO Liquid waste stabilization NCD-Hdrl Baffle -plate scrubber (7,000 MACT FFFF kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle -plate scrubber (7,000 kilogram/hour liquid injection rate average over a 3-hourperiod) NS-F NafionO MMF process NCD-Hdrl Baffle -plate scrubber (7,000 MACT FFFF 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-hour-period) NS-G Nafion0 Resins process NCD-G Venturi vacuum jet caustic scrubber MACT FFFF NS-H NafionO membrane process N/A N/A MACT FFFF DEQ-CFW 00085795 Permit 03735T34 Page 5' • Emission Emission Source Description Control Device Control Device Description Source ID No. ID No. NS-I Nafion® membrane coating N/A N/A MACT FFFF NS-J Naflont semiworks NIA N/A MACT FFFF NS-K Nafion® E-2 Process N/A N/A MACT FFFF NS-L Nafion® TFE/HCl separation unit NCD-Hdrl Baffle -plate scrubber (7,000 kilogram/hour liquid injection rate -or- averaged over a 3-hour period) NCD-Hdr2 Baffle -plate scrubber (7,000 kilogramAour liquid injection rate averaged over a 3-hourperiod) NS-M Nafion® TFE/CO2 separation process N/A N/A NS-N2 HFPO product container decontamination N/A N/A process NS-02 Vinyl Ethers North product container N/A N/A decontamination process NS-P2 Vinyl Ethers South product container N/A N/A decontamination process SW-1 Semiworks polymerization operation N/A N/A SW-2 Semiworks laboratory hood N/A N/A FS-A Fluoroproducts polymer manufacturing FCD-Al Wet scrubber (3 gallons per minute development facility water injection rate averaged over a 3- hour period) (nominal injection rate) Fabric filter (125 square feet of filter FCD-A2 area AS -A APFO Manufacturing Facility ACD-Al Wet scrubber (30 gallons per minute water injection rate averaged over a 3- hour period) (state -enforceable only) Wet scrubber installed on the building ACD-A3 exhaust vent(voluntary use only) WTS-A Extended aeration biological wastewater N/A N/A treatment facility WTS-B, Two (2) Indirect steam -heated, rotary WTCD-1 Impingement -type wet scrubber with WTS-C sludge dryers mist eliminator state -enforceable only) SGS-A SentryGlas a Manufacturing N/A N/A FS-B Polyvinyl Fluoride Manufacturing N/A N/A Facilitv No.1 FS-C' Polyvinyl Fluoride Manufacturing N/A NIA Facility No.2 This emission source (ID No. FS-C) is listed as a I SA NCAC 2Q .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.I. The permit shield described in General Condition R does not apply and compliance certification as described in General Condition P is not required. These emission sources (ID Nos. PS-1, PS-2, PS-C, PS -Temp, NS-N, NS-0, and NS-P) are listed as a 15A NCAC 2Q .0501(c)(2) modification. The Permittee shall file a Title V Air Quality Pernlit 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 to the new and modified conditions and compliance certification as described in General Condition P is not required. DEQ-CFW 00085796 Permit 03735T34 Page 6 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(s) and appurtenances listed below are subject to the following specific terms, conditions, and limitations, including the testing, monitoring, recordkeeping, and reporting requirements as specified herein: A. Natural Gas/No. 2 fuel oil/No. 6 fuel oil -fired boiler (ID No. PS-1)2, 139.4 million Btu per hour maximum heat input, Natural Gas/No. 2 fuel oil/No. 6 fuel oil -fired boiler (ID No. PS-2)', 88.4 million Btu per hour maximum heat input, and Natural Gas/No. 2 fuel oil -fired boiler (ID No. PS-C)2 equipped with a low-NOx burner, 97 million Btu per hour maximum heat input. TkP „n m rohlP r.,,,;Al n ­-, ­1 �ra.,r1� 4. f ,- r} p A7 ---;"A 1.,...o. Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter Affected Sources: PS-1, PS-2 15A NCAC 213.0503 0.2667 pounds particulate per million Btu heat input Affected Sources: PS-C 0.2268 pounds articulate per million Btu heat in -out Sulfur dioxide Affected Sources: PS-1, PS-2 15A NCAC 2D .0516 2.3 pounds SO er million Btu heat in -out, each Sulfur dioxide Affected Source: PS-C 15A NCAC 2D .0524 No. 2 fuel oil sulfur content shall not exceed 0.5% by weight. 40 CFR 60 Subpart DO Visible emissions Affected Source: PS-1 15A NCAC 2D .0521(c) 40 percent opacity Affected Source: PS-2 15A NCAC 213.0521(d) 20 percent o aci Visible emissions Affected Source: PS-C 15A NCAC 2D .0524 20 Dercent opacity 40 CFR 60 Subpart DO PM, PM-10, NO,,, and Affected Source: PS-2 15A NCAC 2Q .0317 SO2 Particulate matter <25 tons per year. (PSD Avoidance) Particulate matter under 10 micron <15 tons per year. Nitrogen oxide <40 tons per year. Sulfur dioxide <40 tons per year. Sulfur dioxide Affected Sources: PS-1, PS-2, PS-C, and PS -Temp 15A NCAC 2Q .0317 Sulfur dioxide <702.5 tons per year. (PSD Avoidance) See Section 2.2. A.1. of this permit 1. 15A NCAC 2D .0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter from the combustion of No. 2 fuel oil/No. 6 fuel oil, that are discharged from the affected boilers (ID Nos. PS-1 and PS-2) into the atmosphere shall not exceed 0.2667 pounds per million Btu heat input. b. Emissions of particulate matter from the combustion of No. 2 fuel oil, that are discharged from the affected boiler (ID No. PS-C) into the atmosphere shall not exceed 0.2268 pounds per million Btu heat input. Testing [15A NCAC 2D .2601] c. If emissions testing is required, the testing shall be performed in accordance General Condition JJ. If the results of DEQ-CFW 00085797 Permit 03735T34 Page 7, this test are above the limits given in Section 2.1 A. La. and/or b. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0503. Monitoring_/Recordkeeping/Reporting [15A NCAC 2Q .0508(f)] d. No monitoring/recordkeeping/reporting is required for particulate emissions from the firing of No. 2 or No. 6 fuel oil in these sources. 2. 15A NCAC 2D .0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES a. Emissions of sulfur dioxide from the affected boilers (ID Nos. PS-1 and PS-2) 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. T s inu [15A NCAC 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ found in Section 3. If the results of this test are above the limit given in Section 2.1 B. l.a. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0516. Monitoring/Recordkeepiing [15A NCAC 2Q .0508(f) and 15A NCAC 2D .0501(c)(4)(A)] c. No monitoring/recordkeeping is required for sulfur dioxide emissions from No. 2 fuel oil burned in these sources. d. The maximum sulfur content of any No. 6 fuel oil received and burned in the boiler shall not exceed 2.1 percent by weight. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0516 if the sulfur content of the fuel oil exceeds this limit. e. To assure compliance, the Permittee shall monitor the sulfur content of the No. 6 fuel oil by using fuel oil supplier certification per shipment received. The results of the fuel oil supplier certifications shall be recorded in a logbook (written or electronic format) on a quarterly basis and include the following information: i. The name of the fuel oil supplier; ii. The maximum sulfur content of the fuel oil received during the quarter; iii. The method used to determine the maximum sulfur content of the fuel oil; and iv. A certified statement signed by the responsible official that the records of fuel oil supplier certification submitted represent all of the No. 6 fuel oil fired during the period. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0516 if the sulfur content of the oil is not monitored and recorded. Reporting [15A NCAC 2Q .0508(f)] f The Permittee shall submit a summary report of the fuel oil supplier certifications 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 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the affected boiler (ID No. PS-1) shall not be more than 40 percent opacity when averaged over a six -minute period. However, six -minute averaging periods may exceed 40 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 90 percent opacity. b. Visible emissions from the affected boiler (ID No. PS-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. DEQ-CFW 00085798 Permit 03735T34 Page 8 Testing [15A NCAC 2D .2601] c. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ. If the results of this test are above the limit given in Section 2.1 A.3.a. or .b above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring [15A NCAC 2Q .0508(f)] d. To assure compliance, each day that an affected source fires No. 6 fuel oil, the Permittee shall observe the emission point of the affected source for any visible emissions above normal. The daily observation must be made for each day of the calendar year period to ensure compliance with this requirement. The Permittee shall be allowed three (3) days of absent observations per semi-annual period. If visible emissions from this source 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 2D .2601 (Method 9) for 12 minutes is below the limit given in Section 2.1 A.3.a, or b. 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 2D .0521. Recordkeening [15A NCAC 2Q .0508(f)] e. 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 2D .0521 if these records are not maintained. Monitoring/Recordkee ing/Repor in [15A NCAC 2Q .0508(f)] f. No monitoring/recordkeeping/reporting is required for visible emissions from the firing of natural gas or No. 2 fuel oil in these sources. Reporting [15A NCAC 2Q .0508(f)] g. 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. 4. 15A NCAC 2D .0524: New Source Performance Standards (40 CFR 60, Subpart Dc) a. For the affected boiler (ID No. PS-C), 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 60, Subpart Dc, including Subpart A, "General Provisions." [I5A NCAC 02D .0524] Emission Limitations [15A NCAC 2D .0524] b. The maximum sulfur content of any fuel oil received and fired in the affected boiler (ID No. PS-C) shall not exceed 0.5 percent by weight. [40 CFR 60.42c(d)] c. Visible emissions from the affected boiler (ID No. PS-C) shall not be more than 20 percent opacity when averaged over a six -minute period, except for one six -minute period per hour of not more than 27 percent opacity. [40 CFR 60.43c(c)] DEQ-CFW 00085799 Permit 03735T34 Page 9' Testing [15A NCAC 2D .2601] d. Within 60 days after achieving the maximum firing rate at the affected boiler (ID No. PS-C), but not later than 180 days after initial startup, the Permittee shall conduct a Method 9 test (6-minute average of 24 observations) to determine the opacity of stack emissions in accordance with 40 CFR 60.45c(a)(8) and 40 CFR 60.8. All testing notifications and reports shall be submitted in accordance with General Condition JJ of this permit. If the Permittee fails to conduct the opacity observation or if the results of the test are above the applicable limit, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524. [40 CFR 60.45c(a)(8)] Monitoring[Recordkeeping [15A NCAC 2Q .0508(f)] e. The Permittee shall retain a record of the quantity of natural gas and No. 2 fuel oil fired at the affected boiler (ID No. PS-C) each calendar month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524 if this record is not created and retained. [49 CFR 60.48c(g)] f. The Permittee shall retain a copy of the fuel supplier certification for any No. 2 fuel oil fired at the affected boiler (ID No. PS-C). The fuel supplier certification shall include the following information: i. The name of the oil supplier; ii. The sulfur content of the oil (in % by weight); and, iii. A statement from the oil supplier that the oil complies with the specification under the definition of distillate oil in 40 CFR 60.41 c. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524 if the sulfur content of the oil exceeds the limit provided in Section 2.1.A.4.b. of this permit or if fuel supplier certifications are not retained as described above. [40 CFR 60.46c(e), 40 CFR 60.48c69] Initial Notification [15A NCAC 2Q .0508(f)] g. The Permittee shall submit a construction notification of the date construction of the affected boiler (ID No. PS-C) is commenced, postmarked no later than 30 days after such date. [40 CFR 60.7(a)(1)J h. The Permittee shall submit an initial notification to the Regional Supervisor within 15 days of actual startup of the affected boiler (ID No. PS-C). The notification shall include: i. The actual date of initial startup; and, ii. The design heat input capacity of the boiler and identification of fuels to be combusted in the boiler. [40 CFR 60.48c(a), 40 CFR 60.7(a)(3)J Reporting [15A NCAC 2Q .0508(f)] The Permittee shall submit a semiannual summary report, acceptable to the Regional Air Quality Supervisor, of the sulfur content of the distillate fuel oil fired, 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 summary report shall include the following information: i. Fuel supplier certification(s) for distillate fuel oil, as provided in Section 2.1.A.4.e. of this permit; ii. A certified statement signed by the owner or operator that the records of fuel supplier certification(s) submitted represents all of the fuel fired at the affected boiler (ID No. PS-C) during the semiannual period; and, iii. All instances of deviations from the requirements of this permit must be clearly identified. DEQ-CFW 00085800 Permit 03735T34 Page 10 5. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of 15A NCAC 2D .0530(g) for major sources and major modifications, the affected boiler (ID No. PS-2 only) shall discharge into the atmosphere less than the following, per consecutive 12-month period. Pollutant Emission Limitation tons per vear Particulate Matter 25 Particulate Matter under 10 microns 15 Nitrogen Oxide 40 Sulfur Dioxide 40 Testing [15A NCAC 2Q .2601] b. If emissions testing is required, the Permittee shall perform such testing in accordance with General Condition JJ. If the results of this test are above the limit given in Section 2.1 A.5.a., the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] c. The Permittee shall keep monthly accounting records of the amount of fuel used and the sulfur content, including certification of the fuel, in a logbook (written or in electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the sulfur content of the fuel is not monitored. Re op rti g, [15A NCAC 2Q .0508(f)] d. 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. The monthly particulate matter, particulate matter below 10 microns, nitrogen oxide, and sulfur dioxide emissions for the previous 17 months. The emissions must be calculated for each of the 12-month periods over the previous 17 months; ii. The monthly quantities of natural gas/No. 2 fuel oil/No. 6 fuel oil consumed for the previous 17 months; iii. The average sulfur content for the fuel oil; and, iv. All instances of deviations from the requirements of this permit must be clearly identified. B. Butacite® Process Area consisting of one butyraldehyde storage tank (ID No. BS-A) controlled by a brine cooled condenser (ID No. BCD -A), Four Butacite® flake reactors (ID Nos. BS-B1.1 through BS-B1.4) controlled by a packed - bed scrubber (ID No. BCD-B1), Four Butacite® flake reactors (ID Nos. BS-B2.1 through BS-B2.4) controlled by a packed - bed scrubber (ID No. BCD-B2), One Butacite® flake dryer (ID No. BS-C) controlled by a cyclone (ID No. BCD-Cl) and fabric filter (ID No. BCD-C2) and, Butacite Line No. 3 Sheeting Extrusion Process, including four (4) extruders (ID No. BS-El) controlled by a water-cooled condenser (ID No. BCD -El) (voluntary use only) Butacite° Line No. 4 Sheeting Extrusion Process, including four (4) extruders (ID No. BS-E2) DEQ-CFW 00085801 Permit 03735T34 Page 1'1 controlled by a water-cooled condenser (ID No. BCD-E2) (voluntary use only) Butacite Line No. 3 Back -End Process, including a quencher, dryer/relaxer, and wind-up area (ID No. BS-E3) Butacite° Line No. 4 Back -End Process, including a quencher, dryer/relaxer, and wind-up area (ID No. BS-E4) One polyvinyl butyral sheeting rotogravure printing operation (ID No. BS-D) controlled by one multi -stage horizontal spray scrubber (ID No. BCD -DI). The following table Drovides a summary of limits and standards for the emission sources described above: Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter Affected Source: BS-C, only 15A NCAC 2D .0515 for process rates less than 30 tons per hour - E=4.10xP"" Where: E = allowable emission rate in pounds per hour, and P = the process weight rate in tons per hour Visible emissions Affected Source: BS-C, only 15A NCAC 2D .0521 20% visible opacity emissions Odors State -enforceable only 15A NCAC 2D .1806 Odorous emissions must be controlled. Organic HAP Affected Source: BS-D, only 15A NCAC 21).1111 National Emission Standards for Hazardous Air (40 CFR 63, Subpart KK) Pollutants Printing and Publishing Industry 15A NCAC 2D .0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the affected source (ID No. BS-C) shall not exceed an allowable emission rate as calculated by the following equation: E=4.10xP"" 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 2D .2601] 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. La. above, the Pernittee shall be deemed in noncompliance with 15A NCAC 2D .0515. Mon itoring/R cP .o� rdkee in [15A NCAC 2Q .0508(f)] Particulate matter emissions from the Butacite flake dryer (ID No. BS-C) shall be controlled by the bagfilter (ID No. BCD-C2) and cyclone separator (ID No. BCD-Cl). To assure 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 is 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 internal inspection of the bagfilter's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if the ductwork and bagfilters are not inspected and maintained. DEQ-CFW 00085802 Permit 03735T34 Page 12 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 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 bagfilters; and iv. Any variance from manufacturer's recommendations, if any, and corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if these records are not maintained. Reporting [15A NCAC 2Q .0508(f)] The Permittee shall submit the results of any maintenance performed on the bagfilters 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 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 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the affected source (ID No. BS-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-hour period. In no event shall the six -minute average exceed 87 percent opacity. Testing [ 15A NCAC 2D .2601 ] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and 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 2D .0521. Monitoring [15A NCAC 2Q .0508(f)] To assure compliance, once a month the Permittee shall observe the emission point of the affected source for any visible emissions above normal. The monthly observation must be made for each month of the calendar year period to ensure compliance with this requirement. If visible emissions from this source are observed to be above normal, the Pernttee 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 2D .2601 (Method 9) for 12 minutes is below the limit given in Section 2.1 13.2.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 2D .0521. Recordkeeping [15A NCAC 2Q .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 2D .0521 if these records are not maintained. Reporting [15A NCAC 2Q .0508(f)] e. The Permittee shall submit a summary report of the observations postmarked on or before January 30 of each DEQ-CFW 00085803 Permit 03735T34 Page 1'3 ' 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. STATF,-ENFORCEABLE ONI,V 3. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. CONDENSER REQUIREMENTS - Odorous emissions from the butyraldehyde storage tank (ID No. BS-A) shall be controlled by a condenser (ID No. BCD -A). To comply with the provisions of this Permit and ensure that maximum control efficiency is maintained, the Permittee shall perform periodic inspections and maintenance as recommended by the manufacturer. The results of the inspections and maintenance shall be recorded in a logbook (either written or electronic). c. SCRUBBER REQUIREMENTS - Gaseous emissions from the Butacite® flake reactor line (ID Nos. BS-B1.1 through BS-B1.4) shall be controlled by packed column scrubber (ID No. BCD-B1). Gaseous emissions from the Butacite flake reactor line (ID Nos. BS-B2.1 through BS-B2.4) shall be controlled by packed column scrubber (ID No. BCD-B2). d. INSPECTION AND MAINTANENCE REQUIREMENTS - To comply with the provisions of this Permit and ensure that maximum control efficiency is maintained, the Permittee shall perform periodic inspections and maintenance as recommended by the manufacturer. As a minimum, the inspection and maintenance program shall include inspection of spray nozzles, packing material, chemical feed system (if so equipped), and the cleaning/calibration of all associated instrumentation. e. MONITORING REQUIREMENTS - The Permittee shall ensure the proper performance of the Flake Reactor Line's packed column scrubbers (ID Nos. BCD-B1 and BCD-B2) by monitoring the following operational parameters: i. Liquid flow rate (minimum of 8 gallons per minute averaged over a 3-hour period), and ii. Differential pressure across the scrubber (maximum of 30 inches of water pressure averaged over a 3-hour period), with a high differential pressure alarm. f. RECORDKEEPING REQUIREMENTS - The Permittee shall record the results of inspections in a scrubber logbook (written or electronic records) that shall be kept on site and made available to Division of Air Quality personnel upon request. Any variance from the manufacturer's recommendations or the permit monitoring requirements, or the failure of the air pollution control equipment to operate in a normal and usual manner, shall be investigated with corrections made and dates of action recorded in the log book. The inspection and maintenance activities, as well as required monitoring for scrubbing liquid flow rates, and scrubber pressure drops, if appropriate, shall be recorded. 4. 15A NCAC 2D .1111: MAXIMUM AVAILABLE, CONTROL TECHNOLOGY (40 CFR 63, Subpart KK: Printing and Publishing Industry) For the polyvinyl butyral (Butacite ) sheeting rotogravure printing operation (ID No. BS-D), the Permittee shall comply with all applicable provisions, including the notification, testing, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .1111 as promulgated in 40 CFR 63, Subpart KK, including Subpart A "General Provisions" except as follows: "Oxidizer" referenced in 40 CFR Part 63.820 through 63.831 shall refer to scrubber (ID No. BCD -DI) and shall require the operation and maintenance of devices to monitor water flow rate and air flow rate (used in dispersion of water in the scrubber) for the scrubber (ID No. BCD -DI) in lieu of a temperature monitoring device for an oxidizer. DEQ-CFW 00085804 Permit 03735T34 Page 14 Control Requirements [15A NCAC 2Q .0508(f)] a. Emissions from the polyvinyl butyral sheeting rotogravure printing operation shall be controlled using a permanent total enclosure for the process area and a multi -stage horizontal spray scrubber (ID No. BCD-D1) that achieves an overall organic HAP control efficiency of at least 95 percent. Monitoring Requirements [15A NCAC 2Q .0508(f)] b. The Permittee shall ensure the proper performance of the scrubber (ID No. BCD -DI) by monitoring the following operational parameters: i. Water flow rate to each nozzle (minimum of 6 gallons per minute, averaged over a three-hour period). ii. Air flow rate to each nozzle (minimum of 63 standard cubic feet per minute, averaged over a three-hour period). iii. General area exhaust fan exit velocity (minimum of 3,950 feet per minute, averaged over a three-hour period). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .1111 if the required monitoring is not conducted or if the monitored parameter exceeds the minimum value. Record keepi ng/Reor in [15A NCAC 2Q .0508(f)] c. The Permittee shall comply with all applicable record keeping and reporting requirements specified in 40 CFR Parts 63.829 and 63.830, and in 40 CFR Part 63 Subpart A - General Provisions, including the following reporting requirements: i. As specified in 40 CFR Part 63.6(e)(3)(iv), if an action taken by the Permittee during a startup, shutdown, or malfunction (including an action taken to correct a malfunction) is not consistent with the procedures specified in the affected source's startup, shutdown, and malfunction plan, the Permittee shall record the actions taken for that event and shall report such actions within 2 working days after commencing actions inconsistent with the plan, followed by a letter within 7 working days after the end of the event, in accordance with 40 CFR Part 63.10(d)(5). ii. The Permittee shall submit to the Regional Supervisor, DAQ, a semi-annual summary report as specified in 40 CFR Part 63.830, by January 30 of each calendar year.for the preceding six-month period between July and December, and by July 30 of each calendar year for the preceding six-month period between January and June. iii. If the actions taken by the Permittee during start-up, shutdown, or malfunction (SSM) are not completely consistent with the procedures specified in the SSM plan, then the Permittee shall submit an SSM report, as specified in 40 CFR 63.830, to the Regional Supervisor, DAQ. However, separate SSM reports are not required if the information is included in the semi-annual summary report specified above in Section 2.1. BA.c.i. C. Nafiona Process Area consisting of one hexfluoropropylene epoxide process (ID No. NS-A) controlled by one baffle -plate scrubber (ID No. NCD-Hdrl or NCD-Hdr2), Two vinyl ethers processes (ID Nos. NS-B and NS-C) EACH controlled by one of two available baffle -plate scrubbers (ID No. NCD-Hdrl or NCD-Hdr2), One RSU process (ID No. NS-D) controlled by one baffle -plate scrubber (ID No. NCD-Hdrl or NCD-Hdr2), One liquid waste stabilization process (ID No. NS-E) controlled by one baffle -plate scrubber (ID No. NCD-Hdrl or NCD-Hdr2), One MMF process (ID No. NS-F) controlled by one baffle -plate scrubber (I) No. NCD-Hdrl or NCD-Hdr2), One resins fluorination process (ID No. NS-G) controlled by a venturi vacuum jet scrubber (ID No. NCD-G), One Nafiona membrane process (ID No. NS-H), One Nafiono membrane coating process (ID No. NS-I), Three Nafion° semiworks processes (ID Nos. SW-1, SW-2, and NS-J), One E-2 Process (ID No. NS-K-), DEQ-CFW 00085805 Permit 03735T34 Page 15 One TFE/HCl separation unit (ID No. NS-L) controlled by one baffle -plate scrubber (ID No. NCD-Hdrl or NCD-Hdr2), and One uncontrolled TFE/CO2 separation unit (ID No. NS-M) One HFPO product container decontamination process (ID No. NS-N)2 One Vinyl Ethers North product container decontamination process (ID No. NS-O)2 One Vinyl Ethers South product container decontamination process (ID No. NS-P)2 The following table provides a summary of limits and standards for the emission source(s) described above: Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter Affected Sources: ID No. NS-I, only 15A NCAC 2D .0515 For process rates less than 30 tons per hour - E = 4.10 P0.67 where: E = allowable emission rate in pounds per hour, and P = process weight rate in tons per hour Visible emissions Affected Sources: ID No. NS-I, only 15A NCAC 2D .0521 20% visible opacity emissions Odors State -enforceable only 15A NCAC 2D .1806 Odorous emissions must be controlled Toxic air pollutants State -enforceable only 15A NCAC 2D .1100 Permit limits for toxic air pollutants shall not be exceeded. See Section 2.2. B.1. and B.2. Volatile organic Affected Sources: ID No. NS-B, only 15A NCAC 2Q .0317 compounds VOC emissions <68.9 tons per consecutive 12-month (PSD Avoidance) period Affected Sources: ID No. NS-G, only VOC emissions <40 tons per consecutive 12-month period Affected Sources: ID No. NS-A, only VOC emissions <85.3 tons per consecutive 12-month period Affected Sources: ID No. NS-N, only VOC emissions <40 tons per consecutive 12-month period Hazardous air Affected Sources: All, excluding ID No. NS-L 15A NCAC 21).1111 pollutants through NS-P (40 CFR 63, Subpart FFFF) Miscellaneous Organic NESHAP MON 1. 15A NCAC 2D .0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the affected source (ID No. NS-I) shall not exceed an allowable emission rate as calculated by the following equation: E=4.10xP"" 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. DEQ-CFW 00085806 Permit 03735T34 Page 16 Testing [15A NCAC 2D .2601] 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. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515. Monitoring/Recordkeening [15A NCAC 2Q .0508(f)] c. The Permittee shall maintain production records such that the process rates "P" in tons per hour, as specified by the formulas contained above (or the formulas contained in 15A NCAC 2D .0515) can be derived, and shall make these records available to a DAQ authorized representative upon request. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if the production records are not maintained or the types of materials and finishes are not monitored. Reporting [15A NCAC 2Q .0508(f)] d. 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 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the affected source (ID No. NS-I) 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 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and 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 2D .0521. Monitoring/Recordkeep ing/Re or in [15A NCAC 2Q .0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from this source. STATF,-F,NFORC'F,ABI.F ONLY 3. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. 4. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the Vinyl Ethers North process (ID No. NS-B) shall discharge into the atmosphere less than 68.9 tons of VOCs per consecutive 12-month period. Monitoring/Recordkee in [15A NCAC 2Q .0508(f)] b. Calculations of VOC emissions per month shall be made within 30 days of the end of each month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the amounts of VOC containing materials or the VOC emissions are not monitored and recorded. c. The total amount of VOC emissions shall be recorded monthly in a logbook (written or electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the VOC emissions exceed this limit. DEQ-CFW 00085807 Permit 03735T34 Page 17 Monitoring [15A NCAC 2Q .0508(f)] d. The Permittee shall ensure the proper performance of the Naflon Baffle Plate -Type Tower Scrubbers (ID Nos. NCD-Hdr-1 and NCD-Hdr-2) by monitoring the following operational parameters: i. Injection liquid flow rate (minimum of 7,000 kilograms per hour, averaged over a three-hour period). Recordkeeping [15A NCAC 2Q .0508(f)] e. The Permittee shall record the results of inspections in a scrubber logbook (written or electronic records), which shall be kept on site and made available to Division of Air Quality personnel upon request. Any variance from the manufacturer's recommendations or the permit monitoring requirements, or the failure of the air pollution control equipment to operate in a normal and usual manner, shall be investigated with corrections made and dates of action recorded in the log book. The inspection and maintenance activities, as well as required monitoring for scrubbing liquid flow rates, and scrubber pressure drops, if appropriate, shall be recorded. Re on ding [15A NCAC 2Q .0508(f)] 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. The monthly VOC emissions for the previous 17 months. The emissions shall be calculated for each of the 12- month periods over the previous 17 months. 5. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the resins process (ID No. NS-G) shall discharge into the atmosphere less than 40 tons of VOCs per consecutive 12-month period. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] b. Calculations of VOC emissions per month shall be made within 30 days, of the end of each month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the amounts of VOC containing materials or the VOC emissions are not monitored and recorded. c. Calculations and the total amount of VOC emissions shall be recorded monthly in a logbook (written or electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the VOC emissions exceed this limit. Reporting [15A NCAC 2Q .0508(f)] d. 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. The monthly VOC emissions for the previous 17 months. The emissions shall be calculated for each of the 12- month periods over the previous 17 months. 6. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the HFPO process (ID No. NS-A) shall discharge into the atmosphere less than 85.3 tons of VOCs per consecutive 12-month period. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] b. Calculations of VOC emissions per month shall be made within 30 days of the end of each month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the amounts of VOC containing materials or the VOC emissions are not monitored and recorded. DEQ-CFW 00085808 Permit 03735T34 Page 18 c. The total amount of VOC emissions shall be recorded monthly in a logbook (written or electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the VOC emissions exceed this limit. Reporting [15A NCAC 2Q .0508(f)] d. 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. The monthly VOC emissions for the previous 17 months. The emissions shall be calculated for each of the 12- month periods over the previous 17 months. 6. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the HFPO Product Container Decontamination Process (ID No. NS- N) shall discharge into the atmosphere less than 40.0 tons of VOCs per consecutive 12-month period. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] b. To demonstrate compliance with the limit provided in Section 2.1 C.6.a., each calendar month the Permittee shall create and retain records and estimate associated VOC emissions, as follows: i. Create a record of each container received at the facility including: (A) The date the container was,decontaminated; and, (B) The total mass of VOC released from the container (in lbs). ii. Calculate the VOC emissions from the process during the previous calendar month (in lb/month) by summing the quantity of VOC released from each container decontaminated during the previous calendar month. iii. Calculate the VOC emissions from the process during the previous consecutive 12-month period (in tons/12- months) by summing the quantity of VOC released for the previous twelve (12) calendar months. Required records shall be maintained in a logbook (written or electronic format) on -site and made available to an authorized representative upon request. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the above records are not created and retained, or if the 12-month rolling VOC emission rate calculated above exceeds the limit in Section 2.1 C.6.a. of this permit. Reporting [15A NCAC 2Q .0508(f)] c. 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. The monthly VOC emissions for the previous 17 months. The emissions shall be calculated for each of the 12- month periods over the previous 17 months. 7. 15A NCAC 2D .1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY (MACT), 40 CFR 63, Subpart FFFF: NESHAP for Miscellaneous Organic Chemical Manufacturing (MON) a. The Permittee shall comply with all applicable provisions contained in Environmental Management Commission Standard 15A NCAC 2D .1111, "Maximum Achievable Control Technology" (MALT) as promulgated in 40 CFR Part 63, Subpart FFFF by May 10, 2008, or as provided in the rule. [40 CFR 63.2445(b)] b. The Permittee shall submit a Notification of Compliance Status to the Fayetteville Regional in accordance with 40 CFR 63.2520(d) by October 7, 2008, or as provided in the rule. DEQ-CFW 00085809 Permit 03735T34 Page 19 D. Fluoroproducts polymer manufacturing development facility (ID No. FS-A) controlled by a wet scrubber (ID No. FCD-Al) and fabric filter (ID No. FCD-A2) The followinn table provides n snmmnry of limits and stnndnrds for the emission snurcek) described above: Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter For process rates less than 30 tons per hour 15A NCAC 2D .0515 E = 4.10 P0.67 Where: E = allowable emission rate in pounds per hour, and P = process weight rate in tons per hour Visible emissions 20% visible opacity emissions 15A NCAC 2D .0521 Odors State -enforceable only 15A NCAC 21).1806 Odorous emissions must be controlled Volatile organic Less than 40 tons per consecutive 12-month period 15A NCAC 2Q .0317 compounds (PSD Avoidance 1. 15A NCAC 2D .0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the affected source (ID No. FS-A) shall not exceed an allowable emission rate as calculated by the following equation: E=4.10xP'-" 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 21) .26011 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 D. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 21) .0515. Monitoring/ Recordkeeping [15A NCAC 2Q .0508(f)] Particulate matter emissions from the Fluoroproducts polymer manufacturing facility (ID No. FS-A) shall be controlled by the bagfilter (ID No. FCD-A2). To assure 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 is 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 internal inspection of the bagfilter's structural integrity. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .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 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 bagfilters; and iv. Any variance from manufacturer's recommendations, if any, and corrections made. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if these records are not maintained. DEQ-CFW 00085810 Permit 03735T34 Page 20 Reporting [15A NCAC 2Q .0508(f)] e. The Permittee shall submit the results of any maintenance performed on the bagfilters 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 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 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the affected source (ID Nos. FS-A) 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 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and 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 2D .0521. Monitoring/Recordkee ing/Reor inu [15A NCAC 2Q .0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from this source. STATE, ENFORCEABLE ONLY 3. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. 4. 15A NCAC 2Q .03I7: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the fluoroproducts polymer manufacturing development facility (ID No. FS-A) shall discharge into the atmosphere less than 40 tons of VOCs per consecutive 12-month period. MonitoringMecordkeeping [15A NCAC 2Q .0508(f)] b. Calculations of VOC emissions per month shall be made within 30 days of the end of each month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the amounts of VOC containing materials or the VOC emissions are not monitored and recorded. c. The total amount of VOC emissions shall be recorded monthly in a logbook (written or electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the VOC emissions exceed this limit. Reporting [15A NCAC 2Q .0508(f)] d. 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. The monthly VOC emissions for the previous 17 months. The emissions shall be calculated for each of the 12- month periods over the previous 17 months. DEQ-CFW 00085811 Permit 03735T34 Page 21 E. APFO manufacturing facility (ID No. AS -A) controlled by a wet scrubber (ID No. ACD-Al) and a building exhaust vent wet scrubber (ID No. ACD-A3) (voluntary use only) The following table nrovides a summary of limits and standards for the emission sources described above: Regulated Pollutant Limits/Standards Applicable Regulation Odors State -enforceable only 15A NCAC 2D .1806 odorous emissions must be controlled Toxic air pollutants State -enforceable only 15A NCAC 2D .1100 Permit limits for toxic air pollutants shall not be exceeded. See Section 2.2.A and B. STATE -ENFORCEABLE ONLY 1. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. STATF-ENFORCEABLE ONLY 2. 15A NCAC 2D .1100: CONTROL OF TOXIC AIR POLLUTANTS a. SCRUBBER REQUIREMENTS - Gaseous and mist emissions from the APFO process area shall be controlled by a wet scrubber (ID No. ACD-Al). The Permittee shall ensure the proper performance of the scrubber by monitoring the following operational parameters: i. Liquid flow rate through the packed bed section (minimum of 30 gallons per minute averaged over a 3-hour period), and ii. Differential pressure across the packed bed section of the scrubber (maximum of 12 inches of water pressure averaged over a 3-hour period), with a high differential pressure alarm. b. RECORDKEEPING REQUIREMENTS - The Permittee shall record the results of inspections in a scrubber logbook (written or electronic records), which shall be kept on site and made available to Division of Air Quality personnel upon request. Any variance from the manufacturer's recommendations or the permit monitoring requirements, or the failure of the air pollution control equipment to operate in a normal and usual manner, shall be investigated with corrections made and dates of action recorded in the log book. The inspection and maintenance activities, as well as required monitoring for scrubbing liquid flow rates, and scrubber pressure drops, if appropriate, shall be recorded. F. Wastewater Treatment Area consisting of an extended aeration biological wastewater treatment facility (ID No. WTS-A) and two indirect steam -heated rotary sludge dryers (ID Nos. WTS-B and WTS-C) controlled by a wet scrubber with mist eliminator (ID No. WTCD-1) The fnllnwinu tahle nrnvides n cnmmnry of limits and stnndards for the emission source(s) described above: Regulated Pollutant Limits/Standards Applicable Regulation Odors State -enforceable only odorous emissions must be controlled 15A NCAC 2D .1806 STATE ENFORCEABLE ONLY 1. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. DEQ-CFW 00085812 Permit 03735T34 Page 22 b. SCRUBBER REQUIREMENTS - Odorous emissions from the wastewater treatment sludge dryers (ID Nos. WTS-B and WTS-C) shall be controlled by an impingement -type scrubber with caustic injection (ID No. WTCD-1). c. INSPECTION AND MAINTANENCE REQUIREMENTS - To comply with the provisions of this Permit and ensure that maximum control efficiency is maintained, the Permittee shall perform periodic inspections and maintenance as recommended by the manufacturer. As a minimum, the inspection and maintenance program shall include inspection of spray nozzles, packing material, chemical feed system (if so equipped), and the cleaning/calibration of all associated instrumentation. d. RECORDKEEPING REQUIREMENTS - The Permittee shall record the results of inspections in a scrubber logbook (written or electronic records) that shall be kept on site and made available to Division of Air Quality personnel upon request. Any variance from the manufacturer's recommendations or the permit monitoring requirements, or the failure of the air pollution control equipment to operate in a normal and usual manner, shall be investigated with corrections made and dates of action recorded in the log book. The inspection and maintenance activities, as well as required monitoring for scrubbing liquid flow rates, and scrubber pressure drops, if appropriate, shall be recorded. G. Temporary Boiler (ID No. PS -Temp), Natural Gas/No. 2 fuel oil -fired (greater than 30.0 and less than 100.0 million Btu per hour maximum heat input) The following table provides a summary of limits and standards for the emission source(s) described above: Regulated Pollutant Limits/Standards Applicable Regulations Particulate Matter 0.2426 pounds of particulate per million Btu 15A NCAC 2D .0503(c) Sulfur Dioxide 0.5 percent sulfur content fuel 15A NCAC 2D .0524 NSPS 40 CFR 60 Sub art DO Visible Emissions 20 percent opacity 15A NCAC 2D .0524 NSPS 40 CFR 60 Subpart Dc Sulfur Dioxide Less than 40 tons per consecutive twelve-month period. 15A NCAC 2Q .0317 PSD Avoidance Sulfur Dioxide Affected Sources: PS-1, PS-2, PS-C, and PS -Temp 15A NCAC 2Q .0317 Sulfur dioxide <702.5 tons per year. (PSD Avoidance) See Section 2.2. A.1. of this permit 1. 15A NCAC 2D .0503: PARTICULATES FROM FUEL BURNING INDIRECT HEAT EXCHANGERS a. Emissions of particulate matter discharged into the atmosphere from the combustion of No. 2 fuel oil at the temporary boiler (ID No. PS -Temp) shall not exceed 0.2426 pounds per million Btu heat input. Testing [15A NCAC 2D .2601] 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 Section 2.1 G. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0503. Monitoring/Recordkeeping/Rg or inu [15A NCAC 2Q .0508(f)] No monitoring/recordkeeping/reporting is required for particulate emissions from the firing of No. 2 fuel oil in this source for this regulation. 2. 15A NCAC 2D .0524: NSPS 40 CFR PART 60 SUBPART Dc a. The Permittee shall comply with all applicable provisions, including the notification, testing, recordkeeping, and DEQ-CFW 00085813 Permit 03735T34 Page 2' monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524 "New Source Performance Standards (NSPS) as promulgated in 40 CFR Part 60 Subpart Dc, including Subpart A "General Provisions." Emission Limitations [15A NCAC 2D .05241 b. The maximum sulfur content of any fuel oil received and burned in the boiler (ID No. PS -Temp) shall not exceed 0.5 percent by weight. c. Visible emissions shall not exceed 20 percent opacity (6 minute average) except for one six -minute period per hour but not more than 27 percent opacity when firing fuel oil. T s in¢ [15A NCAC 2D .0524] d. Within 60 days of installing any temporary boiler, the Permittee shall conduct a Method 9 test (6-minute average of 24 observations) to determine the opacity of stack emissions in accordance with 40 CFR 60.8, 40 CFR 60.45c(a)(8), and General Condition JJ found in Section 3 of this permit. If the Permittee fails to conduct the opacity observation or if the results of the test are above the applicable limit, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524. Monitoring(Recordkeeping [15A NCAC 2Q .0508(f)] e. The Permittee shall retain a record of the quantity of natural gas and No. 2 fuel oil fired at the affected boiler each calendar month. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524 if this record is not created and retained. [49 CFR 60.48c(g)] f. The Permittee shall retain a copy of the fuel supplier certification for any No. 2 fuel oil fired at the affected boiler. The fuel supplier certification shall include the following information: i. The name of the oil supplier; ii. The sulfur content of the oil (in % by weight); and, iii. A statement from the oil supplier that the oil complies with the specification under the definition of distillate oil in 40 CFR 60.41 c. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0524 if the sulfur content of the oil exceeds the limit provided in Section 2.1 G.2.b. of this permit or if fuel supplier certifications are not retained as described above. [40 CFR 60.46c(d), 40 CFR 60.48c6q] Notifications and Reporting [15A NCAC 2Q .0508(f)] The Permittee shall submit the following written notifications to the Regional: i. An initial notification of the date of actual initial startup of the boiler within 15 days of such date [40 CFR 60.7(a)(1)]; ii. An n=naci observation notification indicate the anticipated date that the Permittee will be conducting the Method 9 opacity observation, as required in Section 2.1 G.2.d. of this permit, at least 30 days prior to such date [40 CFR 60.7(a)(6), 40 CFR 60.8(d)]; and, iii. Performance test results with the results of the Method 9 opacity observation, as required in Section 2.1 G.2.d. of this permit, shall be submitted within 30 days of the test. h. Semiannual Report. In addition to any other reporting required by 40 CFR 60.48c or notification requirements to the EPA, the Permittee is required to provide a semiannual summary report, acceptable to the Regional Air Quality Supervisor, of the sulfur content of the distillate fuel oil fired, 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 summary report shall include the following information: i. Fuel supplier certification(s) for distillate fuel oil, as provided in Section 2.1 G.2.d. of this permit; ii. A certified statement signed by the owner or operator that the records of fuel supplier certification(s) submitted represents all of the fuel fired at the affected boiler during the semiannual period; and, iii. All instances of deviations from the requirements of this permit must be clearly identified. DEQ-CFW 00085814 Permit 03735T34 Page 24 3. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of 15A NCAC 2D .0530(g) for major sources and major modifications, the temporary boiler (ID No. PS -Temp) shall discharge into the atmosphere less 40 tons of sulfur dioxide per consecutive twelve- month period. T s ins [15A NCAC 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A General Condition JJ. If the results of this test are above the limits given in Section 2.1 G.3.a. (ID No. PS -Temp) above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring/Recordkee in [15A NCAC 2Q .0508(f)] The Permittee shall keep monthly records of fuel usage in a logbook (written or in electronic format), as follows: i. The total quantity (in 1,000 gal) of No. 2 fuel oil fired at the boiler; and, ii. The fuel oil supplier certification for any fuel oil fired at the boiler, including the sulfur content of the oil (in percent by weight). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if records of the fuel usage and No. 2 fuel oil sulfur content are not created and retained as required above. d. The Pennittee shall calculate monthly and 12-month rolling S02 emissions from the temporary boiler within 30 days after the end of each calendar month. Calculations shall be recorded in a logbook (written or electronic format), according to the following formulas: i. Calculate SO2 emissions from the previous calendar month using the following equation: ES02=142*S*Qfo2 Where, Es02 = S02 emissions (in lbs) during the previous calendar month, S = Sulfur content in the No. 2 fuel oil (in percent by weight), and Qfo2 = Quantity of No. 2 fuel oil fired at the temporary boiler during the previous calendar month (in 1,000 gal) ii. Sum the S02 emissions from the boiler for the previous 12-month period to determine the 12-month rolling emission total. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if records of the monthly calculations listed above are not retained or if the 12-month rolling emission totals are greater than the emission limit provided in Section 2.1 G.3.a. of this permit. Reporting [15A NCAC 2Q .0508(f)] e. 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. The monthly SO2 emissions from the boiler for the previous 17 months; ii. The total SO2 emissions from the boiler for each 12-month period ending during the six month reporting period; and, iii. All instances of deviations from the requirements of this permit must be clearly identified. DEQ-CFW 00085815 Permit 03735T34 Page 2� H. SentryGlas® Manufacturing (ID No. SGS-A) The fnllowinp table nrnvides a summary of limits and standards for the emission source(s) described above: Regulated Pollutant Limits/Standards Applicable Regulation Visible emissions 20% visible opacity emissions 15A NCAC 213.0521 Odors State -enforceable only Odorous emissions must be controlled 15A NCAC 21).1806 11 1. 15A NCAC 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from this source (ID No. SGS-A) 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 21) .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .260land General Condition JJ. If the results of this test are above the limit given in Section 2.1 H. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring/Recordkeeping/Reor in [15A NCAC 2Q .0508(f)] c. No monitoring/recordkeeping/reporting is required for visible emissions from this source. STATF-ENFORCF,ABLE ONI,Y 2. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. I. Polyvinyl Fluoride Polymer Manufacturing Facility No. 1 (ID No. FS-B) Polyvinyl Fluoride Polymer Manufacturing Facility No. 2 (ID No. FS-C) The followine table provides a summary of limits and standards for the emission source(s) described above: Regulated Pollutant Limits/Standards Applicable Regulation Particulate matter Affected Source: Product Collection Systems 15A NCAC 2D .0515 (Vents FEP-B4 & FEP-C4) for process rates less than 30 tons per hour - E = 4.10 P0.67 Where: E = allowable emission rate in pounds per hour, and P = process weight rate in tons per hour Visible emissions Affected Source: Product Collection Systems 15A NCAC 2D .0521 (Vents FEP-B4 & FEP-C4) 20% visible opacity emissions Odors State -enforceable only 15A NCAC 21) .1806 Odorous emissions must be controlled Volatile organic Less than 40 tons per consecutive 12-month period 15A NCAC 2Q .0317 compounds PSD Avoidance 1. 15A NCAC 2D .0515: PARTICULATES FROM MISCELLANEOUS INDUSTRIAL PROCESSES a. Emissions of particulate matter from the Product Collection Systems at the polyvinyl fluoride manufacturing facilities DEQ-CFW 00085816 Permit 03735T34 Page 26 (Vent Nos. FEP-B4 & FEP-C4) shall not exceed an allowable emission rate as calculated by the following equation: E=4.10xPo_6' 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 2D .2601] 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 2.11. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515. Monitoring/Recordkeeping [15A NCAC 2Q .0508(f)] c. The Permittee shall maintain production records such that the process rates "P in tons per hour, as specified by the formulas contained above (or the formulas contained in 15A NCAC 2D .0515) can be derived, and shall make these records available to a DAQ authorized representative upon request. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0515 if the production records are not maintained. Reor in [15A NCAC 2Q .0508(f)] d. 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 2D .0521: CONTROL OF VISIBLE EMISSIONS a. Visible emissions from the Product Collection Systems at the polyvinyl fluoride manufacturing facilities (Vent Nos. FEP-B4 & FEP-C4) 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 2D .2601] b. If emissions testing is required, the testing shall be performed in accordance with 15A NCAC 2D .2601 and General Condition JJ. If the results of this test are above the limit given in Section 2.1 I.2.a. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0521. Monitoring [15A NCAC 2Q .0508(f)] To assure compliance, once a month the Permittee shall observe the emission point of the affected source for any visible emissions above normal. The monthly observation must be made for each month of the calendar year period to ensure compliance with this requirement. The Permittee shall establish "normal" for the PVF Manufacturing Facility No. 2 (ID No. FS-C, Vent No. FEP-C4) within 30 days of initial start-up. If visible emissions from this source 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 2D .2601 (Method 9) for 12 minutes is below the limit given in Section 2.1 I.2.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 2D .0521. Reco� rdkee in¢ [15A NCAC 2Q .0508(f)] d. The results of the monitoring shall be maintained in a logbook (written or electronic format) on -site and made DEQ-CFW 00085817 Permit 03735T34 Page 27 ' 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 2D .0521 if these records are not maintained. Reporting [15A NCAC 2Q .0508(o] 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. STATE -ENFORCEABLE ONLY 3. 15A NCAC 2D .1806: CONTROL AND PROHIBITION OF ODOROUS EMISSIONS a. The Permittee shall not operate the above listed equipment 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. 4. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the Polyvinyl Fluoride (PVF) Manufacturing Facility No. 1 and No. 2 (ID Nos. FS-B and FS-C) shall discharge into the atmosphere less than 40 tons of VOCs per consecutive 12- month period. T stin [15A NCAC 2D .2601] b. If emissions testing is required, the Permittee shall perform such testing in accordance with General Condition JJ. If the results of this test indicate annual emission rates in exceedance of the limit given in Section 2.1 I.4.a. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring/R ecord keeping [15A NCAC 2Q .0508(f)] c. To demonstrate compliance with the limit provided in Section 2.1 I.4.a., each calendar month the Permittee shall create and retain production records and estimate associated VOC emissions, as follows: i. Record the vent flow rates from the Analytical Equipment (QFEP_B1 and QFEP_Ci) at the two affected facilities (Vent Nos. FEP-B 1 and FEP-C1 respectively) during the previous calendar month (in lb/month); ii. Calculate the VOC emissions (EFEP-BC1) from the Analytical Equipment at two affected facilities during the previous calendar month (in lb/month) using the following equation: EFEP-BC] - QFEP-Bl + `GFEP-CI iii. Record the vent flow rates from the Maintenance Headers (QFEP_B2 and QFEP-C2) at the two affected facilities (Vent Nos. FEP-132 and FEP-C2 respectively) during the previous calendar month (in lb/month); iv. Calculate the VOC emissions (EFEP_BC2) from the Maintenance Header at two affected facilities during the previous calendar month (in lb/month) using the following equation: EFEP-BC2 = 0.5\QFEP-B2 + QFEP-C2 ) v. At least once each hour, record the pressure (PFEP_B3 and PFEP_C3) in the Low Pressure Slurry Separators at the two affected facilities (Vent Nos. FEP-B3 and FEP-d respectively) during the previous calendar month (in psig); vi. At least once each hour, record the vinyl fluoride flow rates (QFEP_B3 and QFEP-C3) to the PVF Reactors at the two affected facilities (Vent Nos. FEP-133 and FEP-C3 respectively) during the previous calendar month (in lb/hour); DEQ-CFW 00085818 Permit 03735T34 Page 28 vii. Using an emissions model based on vapor pressure equilibrium data and vinyl fluoride flow rates to the PVF Reactors, determine the hourly VOC emissions (EFEP_133 and EFEp_c;) from the Flash Tank vents at the two affected facilities (Vent Nos. FEP-B3 and FEP-C3 respectively) during the previous calendar month (in lb/hour); viii. Calculate the sum of the hourly VOC emissions (EFEp_Bc3) from the Flash Tanks at the two affected facilities during the previous calendar month (in lb/month) using the following equation: EFEP-BC3 — j: (EFEP-B3 ) + 1: \EFEP-C3 / ix. Calculate the VOC emissions (E) from the two affected facilities during the previous calendar month (in lb/month) using the following equation: E = EFEP-BC] + EFEP-BC2 + EFEP-BC3 x. Calculate the 12-month rolling VOC emissions from the two affected facilities by summing the monthly VOC emissions (E), as calculated in x. above, for the previous consecutive 12-months. The first required monthly compliance demonstration, as described in i. through x. above, shall be required during the calendar month fallowing initial start-up of PVF Manufacturing Facility No. 2 (ID No. FS-C). Required records shall be maintained in a logbook (written or electronic format) on -site and made available to an authorized representative upon request. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the above records are not created and retained, or if the 12-month rolling VOC emission rate calculated in x. above exceeds the limit in Section 2.1 IA.a. of this permit. Reporting [15A NCAC 2Q .0508(f)] d. 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. The monthly VOC emissions from two affected polyvinyl fluoride manufacturing operations for the previous 17 calendar months; ii. The 12-month rolling VOC emissions for each 12-month period ending during the reporting period; and, iii. All instances of deviations from the requirements of this permit must be clearly identified. 2.2 - Multiple Emission Source(s) Specific Limitations and Conditions A. BOILERS: Natural Gas/No. 2 fuel oil/No. 6 fuel oil -fired boiler (ID No. PS-1), 139.4 million Btu per hour maximum heat input; Natural Gas No. 2 fuel oil/No. 6 fuel oil -fired boiler (ID No. PS-22), 88.4 million Btu per hour maximum heat input; Natural Gas/No. 2 fuel oil -fired boiler (ID No. PS-C2) equipped with a low-NOx burner, 97.0 million Btu per hour maximum heat input; and, Temporary Boiler (ID No. PS-Temp2), Natural Gas/No. 2 fuel oil -fired (greater than 30.0 and less than 100.0 million Btu per hour maximum heat input). 1. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 2D .0530: PREVENTION OF SIGNIFICANT DETERIORATION a. In order to avoid applicability of this regulation, the affected boilers (ID Nos. PS-1, PS-2, PS-C, and PS -Temp) DEQ-CFW 00085819 Permit 03735T34 Page 29 shall discharge into the atmosphere less than 702.5 tons of SO-, per consecutive 12-month period. Testing [15A NCAC 2D .2601] b. If emissions testing is required, the Permittee shall perform such testing in accordance with General Condition JJ. If the results of this test indicate annual emission rates in exceedance of the limit given in Section 2.2 A. La. above, the Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530. Monitoring/Recordkee in [15A NCAC 2Q .0508(f)] c. The Permittee shall keep monthly records of fuel usage in a logbook (written or in electronic format), as follows: i. The total quantity (in mmscf) of natural gas fired at the affected boilers; ii. The total quantity (in 1,000 gal) of No. 2 and No. 6 fuel oil fired at the affected boilers; and, iii. The fuel oil supplier certification for any fuel oil fired at the affected boilers, including the sulfur content of the oil (in percent by weight). The Permittee shall be deemed in noncompliance with 15A NCAC 2D ,0530 if records of the fuel usage and fuel oil sulfur contents are not created and retained as required above. d. The Permittee shall calculate monthly and 12-month rolling S02 emissions from the affected boilers within 30 days after the end of each calendar month. Calculations shall be recorded in a logbook (written or electronic format), according to the following formulas: i. Calculate S02 emissions from the previous calendar month using the following equation: ESoz=157*Sfo6 *Qfo6 +142*Sfo2 *Qfo2 +0.6*Q„g Where, Es02 = S02 emissions (in lbs) during the previous calendar month; S fo6 = Sulfur content in the No. 6 fuel oil (in percent by weight); Qfo6 = Quantity of No. 6 fuel oil fired during the previous calendar month (in 1,000 gal); S fo2 = Sulfur content in the No. 2 fuel oil (in percent by weight); Qfo2 = Quantity of No. 2 fuel oil fired during the previous calendar month (in 1,000 gal); and, Q s = Quantity of natural gas fired during the previous calendar month (in 1,000 gal). ii. Sum the S02 emissions from the affected boilers for the previous 12-month period to determine the 12-month rolling emission total. The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if records of the monthly calculations listed above are not retained or if the 12-month rolling emission totals are greater than the emission limit provided in Section 2.2 A. La. of this permit. Reporting [15A NCAC 2Q .0508(f)] e. 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. The monthly S02 emissions from two affected boilers for the previous 17 calendar months; ii. The 12-month rolling S02 emissions for each 12-month period ending during the reporting period; and, iii. All instances of deviations from the requirements of this permit must be clearly identified. DEQ-CFW 00085820 Permit 03735T34 Page 30 B. FACILITY -WIDE STATE-ENFORCEARLE, ONI,Y 1. 15A NCAC 2D .1100: TOXIC AIR POLLUTANT EMISSIONS LIMITATIONS AND REQUIREMENTS a. Pursuant to 15A NCAC 2D .1100 and in accordance with the approved application for an air toxic compliance demonstration- the following hermit limit shall not be exceeded: Toxic Air Pollutant Facility -Wide Emission Limit Acetaldehyde 394.62 lb/hr Acetic Acid 54.08 lb/hr Acrolein 1.17 lb/hr Acrylonitrile 240.06 lb/hr Ammonia 39.461b/hr Ammonium Chromate 0.54 lb/day Ammonium Dichromate 0.541b/day Aniline 14.62 lb/hr Arsenic and Inorganic Arsenic Compounds 0.37 lb/yr Aziridine 5.26 lb/day Benzene 192.05 lb/yr Benzidine and Salts 0.02 lb/yr Benzo(a)pyrene 52.81 lb/yr Benzyle Chloride 7.31 lb/yr Beryllium 6.56 lb/yr Beryllium Chloride 6.56 lb/yr Beryllium Fluoride 6.56 lb/yr Beryllium Nitrate 6.56 lb/yr Bis-Chloromethyl Ether 0.59 lb/yr Bromine 2.92 lb/hr 1,3-Butadiene 272.07 lb/yr Cadmium 8.8 lb/yr Cadmium Acetate 8.8 lb/yr Cadmium Bromide 8.8 lb/yr Calcium Chromate 0.13 lb/yr DEQ-CFW 00085821 Permit 03735T34 Page 31 Toxic Air Pollutant Facility -Wide Emission Limit Carbon Disulfide 163.11 lb/day Carbon Tetrachloride 10,723 lb/yr Chlorine B. 15 lb/hr 32.88 lb/da Chlorobenzene 1,929.23 lb/day Chloroform 6,882 lb/yr Chloroprene 51.15 lb/hr 385.85 lb/day Chromic Acid 0.54 lb/day Chromium (VI) 0.13 lb/yr Cresol 32.15 lb/hr p-Dichiorobenzene 964.62 lb/hr Dichlorodifluoromethane 217,476.92 lb/day Dichlorofluoromethane 438.46 lb/day Di(2-ethylhexyle)phthalate 26.31 lb/day Dimethyl Sulfate 2.63 lb/day 1,4-Dioxane 491.08 lb/day Epichlorohydrin 132,832 lb/yr Ethyl Acetate 2,046.15 lb/hr Ethylenediamine 36.54 lb/hr 263.08 lb/da Ethylene Dibromide 640.2 lb/yr Ethylene Dichloride 6,081 lb/yr Ethylene Glycol Monoethyl Ether 27.77 lb/hr 105.23 lb/day Ethylene Oxide 43.21 lb/yr Ethyl Mercaptan 1.461b/hr Fluorides 3.65 lb/hr 14.03 lb/da Formaldehyde 2.19 lb/hr Hexachlorocyclopentadiene 0.15 lb/hr 0.53 lb/day Hexachlorodibenzo-p-dioxin 0.12 lb/yr DEQ-CFW 00085822 Permit 03735T34 Page 32 Toxic Air Pollutant Facility -Wide Emission Limit n-Hexane 964.62 lb/day Hexane Isomers 5,261.54 lb/hr Hydazine 0.53 lb/day Hydrogen Chloride 10.23 lb/hr Hydrogen Cyanide 16.08 lb/hr 122.77 lb/day Hydrogen Sulfide 30.69 lb/hr Maleic Anhydride 1.461b/hr 10.52 lb/day Manganese & Compounds 27.18 lb/day Manganese Cyclopentadienyl Tricarbonyl 0.53 lb/day Manganese Tetroxide 5.441b/day Mercury, Alkyl 0.05 lb/day Mercury, Aryl & Inorganic 0.53 lb/hr Mercury, vapor 0.53 lb/hr Methyl Chloroform 3,580.77 lb/hr 10 523.08 lb/day Methylene Chloride 24.85 lb/hr 38,409 lb/vr Methyl Ethyl Ketone 1,293.46 lb/hr 3,244.62 lb/day Methyl Isobutyl Ketone 438.46 lb/hr 2 244.92 lb/day Methyl Mercaptan 0.73 lb/hr Nickel Carbonyl 0.53 lb/day Nickel Metal 5.26 lb/day Nickel, Soluble Compounds as Nickel 5.26 lb/day Nickel Subsulfide 3.36 lb/yr Nitric Acid 14.62 lb/hr Nitrobenzene 7.31 lb/hr 52.62 lb/day n-Nitrosodimethlamine 80.02 lb/yr Pentachlorophenol 0.37 lb/hr 2.63 lb/day Perchloroethylene 304,073 lb/yr DEQ-CFW 00085823 Permit 03735T34 Page 33 Toxic Air Pollutant Facility -Wide Emission Limit Phenol 13.88 lb/hr Phosgene 2.19 lb/day Phosphine 1.901b/hr Polycholinated Biphenyls 132.83 lb/yr Potassium Chromate 0.54 lb/day Potassium Dichromate 0.54 lb/day Sodium Chromate 0.54 lb/day Sodium Dichromate 0.54 lb/day Strontium Chromate 0.13 lb/yr Styrene 154.92 lb/hr Sulfuric Acid 1.461b/hr 10.52 lb/da Tetrachlorodibenzo-p-dioxin 0.0048 lb/yr 1,1,1,2-Tetrachloro-2,2-Difluoroethane 45,6001b/day 1,1,2,2,-Tetrachloro-1,2-Difluoroethane 45,6001b/day 1,1,1,2-Tetrachloroethane 10,082 lb/yr Toluene 818.46 lb/hr 4,121.54 lb/day Toluene-2,4-diisocyanate 0.22 lb/hr 0.44 lb/day Trichloroethylene 94,423 lb/yr Trichlorofluoromethane 491,076.92 lb/day 1,1,2-Trichloro-1,2,2-Trifluoroethane 13,885 lb/hr Vinyl Chloride 608.1 lb/yr Vinylidene Chloride 105.23 lb/day Xylene 950 lb/hr 2,367.69 lb/da Zinc Chromate 0.13 lb/yr Recordkeeping b. For compliance purposes, the Permittee shall maintain records of production rates, throughput, material usage, periods of excess emissions, failure of air pollution control equipment to operate in a normal and usual manner, and other process operational information, that allows for evaluation for compliance with the toxic air pollutant limits. These records shall be retained for a minimum of three years from the date of recording, and access to these records shall be provided to the Division of Air Quality staff upon request. DEQ-CFW 00085824 Permit 03735T34 Page 34 Reporting c. For compliance purposes, within thirty (30) days after each calendar year quarter the following shall be reported to the Regional Supervisor, Division of Air Quality: i. Any and all exceedences of applicable toxic air pollutant emission limits during the previous calendar year quarter. ii. The maximum pounds per 1-hour emission rate at any time during the previous calendar year quarter for all applicable toxic air pollutants that have a listed pounds per hour emission rate. iii. The maximum pounds per 24-hour emission rate at any time during the previous calendar year quarter for all applicable toxic air pollutants that have a listed pounds per day emission rate. iv. The yearly emission rate for the 12-month period ending with the previous calendar year quarter for all applicable toxic air pollutants that have a listed pounds per year emission rate. STATE-FNFORC EARLS ONLY 2. 15A NCAC 2D .1100: TOXIC AIR POLLUTANT EMISSIONS LIMITATIONS AND REQUIREMENTS a. Pursuant to 15A NCAC 2D .1100 and in accordance with the approved application for an air toxic compliance demonstration_ the following nermit limit shall not be exceeded: Emission Source Toxic Air Pollutant Emission Limit High dispersion stacks Hydrogen Fluoride 7.28 lb/hr (ID Nos. NEP-Hdr-1, NEP- 52.45 lb/day Hdr-2, AEP-Al, and FEP- Al All other sources Hydrogen Fluoride 2.7 lb/hr 19.4 lb/day Monitories b. The Permittee shall ensure the proper performance of the Nafion Baffle Plate -Type Tower Scrubbers (ID Nos. NCD-Hdr-1 and NCD-Hdr-2) by monitoring the Injection liquid flow rate (minimum of 7,000 kilograms per hour, averaged over a three-hour period). Recordkee-ping c. The Permittee shall record the results of inspections of the Nafion Baffle Plate -Type Tower Scrubbers (ID Nos. NCD-Hdr-1 and NCD-Hdr-2) in a scrubber logbook (written or electronic records) that shall be kept on site and made available to Division of Air Quality personnel upon request. Any variance from the manufacturer's recommendations or the permit monitoring requirements, or the failure of the air pollution control equipment to operate in a normal and usual manner, shall be investigated with corrections made and dates of action recorded in the log book. The inspection and maintenance activities, as well as required monitoring for scrubbing liquid flow rates, and scrubber pressure drops, if appropriate, shall be recorded. d. The Permittee shall maintain records of production rates, throughput, material usage, periods of excess emissions, failure of air pollution control equipment to operate in a normal and usual manner, and other process operational information, that allows for evaluation for compliance with the toxic air pollutant limits. These records shall be retained for a minimum of three years from the date of recording, and access to these records shall be provided to the Division of Air Quality staff upon request. Reporting e. For compliance purposes, within thirty (30) days after each calendar year quarter the following shall be reported to the Regional Supervisor, Division of Air Quality: i. Any and all exceedences of applicable toxic air pollutant emission limits during the previous calendar year quarter. ii. The maximum pounds per 1-hour emission rate at any time during the previous calendar year quarter for all applicable toxic air pollutants that have a listed pounds per hour emission rate. iii. The maximum pounds per 24-hour emission rate at any time during the previous calendar year quarter for DEQ-CFW 00085825 Permit 03735T34 Page 35 all applicable toxic air pollutants which have a listed pounds per day emission rate. STATE-ENFORCEARLF ONLY 3. 15A NCAC 2D .0541: CONTROL OF EMISSIONS FROM ABRASIVE BLASTING a. The Permittee shall ensure that any abrasive blasting operation conducted outside a building or conducted indoors and vented to the atmosphere is performed in accordance with the requirements set forth in 15A NCAC 21) .0521, Control of Visible Emissions. Any visible emissions reading for abrasive blasting performed outside a building shall be taken at a spot approximately one meter above the point of abrasive blasting with a viewing distance of approximately five meters. b. All abrasive blasting operations shall be conducted within a building, except as provided in i. or ii. below. The following abrasive blasting operations need not be conducted within a building: i. Abrasive blasting of an item that exceeds eight feet in any dimension; or, ii. Abrasive blasting of a surface situated at its permanent location or not further away from its permanent location than is necessary to allow the surface to be blasted. Any abrasive blasting operation conducted outside a building, as provided in Section 2.2. B.3. b.i. or ii. above, shall take appropriate measures to ensure that the fugitive dust emissions created by the abrasive blasting operation do not migrate beyond the property boundaries in which the abrasive blasting operation is being conducted. Appropriate measures include the following: i. Addition of a suppressant to the abrasive blasting material; ii. Wet abrasive blasting; iii. Hydroblasting; iv. Vacuum blasting; v. Shrouded blasting; or vi. Shrouded hydroblasting. 4. 40 CFR Part 68 "ACCIDENTAL RELEASE PREVENTION REQUIREMENTS: RISK MANAGEMENT PROGRAMS UNDER THE CLEAN AIR ACT, SECTION 112(r)" - The Permittee shall comply with all applicable requirements in accordance with 40 CFR Part 68 including submitting a Risk Management plan to EPA pursuant to 40 CFR Part 68.150 prior to June 21, 1999 or as specified in 40 CFR Part 68.10. DEQ-CFW 00085826 Permit 03735T34 Page 36 SECTION 3 - GENERAL CONDITIONS (v2.22.1) This section describes terms and conditions applicable to this Title V facility. A. General Provisions [NCGS 143-215 and 15A NCAC 2Q .0508(i)(16)] 1. Terms not otherwise defined in this permit shall have the meaning assigned to such terms as defined in 15A NCAC 2D and 2Q. 2. The terms, conditions, requirements, limitations, and restrictions set forth in this permit are binding and enforceable pursuant to NCGS 143-215.114A and 143-215.11413, 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 pernut 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 pemut does not relieve the Permittee from liability 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 enforceable 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 2Q .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 Environment and Natural Resources upon request. C. Severabilify Clause [15A NCAC 2Q .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 [15A NCAC 2Q .0507(e) and 2Q .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 (GEMS) 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 E. Duty to Comply [15A NCAC 2Q .0508(i)(2)] 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 DEQ-CFW 00085827 Permit 03735T34 Page 37 the Federal Clean Air Act. Noncompliance with any permit condition is grounds for enforcement action, for permit termination, revocation and reissuance, or modification, or for denial of a permit renewal application. 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 perniit, 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 2Q .0514] The Permittee shall submit an application for an administrative permit amendment in accordance with 15A NCAC 2Q .0514. 2. Transfer in Ownership or Operation and Application Submittal Content [ 15A NCAC 2Q .0524 and 2Q .0505] The Permittee shall submit an application for an ownership change in accordance with 15A NCAC 2Q.0524 and 2Q .0505. 3. Minor Permit Modifications [15A NCAC 2Q .0515] The Pernittee shall submit an application for a minor permit modification in accordance with 15A NCAC 2Q .0515. 4. Significant Permit Modifications [15A NCAC 2Q .0516] The Permittee shall submit an application for a significant permit modification in accordance with 15A NCAC 2Q .0516. 5. Reopening for Cause [15A NCAC 2Q .0517] The Permittee shall submit an application for reopening for cause in accordance with 15A NCAC 2Q .0517. H. Changes Not Requiring Permit Modifications 1. Section 502(b)(10) Changes [15A NCAC 2Q .0523(a)] a. "Section 502(b)(10) changes" means 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 Pernuttee 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)(10) changes shall be made in the permit the next time that the permit is revised or renewed, whichever comes first. 2. Off Permit Changes [15A NCAC 2Q .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. 3. Emissions Trading [15A NCAC 2Q .0523(c)] To the extent that emissions trading is allowed under 15A NCAC 2D, including subsequently adopted maximum achievable control technology standards, emissions trading shall be allowed without permit revision pursuant to 15A NCAC 2Q .0523(c). DEQ-CFW 00085828 Permit 03735T34 Page 38 I.A. Reporting Requirements for Excess Fmissionc and Permit Deviations [15A NCAC 2D .0535(f) and 2Q .0508(f)(2)] "Excess Emissions" - means an emission rate that exceeds any applicable emission limitation or standard allowed by any rule in Sections .0500, .0900, .1200, or .1400 of Subchapter 2D; or by a permit condition; or that exceeds an emission limit established in a permit issued under 15A NCAC 2Q .0700. (Note: Definitions of excess emissions under 2D .1110 and 2D . I I I I shall apply where defined by rule) "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 Fmissiom 1. If a source is required to report excess emissions under NSPS (15A NCAC 2D .0524), NESI IAPS (15A NCAC 2D .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 2D .0524), NESHAPS (15A NCAC 2D .1110 or .1111), or these rules do NOT define "excess emissions," the Permittee shall report excess emissions in accordance with 15A NCAC 2D .0535 as follows: a. Pursuant to 15A NCAC 2D .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 2D .0535(f)(3). Permit Deviations 3. Pursuant to 15A NCAC 2Q .0508(f)(2), the Permittee 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 2D .0535 quarterly. A written report to the Regional Supervisor shall include the probable cause of such deviation and any corrective actions or preventative actions taken. The responsible official shall certify all deviations from permit requirements. I.B. Other Requirements coder 15A NCAC 2D 0535 The Pemuttee shall comply with all other applicable requirements contained in 15A NCAC 2D .0535, including 15A NCAC 2D .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 rule 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 2D .0535(c)(1) through (7). 2. 15A NCAC 2D .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. Emergency Provisions [40 CFR 70.6(g)] The Perrnittee 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 DEQ-CFW 00085829 Permit 03735T34 Page 39 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. 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 2Q .0508(e) and 2Q .0513(b)] This permit is issued for a fixed term of five years for facilities subject to Title IV requirements and for a term not to exceed five years in the case of all other facilities. This permit shall expire at the end of its term. Permit expiration terminates the facility's right to operate unless a complete renewal application is submitted at least nine months before the date of permit expiration. If the Permittee or applicant has complied with 15A NCAC 2Q .0512(b)(1), this permit shall not expire until the renewal permit has been issued or denied. All terms and conditions of this permit shall remain in effect until the renewal permit has been issued or denied. L. Need to Halt or Reduce Activity Not a Defense [15A NCAC 2Q .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. Duty to Provide information (submittal of information) [15A NCAC 2Q .0508(i)(9)] 1. The Permittee shall furnish to the DAQ, in a timely manner, any reasonable information that the Director may request in wri ing 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. DDuty to Supplement [15A NCAC 2Q .0507(f)] The Permittee, upon becoming aware that any relevant facts were omitted or incorrect infomnation 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. O. Retention of Records [ 15A NCAC 2Q .0508(f) and 2Q .0508 (1)] The Permittee shall 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 DEQ-CFW 00085830 Permit 03735T34 Page 40 available to DAQ personnel for inspection upon request. P. Compliance Certification [15A NCAC 2Q .0508(n)] The Permittee shall submit to the DAQ and the EPA (Air and EPCRA Enforcement Branch, EPA, Region 4, 61 Forsyth Street, Atlanta, GA 30303) postmarked on or before March 1 a compliance certification (for the preceding calendar year) by a responsible official with 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 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 2Q .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 2Q .0512] 1. 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 of permit 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 2Q .0523. 4. A permit shield does not extend to minor permit modifications made under 15A NCAC 2Q .0515. S. Termination, Modification, and Revocation of the Permit [15A NCAC 2Q .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 ofNCGS Chapter 143, Article 21B. T. Insignificant Activities [15A NCAC 2Q .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 Perniittee shall have available at the facility at all times and made available to an authorized representative upon request, documentation, including calculations, if necessary, to demonstrate that an emission source or activity is insignificant. DEQ-CFW 00085831 Permit 03735T34 Page 41 U. Proper _y Rights [15A NCAC 2Q .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 2Q .0508(1) and NCGS 143-215.3(a)(2)] 1. Upon presentation of credentials and other documents as may be required by law, the Permittee 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 times 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 pemlit or applicable requirements at reasonable times. Nothing in this condition shall limit the ability of the EPA to inspect or enter the premises of the Permittee 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 2Q .0508(i)(10)] 1. The Permittee shall pay all fees in accordance with 15A NCAC 2Q .0200. 2. Payment of fees may be by check or money order made payable to the N.C. Department of Environment and Natural Resources. 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 2Q .0519. X. Annual Fmission Inventory Requirements [15A NCAC 2Q .0207] The Permittee shall report by June 30 of each year the actual emissions of each air pollutant listed in 15A NCAC 2Q .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 2Q .0107 and 2Q. 0508(i)(9)] Whenever the Permittee submits information under a claim of confidentiality pursuant to 15A NCAC 2Q .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 2Q .0107. Z. Construction and Operation Permits [15A NCAC 2Q .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 2Q .0100 and .0300. AA. Standard Application Form and Required information [15A NCAC 2Q .0505 and .0507] The Permittee shall submit applications and required information in accordance with the provisions of 15A NCAC 2Q .0505 and .0507. 1313. Financial Responsibility and Compliance, HistorQ [15A NCAC 2Q .0507(d)(3)] The DAQ may require an applicant to submit a statement of financial qualifications and/or a statement of substantial compliance history. DEQ-CFW 00085832 Permit 03735T34 Page 42 CC. Refrigerant Requirements (Stratospheric Ozone and Climate Protection) [15A NCAC 2Q .0501(e)] l . If the Permittee has appliances or refrigeration equipment, including air conditioning equipment, which use Class I or II ozone -depleting substances such as chlorofluorocarbons and hydrochlorofluorocarbons 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 II 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(rl [15A NCAC 2Q .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 I I2(r)W - 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 Permittee has a general duty to take such steps as are necessary to prevent the accidental release of such substance and to minimize the consequences of any release. FF. Title 1V Allowances [15A NCAC 2Q .0508(i)(1)] This permit does not limit the number of Title IV allowances held by the Permttee, but the Permittee may not use allowances as a defense to noncompliance with any other applicable requirement. The Pemuttee's emissions may not exceed any allowances that the facility lawfully holds under Title IV of the Federal Clean Air Act. GG. Air Pollution Emergency F iz 'code [15A NCAC 2D .0300] Should the Director of the DAQ declare an Air Pollution Emergency Episode, the Permittee will be required to operate in accordance with the Permittee's previously approved Emission Reduction Plan or, in the absence of an approved plan, with the appropriate requirements specified in 15A NCAC 2D .0300. HH. Registration of Air Pollution Sources [15A NCAC 2D .0200] The Director of the DAQ may require the Permittee to register a source of air pollution. If the Pemuttee is required to register a source of air pollution, this registration and required information will be in accordance with 15A NCAC 2D .0202(b). H. Ambient Air Quality Standards [15A NCAC 2D .0501(e)] 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 2D .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. JJ. General Emissions Testing and Re or ing Requirements [15A NCAC 2Q .0508(i)(16)] If emissions testing is required by this permit or the DAQ or if the Permittee submits emissions testing to the DAQ in support of a permit application or to demonstrate compliance, the Permittee shall perform such testing in accordance with 15A NCAC 2D .2600 and follow the procedures outlined below: 1. The Permittee shall submit a completed Protocol Submittal Form to the DAQ Regional Supervisor at least 45 days prior to the scheduled test date. A copy of the Protocol Submittal Form may be obtained from the Regional Supervisor. 2. The Permittee shall notify the Regional Supervisor of the specific test dates at least 15 days prior to testing in order to afford the DAQ the opportunity to have an observer on -site during the sampling program. 3. During all sampling periods, the Permittee shall operate the emission source(s) under maximum normal operating DEQ-CFW 00085833 Permit 03735T34 Page 43 conditions or alternative operating conditions as deemed appropriate by the Regional Supervisor or his delegate. The Permittee shall submit two copies of the test report to the DAQ. The test report shall contain at a minimum the following information: a. A description of the training and air testing experience of the person directing the test; b. A certification of the test results by sampling team leader and facility representative; c. A summary of emissions results and text detailing the objectives of the testing program, the applicable state and federal regulations, and conclusions about the testing and compliance status of the emission source(s); d. A detailed description of the tested emission source(s) and sampling location(s) process flow diagrams, engineering drawings, and sampling location schematics should be included as necessary; e. All field, analytical, and calibration data necessary to verify that the testing was performed as specified in the applicable test methods; f. Example calculations for at least one test run using equations in the applicable test methods and all test results including intermediate parameter calculations; and g. Documentation of facility operating conditions during all testing periods and an explanation relating these operating conditions to maximum normal operation. If necessary, provide historical process data to verify maximum normal operation. The testing requirement(s) shall be considered satisfied only upon written approval of the test results by the DAQ. The DAQ will review emission test results with respect exclusively to the specified testing objectives as proposed by the Permittee and approved by the DAQ. KK. Reopening for Cause [15A NCAC 2Q .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 years; b. Additional requirements (including excess emission requirements) become applicable to a source covered by Title 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 2Q .0513(c). 3. Except for the state -enforceable only portion of the permit, the procedures set out in 15A NCAC 2Q .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 2Q .0300 shall be followed. The proceedings shall affect only those parts of the permit for which cause 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 2Q .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. During operation the monitoring recordkeeping and reporting requirements as prescribed by the permit shall be implemented within the monitoring period. M.M. Fugitive Dust Control Requirement [15A NCAC 2D .0540] -STATE ENFORCEABLE ONLY As required by 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible emissions beyond the property boundary. If substantive complaints or excessive fugitive dust emissions from the facility are observed beyond the property DEQ-CFW 00085834 Permit 03735T34 Page 44 boundaries for six minutes in any one hour (using Reference Method 22 in 40 CFR, Appendix A), the owner or operator may be required to submit a fugitive dust plan as described in 2D .0540(f). "Fugitive dust emissions" means particulate matter 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. 1. For modifications made pursuant to 15A NCAC 2Q .0501(c)(2), the Permittee shall file a Title V Air Quality Pen -nit 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 2Q .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 2Q .0523(a)(1)(C), the Penriittee shall notify the Director and EPA (EPA - Air Planning Branch, 61 Forsyth St., Atlanta, GA 30303) in siting 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 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 pre -construction requirements. DEQ-CFW 00085835 Pernut 03735T34 Page 45 ATTACHMENT List of Acronyms AOS Alternate Operating Scenario BACT Best Available Control Technology Btu British thermal unit CEM Continuous Emission Monitor CFR Code of Federal Regulations CAA Clean Air Act DAQ Division of Air Quality DENR Department of Environment and Natural Resources EMC Environmental Management Commission EPA Environmental Protection Agency FR Federal Register GACT Generally Available Control Technology HAP Hazardous Air Pollutant MACT Maximum Achievable Control Technology NCAC North Carolina Administrative Code NCGS North Carolina General Statutes NESHAPS National Emission Standards for Hazardous Air Pollutants NOx Nitrogen Oxides NSPS New Source Performance Standard OAH 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 SIC Standard Industrial Classification SIP State Implementation Plan SO2 Sulfur Dioxide tpy Tons Per Year VOC Volatile Organic Compound DEQ-CFW 00085836