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HomeMy WebLinkAbout20070280 Ver 1_Application_2007021669 SF'Al'~IGLER ENVIRONMENTAL, It~tC. 2oo7o2so Land Planning • Permitting • Environmental Consulting • Construction Management • Expert Testimony February 16, 2007 ~, ~~ r VIA HAND DELIVERY ~~~~ i ~~~ ~~T /Ms. Cyndi Karoly, 401/Wetlands Supervisor 7 copies w/fee ($200) RECEIVED NCDWQ Wetlands/401 Office Crabtree Boulevard 1650 Mail Service Center Raleigh, NC 27699-1650 Ms. Cynthia Vanderwiele, Express Review Coordinator Icopy NCDWQ Wetlands/401 Office Crabtree Boulevard 1650 Mail Service Center Raleigh, NC 27699-1650 Mr. Ken Averitte 1 copy NCDWQ Fayetteville Regional Office 225 Green Street Suite 714 Fayetteville, NC 28301-5094 Mr. Ronnie D. Smith 3 copies US Army Corps of Engineers Wilmington Regulatory Field Office 69 Darlington Avenue Wilmington, NC 28403 RE: E85 Ethanol Plant 404/401 PCN Ladies and Gentlemen: Please find attached the requisite number of copies of a PCN for less than 0.48 acres of permanent wetland impact in Fayetteville, Cumberland County. There are no additional temporary or off-site impacts. This PCN is associated with a major economic development initiative and industrial facility that will manufacture E85 ethanol fuel for the eastern United States. This will be the first plant of its kind in the eastern US, and a groundbreaking ceremony is scheduled for the first week of April. We, as Agents for the Applicant, would appreciate the expeditious review and approval/authorization of this PCN. Please contact me directly if you have any questions. Sincerely, Spangler E r mental, Inc. Ja angler President Attachments CC: Mark Dassel--E85, Inc. Paul Jordan-NC Dept. of Commerce Phyllis Owens-Cumberland Co. Business Council Allan Campbell, PE-FruCon Engineering, Inc. John Shady-Malcolm Pirnie Engineering Gordon Rose, PE-McKim & Creed 224 Fayetteville. Street, Suite 400 P.O. Box 387 Raleigh, N.C. 27602 te1919-546-0754 fax 919-546-0757 toll free. 1-866-SPANGLER 3961-B Market Street Wilmington, N.C. 28403 te1910-343-9375 fax 910-34,3-8351 wwwspanglerenvironmental.com 85iC1C February 12, 2007 To Whom It May Concern: e85, Inc. PO Box 560 Kingston, WA 98346 +1.360.297.7619 (P) +1.360.297.7617 (F) www.e85.us This letter serves to inform you that E85, Inc. Optionee of property located on approximately one hundred and fifty (150) acres of land located east of the Good Year tire plant in Fayetteville, NC and further located on the immediate western boundary of the CSX rail line authorizes Spangler Environmental, Inc. to act as our technical agent for the purposes of environmental issues, including wetland and stream identification, permitting, mitigation planning and regulatory agency coordination at the property known as Cape Fear River Holdings, LLC property, and as shown in Cumberland County records as tax parcel numbers 0541-68-6116 and 0541-66-3131. All site visits by regulatory personnel must be coordinated in advance with our agent, Spangler Environmental, Inc. This letter supersedes all previous Agent-related correspondence. The following contact persons should be copied on all correspondence: Property Optionee (Agent): E85, Inc. C/O Mark W. Dassel PO Box 560 Kingston, WA 98346 360.297.7619 (O) 360.860.1787 (C) Technical Agent: James A. Spangler Spangler Environmental, Inc PO Box 387 Raleigh, NC 27602-0387 919-546-0754 Fax 919-546-0757 Sincerely, E85, Inc. 7 `~ Mark .Dassel Senio Vice President and Director ,.. I~ F / Office Use Only: USAGE Action ID No. RECEIVED DWQ No. ~~~ W A T~~~ rr„~O GP 1 vJ f fl ~ L 0 0 7 0 2 8 0 If any particular item is not applicable to this project, please enter "Not Applicable" or "N/A" rather than leaving the space blank. I. II. Processing Check all of the approval(s) requested for this project: Section 404 Permit ^ Section 10 Permit 401 Water Quality Certification ^ Riparian or Watershed Buffer Rules 2. Nationwide, Regional or General Permit Number(s) Requested: NWP 39 / GC 3402 3. If this notification is solely a courtesy copy because written approval for the 401 Certification is not required, check here: ^ 4. If payment into the North Carolina Ecological Enhancement Program (NCEEP) is proposed for mitigation of impacts (see section VIII -Mitigation), check here: ^ Applicant Information 1. Owner/Applicant Information Name: E85, Inc. Mailing Address: C/O Mr. Mark Dassel, PO Box 560, Kingston, WA 98346 Telephone Number: 360-297-7619 Fax Number: E-mail Address:dasse1.e85(cr~,~mail.com 2. Agent Information (A signed and dated copy of the Agent Authorization letter must be attached if the Agent has signatory authority for the owner/applicant.) Name: James A. Spangler Company Affiliation: Spangler Environmental, Inc. Mailing Address: PO Box 387, Raleigh, NC 27602 Telephone Number: 919-546-0754 Fax Number: 919-546-0757 E-mail Address:~pan~ler(a,span~lerenvironmental.com Page 1 of 9 III. Project Information Attach a vicinity map clearly showing the location of the property with respect to local landmarks such as towns, rivers, and roads. Also provide a detailed site plan showing property boundaries and development plans in relation to surrounding properties. Both the vicinity map and site plan must include a scale and north arrow. The specific footprints of all buildings, impervious surfaces, or other facilities must be included. If possible, the maps and plans should include the appropriate USGS Topographic Quad Map and NRCS Soil Survey with the property boundaries outlined. Plan drawings, or other maps may be included at the applicant's discretion, so long as the property is clearly defined. For administrative and distribution purposes, the USACE requires information to be submitted on sheets no larger than 11 by 17-inch format; however, DWQ may accept paperwork of any size. DWQ prefers full-size construction drawings rather than a sequential sheet version of the full-size plans. If full-size plans are reduced to a small scale such that the final version is illegible, the applicant will be informed that the project has been placed on hold until decipherable maps are provided. 1. Name of project: E85--100 MGY DENATURED ETHANOL PLANT 2. T.I.P. Project Number (NCDOT Only): N/A 3. Property Identification Number (Tax PIN): Cumberland Co. 0541-68-6116 and 0541-66- 3131 4. Location County: Cumberland Nearest Town: Fayetteville Subdivision name (include phase/lot number):N/A Directions to site (include road numbers, landmarks, etc.): 401 North from Fayetteville. Turn Right on Bethune Road, lust past Goodyear Plant. Site is at end of Bethune Road 5. Site coordinates, if available (UTM or Lat/L,ong): (Note - If project is linear, such as a road or utility line, attach a sheet that separately lists the coordinates for each crossing of a distinct waterbody.) Describe the existing land use or condition of the site at the time of this application: Partially wooded, majority recently clearcut. Undeveloped rural 6. Property size (acres): 150 acres +/-. 7. Nearest body of water (stream/river/sound/ocean/lake):UT to Cape Fear River 8. River Basin: Cape Fear (03030004) (Note -this must be one of North Carolina's seventeen designated major river basins. The River Basin map is available at http://h2o.enr.state.nc.us/admin/maps/.) Describe the purpose of the proposed work: (See Exhibit 5) Construction of 100 million ~allon/year ethanol fuel (E85) production facility including 13 000 + linear feet of new rail Page 2 of 9 r line (dual loop plus rail ladder), rail ladder for on- and off-load of bulk materials above- ground tank farm, automobile access fire-protection roads roadway infrastructure improvements, storm water and utility infrastructure construction and industrial process builin~s and infrastructure. List the type of equipment to be used to construct the project: Mechanical Describe the land use in the vicinity of this project:Adiacent land uses include Goodyear Plant (industrial. Norfolk Southern rail line (industrial) and undevelopedlwooded/clearcut industrial-zoned acreage. Rural/residential/farm acreage adioins parcel to be developed but is separated by wetlands and wooded- pine stands from the proposed facility IV. Prior Project History If jurisdictional determinations and/or permits have been requested and/or obtained for this project (including all prior phases of the same subdivision) in the past, please explain. Include the USACE Action ID Number, DWQ Project Number, application date, and date permits and certifications were issued or withdrawn. Provide photocopies of previously issued permits, certifications or other useful information. Describe previously approved wetland, stream. and • buffer impacts, along with associated mitigation (where applicable). If this is a NCDOT.project; list and describe permits issued .for prior segments of the same T.LP. project; along with ' construction schedules. Prior permits issued include NC Division of Air Quality Permit #09722R00• (Site Number 06/26/00221 (Attached as Exhibit 22) issued February 5 2007 Storm water permit and wastewater pre-discharge permits are pending from Fayetteville PWC V. Future Project Plans Are any additional permit requests anticipated for this project in the future? If so, describe the anticipated work, and provide justification for the exclusion of this work from the current application: No other 404 permits or 401 certifications are anticipated for this project Page 3 of 9 VI. Proposed Impacts to Waters of the United States/Waters of the State It is the applicant's (or agent's) responsibility to determine, delineate and map all impacts to wetlands, open water, and stream channels associated with the project. The applicant must also provide justification for these impacts in Section VII below. All proposed impacts, permanent and temporary, must be listed herein, and must be clearly identifiable on an accompanying site plan. All wetlands and waters, and all streams (intermittent and perennial) must be shown on a delineation map, whether or not impacts are proposed to these systems. Wetland and stream evaluation and delineation forms should be included as appropriate. Photographs may be included at the applicant's discretion. If this proposed impact is strictly for wetland or stream mitigation, list and describe the impact in Section VIII below. If additional space is needed for listing or description, please attach a separate sheet. 1. Wetland Impacts Wetland Impact Site Number (indicate on ma Type of Impact* Area of Impact acres Located within 100-year Floodplain** es/no Distance to Nearest Stream linear feet Type of Wetland*** A (Exhibit 10) Permanent_ 0.015 No >1,000 Forested wetland B/C (Exhibit 7) Permanent 0.139 No >1,000 Forested wetland. D_(Exhibit 8) Permanent ~ 0.318 No >1,000 Clear-cut (for. :wetland?) 0.~}1a. ' List eacn impact separately and identity temporary impact'3. Impacts include, but are not limited to: mechanized clearing, grading, fill, excavation, flooding, ditching/drainage, etc. For dams, separately list impacts due to both structure and flooding. ** 100-Year floodplains are identified through the Federal Emergency Management Agency's (FEMA) Flood Insurance Rate Maps (FIRM), or FEMA-approved local floodplain maps. Maps are available through the FEMA Map Service Center at 1-800-358-9616, or online at http://www.fema.~. *** List a wetland type that best describes wetland to be impacted (e.g., freshwater/saltwater marsh, forested wetland, beaver pond, Carolina Bay, bog, etc.) List the total acreage (estimated) of existing wetlands on the property: est. 18.5 acres Total area of wetland impact proposed: 0.48 acres 2. Stream Impacts, including all intermittent and perennial streams Stream Impact Site Number (indicate on ma) Type of Impact* Length of Impact (linear feet) Stream Name** Average Width of Stream Before Im act Perennial or Intermittent? leases eci ) None Page 4 of 9 k List each impact separately and identify temporary impacts. Impacts include, but are not limited to: culverts and associated rip-ran. dams (separately list impacts due to both structure and flooding), relocation (include linear feet before and after, and net loss/gain), stabilization activities (cement wall, rip-rap, crib wall, gabions, etc.), excavation, ditching/straightening, etc. If stream relocation is proposed, plans and profiles showing the linear footprint for both the original and relocated streams must be included. ** Stream names can be found on USGS topographic maps. If a stream has no name, list as UT (unnamed tributary) to the nearest downstream named stream into which it flows. USGS maps are available through the USGS at 1-800-358-9616, or online at www.usgs.gov. Several Internet sites also allow direct download and printing of USGS maps (e.g., www.topozone.com, www.mapouest.com, etc.). Cumulative impacts (linear distance in feet) to all streams on site: None 3. Open Water Impacts, including Lakes, Ponds, Estuaries, Sounds, Atlantic Ocean and any other Water of the U.S. Open Water Impact Site Number (indicate on ma) Type of Impact* Area of Impact acres) Name of Waterbody (if applicable) Type of Waterbody (lake, pond, estuary, sound ba ,ocean, etc.) None.' „ - "` List each impact separately and identify temporary impacts. Impacts include, but are not limited to: fill, excavation, dredging, flooding, drainage, bulkheads, etc. 4. Pond Creation If construction of a pond is proposed, associated wetland and stream impacts should be included above in the wetland and stream impact sections. Also, the proposed pond should be described here and illustrated on any maps included with this application. Pond to be created in (check all that apply): ^ uplands ^ stream ^ wetlands Describe the method of construction (e.g., dam/embankment, excavation, installation of draw-down valve or spillway, etc.): N/A Proposed use or purpose of pond (e.g., livestock watering, irrigation, aesthetic, trout pond, local stormwater requirement, etc.): N/A Size of watershed draining to pond: N/A Expected pond surface area: N/A VII. Impact Justification (Avoidance and Minimization) Specifically describe measures taken to avoid the proposed impacts. It may be useful to provide information related to site constraints such as topography, building ordinances, accessibility, and financial viability of the project. The applicant may attach drawings of alternative, lower-impact site layouts, and explain why these design options were not feasible. Also discuss how impacts Page 5 of 9 were minimized once the desired site plan was developed. If applicable, discuss construction techniques to be followed during construction to reduce impacts. Seven different site plans were prepared and analyzed for wetland impacts (See Exhibit 14). The preferred alternative achieves impact minimization in light of the following: • railroad horizontal curve and vertical curve design constraints • fire protection access road requirements • provision for over 3.5 acres of storm water detention/treatment • industrial facility grading design finish floor/conveyor connection/pumping and operation constraints (see Exhibit 6) • overhead utility line constraints (31 feet of vertical clearance and 15 feet of horizontal clearance from both the 7,200 V South River EMC lines and the 1 Z.5 KV Progress Energy Lines) • automobile/truck traffic engineering design constraints (vertical and horizonatal design seed curve radii andtraffic circulation/staging/parkin fg_ or separate bulk production material trucks and employee vehicles). Construction methods to minimize impacts include the following_ • accessing rail-crossing location via proposed fire protection access road. THE ONLY IMPACTS ASSOCIATED WITH THE PREFERRED ALTERNATIVE ARE FOR RAIL - L1NE CONSTRUCTION AND FIRE PROTECTION ROAD ACCESS TO THE RAIL~L'INE ON SHARED ALIGNMENT. _ ~ ,, ; , VIII. Mitigation DWQ - In accordance with 15A NCAC 2H .0500, mitigation may be required by the NC Division of Water Quality for projects involving greater than or equal to one acre of impacts to freshwater wetlands or greater than or equal to 150 linear feet of total impacts to perennial streams. USACE - In accordance with the Final Notice of Issuance and Modification of Nationwide Permits, published in the Federal Register on March 9, 2000, mitigation will be required when necessary to ensure that adverse effects to the aquatic environment are minimal. Factors including size and type of proposed impact and function and relative value of the impacted aquatic resource will be considered in determining acceptability of appropriate and practicable mitigation as proposed. Examples of mitigation that may be appropriate and practicable include, but are not limited to: reducing the size of the project; establishing and maintaining wetland and/or upland vegetated buffers to protect open waters such as streams; and replacing losses of aquatic resource functions and values by creating, restoring, enhancing, or preserving similar functions and values, preferable in the same watershed. If mitigation is required for this project, a copy of the mitigation plan must be attached in order for USACE or DWQ to consider the application complete for processing. Any application lacking a required mitigation plan or NCWRP concurrence shall be placed on hold as incomplete. An applicant may also choose to review the current guidelines for stream restoration in DWQ's Draft Technical Guide for Stream Work in North Carolina, available at http://h2o.enr.state.nc.us/ncwetlands/strm~ide.html. Page 6 of 9 1. Provide a brief description of the proposed mitigation plan. The description should provide as much information as possible, including, but not limited to: site location (attach directions and/or map, if offsite), affected stream and river basin, type and amount (acreage/linear feet) of mitigation proposed (restoration, enhancement, creation, or preservation), a plan view, preservation mechanism (e.g., deed restrictions, conservation easement, etc.), and a description of the current site conditions and proposed method of construction. Please attach a separate sheet if more space is needed. Mitigation is not reauired for this project as impacts of less than 0.5 acre are proposed However, all remaining wetlands inside the rail loop (approximately 14.2 acres) can be placed into conservation easement dedicated to a third party or deed restriction prohibiting future impacts to those remaining wetlands inside the rail loop can be recorded within 30 days of permit/certification issuance/coverage as a condition of approval Mitigation via this method will include preservation of nearly 30:1, and enhancement/restoration within the preserved area through natural seed recruitment of wetland areas clear-cut previous) a~ an proximate ratio of 15:1. This mitigation is 100% on-site. 2. Mitigation may also be made by payment into the North Carolina Wetlands Restoration Program (NCWRP) with the NCWRP's written agreement. Check the box indicating that -- _ you would like to pay into the NCWRP. Please note that payment into the NCWRP must be reviewed and approved before it can be used to satisfy mitigation requirements. Applicants will be notified early in the review process by the 401/Wetlands. Unit if payment into the NCWRP is available as an option. For additional information regarding the application process for the NCWRP, check the NCWRP website at http://h2o.enr.state.nc.us/wro/index.htm. If use of the NCWRP is proposed, please check the appropriate box on page three and provide the following information: Amount of stream mitigation requested (linear feet): None Amount of buffer mitigation requested (square feet): None Amount of Riparian wetland mitigation requested (acres): None Amount ofNon-riparian wetland mitigation requested (acres): None Amount of Coastal wetland mitigation requested (acres): None IX. Environmental Documentation (DWQ Only) Does the project involve an expenditure of public funds or the use of public (federal/state/local) land? Yes ^ No If yes, does the project require preparation of an environmental document pursuant to the requirements of the National or North Carolina Environmental Policy Act (NEPA/SEPA)? Note: If you are not sure whether a NEPA/SEPA document is required, call the SEPA coordinator at (919) 733-5083 to review current thresholds for environmental documentation. Yes ^ No If yes, has the document review been finalized by the State Clearinghouse? If so, please attach a copy of the NEPA or SEPA final approval letter. Page 7 of 9 Yes ^ No X. Proposed Impacts on Riparian and Watershed Buffers (DWQ Only) It is the applicant's (or agent's) responsibility to determine, delineate and map all impacts to required state and local buffers associated with the project. The applicant must also provide justification for these impacts in Section VII above. All proposed impacts must be listed herein, and must be clearly identifiable on .the accompanying site plan. All buffers must be shown on a map, whether or not impacts are proposed to the buffers. Correspondence from the DWQ Regional Office may be included as appropriate. Photographs may also be included at the applicant's discretion. Will the project impact protected riparian buffers identified within 15A NCAC 2B .0233 (Meuse), 15A NCAC 2B .0259 (Tar-Pamlico), 15A NCAC 2B .0250 (Randleman Rules and Water Supply Buffer Requirements), or other (please identify )? Yes ^ No ~ If you answered "yes", provide the following information: Identify the square feet and acreage of impact to each zone of the riparian buffers. If buffer mitigation is required calculate the required 'amount of mitigation by applying the buffer multipliers. Zone* Impact:. (s uare feet) Multiplier Required Miti ation 1 N/A 3, 2 N/A 1.5 Total N/A * Zone 1 extends out 30 feet perpendicular from near bank of channel; Lone "l extends an additional 20 feet from the edge of Zone 1. If buffer mitigation is required, please discuss what type of mitigation is proposed (i.e., Donation of Property, Conservation Easement, Riparian Buffer Restoration /Enhancement, Preservation or Payment into the Riparian Buffer Restoration Fund). Please attach all appropriate information as identified within I SA NCAC 2B .0242 or .0260. N/A XI. Storm water (DWQ Only) Describe impervious acreage (both existing and proposed) versus total acreage on the site. Discuss stormwater controls proposed in order to protect surface waters and wetlands downstream from the property. Impervious acreas?e: approximately 18.1 acres proposed. 0.0 acres existins;. Construction BPS Lursuant to S/e Plan approved by NCDLR-LQS shall be implemented. Post-construction storm water detention/retention treatment of approximately 3.8 surface acres is provided on the plan, with adequate separation from wetlands for level-spreaders and vegetated buffers. No direct discharge into wetlands or streams shall occur. Plans are pending_approval from PWC. Page 8 of 9 XII. Sewage Disposal (DWQ Only) Clearly detail the ultimate treatment methods and disposition (non-discharge or discharge) of wastewater generated from the proposed project, or available capacity of the subject facility. Diischarge into Fayetteville PWC existing infrastructure. XIII. Violations (DWQ Only). Is this site in violation of DWQ Wetland Rules (15A NCAC 2H .0500) or any Buffer Rules? Yes ^ No Is this anafter-the-fact permit application? Yes ^ No XIV. Other Circumstances (Optional): It is the applicant's responsibility to submit the application sufficiently in advance of desired construction dates to .allow. ,processing • time: for these permits. However, an applicant may choose to list constraints. associated with construction or sequencing that may impose limits on . work schedules (e.g., draw-down schedules for lakes, dates .associated with Endangered. and; Threatened Species, accessibility problems,. or-other issues outside of the applicant's control): This is a maior economic development project for Cumberland County and the- only plant of :its _ kind proposed in North- Carolina: This site is the only location within economically feasible ~• distance from highway.: infrastructure (I-295 and I-95 are less than 2 miles- south) and rail infrastructure (immediate)~adjacent); with adequate utility infrastructure in place, and with,.: existing Industrial zoning in place. Negotiations with Norfolk Southern on minimum design tolerances have limited the ability to further minimize impacts due to the rail. line. loop, and fire- protection access to rail cars carr~g bulk ethanol fuel requires the construction of the fire protection access road on alignment with the rail loop. The production facility and rail infrastructure have been re-designed seven times to minimize and subsequently eliminate wetland impacts. This site has recently been nearly completely clear-cut for silviculture) purposes. Wetlands on the site are of low quality, with the exception of those that have not been impacted by logging. Permits have been issued by other state re ug latorv agencies for this facility. 2.15- c~7 Date (Agent's signature is valid only if an authorization letter from the applicant is provided.) AGENT AUTHORIZATION IS INCLUDED. Page 9 of 9 E85 404/401 PCN EXHIBITS -. i • ~~ .fr ~ ~ '~ ; ,~'~ , , ~, ~~ I } \ I - ~ ~, s -7I1 r~ ~~: to ~ ~.' .. ~ i ... 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Raleigh, NC 27602-0387 ~;,„,...szrssr _ra:s:suers.:~~.s~cs~:r~:.~v.=:i'~=~3r. ..:.,, 9IA-346-0734 9IA-346-0T37Fax ~~ F R i a t O O Z Q J H W 3 m 0 Z a J H W 3 Q O z a J W 3 W$ ~~~ ~~ U W~ OD U ~ - ~ m U ~ Z Z Z O O O b R _ _ ~ ~ ~ Y __ ~ ~ W W W fn fn fn +~~r(. ~ T y W m IY~ j ~_' ~~ee s ~ l~ ~ ~ ~ ~ I m ~u ~~ Vlur~' O J <r- ~3 W W < m~ ~m 0 o y < ~ s~ ~ m .n ~q ~ mm c> ~V ~' dam '~ ~ = e; IY m; ,~ Y ~m ~~ ~~ ~~~ < ~ ~ o ~ ~ o 0 ~ o ff a s m~ J ~ffi ~ ' ~ ~ ~ N Q N b ~~ ~~ ~~ s Z o m ~ m ~~~~d i ~ ~ W ~ e ~ ~ ; ~ ~ C Z.= N ~i E85 404/401 PCN EXHIBIT 9 224 Fayetteville Street suite 400 SPANGLER P-O. fox 387 DnnaaRa~xr~u., wc. Raleigh, NC 27602-0387 919-546-0754 919-546-0757 Far i 9 a S A R R B w O~ Q ~~ rg rrr~ ~[1 R _-~ , ~ a ~_L~ ~~~ ~ ~ -~ o ~ _ ~. d/ ~ 0 ~ -~: C~ O _-~ N o ~ ,--- ~ ~ o N Z ~~, 0 ~ O U " ~ ~~ \~~ 0 ~{ iE ~ W ~ I- ~ ~ 8 Z ~ ~ ~ ~' ~ ! o PC = 46+03.1 + ~ Q Z ~ y- ~ WW ~ ~ 2f ~e~~ ~ °- ~ ~°~~ ~C~I~ i i i ist i i i~~ ~_ ~_ a~ ~ o 0 o~ ~ o rn ~ M O E85 404/401 PCN EXHIBIT 10 0 ~ ~ 224 Fayetteville Street °~ Suite 400 SPANGLER P•O. Box 387 ~~ ~,y,, ~, Raleigh, NC 27602-0387 ~ rse:rsa:ax= _~,s~rr~e::s.~.z~~es3.sz:r~;~esix.~r , ::~ ,~r: ~~ Q ~z Q w E85 404/401 PCN EXHIBIT 11 224 Fayetteville Street Suite 400 SPANGLER P•O. Box 387 Envwo~e~rru, d+c. Raleigh, NC 27602-0387 .. s ... .. .. _ .. z Q m 0 c) ~~ O ::~ S) ~ ~~~~ z Q _ `C ~ `-J ~_~ CCi Cii if i i(] W ~ . ..,.~..._ . I I ~ 1...... I I .....I..7..1 I I ~ i ~~.. ... ...... I : ..~: I I I I I ~. ..._.i _...., ...1 .. I I I I i I - I a. i ~ - ~ ~ ..... 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I I E85 404/401 PCN EXHIBIT 13 224 Fayetteville Street Suite 400 SPANGLER P•0- Box 387 ~,~,., ~,,1e, Raleigh, NC 27602-0387 919-546-0754 919-546-0757 Fax E85 Fayetteville 404/401 PCN Alternatives Considered /Impact Minimization Comparisons Alternative # /Description /Impact 1 (Exhibit 15) Process facility optimally located adjacent to existing Norfolk Southern Rail line. Minimal impervious area because of minimized roadway infrastructure. TOTAL IMPACT 11.84 ACRES 1.1 (Exhibit 16) Facility moved inside rail loop to minimize wetlands impacts. Increase rail impervious area. Requires that rail bridge over access roads. Radii of rail curves tighter than allowable by Norfolk Southern. No off-load rail ladder, no fire protection. TOTAL IMPACT 3.04 ACRES 2 (Exhibit 17) Facility moved outside single rail loop. Increase impervious area by 40%. One rail loop curve radius of rail loop tighter than allowable. Topographic features under plant site necessitate large area-wide fill of wetlands. TOTAL IMPACT 2.39 ACRES 3 (Exhibit 18) Facility moved outside rail loop. Rail loop shortened and impervious area reduced. Rail loop too short to allow for off-load rail ladder or effective transfer from existing Norfolk Southern right-of--way. Single rail loop with no fire protection access. TOTAL IMPACT 0.918 ACRES 4 (Exhibit 19) Facility outside dual rail loop, rail curves adjusted to allow for future off-load rail ladder inside loop. Forces facility to impact northern wetlands. TOTAL IMPACT 1.85 ACRES 5 (Exhibit 20) Facility separated to minimize impact to northern wetlands, necessitates placement of bulk ethanol storage tanks inside rail loop, limiting off-load rail ladder. Lacking fire protection access road adjacent to loop. TOTAL IMPACT 0.49 ACRE 6 (Exhibit 21) Facility outside rail loops, but no longer segmented and eliminates impact to northern wetland. Plan lacks storm water facility, and does not include rail ladder. TOTAL IMPACT 0.48 ACRE PREFERRED ALTERNATIVE (Exhibit 5) Facility outside rail loop, rail ladder and storm water locations added, fire protection access road around loop added. TOTAL IMPACT 0.48 ACRE E85 ---Fayetteville 404/401 PCN EXHIBIT 14 !~ ~PAI~i~LER ENVIRONMENTAL, (NC. ;Ry52 i~12~5 0 '~ a o~ ~~~ ~~ a b~ ` 1 L~~\-~i \ , \ e ~ II t ~\ y~i 1' `~ Z ~z , . 4 \ ~ ~ ` !.S W ,J ' ` `\ = ~_ / ~ \ ti - \ w W <7 z ~' ~ _ '~ _ ~ > . ~ \\ ~p \ (... 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Raleigh, NC 27602-0387 91A-S46-0754 9lla-S46-0~57Faz R R 2U5 aao s ~~~~ ~ ~ ~ ~ ~ ~ ~ \ M __ ~ \ 4 . ~ Fi~'~ 4~ ' 4 y p ~ '~6 \ o ~ ~ 1 '. ~ ~ Ab ~ ~ . ~ \ 4~ ~ 4 \ \~ ~/~ qe ~, \ \ 4 e ' ~~ \ ~ \ t" ~ `u \ ~ \ i ~ ti ~ i rQ za_ SF~ a ~ °za a ~~ Vf OP .\ • `F ,\ ~ ~ 2 ~ ~`~ 7 ~~ d 4 2 4 { t ~ ~ ._......._.... V W j = Vl K W t Z ~ ~ p ~ Y ~+ 1 ~ r l e \ ,\ ~ `\, t \ ~ \ ~ U ~~ \ arr Z ~ ~ Z O ~ ~, 4g ~ ~ w ~ ~ ` Z W a i . ~ , W _ ._..._ . _- ,, ;:.. t: ~ .a, ~ - - - .. % ~~ _-...._..__...__..... ~i a: I ~;._...._.__..._........._...._ -- i ~_ _ ~~.,,.._ ~ ~r ,_, , .~ ~~ .~ 4`~~ ~ I _..p t ~ ~«~~~Hy~~~~ .. .. -. - ~}a~ ' .. 1 .f. ~ \\ _ _.. j. ~'~ __.. ./ ___- ` - '- ~,,, __ _...... ~ _. ~ e Q p / \ i~/~_r'' .r ~~~,~ Y ~ ~a ~~ /~ ~ o ...~a i~q,4. ~ ~44. ~~ ~ ~~~~4 I ~~ ~d ~~ ~ ~;+~ ~ ~ K . //, .'/~ / .' r'~ ,/ r- / ~ ~"~ G j.•~ a CS:tiGCt~:rL'CRi43Ci~'SPLL`~~ UTl.""~~.,S"~"~'~ ~S E85 404/401 PCN EXHIBIT 18 224 Fayetteville Street Suite 400 - SPANGLER P-O. Box 387 ~ ~maokw~rnu, nec. Raleigh, NC 27602-0387 919-546-0754 919 546-0757 Fax Q ~ ~ ~ z~ ~ ~ ~~ a \ ~ ~~~ ~ ~ ~ ~ ~ ye ~ \ «~` \ ~~`~\ ~ ~ •*`- ~~4,`~ti ~:~ e ~, «`~ ~~ , ~~ :`.S~T.:r".rL~?iTi~3ST ~~.L:+3t~^.~5~"l1.~~. .~ ©~®® ~~ - o = •~ ~' r ~`. bi4~MN 0-i~ cw.. ii~s~ +t+ ~~ ~~ //' - ~Sti~~~ -~ '~ ~~ `~4 .,~ ~ ~~~ ~ _~ ~~ . O U `~L ~ \ Cn ~ ~ *~,. Z O ~, U Y3 W ~ ~ \ ^ ~ `~w ~ O ~ ... Z 8 '1.\ I Z ~ ~ ~ ~ ~ 3~ . Q CZ W tl = „ py~. W ~ 7~ ~'~ '~ w ~a~~3 ` $ ` '~S ~F \,9 /` r S' ~~ n y f n / ~., /~ / -, ,--=- - - ~ - ~ ~ E85 404/401 PCN EXHIBIT 19 // ~~ 224 Fayetteville Street Suite 400 SPANGLER P-O. Box 387 Ear~~, qac. Raleigh, NC 27602-0387 w .a. rv~ ~+.... r... w ~ru 919 546-0754 919-546-0757 Far W ~~ Q ~~ ~~ / '_~j; // ~ / E$5 404/401 PCN EXHIBIT 20 __ _. _ SP~~,E~ 224 Fayetteville Street Suite 400 P.O. Box 387 Raleigh, NC 27602-0387 91 X546-0754 9I A-S46-07S7 Fez Cm ~ z YA ~~ ~~ ryey" ~~i 4 :~- ~ k' ~~ i • Z ~ ~~. w~ic.~ ~ ~ \ • °s~ a``4 a\ ~°~ \ "0 'i~ "/~ .~ `' `~ //..° 1 i~ a • 3~•~~ ~ ~~ .~ ,~~ ~ °~ U ~ ` ~ e Z ~ ~+ g~ w ~ ~ ~~~ ~ ir ~ L`i ~ \ ` O 8 Z ~~\ ~ ~ z ~ ~ ~ . .`\ Z ~~ ~~ W i `` i \ J W 2. ~~ ~' ~ I ~ ~g~~ ~ ~ *r.'t~~-,f d• ~ ~~~1 r'° 9'~ ~ ~~ fa •,~ a / .. ~ J ~ e ~~ `~~~ ~ fi ~ i ~ I " --1 * ~ • ! \ ~a ~ s± ~ ~B ~ y 7 [~ ~r C~ ~® ~~ ~ R~ E ', C v ~s~ r ~`` • ~~L `` } W ~. ~ v+a `/ /~ - - ,/ ~--~~- j ; - ~ E 85 404/401 PCN EXHIBIT 21 224 Fayetteville Sheet Suite 400 SPANGLER p•~• Box 387 ~- ~,~~ Raleigh, NC 27602-0387 ,. ~..,w~.,.,,..,. 919-546-0754 4l9-Sd6-0757 Fmc E85 404/401 PCN EXHIBIT 22 ~~~ ter.'"` ::rz~~~ N~DENR. North Carolina Department of Environment and Natural Resources DIVISION OF AIR QUALITY Michael F. Easley, Governor February 5, 2007 Mr. Mark Dassel Senior Vice President E85, Inc. PO Box 560 Kingston, WA 98346 Subject: Air Permit No. 09722R00 E85, Inc. Fayetteville, Cumberland County, North Carolina Fee Class: Synthetic Minor Site Number: 06/26/00221 Dear Mr. Dassel: William G. Ross Jr., Secretary B. Keith Overcash, P.E., Director In accordance with your completed application received December 4, 2006 and additional information received January 24, 2007, we are forwarding herewith Permit No. 09722R00 to E85, Inc., Fayetteville, Cumberland County, North Carolina for the construction and operation of air emissions sources or air cleaning devices and appurtenances. Additionally, any emissions activities determined from your air permit application as meeting the exemption requirements contained in 15A NCAC 2Q .0102 or 15A NCAC 2Q .0503 have been listed for information purposes as an "ATTACHMENT" to the enclosed air permit. Please note the records retention requirements are contained in General Condition 2 of the General Conditions and Limitations. If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have the right to request a formal adjudicatory hearing within 30 days following receipt of this permit, identifying the specific issues to be contested. Such a request will stay the effectiveness of the entire permit. This hearing request must be in the form of a written petition, conforming to G.S. 150B-23 of the North Carolina General Statutes, and filed with the Office of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714. The form for requesting a formal adjudicatory hearing maybe obtained upon request from the Office of Administrative Hearings. Unless a request for a hearing is made pursuant to G.S. 150B-23, this air permit shall be final and binding. You may request modification of your air permit through informal means pursuant to G.S. 150B-22. This request must be submitted in writing to the Director and must identify the specific Fayetteville Regional Office flue Systel Building, 225 Green Street, Suite 714, Fayetteville, North Carolina 28301-5094 NorthCarc~lina Phone: (910) 433-3300 /FAX: (910) 485-7467 /Internet: www.ncair.org ~~~~N~ J/~ An Equal Opportunity /Affirmative Action Employer - 50% Recycled / 10% Post Consumer Paper f " Mark Dassel February 5, 2007 Page 2 provisions or issues for which the modification is sought. Please note that the permit will become final and binding regardless of a request for informal modification unless a request for a hearing is also made under G.S. 150B-23. Unless exempted by a condition of this permit or the regulations, construction of new air pollution sources or air cleaning devices, or modifications to the sources or air cleaning devices described in this permit must be covered under a permit issued by the Division of Air Quality prior to construction. Failure to do so is a violation of G.S. 143-215.108 and may subject the Permittee to civil or criminal penalties as described in G.S. 143-215.114A and 143- 215.114B. This permit shall be effective from February 5, 2007 until January 31, 2009, is nontransferable to future owners and operators, and shall be subject to the conditions and limitations as specified therein. The Permittee is responsible for carefully reading the entire permit and evaluating .the requirements of each permit stipulation. The Permittee shall comply with all terms, conditions, requirements, limitations and restrictions set forth in this permit. Noncompliance with any permit condition is grounds for enforcement action, for permit termination, revocation and reissuance, or modification, or for denial of a permit renewal application. Should you have any questions concerning this matter, please contact Christy Richardson at (910) 433-3377. Sincerely, /~ Steven Vozzo Regional Air Quality Supervisor CTR Enclosures Central Files Fayetteville Regional Office Permit No. 09722R00 Page 2 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIItONMENT AND NATURAL RESOURCES DIVISION OF A1R QUALITY AIR PERMIT NO. 09722R00 Issue Date: February 5, 2007 Expiration Date: January 31, 2009 Effective Date: February 5, 2007 Replaces Permit: (new) To construct and operate air emission source(s) and/or air cleaning device(s), and for the discharge of the associated air contaminants into the atmosphere in accordance with -the provisions of Article 21 B of Chapter 143, General Statutes of North Carolina (NCGS) as amended, and other applicable Laws, Rules and Regulations, E85, Inc. 557 Bethune Drive Fayetteville, Cumberland County, North Carolina Fee Class: Synthetic Minor Site Number: 06/26/00221 (the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenances described below: Emission Emission Source ~ Control Control System 'Source ID Description ;System ID Description ;Raw Material Receiving and Storage ES-1201 Rail Receiving CD-1203 Baghouse (Size To $e Determined) (NSPS) (unloading pit with 2-wall enclosure) ES-1202 Truck Receiving (with 2-wall enclosure) CD-1204 Baghouse (Size To Be Determined) (NSPS) _ _ _ . ES-1205 _ Grain Bin Feed #1 CD-1205 . Baghouse (Size To Be Determined) (NSPS) (Size To Be Determined) ES-1206 Grain Bin Feed #2 CD-1206 Baghouse (Size To Be Determined) (NSP ) ze o e eterm ne ( ) ES-1207 Grain Bin Feed #3 (NSPS) (Size To Be Determined) ES-1208 Scalper /Surge Bin (NSPS} Si T B D i d S CD-1207 Baghouse {Size To Be Determined) CD-1208 Baghouse (Size To Be Determined) Permit No. 09722R00 Page 3 ...._ ___.._ Emission _______. _~ __.. _._.___ _ _._ __... _ .___ ... _ . Emission Source _ _. _. _.__.- -- Control -. - -.---- _ ..._..__--_- _ -._ y__ _. _.. _.._ .._. Control S stem :Source ID Description ~ System ID Description .Ethanol P rocessing __ .._ __ ' CD-1302 ~ Hammermills Discharge Baghouse ES-1300 Four (4) Grain Hammermills " ~ (Stze To Be Determined) (maximum capacity of 35 tons per hour each) Hammermills Baghouse CD-1301 (Size To Be Determined) Fermentation Process CD-1401 __ Pre Fermentation Scrubber ES-1400 (maximum 115,000,000 gallons per year- ; . ._. _. (Size To Be Determined) ____..__._ _____._.. __..____._. denatured) CD-1402 ~ Main Fermentation Scrubber (Size To Be Determined) -- ES-1500 Distillation /Dehydration Process (maximum CD-1501 ' Distillation Scrubber 115,000,000 gallons per year -denatured) (Size To Be Determined) !Distillers Dried Grain Solubles (DDGS) Processing, Storage, and Loadout ES-1600 Evaporation Process N/A N/A ES-1700 " Stillage Decanting N/A j N/A Two (2) Natural Gas-Fired Swiss Combi DDGS ES-1800 Dryers (64 mmBTU/hr each) with low NOX CD-1800 Integrated Thermal Oxidizer burners and integrated thermal oxidizer ES-1851 Dry DDGS Storage Silo CD-1851 Baghouse (Size To Be Determined) ES-1852 Dry DDGS Transfer to Loadout ; CD-1852 _.. _.. Baghouse (Size To Be Determined) __ ES-1853 __..... g __ _ ___... Wet DDGS Stora e and Loadout _. N/A _ .._.._. __. _. ___._ _ N/A Product and Denaturant Storage ES-2800 Ethanol Shift Tank #1(200,000 gallons capacity, __ N/A __ N/A (NSPS) 200 proof, internal floating roof) ~ ES-2900 'Ethanol Shift Tank #2 (200,000 gallons capacity, N/A N/A (NSPS) 200 proof, internal floating roof) ES-3000 Denaturant Gasoline Tank (250,000 gallons N/A N/A , (NSPS) capacity, internal floating roof) ES-3100 :Product Storage Tank #1 (1,600,000 gallons, 200 N/A N/A (NSPS) proof, internal floating roof) ES-3200 Product Storage Tank #2 (1,600,000 gallons, 200 N/A N/A (NSPS) proof, internal floating roof) ES-2150 Truck and Rail Product Loadout with Flare CD-2151 ~ Natural Gas-Fired Flare (2.75 mmBTU/hr maximum capacity) - __ Power House _ ES-2201 Natural Gas-Fired Boiler with ultra-low NOx N/A N/A (NSPS) ;burners (146.5 mmBTU/hr maximum heat input) , ES-2202 Natural Gas-Fired Boiler with ultra-low NO, N/A N/A (NSPS) .burners (146.5 mn-BTU/hr maximum heat input) ES-2500 No. 2 Fuel Oil-Fired Generator N/A N/A (4,500 kW maximum capacity) Permit No. 09722R00 Page 4 Emission . Emission Source Control Control System :Source ID ~ Description i System ID Description _. _ _ _____ ;Fugitive Emissions ES-LDAR Fugitive Emission from Equipment Leaks N/A ~ N/A i _ ~. ES-Roads Fugitive Emissions from Plant Roads and Parking ; N/A N/A Areas ..Wastewater Treatment ES-2400 ~ Biomethanator and Flare CD-2401 Methane Flare (5.42 mmBTU/hr maximum capacity) in accordance with the completed application 2600221.06A received December 4, 2006, and additional information received January 24, 2007, including any plans, specifications, previous applications, and other supporting data, all of which are filed with the Department of Environment and Natural Resources, Division of Air Quality (DAQ) and are incorporated as part of this permit. This permit is subject to the following specified conditions and limitations including any TESTING, REPORTING. OR MONITORING REQUIREMENTS: A. SPECIFIC CONDITIONS AND LIMITATIONS 1. Any air emission sources or control devices authorized to construct and operate above must be operated and maintained in accordance with the provisions contained herein. The Permittee shall comply with applicable Environmental Management Commission Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0503, 2D .0515, 2D .0516, 2D .0521, 2D .0524 (40 CFR 60, Subpart Kb, Subpart Db, Subpart DD, Subpart VV), 2D .0535, 2D .0605, 2D .0958, 2D .1100, 2D .1806, 2D .2100, 2Q .0304, 2Q .0315, 2Q .0317 {Avoidance) and 2Q .0711. 2. EMISSION INVENTORY REQUIREMENT - At least 90 days prior to the expiration date of this permit, the Permittee shall submit the air pollution emission inventory report in accordance with 15A NCAC 2D .0202, pursuant to N.C. General Statute 143 215.65. The report shall be submitted to the Regional Supervisor, DAQ. The report shall document air pollutants emitted for the 2006 calendar year. The Regional Office will send information on how to submit the emissions inventory, along with a reminder to renew your permit, about six months prior to your permit expiration. If you do not receive this information, please contact the Regional Supervisor, DAQ. 3. PARTICULATE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0503 "Particulates from Fuel Burning Indirect Heat Exchangers," particulate matter emissions from the fuel burning indirect heat exchangers shall not exceed the allowable emission rates listed below: Source Emission Limit (lbs/million Btu) Natural Gas-Fired Boiler (ES-2201) 0.25 Natural Gas-Fired Boiler (ES-2202) 0.25 Permit No. 09722R00 Page 5 4. PARTICULATE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the emission sources shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .OS 15, a function of the process weight rate and shall be determined by the following equation(s), where P is the process throughput rate in tons per hour (tons/hr) and E is the allowable emission rate in pounds per hour (lbs/hr). E = 4.10 * (P) 0'67 for P <= 30 tons/hr, or E = 55 * (P) °'" - 40 for P >30 tons/hr SULFUR DIOXIDE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the combustion sources shall not exceed 2.3 pounds per million Btu heat input. 6. VISIBLE EMISSIONS CONTROL REQUIREMENT - As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over asix-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein. 7. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" -For the Natural Gas-Fired Boilers (ID Nos. ES-2201 & ES-2202), the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524 "New Source Performance Standards" (NSPS) as referenced in 40 CFR 60, Subpart Db, (Standards for Performance for Industrial-Commercial-Institutional a. NSPS Reporting Requirements - In addition'to any other notification requirements to the Environmental Protection Agency (EPA), the Permittee is required to NOTIFY the Regional Supervisor, DAQ, in WRITING, of the following: The date construction (40 CFR 60.7) or reconstruction (40 CFR 60.15) of an affected source is commenced, postmarked no later than 30 days after such date. This requirement shall not' apply in the case ofmass-produced facilities which are purchased in completed form; ii. The actual date of initial start-up of an affected source, postmarked within 15 days after such date; and iii. Prior to initial startup of the affected facilities, the Permittee must submit the following, in writing to the Regional Supervisor, DAQ: 1. The category (high heat release rate or low heat release rate) as defined in 60.41b which describes the affected sources; and ~- Permit No. 09722R00 Page 6 2. The monitoring requirements option as outlined in 60.48b, which the Permittee has elected to conduct. iv. Within 30 days after each six-month period of the calendar year, the Permittee must submit, in writing to the Regional Supervisor, DAQ, excess emission reports for any excess emissions, which occurred during the reporting period. Excess emission is defined as "any calculated 30-day rolling average nitrogen oxides emission rate, as determined under 60.46b(e), which exceeds the applicable emission limits in 60.44b. b. NSPS Emissions Limitations - As required by 15A NCAC 2D .0524, the following emission limits shall not be exceeded: Affected Source(s) Pollutant Emission Limit _. _ _.. O. l O lbs/mmBTU ` Natural Gas-Fired Boilers NOx (for boilers with low heat release rate) _. _ ES-2201 & ES-2202 ( ) 0.20 lbs/mmBTU (for boilers with high heat release rate) i. The emissions rates are determined on a 30-day rolling average basis. ii. The applicable NOx standards apply at all times including periods of startup shutdown, or malfunction. c. NSPS Performance Testing - As required by 15A NCAC 2D .0524, the following performance tests shall be conducted: To detennine compliance with the emission limits for nitrogen oxides required under 60.44b, the owner of operator of an affected facility shall conduct the performance test as required under 60.8 using the continuous system for monitoring nitrogen oxides under 60.48(b). For the initial compliance test, nitrogen oxides from the steam generating units are monitored for 30 successive steam generating unit operating days and the 30-day average emission rate is used to determine compliance with the nitrogen oxide emission standards. The 30-day average is calculated as the average of all hourly emissions data recorded by the monitoring system during the 30-day test period. i. All performance tests shall be conducted in accordance with EPA Reference Methods, contained in 40 CFR 60, Appendix A. ii. The EPA Administrator retains the exclusive right to approve equivalent and alternative test methods, continuous monitoring procedures, and reporting requirements. iii. Within 60 days after achieving the maximum production rate at which the equipment will be operated, but not later than 180 days after the initial start- up of the equipment, the Permittee shall conduct the required performance Permit No. 09722R00 Page 7 test(s) and submit two copies of a written report of the test(s) to the Regional Supervisor, DAQ. iv. The Permittee shall be responsible for ensuring, within the limits of practicality, that the equipment or process being tested is operated at or near its maximum normal production rate or at a lesser rate if specified by the Director or his delegate. v. All associated testing costs are the responsibility of the Permittee d. NSPS Recordkeeping_Requirements -The Permittee shall maintain records of the following information for each steam generating unit operating day: i. Calendar date; ii. The average hourly nitrogen oxides emission rates (expressed as NOZ) (ng/J or lb/mmBTU heat input) measured or predicted; iii. The 30-day average, nitrogen oxides emission rates (ng/J or lb/mmBTU heat input) calculated at the end of each steam generating unit operating day from the measured or predicted hourly nitrogen oxide emission rates for the preceding 30 steam generating unit operating days; iv. Identification of the steam generating unit operating days when the calculated 30-day average nitrogen oxides emission rates are in excess of the nitrogen oxides emissions standards under 60.44b, with the reasons for such excess emissions as well as a description of corrective actions taken; v. Identification of the steam generating unit operating days for which pollutant data have not been obtained, including reasons for not obtaining sufficient data and a description of corrective actions taken; vi. Identification of the times when emission data have been excluded from the calculation of average emission rates and the reasons for excluding data; vii. Identification of "F" factor used for calculations, method of determination, and type of fuel combusted; viii. Identification of the times when the pollutant concentration exceeded full span of the continuous monitoring system; ix. Description of any modifications to the continuous monitoring system that could affect the ability of the continuous monitoring system to comply with Performance Specification 2 or 3; x. Results of daily CEMS drift tests and quarterly accuracy assessments as required under appendix F, Procedure 1; and xi. All records must be maintained for a minimum of two years. - Permit No. 09722R00 Page 8 e. NSPS Monitoring Requirements -The Permittee shall Comply with the provisions of 60.48b (b), (c), (d), (e}(2), (e)(3), and (f) by installing, calibrating, maintaining, and operating a continuous monitoring system to record nitrogen oxides emission rates; OR ii. Monitor steam generating unit operating conditions and predict nitrogen oxides emission rates as specified in a plan submitted pursuant to 60.49b(c). The plan shall be submitted for approval within 360 days of initial startup of the affected facility. 8. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" -For the affected facility equipment (raw material receiving and storage), the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524 "New Source Performance Standards" (NSPS) as referenced in 40 CFR 60, Subpart DD, (Standards for Performance for Grain Elevators), and including Subpart A "General Provisions." a. NSPS Reporting Requirements - In addition to any other notification requirements to the Environmental Protection Agency (EPA), the Permittee is required to NOTIFY the Regional Supervisor, DAQ, in WRITING, of the following: i. The date construction (40 CFR 60.7) of an affected source is commenced, postmarked no later than 30 days after such date; and ii. The actual date of initial start-up of an affected source, postmarked within 15 days after such date. b. NSPS Emissions Limitations - As required by 15A NCAC 2D .0524, the following emission limits shall not be exceeded: __ _ _... Affected Source(s) Pollutant Emission Limit _. _ _ _ Rail Receiving (ES-1201) __ _ Truck Receiving (ES-1202) Grain Bin Feed #1 (ES-1205) PM < 0.01 gr/dscf _ _ PM & Opacity & 0% opacity Grain Bin Feed #2 (ES-1206) __ __ Grain Bin Feed #3 (ES-1207) ,- Scalper /Surge Bin (ES-1208) Permit No. 09722R00 Page 9 c. NSPS Performance Testing - As required by 1 SA NCAC 2D .OS24, the following performance tests shall be conducted: Affected Source(s) Pollutant Test Method Rail Receiving (ES-1201) __ __ Truck Receiving (ES-1202); ___ . Method S, Grain Bin Feed #1 (ES-1205) _.... __ _. i PM & Opacity i, Method 2, & Grain Bin Feed #2 (ES-1206) Method 9 Grain Bin Feed #3 (ES-1207) Scalper /Surge Bin (ES-1208) i. All performance tests shall be conducted in accordance with EPA Reference Methods, contained in 40 CFR 60, Appendix A. ii. The EPA Administrator retains the exclusive right to approve equivalent and alternative test methods, continuous monitoring procedures, and reporting requirements. iii. Within 60 days after achieving the maximum production rate at which the equipment will be operated, but not later than 180 days after the initial start- up of the equipment, the Permittee shall conduct the required performance test(s) and submit two copies of a written report of the test(s) to the Regional Supervisor, DAQ. iv. The Permittee shall be responsible for ensuring, within the limits of practicality, that the equipment or process being tested is operated at or near its maximum normal production rate or at a lesser rate if specified by the Director or his delegate. v. All associated testing costs are the responsibility of the Permittee. 9. 1SA NCAC 2D .OS24 "NEW SOURCE PERFORMANCE STANDARDS" -For the affected facility equipment, the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and monitoring requirements contained in Environmental Management Commission Standard 1SA NCAC 2D .OS24, "New Source Performance Standards" (NSPS) as referenced in 40 CFR 60, Subpart VV, (Standards for Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals Manufacturing Industry) including Subpart A "General Provisions." a. NSPS Reportin~_Requirements i. The Permittee is required to NOTIFY the Regional Supervisor, DAQ, the date construction (40 CFR 60.7) or reconstruction (40 CFR 60.1 S) of an affected source is commenced, postmarked no later than 30 days after such date. This requirement shall not apply in the case ofmass-produced facilities which are purchased in completed form; Permit No. 09722R00 Page 10 ii. The Permittee is required to NOTIFY the Regional Supervisor, DAQ, the actual date of initial start-up of an affected source, postmarked within 15 days after such date; iii. The Permittee shall submit semiannual reports to the Regional Supervisor, DAQ beginning six months after the initial startup date. The initial semiannual report to the Administrator shall include the following information in addition to that required for all other semiannual reports: A. process unit identification. B. number of valves subject to the requirements of 40 CFR 60.482-7, excluding those valves designated for no detectable emissions under the provisions of 40 CFR 60.482-7(f). C. number of pumps subject,to the requirements of 40 CFR 60.482-2, excluding those pumps designated for no detectable emissions under the provisions of 40 CFR 60.482-2(e) and those pumps complying with 40 CFR 60.482-2(f). D. number of compressors subject to the requirements of 40 CFR 60.482-3, excluding those compressors designated for no detectable emissions under the provisions of 40 CFR 60.482-3(i) and those compressors complying with 40 CFR 60.482-3(h). All semiannual reports to the Regional Supervisor, DAQ shall include the following information, summarized from the information in 40 CFR 60.486: A. process unit identification. B. For each month during the semiannual reporting period, I. number of valves for which leaks were detected as described in 40 CFR 60.482-7, II. number of valves for which leaks were not repaired as described in 60.482-7 and 60.482-9, III. number of pumps for which leaks were detected as described in 40 CFR 60.482-2, IV. number of pumps for which leaks were not repaired described in 40 CFR 60.482-2 and 40 CFR 60.482-9, V. number of compressors for which leaks were detected as described in 40 CFR 60.482-3, Permit No. 09722R00 Page 11 VI. number of compressors for which leaks were not repaired described in 40 CFR 60.482-3 and 40 CFR 60.482-9, and VII. the facts that explain each delay of repair and, where appropriate, why a process unit shutdown was technically infeasible. C. Dates of process unit shutdowns, which occurred within the semiannual reporting period. D. If the Permittee chooses to comply with the provisions of 40 CFR 60.483-1 or 60.483-2 as an alternative standard, the Permittee shall notify the Regional Supervisor, DAQ of the alternative standard selected 90 days before implementing either of the provisions. E. Revisions to items reported in the initial semiannual report if changes have occurred since the initial report or subsequent revisions to the initial report. iv. The Permittee shall report the results of all performance tests in accordance with 40 CFR 60.8 of the General Provisions. The provisions of 40 CFR 60.8(d} do not apply to affected facilities subject to the provisions of this subpart except that an owner or operator must notify the Regional Supervisor, DAQ of the schedule for the initial performance tests at least 30 days before the initial performance tests. b. NSPS Recordkeeping_Requirements i. When each leak is detected as specified in 40 CFR 60.482-2, 60.482-3, 60.482-7, and 60.482-8, the following requirements apply: A. A weatherproof and readily visible identification, marked with the equipment identification number, shall be attached to the leaking equipment. B. The identification on a valve may be removed after it has been monitored for 2 successive months as specified in 40 CFR 60.482-7 and no leak has been detected during those 2 months. C. The identification on equipment except on a valve, maybe removed after it has been repaired. ii. When each leak is detected as specified in 40 CFR 60.482-2, 60.482-3, 60.482-7, and 60.482-8, the following information shall be recorded in a log and shall be kept for 2 years in a readily accessible location: A. the instrument and operator identification numbers and the equipment identification number, Permit No. 09722R00 Page 12 B. the date the leak was detected and the dates of each attempt to repair the leak, C. repair methods applied in each attempt to repair the leak, D. "Above 10,000" if the maximum instrument reading measured by the methods specified in 40 CFR 60.485 after each repair attempt is equal to or greater than 10,000 ppm, E. "Repair delayed" and the reason for the delay if a leak is not repaired within 15 calendar days after discovery of the leak, F. the signature of the owner or operator (or designate) whose decision it was that repair could not be effected without a process shutdown. G. the expected date of successful repair of the leak if a leak is not repaired within 15 days, H. dates of process unit shutdowns that occur while the equipment is unrepaired, and I. the date of successful repair of the leak. iii. The following information pertaining to the design requirements for closed vent systems and control devices described in 40 CFR 60.482-10 shall be recorded and kept in a readily accessible location: A. detailed schematics, design specifications, and piping and instrumentation diagrams, B. the dates and descriptions of any changes in the design specifications, C. a description of the parameter or parameters monitored, as required in 40 CFR 60.482-10(e), to ensure that control devices are operated and maintained in conformance with their design and an explanation of why that parameter (or parameters) was selected for the monitoring, D. Periods when the closed vent systems and control devices required in 40 CFR 60.482-2, 60.482-3, 60.482-4, and 60.482-5 are not operated as designed, including periods when a flare pilot light does not have a flame, and E. dates of startups and shutdowns of the closed vent systems and control devices required 40 CFR 60.482-2, 60.482-3, 60.482-4, and 60.482-5. Permit No. 09722R00 Page 13 iv. The following information pertaining to all equipment subject to the requirements in 40 CFR 60.482-1 to 60.482-10 shall be recorded in a log that is kept in a readily accessible location: A. a list of identification numbers for equipment subject to the requirements of this subpart, B. a list of identification numbers for equipment that are designated for no detectable emissions under the provisions of 40 CFR 60.482-2(e), 60.482-3(i) and 60.482-7(f), C. the designation of equipment as subject to the requirements of 40 CFR 60.482-2(e), 60.482-3(i), or 60.482-7(f) shall be signed by the owner or operator, D. a list of equipment identification numbers for pressure relief devices required to comply with 40 CFR 60.482-4, E. the dates of each compliance test as required in 40 CFR 60.482-2(e), 60.482-3(i), 60.482-4, and 60.482-7(f), F. the background level measured during each compliance test required in 40 CFR 60.482-2(e), 60.482-3(i), 60.482-4, and 60.482-7(f), G. the maximum instrument reading measured at the equipment during each compliance test required in 40 CFR 60.482-2(e), 60.482-3(i), 60.482-4, and 60.482-7(f), and H. a list of identification numbers for equipment in vacuum service. v. The following information pertaining to all valves subject to the requirements of 40 CFR 60.482-7(g) and (h) and to all pumps subject to the requirements of 40 CFR 60.482-2(g) shall be recorded in a log that is kept in a readily accessible location: A. a list of identification numbers for valves and pumps that are designated as unsafe-to-monitor, an explanation for each valve or pump stating why the valve or pump is unsafe-to-monitor, and the plan for monitoring each valve or pump. B. a list of identification numbers for valves that are designated as difficult-to-monitor, an explanation for each valve stating why the valve is difficult-to-monitor, and the schedule for monitoring each valve. vi. The following information shall be recorded in a log that is kept in a readily accessible location: Permit No. 09722R00 Page 14 A. design criterion required in 40 CFR 60.482-2(d)(5) and 60.482- 3(e)(2) and explanation of the design criterion; and B. any changes to this criterion and the reasons for the changes. vii. The following information shall be recorded in a log that is kept in a readily accessible location for use in determining exemptions as provided in 40 CFR 60.480(d): A. An analysis demonstrating that equipment is not in VOC service. vii. Information and data used to demonstrate that a piece of equipment is not in VOC service shall be recorded in a log that is kept in a readily accessible location. viii. The following information shall be recorded for valves complying with 40 CFR 60.483-2: A. schedule of monitoring, and B. the percent of valves found leaking during each monitoring period. c. NSPS Emissions Limitations 40 CFR 60.482-2 Standards: Pumps in light liquid service Each pump in light liquid service shall be monitored monthly to detect leaks by the methods specified in 40 CFR 60.485(b), except as provided in 40 60.482-1(c) and for the following pumps: A. pumps equipped with dual mechanical seal systems that include a barrier fluid system as provided in 40 CFR 60.482-2 (d). Requirements for the dual mechanical seals are: I. Each dual mechanical seal system is operated with the bamer fluid at a pressure that is at all times greater than the pump stuffing box pressure; or each dual mechanical seal system is operated with the barrier fluid at a pressure that is at all times greater than the pump stuffing box pressure; or each dual mechanical seal system is equipment with a barrier fluid degassing reservoir that is routed to a process or fuel gas system or connected by a closed vent system to a control device that complies with the requirements of §60.482-10; or Permit No. 09722R00 Page 15 each dual mechanical seal system is equipped with a system that purges the barrier fluid into a process stream with zero VOC emissions to the atmosphere. II. Each pump is checked by visual inspection, each calendar week, for indications of liquids dripping from the pump seals. III. The barrier fluid system shall be in heavy liquid service or shall not be in VOC service. Each bamer fluid system shall be equipped with a sensor that will detect failure of the seal system, barrier fluid system, or both. The Permittee shall determine, based on design considerations and operating experience, a criterion that indicates failure of the seal system, the barrier fluid system, or both. IV. The sensors shall be checked daily or shall be equipped with an audible alarm. Leaks are detected by the following: Affected Source(s) Pollutant Leak detected Pumps in light liquid service VOC ~ Sensor failure detection based upon established criterion Pumps in light liquid service VOC Liquids dripping from pump seal When a leak is detected, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected, except as provided in 40 CFR 60.482-9. A first attempt at repair shall be made no later than 5 calendar days after each leak is detected. B. pumps designated for no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background, as provided in 40 CFR 60.482-2 (e), C. pumps equipped with a closed vent system capable of capturing and transporting any leakage from the seal or seals to a process or to a fuel gas system or to a control device that complies with the requirements of 40 CFR 60.482-10 Each pump in light liquid service shall be checked by visual inspection each calendar week for indications of liquids dripping from the pump seal. Leaks are detected by the following limits: Affected Source(s) Pollutant Leak detected __ __ _. Pumps in light liquid service VOC 10,000 ppm _-_ Pumps in light liquid service VOC 'Liquids dripping from pump seal Permit No. 09722R00 Page 16 When a leak is detected, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected, except as provided in 40 CFR 60.482-9. A first attempt at repair shall be made no later than 5 calendar days after each leak is detected. Pumps deemed unsafe=to-monitor maybe exempted from monthly monitoring and weekly visual inspections by 40 CFR 482-2 (g). ii. 40 CFR 60.482-3 Standards: Compressors Each compressor shall be equipped with a seal system that includes a bamer fluid system and that prevents leakage of VOC to the atmosphere, except as provided in 40 CFR 60.482-1(c) and for the following compressors: A. compressors equipped with a closed vent systems to capture and transport leakage from the compressor drive shaft back to a process or fuel gas system or to a control device that complies with the requirements of 40 CFR 60.482-10 as provided in 40 CFR 60.482-3 (h)• B. compressors designated for no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background, as provided in 40 CFR 60.483 (i). Each compressor seal system shall be: A. Operated with the barrier fluid at a pressure that is greater than the compressor stuffing box pressure; or B. Equipped with a barrier fluid system degassing reservoir that is routed to a process or fuel gas system or connected by a closed vent system to a control device that complies with the requirements of 40 CFR 60.482-10; or C. Equipped with a system that purges the barrier fluid into a process stream with zero VOC emissions to the atmosphere. The barrier fluid system shall be in heavy liquid service or shall not be in VOC service. Each barrier fluid. system shall be equipped with a sensor that will detect failure of the seal system, barrier fluid system, or both. The Permittee shall determine, based on design considerations and operating experience, a criterion that indicates failure of the seal system, the barrier fluid system, or both. The sensors shall be checked daily or shall be equipped with an audible alarm. Leaks are detected by the following: Permit No. 09722R00 Page 17 Affected Source(s) Pollutant Leak detected Compressors VOC Sensor failure detection based upon established criterion When a leak is detected, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected, except as provided in 40 CFR 60.482-9. A first attempt at repair shall be made no Iater than 5 calendar days after each leak is detected. iii. 40 CFR 60.482-4 Standards: Pressure relief devices in gas/vapor service Except during pressure releases, each pressure relief device in gas/vapor service shall be operated with no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background. After each pressure release, the pressure relief device shall be returned to a condition of no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background, as soon as practicable, but no later than 5 calendar days after the pressure release, except as provided in 40 CFR 60.482-9. No later than 5 calendar days after the pressure release, the pressure relief device shall be monitored to confirm the conditions of no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background. Pressure relief devices meeting the following specifications may be exempted from the above requirements: A. any pressure relief device that is routed to a process or fuel gas system or equipped with a closed vent system capable of capturing and transporting leakage through the pressure relief device to a control device as described in 40 CFR 60.482-10 as provided in 40 CFR 60.482-4(c). B. any pressure relief device that is equipped with a rupture disk upstream of the pressure relief device as provided in 40 CFR 60.482- 4(d). iv. 40 CFR 60.482-5 Standards: Sampling connection systems Each sampling connection system shall be equipped with aclosed-purged, closed-loop, or closed-vent system, except as provided in 40 CFR 60.482-1. Gases displaced during filling of the sample container are not required to be collected or captured. Each closed-purge, closed-loop, or closed-vent system shall: Permit No. 09722R00 Page 18 A. return the purged process fluid directly to the process line; or B. collect and recycle the purged process fluid to a process; or C. be designed and operated to capture and transport all the purged process fluid to a control device that complies with the requirements of 40 CFR 60.482-10; or D. collect, store, and transport the purged process fluid to any of the following systems or facilities: I. A waste management unit as defined in 40 CFR 63.111, if the waste management unit is subject to, and operated in compliance with the provisions of 40 CFR part 63, subpart G, applicable to Group 1 wastewater streams; II. A treatment, storage, or disposal .facility subject to regulation under 40 CFR part 262, 264, 265, or 266; or III. A facility permitted, licensed, or registered by a State to manage municipal or industrial solid waste, if the process fluids are not hazardous waste as defined in 40 CFR part 261. In situ sampling systems and sampling systems without purges are exempt from the above requirements. v. 40 CFR 60.482-6 Standards: Open ended valves or lines Each open-ended valve or line shall be equipped with a cap, blind flange, plug, or a second valve, except as provided in 40 CFR 60.482-1(c). The cap, blind flange, plug, or second valve shall seal the open end at all times except during operations requiring process fluid flow through the open- ended valve or line. Each open-ended valve or line equipped with a second valve shall be operated in a manner such that the valve on the process fluid end is closed before the second valve is closed. When a double block-and-bleed system is being used, the bleed valve or line may remain open during operations that require venting the line between the block valves but shall be equipped with a cap, blind flange, plug, or a second valve at all other times. The following valves and lines are exempt from the above requirements: Permit No. 09722R00 Page 19 A. Open-ended valves or lines in an emergency shutdown system, which are designed to open automatically in the event of a process upset, are exempt from the above requirements. B. Open-ended valves or lines containing materials which would autocatalytically polymerize or would present an explosion, serious overpressure, or other safety hazard if capped or equipped with a double block and bleed system as specified in paragraphs (a) through (c) of this section are exempt from the requirements of paragraphs (a) through (c) of this section. vi. 40 CFR 60.482-7 Standards: Valves in as/vapor service and in light liquid service. Each valve shall be monitored monthly to detect leaks by the methods specified in §60.485(b}. Leaks are detected by the following limit: Affected Source(s) Pollutant Leak detected Valves in gas/vapor service and in VOC 10,000 ppm ; light liquid service. Any valve for which a leak is not detected for 2 successive months maybe monitored the first month of every quarter, beginning with the next quarter, until a leak is detected. If a leak is detected, the valve shall be monitored monthly until a leak is not detected for 2 successive months. When a leak is detected, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected, except as provided in 40 CFR 60.482-9. A first attempt at repair shall be made no later than 5 calendar days after each leak is detected. First attempts at repair include, but are not limited to, the following best practices where practicable: A. tightening of bonnet bolts; B. replacement of bonnet bolts; C. tightening of packing gland nuts; and D. injection of lubricant into lubricated packing. The following valves may be exempted from the above requirements: A. Valves designated for no detectable emissions, as indicated by an instrument reading of less than 500 ppm above background, maybe exempted from the above requirements as provided in 40 CFR 60.482-7(fl. Permit No. 09722R00 Page 20 B. Valves designated as an unsafe-to-monitor maybe exempted from the above requirements as provided in 40 CFR 60.482-7(g). The Permittee may elect to use one of the alternative standard for valves, 40 CFR 60.483-1 or 40 CFR 60.483.2. If so, the Permittee shall notify the Regional Supervisor, DAQ of the alternative standard selected 90 days before implementing either of the provisions. vii. 40 CFR 60.482-8 Standards: Pumps and valves in heavy liquid service pressure relief devices in li t liquid or heavy liquid service and connectors If evidence of a potential leak is found by visual, audible, olfactory, or any other detection method at pumps and valves in heavy liquid service, pressure relief devices in light liquid or heavy liquid service, and connectors, the Permittee shall follow either one of the following procedures: A. The Permittee shall monitor the equipment within 5 days by the method specified in §60.485(b). Leaks are detected by the following limit: ___-- _ ._ Affected Source(s) Pollutant Leak detected Pumps and valves in heavy liquid service, pressure relief devices in light liquid or heavy VOC + l 0,000 ppm liquid service, and connectors When a leak is detected, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected, except as provided in 40 CFR 60.482-9. A first attempt at repair shall be made no later than 5 calendar days after each leak is detected. First attempts at repair include, but are not limited to, the following best practices where practicable: I. tightening of bonnet bolts; II. replacement of bonnet bolts; III. tightening of packing gland nuts; and IV. injection of lubricant into lubricated packing. B. The Permittee shall eliminate the visual, audible, olfactory, or other indication of a potential leak. viii. 40 CFR 60.482-9 Standards: Deli of repair ~, Permit No. 09722R00 Page 21 Delay of repair of equipment for which leaks have been detected will be allowed if repair within 15 days is technically infeasible without a process unit shutdown. Repair of this equipment shall occur before the end of the next process unit shutdown. Delay of repair beyond a process unit shutdown will be allowed for a valve, if valve assembly replacement is necessary during the process unit shutdown, valve assembly supplies have been depleted, and valve assembly supplies had been sufficiently stocked before the supplies were depleted. Delay of repair beyond the next process unit shutdown will not be allowed unless the next process unit shutdown occurs sooner than 6 months after the first process unit shutdown. Delay of repair of equipment will be allowed for equipment which is isolated from the process and which does not remain in VOC service. .Delay of repair for valves will also be allowed if: A. the Permittee demonstrates that emissions of purged material resulting from immediate repair are greater than the fugitive emissions likely to result from delay of repair, and B. when repair procedures are effected, the purged material is collected and destroyed or recovered in a control device complying with 40 CFR 60.482-10. Delay of repair for pumps will also be allowed if: A. repair requires the use of a dual mechanical seal system that includes a barrier fluid system, and B. repair is completed as soon as practicable, but not later than 6 months after the leak was detected. ix. 40 CFR 60.482-10 Standards: Closed vent systems and control devices Standard for vapor recovery systems: Affected Source(s) 'Pollutant Emission limit Efficiency of 95 percent or greater; or Vapor recovery systems VOC 20 parts per million by volume (whichever is less stringent) Permit No. 09722R00 Page 22 Standard for enclosed combustion devices: Affected Source(s) Pollutant Emission limit _ _ __ .. _ Efficiency of 95 percent or greater; or -20 parts per million by volume, on a dry basis, corrected to 3 percent oxygen; (whichever is less stringent) Enclosed combustion devices . OR VOC i Provide a minimum residence time of 0.75 ''seconds at a minimum temperature of 816 °C. Flares used to comply with this subpart shall comply with the requirements of 40 CFR 60.18. The Permittee shall monitor control devices to ensure that they are operated and maintained in conformance with their designs. Each closed vent system shall be inspected according to the following procedures: A. If the vapor collection system or closed vent system is constructed ofhard-piping, the Permittee shall comply with the following requirements: I. Conduct an initial inspection according to the procedures in 40 CFR 60.485(b); and II. Conduct annual visual inspections for visible, audible, or olfactory indications of leaks. B. If the vapor collection system or closed vent system is constructed of ductwork, the owner or operator shall: I. Conduct an initial inspection according to the procedures in 40 CFR 60.485(b); and II. Conduct annual inspections according to the procedures in 40 CFR 60.485(b). Leaks from the above inspections are indicated by the following limit: Affected Source(s) Pollutant Leak detected Closed vent systems and VOC Instrument reading greater than 500 parts per control devices million by volume above background Pennit No. 09722R00 Page 23 When a leak is detected by instrument reading or visual inspection, it~ shall be repaired not later than 15 calendar days after it is detected. A first attempt at repair shall be made no later than 5 calendar days after each leak is detected. The following vapor collection systems and closed vent systems are exempt from the above inspection requirements: A. If the vapor collection system or closed vent system is operated under a vacuum, it is exempt from the inspection requirements. B. Any parts of the closed vent system that are designated as unsafe to inspect are exempt from the inspection requirements as provided in 40 CFR 60.482-10(j). C. Any parts of the closed vent system that are designated as difficult to inspect are exempt from the inspection requirements as provided in 40 CFR 60.482-10(k). The Permittee shall record the following information: A. Identification of all parts of the closed vent system that are designated as unsafe to inspect, an explanation of why the equipment is unsafe to inspect, and the plan for inspecting the equipment. B. Identification of all parts of the closed vent system that are designated as difficult to inspect, an explanation of why the equipment is difficult to inspect, and the plan for inspecting the equipment. C. For each inspection during which a leak is detected, a record of the information specified in 40 CFR 60.486(c). D. For each inspection conducted in accordance with 40 CFR 60.485(b) during which no leaks are detected, a record that the inspection was performed, the date of the inspection, and a statement that no leaks were detected. E. For each visual inspection conducted for vapor collection systems or closed vent systems constructed ofhard-piping during for which no leaks are detected, a record that the inspection was performed, the date of the inspection, and a statement that no leaks were detected. Closed vent systems and control devices used to comply with provisions of this subpart shall be operated at all times when emissions maybe vented to them. ,. Permit No. 09722R00 Page 24 d. NSPS Performance Testing The Permittee shall comply with the testing procedures in 40 CFR 60.485. i. As required by 60.485(b), The Permittee shall determine compliance with the standards in 40 CFR 60.482, 60.483, and 60.484 as follows: Affected Source(s) 'Pollutant Test method Method 21 Pumps in light liquid service, compressors, and pressure relief devices in gas/vapor service ..._._ _ Calibration gases: VOC ~ Zero air (less than 10 ppm of hydrocarbon in air); and a mixture of methane or n-hexane and air at a concentration of about, but less than, 10,000 ppm methane or n-hexane. ii. As required by 60.485(c), the Permittee shall determine compliance with the ~., no detectable emission standards in 40 CFR 60.482-2(e), 60.482-3(i), , 60.482-4, 60.482-7(f), and 60.482-10(e) as follows: Affected Source(s) Pollutant ~ Test method _. ' ~ Method 21 Pumps in light liquid service, compressors, pressure relief devices in gas/vapor service, valves in gas/vapor service and in light liquid service, closed vent systems and control devices VOC Calibration gases: Zero air (less than 10 ppm of hydrocarbon in air); and a mixture of methane or n-hexane and air at a concentration of about, but less than, 10,000 ppm methane or n-hexane. Method 21 shall be used to determine the background level. All potential leak interfaces shall be traversed as close to the interface as possible. The arithmetic difference between the maximum concentration indicated by the instrument and the background level is compared with 500 ppm for determining compliance. iii. The Permittee shall test each piece of equipment unless he demonstrates that a process unit is not in VOC service, i.e., that the VOC content would never be reasonably expected to exceed 10 percent by weight. The methods of 40 CFR 60.485(d) shall be used to demonstrate this. Permit No. 09722R00 Page 25 iv. The Permittee shall demonstrate that equipment is in light liquid service by showing that all the following conditions apply: A. The vapor pressure of one or more of the components is greater than 0.3 kPa at 20 °C (1.2 in. H2O at 68 °F). Standard reference texts or ASTM D2879-83, 96, or 97 {incorporated by reference-see 40 CFR 60.17) shall be used to determine the vapor pressures. B. The total concentration of the pure components having a vapor pressure greater than 0.3 kPa at 20 °C (1.2 in. H2O at 68 °F) is equal to or greater than 20 percent by weight. C. The fluid is a liquid at operating conditions. v. The Permittee shall determine compliance with the standards of flares by the procedures listed in 40 CFR 60.485(g) vi. Samples used in conjunction with Conditions A.9.d.iii, iv, and v shall be representative of the process fluid that is contained in or contacts the equipment or the gas being combusted in the flare. 10. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" -For the following equipment, The Permittee shall comply with all applicable provisions, including the notification, testing, reporting, recordkeeping, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524 for NSPS as promulgated in 40 CFR 60, Subpart Kb (Standards of Performance for Volatile Organic Liquid Storage Vessels), indicated below, and including Subpart A "General Provisions." The following tanks are equipped with internal floating roofs: Tank ID No. 'Tank Description __ ES-2800 ethanol shift tank (200,000 gallons capacity) ES-2900 ethanol shift tank (200,000 gallons capacity) ES-3000 ,denaturant gasoline tank (250,000 gallons capacity) _ __ ES-3100 'product storage tank #1 (1,600,000 gallons capacity) i.. ........ ... .. _. _. ES-3200 :product storage tank #Z (1,600,000 gallons capacity} a. NSPS Reporting_Requirements - In addition to any other notification requirements to the Environmental Protection Agency (EPA), the Penmittee is required to NOTIFY the Regional Supervisor, DAQ, in WRITING, of the following: i. The date construction (40 CFR 60.7) or reconstruction (40 CFR 60.15) of an affected source is commenced, postmazked no later than 30 days after such date. This requirement shall not apply in the case ofmass-produced facilities which are purchased in completed form; Permit No. 09722R00 Page 26 ii. The actual date of initial start-up of an affected source, postmarked within 15 days after such date; iii. As an attachment to the actual date of start-up report, a report that describes the control equipment and certifies that the control equipment meets the specifications of 40 CFR 60.112b(a)(1) and 40 CFR 60.113b(a)(1) (see emissions limitations and testing requirements below). iv. If any of the conditions described in 40 CFR 60.113b(a)(2) are detected during the annual visual inspection required by 40 CFR 60.113b(a)(2), a report shall be furnished to the Regional Supervisor, DAQ within 30 days of the inspection. Each report shall identify the storage vessel, the nature of the defects, and the date the storage vessel was emptied or the nature of and date the repair was made (see testing requirements below). v. After each inspection required by 40 CFR 60.113b(a)(3) that finds holes or tears in the seal or seal fabric, or defects in the internal floating roof, or other control equipment defects listed in 40 CFR 60.113b(a)(3)(ii), areport shall be furnished to the Regional Supervisor, DAQ within 30 days of the inspection. The report shall identify the storage vessel and the reason it did not meet the specifications of 40 CFR 60.112b(a)(1) or §60.113b(a)(3) and list each repair made (see emissions limitations and testing requirements below). b. NSPS Recordkeeping Requirements i. The Permittee shall keep a record of each inspection performed as required by 40 CFR 60.113b (a)(1), (a)(2), (a)(3), and (a)(4). Each record shall identify the storage vessel on which the inspection was performed and shall contain the date the vessel was inspected and the observed condition of each component of the control equipment (seals, internal floating roof, and fittings). These records shall be kept for a minimum of two years. (see testing requirements below). ii. The Permittee keep readily accessible records showing the dimensions of the facility storage vessel and an analysis showing the capacity of the storage vessel for the life of each source. iii. For each storage vessel, a record of the VOL stored, the period of storage, and the maximum true vapor pressure of that VOL during the respective storage period shall be maintained. These records shall be kept for a minimum of two years. c. NSPS Emissions Limitations -The facility storage vessels, will all have design capacities greater than or equal to 151 m 3 and each will contain a VOL that, as stored, has a maximum true vapor pressure equal to or greater than 5.2 kPa but less than 76.6 kPa. Each will be controlled by a fixed roof in combination with an internal floating roof. As required by 40 CFR 60.112b(a)(1): Permit No. 09722R00 Page 27 The internal floating roof shall rest or float on the liquid surface (but not necessarily in complete contact with it) inside a storage vessel that has a fixed roof. The internal floating roof shall be floating on the liquid surface at all times, except during initial fill and during those intervals when the storage vessel is completely emptied or subsequently emptied and ref lied. When the roof is resting on the leg supports, the process of filling, emptying, or refilling shall be continuous and shall be accomplished as rapidly as possible. ii. Each internal floating roof shall be equipped with one of the following closure devices between the wall of the storage vessel and the edge of the internal floating roof: A. A foam- or liquid-filled seal mounted in contact with the liquid (liquid-mounted seal). Aliquid-mounted seal means afoam- or liquid-filled seal mounted in contact with the liquid between the wall of the storage vessel and the floating roof continuously around the circumference of the tank. B. Two seals mounted one above the other so that each forms a continuous closure that completely covers the space between the wall of the storage vessel and the edge of the internal floating roof. The lower seal may be vapor-mounted, but both must be continuous. C. A mechanical shoe seal. A mechanical shoe seal is a metal sheet held vertically against the wall of the storage vessel by springs or weighted levers and is connected by braces to the floating roof. A flexible coated fabric (envelope) spans the annular space between the metal sheet and the floating roof. iii. Each opening in a noncontact internal floating roof except for automatic bleeder vents (vacuum breaker vents) and the rim space vents is to provide a projection below the liquid surface. iv. Each opening in the internal floating roof except for leg sleeves, automatic bleeder vents, rim space vents, column wells, ladder wells, sample wells, and stub drains is to be equipped with a cover or lid which is to be maintained in a closed position at all times (i.e., no visible gap) except when the device is in actual use. The cover or lid shall be equipped with a gasket. Covers on each access hatch and automatic gauge float well shall be bolted except when they are in use. v. Automatic bleeder vents shall be equipped with a gasket and are to be closed at all times when the roof is floating except when the roof is being floated off or is being landed on the roof leg supports. vi. Rim space vents shall be equipped with a gasket and are to be set to open only when the internal floating roof is not floating or at the manufacturer's recommended setting. Permit No. 09722R00 Page 28 vii. Each penetration of the internal floating roof for the purpose of sampling shall be a sample well. The sample well shall have a slit fabric cover that covers at least 90 percent of the opening. viii. Each penetration of the internal floating roof that allows for passage of a column supporting the fixed roof shall have a flexible fabric sleeve seal or a gasketed sliding cover. ix. Each penetration of the internal floating roof that allows for passage of a ladder shall have a gasketed sliding cover. d. NSPS Performance Testing -After installing the permanently affixed roof and internal floating roof on each facility tank, the Permittee shall: As required by 40 CFR 60.113b(a)(1), visually inspect the internal floating roof, the primary seal, and the secondary seal (if one is in service), prior to filling the storage vessel with VOL. If there are holes, tears, or other openings in the primary seal, the secondary seal, or the seal fabric or defects in the internal floating roof, or both, the owner or operator shall repair the items before filling the storage vessel. ii. As required by 40 CFR 60.113b(a)(2), for Vessels equipped with aliquid- mounted or mechanical shoe primary seal, visually inspect the internal floating roof and the primary seal or the secondary seal (if one is in service) through manholes and roof hatches on the fixed roof at least once every 12 months after initial fill. If the internal floating roof is not resting on the surface of the VOL inside the storage vessel, or there is liquid accumulated on the roof, or the seal is detached, or there are holes or tears in the seal fabric, the owner or operator shall repair the items or empty and remove the storage vessel from service within 45 days. If a failure that is detected during inspections required in this paragraph cannot be repaired within 45 days and if the vessel cannot be emptied within 45 days, a 30-day extension maybe requested from the Regional Supervisor, DAQ, in the inspection report required in 40 CFR 60.115b(a)(3). Such a request for an extension must document that alternate storage capacity is unavailable and specify a schedule of actions the company will take that will assure that the control equipment will be repaired or the vessel will be emptied as soon as possible. iii. As required by 40 CFR 60.113b(a)(3), for vessels equipped with adouble- seal system: A. Visually inspect the vessel as specified in Condition A.1 O.d.iv of this Permit at least every 5 years; or B. Visually inspect the vessel as specified in Condition A.1 O.d.ii of this Permit. Permit No. 09722R00 Page 29 iv. As required by 40 CFR 60.113b(a)(4), visually inspect the internal floating roof, the primary seal, the secondary seal (if one is in service), gaskets, slotted membranes and sleeve seals (if any) each time the storage vessel is emptied and degassed. If the internal floating roof has defects, the primary seal has holes, tears, or other openings in the seal or the seal fabric, or the secondary seal has holes, tears, or other openings in the seal or the seal fabric, or the gaskets no longer close off the liquid surfaces from the atmosphere, or the slotted membrane has more than 10 percent open area, the Permittee shall repair the items as necessary so that none of the circumstances specified in this Condition exist before refilling the storage vessel with VOL. In no event shall inspections conducted in accordance with this provision occur at intervals greater than 10 years in the case of vessels conducting the annual visual inspection as specified in Conditions A.1 O.d.ii and A.1 O.d.iii.B. of this Permit and at intervals no greater than 5 years in the case of vessels specified in Condition A.10.d.ii.A of this Permit. v. As required by 40 CFR 60.113b(a)(5), Notify the Regional Supervisor, DAQ, in writing at least 30 days prior to the filling or refilling of each storage vessel for which an inspection is required above to afford the DAQ the opportunity to have an observer present. If the inspection required by Condition A.1 O.d.iv of this section is not planned and the Permittee could not have known about the inspection 30 days in advance or refilling the tank, the Permittee shall notify the Regional Supervisor, DAQ at least 7 days prior to the refilling of the storage vessel. Notification shall be made by telephone immediately followed by written documentation demonstrating why the inspection was unplanned. Alternatively, this notification including the written documentation maybe made in writing and sent by express mail so that it is received by the Regional Supervisor, DAQ, at least 7 days prior to the refilling. 1 l .NOTIFICATION REQUIREMENT - As required by 15A NCAC 2D .0535, the Permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall: a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence and describe: i. the name and location of the facility, ii. the nature and cause of the malfunction or breakdown, iii. the time when the malfunction or breakdown is first observed, iv. the expected duration, and v. an estimated rate of emissions. Permit No. 09722R00 Page 30 b. Notify the Director or his designee immediately when the corrective measures have been accomplished. This reporting requirement does not allow the operation of the facility in excess of Environmental Management Commission Regulations. 12. TESTING REQUIREMENT -Under the provisions of North Carolina General Statute 143- 215.108 and in accordance with 15A NCAC 2D .0605, the Permittee shall demonstrate compliance with the emission limit(s) by testing the emission source(s) for the specified pollutant(s) as follows: _ Affected Source(s) .... .. .__ _._ 'Pollutant Emission Limit ~ Test Method __. _ atural Gas-Fired Boiler (ES-2201) _ NOX 0.011 lbs/mmBTU , _ Natural Gas-Fired Boiler (ES-2202) _. : NOX 0.011 Ibs/mmBTU Two (2) Natural Gas-Fired Swiss _ __ _ __ Combi DDGS Dryers (ES-1800) ._ . _. _ _ NOX 15.91bs/hr ';DAQ Approved Methods Natural Gas-Fired Boiler (ES-2201) _ ... _ _ CO _.... ' 0.0221bs/mmBTU Natural Gas-Fired Boiler (ES-2202) CO ~ 0.022 lbs/mmBTU a. At least 45 days prior to performing any required emissions testing, the Permittee must submit a testing protocol to the Regional Supervisor, DAQ for review and approval. All testing- protocols must be approved by the DAQ prior to performing such tests. b. To afford the Regional Supervisor, DAQ, the opportunity to have an observer present, the Permittee shall PROVIDE the Regional Office, in WRITING, at least 15 days notice of any required performance test(s). c. The test results must be submitted to the Regional Supervisor, DAQ, in accordance with the approved procedures of the Environmental Management Commission within 180 days of the initial operation date. d. This permit maybe revoked, with proper notice to the Permittee, or enforcement procedures initiated, if the results of the test(s) indicate that the facility does not meet applicable limitations. e. The source shall be responsible for ensuring, within the limits of practicality, that the equipment or process being tested is operated at or near its maximum normal production rate, or at a lesser rate if specified by the Director or his delegate. f. All associated testing costs are the responsibility of the Permittee. 13. WORK PRACTICES REQUIREMENTS - As required by 15A NCAC 2D .0958(c) "Work Practices for Sources of Volatile Organic Compounds," the Perrnittee shall adhere to the following required work practices: r Permit No. 09722R00 Page 31 a. The Permittee shall store all VOC-containing material not in use (including waste material) in containers covered with a tightly fitting lid that is free of cracks, holes, or other defects. b. The Permittee shall clean up spills as soon as possible following proper safety procedures. c. The Permittee shall store wipe rags in closed containers. d. The Permittee shall not clean sponges, fabric, wood, paper products, and other absorbent materials. e. The Permittee shall drain solvents used to clean supply lines and other coating equipment into closable containers and close containers immediately after each use. f. The Permittee shall clean mixing, blending, and manufacturing vats and containers by adding cleaning solvent, closing the vat or container before agitating the cleaning solvent. g. The Permittee shall pour spent cleaning solvent into closable containers and close containers immediately after each use. 14. TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND REPORTING REQUIREMENT -Pursuant to 15A NCAC 2D .1100 "Control of Toxic Air Pollutants," and in accordance with the approved application for an air toxic compliance demonstration, the following permit limits shall not be exceeded: Affected Source(s) Toxic Air Pollutant Emission Limit Two (2) Natural Gas-Fired Swiss Combi 3.38 ]b/yr DDGS Dryers (ES-1800) Denaturant Gasoline Tank (ES-3000) ~ Benzene (71-43-2) 21.45 lbs/yr Truck and Rail Product Loadout with Flare 0.68 ]bs/yr (ES-2150) _ _ __ __ _ __ _ Two (2) Natural Gas-Fired Swiss Combi 'Formaldehyde (50-00-0) ' 0.47 lbs/hr DDGS Dryers (ES-1800) a. Restrictions -The Permittee shall at all times properly operate, inspect, and maintain the control devices, as specified in Specific Condition 18, to ensure compliance with the above toxic air pollutant limits. This data must be reevaluated if the removal efficiencies listed in Specific Condition 18 cannot be achieved. 15. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS - As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions" the Permittee shall not operate the facility without implementing management practices or installing and operating odor control equipment sufficient to prevent odorous emissions from the facility from causing or contributing to objectionable odors beyond the facility's boundary. Permit No. 09722R00 Page 32 16.40 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 68.150 or as specified in 40 CFR 68.10. 17. ZONING SPECIFIC CONDITION -Prior to construction or operation of the facility under this permit, the Permittee shall comply with all lawfully adopted local ordinances that apply to the facility at the time of construction or operation of the facility. The local zoning authority shall have the responsibility of enforcing all lawfully adopted local zoning or subdivision ordinances. 18. LIMITATION TO AVOID 15A NCAC 2Q .0501 -Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities," to avoid the applicability of 15A NCAC 2Q .0501 "Purpose of Section and Requirement for a Permit," as requested by the Permittee, facility-wide emissions shall be less than the following: Pollutant Emission Limit ;(Tons per consecutive 12-month period); PM10 100 VOC 100 CO __ _ . 100 Individual HAPs __ 10 Total HAPs __ 25 a. Operations Restrictions - To ensure emissions do not exceed the limitations above, the following restrictions shall apply: i. the Permittee shall properly operate, inspect, and maintain the control devices at all times and ii. the Permittee shall conduct source testing as specified in this condition and in specific condition no. 12. b. Inspection and Maintenance Requirements - i. Bagfilter Requirements -Particulate matter emissions shall be controlled as described in the permitted equipment list. To comply with the provisions of this permit and ensure that emissions do not exceed the regulated limits, the Permittee shall perform periodic inspections and maintenance (I&M) as recommended by the manufacturer. In addition, the Permittee shall perform an annual internal inspection of each bagfilter system. ii. Scrubber Requirements -Particulate matter emissions shall be controlled as described in the permitted equipment list. To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits, the Permittee shall perform periodic inspections and maintenance (I&M) as Permit No. 09722R00 Page 33 recommended by the manufacturer. In addition, the Permittee shall perform an annual internal inspection of each scrubber system. As a minimum, the I&M program and each annual inspection should include the following: 1. inspection of spray nozzles, packing material, chemical feed system (if so equipped), and the cleaning/calibration of all associated instrumentation annually. 2. two weeks following initial start-up and startup following major maintenance of each scrubber, the Permittee shall shut down the system and inspect for nozzle plugging and settling of the packing. iii. Thermal Oxidizer Requirements -Emissions shall be controlled as described in the permitted equipment. list. To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits, the Permittee shall perform periodic inspections and maintenance (I&M) as recommended by the manufacturer. As a minimum, the Permittee shall perform an annual internal inspection of each primary heat exchanger and associated inlet/outlet valves to ensure. structural integrity. iii. Flare System Requirements -The flare system shall be operated at all times when emissions may be vented to it. The presence of the flare pilot flame shall be monitored using a thermocouple or any other equivalent device to detect the presence of a flame. The Permittee shall perform annual inspections of the flare system. In addition, the Permittee shall perform inspections and maintenance periodically as recommended by the manufacturer. c. Monitoring Requirements -Following the submittal of control device specifications to the Regional Supervisor, DAQ, as specified below, monitoring requirements will be included in the air permit. d. Control Device Specification and Testing Requirements - i. Before facility start-up, the Permittee must specify and submit to the Regional Supervisor, DAQ, as a minimum, the following control device parameters and document the validity of these parameters: 1. For Bagfilters: Filter surface area, inlet air flow rate, filter maximum operating temperature, filter material, filter cleaning procedures, method for determining when to clean the filters, and method for determining when to replace bags. 2. For Scrubbers: Pressure drop, minimum liquid injection rate, percent of liquid recirculated, inlet airflow rate, type of packing, and inlet gas temperature. Permit No. 09722R00 Page 34 3. For Flares: Inlet airflow rate, combustion temperature, and residence time. ii. As required by 15A NCAC 2Q .0112, the control device technical information to include design, determination of applicability and appropriateness, and determination and interpretation of performance must be sealed by a professional engineer registered in North Carolina, except as exempted under 15A NCAC 2Q .0112(c). The Permittee must submit this information to the Regional Supervisor, DAQ, before facility start-up. iii Affected Source(s) Under the provisions of North Carolina General Statute 143-215.108 and in accordance with 15A NCAC 2D .0605, the Permittee shall perform and submit to the Regional Supervisor, DAQ, the results of stack tests of the following emission sources and associated control devices to ensure compliance with the emissions limits listed below and to compare the removal efficiencies (capture efficiencies X control efficiencies) achieved with those listed below: .. _ ___ Facility-wide Control Device(s) Removal ,Test Methods ' Emission Limit(s) Efficiency _. Pre-Fermentation Scrubber ' VOC >_ 99.37% ; SingO HAPO< 0 PY (CD-1401) HAPs>_ 99.37% Total HAP < 25 TPY Main Fermentation Scrubber VOC >_ 99.5% (CD-1402) 'HAPs >_ 99.5% Fermentation Process (ES-1400) Distillation /Dehydration Process VOC < 100 TPY Distillation Scrubber VOC ? 99.67% DAQ Approved (ES-1500) Single HAP < 10 TPY (CD-1501) !HAPs >_ 99.67% Methods Total HAP < 25 TPY PM-10 < 100 TPY PM-10 > 90% Two (2) Natural Gas-Fired Swiss ' CO < 100 TPY Integrated Thermal Oxidizer CO > 90% Combi DDGS Dryers (ES-1800) VOC < 100 TPY (CD-1800) VOC> 95% Single HAP < 10 TPY ' HAPs ? 95% Total HAP < 25 TPY 1. If any emission rates or removal efficiencies achieved during the stack testing indicate emission rates that are higher than those listed in the initial application, the Pennittee must recalculate facility-wide emissions using the rates obtained in the stack tests and include the results and conclusions with the stack test results. 2. In the event that the facility cannot meet the limits specified above, the Permittee will take immediate steps to reduce emissions below major source thresholds, including, but not limited to, adding additional control systems or reducing production capacity. Failure to demonstrate facility-wide emissions of less than 100 tons per year for VOC and/or less than 10 tons per year for acetaldehyde will require the Permittee to submit an application for an Air Permit under the requirements of 15A NCAC 2Q .0500, "Title V Procedures." Failure to demonstrate PTE of less than 100 tons per year for VOC will require the Permittee to submit an application for an Air Permit under the requirements of 15A NCAC 2D .0530, "Prevention of Significant ~, Permit No. 09722R00 Page 35 Deterioration." Also, failure to demonstrate PTE of less than 100 tons per year for VOC and/or less than 10 tons per year for acetaldehyde will be considered a violation for operating without a proper Air Permit. 3. All source testing shall meet the following requirements: a. At least 45 days prior to performing any required emissions testing, the Permittee must submit a testing protocol to the Regional Supervisor, DAQ, for review and approval. All testing protocols must be approved by DAQ prior to performing such tests. b. To afford the Regional Supervisor, DAQ, the opportunity to have an observer present, the Permittee shall PROVIDE the Regional Office, in WRITING, at least 15 days notice of any required performance test(s). c. The test results must be submitted to the Regional Supervisor, DAQ, in accordance with the approved procedures of the Environmental Management Commission within 180 days of initial operation date. If the facility is not operating at greater than 90% capacity at the time of the initial test, the facility must perform a second test when the facility is at more than 90% production capacity. d. This permit maybe revoked, with proper notice to the Permittee, or enforcement procedure initiated, if the results of the tests indicate that the facility does not meet applicable limitations e. The source shall be responsible for ensuring, within the limits of practicality, that the equipment or process being tested is operated at or near its maximum normal production rate, or at a lesser rate if specified by the Director or his delegate. f. All associated testing costs are the responsibility of the Permittee. e. Recordkeeping Requirements i. The Permittee shall record monthly and total annually the following: 1. particulate matter (PM-10) emissions, carbon monoxide (CO) emissions, volatile organic compounds (VOC) emissions, acetaldehyde (single highest HAP) emissions, and total HAP emissions Permit No. 09722R00 Page 36 ii. A logbook shall be kept on site for each control device and made available to Division of Air Quality personnel upon request. The Pennittee shall record all inspection, maintenance and monitoring requirements listed above in the logbook. Any variance from the manufacturer's recommendations shall be investigated with corrections made and date of actions recorded in the logbook. f. Reporting Requirements -Within 30 days after each calendar year quarter, regardless of the actual emissions, the Permittee shall submit the following: emissions and/or operational data listed below. The data should include monthly and 12 month totals for the previous 14 months. The data must be calculated for each of the three 12 month periods over the previous 14 months. A. particulate matter (PM-10) emissions, carbon monoxide (CO) emissions, volatile organic compounds (VOC) emissions, acetaldehyde (single highest HAP} emissions, and total HAP emissions. ii. summary of all control device monitoring and recordkeeping activities described above for the previous 3 months. 19. LIMITATION TO AVOID 15A NCAC 2D .0530 "PREVENTION OF SIGNIFICANT DETERIORATION" - In accordance with 15A NCAC 2Q .0317, to comply with this permit and avoid the applicability of 15A NCAC 2D .0530 "Prevention of Significant Deterioration," as requested by the Permittee, emissions shall be limited as follows: Affected Source(s) Pollutant Emission Limit (Tons Per Consecutive 12-month Period) __ _ _ _ ___ Facility Wide VOC 100 a. Operations Restrictions - To ensure emissions do not exceed the limitations above, the facility shall comply with the Operations Requirements listed in Specific Permit Condition no. 18, "Limitation to Avoid 15A NCAC 2Q .0501." b. Recordkee~ng and Reporting Requirements -The Permittee shall comply with the Recordkeeping and Reporting Requirements listed in Specific Permit Condition no. 18, "Limitation to Avoid 15A NCAC 2Q .0501." 20. LIMITATION TO AVOID 15A NCAC_ 2D .1111 "MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY" - To comply with this permit and avoid the applicability of 15A NCAC 2D .1111 "Maximum Achievable Control Technology," as requested by the Permittee, facility-wide individual hazardous air pollutant (HAP) emissions shall be less than 10 tons per consecutive 12-month period, and facility-wide total HAP emissions shall be less than 25 tons per consecutive 12-month period. The Permittee shall be deemed in a Permit No. 09722R00 Page 37 noncompliance with this condition and 15A NCAC 2D .1111 if the HAP emissions exceed this limit. a. The synthetic minor requirements for HAPs specified above in Specific Condition no. 18 shall satisfy the requirements for MACT avoidance. b. The Permittee shall properly operate, inspect, and maintain the control devices as specified above in Specific Condition no. 18. 21. TOXIC AIR POLLUTANT EMISSIONS LIMITATION REQUIREMENT -Pursuant to 15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," for each of the below listed toxic air pollutants (TAPS), the Permittee has made a demonstration that facility-wide actual emissions do not exceed the Toxic Permit Emission Rates (TPERs) listed in 15A NCAC 2Q .0711. The facility shall be operated and maintained in such a manner that emissions of any listed TAPS from the facility, including fugitive emissions, will not exceed TPERs listed in 15A NCAC 2Q .0711. a. A permit to emit any of the below`listed TAPS shall be required for this facility if actual emissions from all sources -will become greater than the corresponding TPERs. b. PRIOR to exceeding any of these listed TPERs, the Permittee shall be responsible for obtaining a permit to emit TAPS and for demonstrating compliance with the requirements of 15A NCAC 2D .1100 "Control of Toxic Air Pollutants". c. In accordance with the approved application, the Permittee shall maintain records of operational information demonstrating that the TAP emissions do not exceed the TPERs as listed below: Chronic Acute Systemic ~ Acute Pollutant :Toxicants Toxicants Irritants (Ib/day) (Ib/hr) (Ib/hr) Acetaldehyde (75-07-0) ' 6.8 Acetic acid (64-19-7) 0.96 Ammonia (as NH3) (7664-41-7} ~ ~Q Dichlorobenzene(p), 1,4- (106-46-7) _ _... _ _ Ethyl acetate (141-78-6) ___ Manganese & compounds (MNC) ___ _ Toluene (108-88-3) _ _ _. Xylene (1330-20-7) r Permit No. 09722R00 Page 38 22. Equipment Specifications Reporting - a. Prior to startup of the facility, the Permittee shall submit the following to the Regional Supervisor, DAQ, in writing: 1. Equipment specifications and updated permit application forms for all applicable emission sources and control devices; and 2. Manufacturer guarantees for NOX and CO emissions on both boilers (ID Nos. ES-2201 & ES-2202). b. Prior to installation, the Permittee shall submit the following to the Regional Supervisor, DAQ, in writing: 1. Equipment specifications for the No. 2 fuel oil-fired emergency generator (ID No. ES-2500) and fire pump (ID No. IES-2505) so that a determination can be made on the applicability of NSPS Subpart IIII (Stationary Compression Ignition Internal Combustion Engines). ~ ~ . 23. Operational Limitation for NOx -The Permittee has claimed the integral equipment selected, and configured, will result in facility-wide NOX emissions below 100 tons per year. Equipment shall meet the following limitations: Affected Source(s) Pollutant Emission Limit Natural Gas-Fired Boiler (ES-2201) NOX ~ 0.011 lbs/mmBTU _.._ __ . Natural Gas-Fired Boiler (ES-2202) ; NOX :0.011 Ibs/mmBTU Two (2) Natural Gas-Fired Swiss NOX 15.91bs/hr Combi DDGS Dryers (ES-1800) To ensure emissions do not exceed the limitations above, the Permittee shall: a. Maintain manufacturer's emission rate guarantees; b. Conduct on-site testing as specified in Stipulation 12; and c. Maintain documentation on-site to verify types of burners tested above. Permit No. 09722R00 Page 39 B. GENERAL CONDITIONS AND LIMITATIONS 1. TWO COPIES OF ALL DOCUMENTS REPORTS TEST DATA MONITORING DATA NOTIFICATIONS, REQUESTS FOR RENEWAL AND ANY OTHER INFORMATION REQUIRED BY THIS PERMIT shall be submitted to the: Regional Air Quality Supervisor North Carolina Division of Air Quality Fayetteville Regional Office Systel Building 225 Green Street, Suite 714 Fayetteville, NC 28301-5094 (910) 433-3300 2. RECORDS RETENTION REQUIREMENT -Any records required by the conditions of this permit shall be kept on site and made available to DAQ personnel for inspection upon request. These records shall be maintained in a form suitable and readily available for expeditious inspection and review. These records must be kept on site for a minimum of 2 years, unless another time period is otherwise specified. 3. PERMIT RENEWAL REQUIREMENT -The Permittee, at least 90 days prior to the expiration date of this permit, shall request permit renewal by letter in accordance with 15A NCAC 2Q .0304(d) and (f}. Pursuant to 15A NCAC 2Q .0203(1), no permit application fee is required for renewal of an existing air permit. The renewal request should be submitted to the Regional Supervisor, DAQ. 4. ANNUAL FEE PAYMENT -Pursuant to 15A NCAC 2Q .0203(a), the Permittee shall pay the annual permit fee within 30 days of being billed by the DAQ. Failure to pay the fee in a timely manner will cause the DAQ to initiate action to revoke the permit. 5. EQUII'MENT RELOCATION -Anew air permit shall be obtained by the Permittee prior to establishing, building, erecting, using, or operating the emission sources or air cleaning equipment at a site or location not specified in this permit. 6. This permit is subject to revocation or modification by the DAQ upon a determination that information contained in the application or presented in the support thereof is incorrect, conditions under which this permit was granted have changed, or violations of conditions contained in this permit have occurred. The facility shall be properly operated and maintained at all times in a manner that will effect an overall reduction in air pollution. Unless otherwise specified by this permit, no emission source maybe operated without the concurrent operation of its associated air cleaning device(s) and appurtenances. 7. REPORTING REQUIREMENT - Any of the following that would result in previously unpermitted, new, or increased emissions must be reported to the Regional Supervisor, DAQ: a. changes in the information submitted in the application regarding facility emissions; b. changes that modify equipment or processes of existing permitted facilities; or Permit No. 09722R00 Page 40 c. changes in the quantity or quality of materials processed. If appropriate, modifications to the permit may then be made by the DAQ to reflect any necessary changes in the permit conditions. In no case are any new or increased emissions allowed that will cause a violation of the emission limitations specified herein. 8. This permit is nontransferable by the Permittee. Future owners and operators must obtain a new air permit from the DAQ. 9. This issuance of this permit in no way absolves the Permittee of liability for any potential civil penalties which may be assessed for violations of State law which have occurred prior to the effective date of this permit. 10. This permit does not relieve the Permittee of the responsibility of complying with all applicable requirements of any Federal, State, or Local water quality or land quality control authority. 11. Reports on the operation and maintenance of the facility shall be submitted by the Permittee to the Regional Supervisor, DAQ at such,intervals and in-such form and detail as maybe required by the DAQ. Information required in such reports may include, but is not limited to, process weight rates, firing rates, hours of operation, and preventive maintenance schedules. 12. A violation of any term or condition of this permit shall subject the Permittee to enforcement pursuant to G.S. 143-215.114A, 143-215.114B, and 143-215.114C, including assessment of civil and/or criminal penalties. 13. Pursuant to North Carolina General Statute 143-215.3(a)(2), no person shall refuse entry or access to any authorized representative of the DAQ who requests entry or access for purposes of inspection, and who presents appropriate credentials, nor shall any person obstruct, hamper, or interfere with any such representative while in the process of carrying out his official duties. Refusal of entry or access may constitute grounds for permit revocation and assessment of civil penalties. 14. The Permittee must comply with any applicable Federal, State, or Local requirements governing the handling, disposal, or incineration of hazardous, solid, or medical wastes, including the Resource Conservation and Recovery Act (RCRA) administered by the Division of Waste Management. 15. PERMIT RETENTION REQUIREMENT -The Permittee shall retain a current copy of the air permit at the site. The Permittee must make available to personnel of the DAQ, upon request, the current copy of the air permit for the site. lb. CLEAN AIR ACT SECTION 112(r) RE ~UIR.EMENTS -Pursuant to 40 CFR Part 68 Accidental Release Prevention Requirements: Risk Management Programs Under the Clean Air Act, Section 11 Z(r)," if the Permittee is required to develop and register a risk management plan pursuant to Section 112(r) of the Federal Clean Air Act, then the Permittee is required to register this plan in accordance with 40 CFR Part 68. Permit No. 09722R00 Page 41 17. PREVENTION OF ACCIDENTAL RELEASES -GENERAL DUTY -Pursuant to Title I Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants -Prevention of Accidental Releases -Purpose and General Duty," although a risk management plan may not be required, if the Permittee produces, processes, handles, or stores any amount of a listed hazardous substance, the Permittee has a general duty to take such steps as are necessary to prevent the accidental release of such substance and to minimize the consequences of any release. This condition is federally enforceable only. Permit issued this the 5`h of February 2007. NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Regional Air Quality Supervisor By Authority of the Environmental Management Commission Air Permit No. 09722R00 i r ~ Y ATTACHMENT to Permit No. 09722R00, February 5, 2007 Insignificant /Exempt Activities Date of 'Exemption ;Source :Source of Source ;Application Regulation iof TAPS? Title V _ _ _ ;Pollutants?' IES 2505 -Fire Purnp 2Q 0102 (maximum capacity to be determined) 12/04/2006 ; (c)(2)(E)(i) No No IES-2300 -Cooling Tower 12/04/2006 2Q '0102 Yes Yes (c)(2)(E)(i) ___ __ __ 1. Because an activity is exempted from being required to have a permit or permit modification does not mean that the activity is exempted from an applicable requirement or that the owner or operator of the source is exempted from demonstrating compliance with any applicable requirement. 2. When applicable, emissions from stationary source activities identified above shall be included in determining compliance with the permit requirements for toxic air pollutants under 15A NCAC 2D .1100 "Control of Toxic Air Pollutants" or 2Q .0711 "Emission Rates Requiring a Permit."