[38 Pa.B. 3670]
[Saturday, July 5, 2008]
[Continued from previous Web Page]
AIR QUALITY
PLAN APPROVAL AND OPERATING PERMIT APPLICATIONS
NEW SOURCES AND MODIFICATIONS The Department of Environmental Protection (Department) has developed an ''integrated'' plan approval, State operating permit and Title V operating permit program. This integrated approach is designed to make the permitting process more efficient for the Department, the regulated community and the public. This approach allows the owner or operator of a facility to complete and submit all the permitting documents relevant to its application one time, affords an opportunity for public input and provides for sequential issuance of the necessary permits.
The Department has received applications for plan approvals and/or operating permits from the following facilities.
Copies of the applications, subsequently prepared draft permits, review summaries and other support materials are available for review in the regional office identified in this notice. Persons interested in reviewing the application files should contact the appropriate regional office to schedule an appointment.
Persons wishing to receive a copy of a proposed plan approval or operating permit must indicate their interest to the Department regional office within 30 days of the date of this notice and must file protests or comments on a proposed plan approval or operating permit within 30 days of the Department providing a copy of the proposed document to that person or within 30 days of its publication in the Pennsylvania Bulletin, whichever comes first. Interested persons may also request that a hearing be held concerning the proposed plan approval and operating permit. Comments or protests filed with the Department regional offices must include a concise statement of the objections to the issuance of the Plan approval or operating permit and relevant facts which serve as the basis for the objections. If the Department schedules a hearing, a notice will be published in the Pennsylvania Bulletin at least 30 days prior the date of the hearing.
Persons with a disability who wish to comment and require an auxiliary aid, service or other accommodation to participate should contact the regional office identified before the application. TDD users should contact the Department through the Pennsylvania AT&T Relay Service at (800) 654-5984. Final plan approvals and operating permits will contain terms and conditions to ensure that the source is constructed and operating in compliance with applicable requirements in 25 Pa. Code Chapters 121--143, the Federal Clean Air Act (act) and regulations adopted under the act.
PLAN APPROVALS
Plan Approval Application Received under the Air Pollution Control Act (35 P. S. §§ 4001--4015) and 25 Pa. Code Chapter 127, Subchapter B that may have special public interest. These applications are in review and no decision on disposition has been reached.
Northwest Region: Air Quality Program, 230 Chestnut Street, Meadville, PA 16335-3481, George Monasky, New Source Review Chief, (814) 332-6940.
25-025M: GE Transportation (2901 East Lake Road, Erie, PA 16351) for modification of three existing engine test cells and the construction of three new engine test cells in Lawrence Park Township, Erie County. This is a Title V facility.
Intent to Issue Plan Approvals and Intent to Issue or Amend Operating Permits under the Air Pollution Control Act (35 P. S. §§ 4001--4015) and 25 Pa. Code Chapter 127, Subchapter B. These actions may include the administrative amendments of an associated operating permit.
Southeast Region: Air Quality Program, 2 East Main Street, Norristown, PA 19401, Sachin Shankar, New Source Review Chief, (484) 250-5920.
23-0109A: Catalyst International, Inc. (1050 Ashland Avenue, Folcroft, PA 19032) for incorporation of Standards of Performance for New Stationary Sources (NSPS) for existing laminating operation at an existing facility at 1050 Ashland Avenue, Folcroft, PA 19032, Folcroft Borough, Delaware County. The Plan Approval will contain the requirements of 40 CFR Part 60, Subpart FFF--Standards of Performance for Flexible Vinyl and Urethane Coating and Printing. The Plan Approval will contain additional monitoring, recordkeeping, reporting and operating restrictions designed to keep the facility operating within all applicable air quality requirements including the NSPS.
09-0205: Jenbrooke Properties, Inc. (6120 Easton Road, Plumsteadville, PA 18947) for installation of a new scrap wood-fired boiler and associated new multiclone at their facility in Plumstead Township, Bucks County. The facility is a non-Title V facility.
The boiler is being installed to provide comfort heat to the facility as well as to consume scrap wood generated by the office furniture manufacturing operation at the facility. The multiclone is being installed to minimize PM emissions from the boiler. The boiler and multiclone will meet all applicable air quality requirements, including the BAT requirements of 25 Pa. Code §§ 127.1 and 127.12. The potentials to emit CO, NOx, PM, SOx and VOCs are 0.07, 5.91, 0.80, 2.17 and 0.02 tpy, respectively. The plan approval will include monitoring, recordkeeping, reporting and work practice requirements designed to keep the facility operating within all applicable air quality requirements.
23-0049: PPL Interstate Energy Co. (1111 Ridge Road, Linwood, PA 19061) for reactivation of three existing mainline fuel heaters at their Marcus Hook pump station facility in Lower Chichester Township, Delaware County. The facility is a non-Title V facility.
The mainline fuel heaters are currently permitted under State-only Operating Permit No. 23-00049. However, a plan approval is required to reactivate the mainline fuel heaters since they have each been out of operation for more than 1 year without a maintenance plan, under 25 Pa. Code § 127.11a.
Based on the existing combined fuel usage restriction for the mainline fuel heaters in the State-only Operating Permit, the potentials to emit SOx and NOx will not exceed the major facility thresholds of 100 and 25 tpy, respectively. The plan approval will contain monitoring, recordkeeping, reporting and work practice requirements designed to keep the facility operating within all applicable air quality requirements, including the BAT requirements of 25 Pa. Code §§ 127.1 and 127.12.
Northeast Region: Air Quality Program, 2 Public Square, Wilkes-Barre, PA 18711-0790, Ray Kempa, New Source Review Chief, (570) 826-2531.
35-318-094: Gentex Optics, Inc. (P. O. Box 336, Carbondale, PA 18407) for installation of a Regenerative Thermal Oxidizer (RTO) at their facility in Fell Township, Lackawanna County. The VOC emissions from the facility, (including Gentex Corporation) will remain unchanged, never to equal or exceed 50 tpy of VOC, based on a 12-month rolling sum as stated in the company's Title V Permit. The HAPs from the facility (including Gentex Corporation) must never equal or exceed 10 tpy of any single HAP and must never equal or exceed 25 tpy of all aggregated HAPs, based on a 12-month rolling sum. The company has proposed no other changes. Gentex Optics is a major facility subject to Title V permitting requirements. The company currently has a Title V Permit 35-00008. The Operating Permit will include testing, monitoring, recordkeeping and reporting requirements designed to keep the sources operating within all applicable air quality requirements. The Plan Approval will, in accordance with 25 Pa. Code § 127.450, be incorporated into the Title V Operating Permit through an administrative amendment at a later date. For further details, contact Mark J. Wejkszner at (570) 826-2511 within 30 days after publication date.
Southcentral Region: Air Quality Program, 909 Elmerton Avenue, Harrisburg, PA 17110, William R. Weaver, New Source Review Chief, (717) 705-4702.
06-05066F: Exide Technologies (P. O. Box 13995, Reading, PA 19612-3995) for installation of a replacement thermal oxidizer to control emissions from the No. 2 secondary lead smelting system at their Reading Smelter in Laureldale Borough and Muhlenberg Township, Berks County. The new oxidizer will replace an existing oxidizer. The oxidizers are used to control emissions of VOCs and CO emitted from the blast furnace and reverberatory furnace associated with system No. 2. The furnaces are subject to 40 CFR Part 52, Subpart A, Prevention of Significant Deterioration; Part 60, Subpart L, Performance Standards for New Stationary Sources; and Part 63, Subpart X, National Emission Standards for HAPs from Secondary Lead Smelters. The plan approval will include monitoring, work practices, recordkeeping and reporting requirements designed to keep the source and control device operating within all applicable air quality requirements. The facility is presently covered by the Title V operating permit No. 06-05066. The plan approval will be incorporated into this permit in accordance with 25 Pa. Code § 127.450 (Administrative Amendment).
Northcentral Region: Air Quality Program, 208 West Third Street, Williamsport, PA 17701, David Aldenderfer, Program Manager. (570) 327-3637.
17-00063B: Bionol Clearfield, LLC (2 Batterymarch Park, Suite 301, Quincy, MA 02169) for the construction and operation of a 115.5 mmGal/yr dry mill ethanol manufacturing facility at a site located at the Clearfield Tech Park in Clearfield Borough, Clearfield County. On September 14, 2007, the Department of Environmental Protection (Department) issued plan approval 17-00063A to Bionol for the construction and operation of a 108 mmGal/yr ethanol production facility. The current plan approval application is for essentially the same proposed facility. However, due to design changes, the Department must re-evaluate the newly proposed design for compliance with all applicable requirements. The ethanol manufacturing facility consists of corn receiving and storage, corn milling, corn processing and fermentation, distillation and purification, stillage separation, distillers dried grain with solubles (DDGS) dryers, DDGS storage and loadout, ethanol loadout, two natural-gas fired boilers, two emergency diesel-fired engines, eight tanks storing VOC containing material, and a cooling tower.
The NOx and CO emissions from the natural gas fired boilers will be controlled by ultra-low NOx burners and good combustion practices. The PM/PM10 emissions from the corn receiving and storage, corn milling, and DDGS storage and loadout will each be controlled by one of the three fabric collectors, respectively. The VOC and HAP emissions from the ethanol production sources will be controlled by a packed-bed water scrubber and three regenerative thermal oxidizers (RTOs). The VOC and HAP emissions from the tanks storing VOC and HAP containing materials will be controlled by internal floating roofs with primary and secondary tank seals. The VOC and HAPs emissions from the ethanol railcar and truck loading operations will be controlled by a ventura burner oxidizer (VBO). Combustion emissions, including CO, total PM/PM10, VOCs and HAPs, from the DDGS dryers will be controlled by the RTOs. The ethanol manufacturing facility will be considered as a State-only facility.
The Department's review of the information provided by Bionol Clearfield, Inc. indicates that the sources at the facility will comply with all air quality requirements, including the BAT requirements of 25 Pa. Code §§ 127.1 and 127.12; 40 CFR Part 60, Subpart Db, §§ 60.40b through 60.49b; 40 CFR Part 60, Subpart Kb, §§ 60.110b through 60.117b; 40 CFR Part 60, Subpart VVa, §§ 60.480a through 60.489a; 40 CFR Part 60, Subpart IIII, §§ 60.4200 through 60.4219; and 40 CFR Part 63, Subpart ZZZZ, §§ 63.6580 through 63.6675, pertaining to air contamination sources and the emission of air contaminants. Based on this finding, the Department intends to issue a plan approval for the proposed construction and operation of the sources. Additionally, if the Department determines that the proposed sources and the air cleaning devices are operating in compliance with the plan approval conditions, the conditions established in the plan approval will be incorporated into a State-only operating permit by means of an administrative amendment under 25 Pa. Code § 127.450.
The following is a summary of the conditions that the Department proposes to place in the plan approval to ensure compliance with all applicable regulatory requirements.
1. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs from all sources at the facility shall not equal or exceed 56.2 tons, 93.8 tons, 31.5 tons, 62.9 tons, 46.1 tons, 42.6 tons and 11.4 tons in any 12-consecutive month period respectively. This condition supersedes Section C, Conditions No. 011, Nos. 003--008 of Plan Approval 17-00063A.
2. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of VOCs resulting from the process equipment shall not exceed 2.02 pounds per hour and 8.85 tons in any 12-consecutive month period. This condition supersedes Section C, Condition No. 009 of Plan Approval 17-00063A.
3. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the wet distiller's grain with solubles (WDGS) storage area shall be limited to use for emergency purposes only. The emission of VOCs from the WDGS storage area shall not exceed 3.32 tons in any 12-consecutive month period.
4. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the facility shall process no more than 40 million bushels of corn in any 12-consecutive month period. This condition supersedes Section C, Condition No. 013 of Plan Approval 17-00063A.
5. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the facility shall produce no more than 115.5 million gallons of denatured ethanol in any 12-consecutive month period. This condition supersedes Section C, Condition No. 014 of Plan Approval 17-00063A.
6. The stack testing required by this plan approval shall be performed using reference method test procedures acceptable to the Department. At least 60 days prior to the performance of the stack testing required by this plan approval, a test plan shall be submitted to the Department for evaluation. The plan shall contain a description of the proposed test methods and dimensioned drawings or sketches showing the test port locations. The Department (Northcentral Regional Office and Central Office, Source Testing Section) shall be given at least 14 days advance notice of the scheduled dates for the performance of the stack testing required by this plan approval. Within 60 days of the completion of the stack testing required by this plan approval, two copies of the test report shall be submitted to the Department (Northcentral Regional Office). The report shall contain the results of the tests, a description of the testing and analytical procedures actually used in performance of the tests, all process and operating data collected during the tests, a copy of all raw data, and a copy of all calculations generated during data analysis. In addition, the permittee shall keep records of the test report.
7. Within 120 days of achieving normal production, but no later than 180 days after initial startup, the permittee shall perform testing on the exhaust of each fabric collector to verify compliance with the total PM/PM10 emissions limitations for each respective fabric collector associated with the respective sources. All testing shall be performed while the respective sources and control device is operating at its maximum rate of production, using EPA Method 5, or equivalent test methods specifically approved, in writing, by the Department.
8. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each fabric collector at the facility shall be equipped with instrumentation to monitor the differential pressure across the fabric collector and the actual differential pressure shall be displayed on a continuous basis.
9. The permittee shall keep records of the supporting calculations on a monthly basis for NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs emissions from all sources at the facility to verify compliance with the NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs emission limitations of tons in any 12-consecutive month period.
10. The permittee shall keep records of the pressure differential across each fabric collector within the facility at least once per day during the operation of the respective fabric collector.
11. The permittee shall keep records of the amount of corn, in bushels, processed in the facility on a monthly basis to verify compliance with the corn throughput limitation in any 12-consecutive month period.
12. The permittee shall keep records of the supporting calculations on a monthly basis for VOC emissions from the process equipment to verify compliance with the VOC emission limitations of pounds per hour and tons in any 12-consecutive month period.
13. The permittee shall keep records of the amount of denatured ethanol produced by the facility on a monthly basis to verify compliance with the denatured ethanol production limitation of gallons in any 12-consecutive month period.
14. All records required by the conditions contained in Plan Approval 17-00063B shall be retained for a minimum of 5 years and shall be made available to the Department upon request.
15. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the NOx, CO, SOx, PM/PM10, VOCs, and total combined HAPs emissions limitations for all sources at the facility in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
16. The permittee shall submit reports to the Department on a semi-annual basis that include the amount of denatured ethanol produced on a monthly basis to verify compliance with the denatured ethanol production limitation in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
17. The permittee shall submit reports to the Department on a semi-annual basis that include amount of corn, in bushels, processed in the facility to verify compliance with the corn throughput limitation in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
18. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the VOC emissions limitation for the process equipment in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
19. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall keep on hand a sufficient quantity of spare fabric collector bags for each fabric collector at the facility in order to be able to immediately replace any bags requiring replacement due to deterioration.
20. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the air compressors supplying the compressed air for the fabric collectors at the facility shall be equipped with an air dryer and oil trap.
21. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each fabric collector associated with the respective sources at the facility shall have an effective air-to-cloth ratio under actual conditions of no more than 5.5:1.
22. Within 30 days of selection, but no less than 120 days prior to the installation, for sources and control devices as specified in Plan Approval 17-00063B, the permittee shall submit to the Department for approval, the manufacturer name and model number with design specifications of each specific source and control device selected, by submitting the appropriate pages of the plan approval application.
23. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall implement a leak detection and repair program which is compliant with Subpart VVa, 40 CFR 60.480a through 60.489a. Additionally, the facility is subject to 40 CFR Part 60, Subpart VVa. The permittee shall comply with all the applicable requirements specified in 40 CFR 60.480a through 60.489a.
24. The Department will evaluate the actual emission rates and will decrease or increase the allowable emission rates, if necessary, based upon demonstrated performance (emissions data, vendors' data and/or stack test results) during the first 2 years of operation. Any revision of the allowable emission rates below the thresholds for a ''major facility'' (as defined in 25 Pa. Code § 121.1) shall be accomplished by minor modification provided that it is consistent with the BAT as determined by the Department on the date of the Plan Approval and that it is not a result of a physical change at the facility.
25. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx from each boiler shall not exceed 0.012 pound per million Btu (on an hourly average basis), 1.70 pounds per hour and 7.46 tons in any 12-consecutive month period. The emission of CO from each boiler shall not exceed 0.023 pound per million Btu, 3.26 pounds per hour and 14.30 tons in any 12-consecutive month period. The emission of SOx, expressed as SO2, from each boiler shall not exceed 0.001 pound per million Btu, 0.09 pound per hour, and 0.37 ton in any 12-consecutive month period. The emission of PM/PM10 from each boiler shall not exceed 0.005 pound per million Btu, 0.71 pound per hour and 3.11 tons in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of each boiler. The emission of VOCs from each boiler shall not exceed 0.004 pound per million Btu, 0.57 pound per hour and 2.49 tons in any 12-consecutive month period. The emission of total combined HAPs from each boiler shall not exceed 0.26 pound per hour and 1.15 tons in any 12-consecutive month period.
26. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, only natural gas shall be fired in each boiler.
27. Within 120 days of achieving normal production, but no later than 180 days after initial startup, the permittee shall perform testing on the exhaust of each boiler to verify compliance with the CO emissions limitations. All testing shall be performed while each boiler is operating at its maximum capacity, using EPA reference test methods, as approved by the Department.
28. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall install, certify, maintain and operate a continuous emission monitoring system (CEMS) for NOx, and oxygen (or CO2) on each boiler in accordance with all applicable requirements specified in 25 Pa. Code Chapter 139 and the Department's current Continuous Source Monitoring Manual. The CEMS specified previously shall be installed prior to startup of each boiler. No CEMS may however be operated unless Phase I approval has first been obtained from the Department. The NOx and oxygen (or CO2) emission monitoring systems shall be capable of monitoring the NOx and oxygen (or CO2) concentrations expressed in ppmv, emission rates expressed in pounds per hour and pounds per million Btu, and total emissions in any 12-consecutive month period, expressed in tpy, for each boiler.
29. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall submit a Phase I application to the Department for the NOx and oxygen (or CO2) continuous emission monitoring system which shall be constructed and installed at least 6 months prior to the anticipated startup date of each respective boiler.
30. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each respective boiler shall not be operated for any reason unless the associated NOx and oxygen (or CO2) continuous emission monitoring systems have received Phase I approval from the Department and have subsequently been installed and made operational in accordance with the conditions of this plan approval. Furthermore, the continuous emission monitoring systems shall be operated any time each respective boiler is operating in accordance with all applicable requirements specified in 25 Pa. Code Chapter 139, as well as with the Department's current Continuous Source Monitoring Manual unless superseded by conditions contained in this plan approval. The required relative accuracy testing shall have been completed on the continuous emission monitoring systems and the monitoring systems shall be fully certified in accordance with the Department's current Continuous Source Monitoring Manual within 180 days of startup of each boiler.
31. The permittee shall keep records associated with the continuous emission monitoring system for NOx and oxygen (or CO2) from each boiler in accordance with all applicable requirements specified in 25 Pa. Code Chapter 139 and the Department's current Continuous Source Monitoring Manual.
32. The permittee shall keep records of: the supporting calculations on a monthly basis for the NOx, CO, SOx, PM/PM10 and VOCs emissions from each boiler to verify compliance with the NOx, CO, SOx, PM/PM10 and VOCs emissions limitations of pounds per million Btu, pounds per hour and tons in any 12-consecutive month period; and the supporting calculations on a monthly basis for the total combined HAPs emissions from each boiler to verify compliance with the total combined HAPs emissions limitation of pounds per hour and tons in any 12-consecutive month period.
33. The permittee shall keep records of the amount of natural gas combustion in each boiler on a monthly basis.
34. The permittee shall submit all reports to the Department associated with the continuous emission monitoring system for NOx and oxygen (or CO2) on each boiler in accordance with all applicable requirements specified in 25 Pa. Code Chapter 139 and the Department's current Continuous Source Monitoring Manual.
35. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs emissions limitations for each boiler in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
36. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall utilize ultra low- NOx burners (ULNB) and flue gas recirculation (FGR) technology to control NOx emissions from each boiler. Each boiler shall be operated with the operation of ULNB and FGR. Each boiler shall be rated at 141.9 mmBtu/hr of heat input.
37. Each boiler at the facility is subject to the New Source Performance Standards, 40 CFR Part 60, Subpart Db and shall comply with all applicable requirements as specified in 40 CFR 60.40b through 60.49b.
38. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the PM/PM10 emissions from the corn receiving and storage fabric collector shall not exceed 0.003 grain per dry standard cubic foot (gr/dscf), 1.0 pound per hour, and 4.39 tons in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the fabric collector.
39. The permittee shall keep records of the supporting calculations on a monthly basis for the total PM/PM10 emissions from the fabric collector associated with the corn receiving and storage operations to verify compliance with the total PM/PM10 emissions limitations of pounds per hour and tons in any 12-consecutive month period. Additionally, the permittee shall keep records of all stack tests reports to verify compliance with the PM/PM10 emissions limitations in gr/dscf for the fabric collector associated with the corn receiving and storage operations.
40. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the total PM/PM10 emissions limitations for the corn receiving and storage operations in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
41. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the corn receiving from railcar operation shall be enclosed on the top and sides. The corn receiving from truck operation shall be enclosed on the top and sides and be equipped with doors, which shall be shut during corn receiving from truck to create a total enclosure.
42. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the corn receiving and storage operations without the simultaneous operation of the corn receiving and storage fabric collector. The PM emissions from the corn receiving and storage operations shall be controlled by the corn receiving and storage fabric collector.
43. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, all augers, conveyors, elevators, bin sweeps and storage silos associated with the corn receiving and storage operations, which are not entirely located inside a building, shall be fully enclosed.
44. The maximum railcar-to-dump pit corn drop height shall not exceed 4 feet. The corn receiving operation shall consist of truck dump pit No. 1, truck dump pit No. 2, railcar dump pit, truck dump pit No. 1 auger, truck dump pit No. 2 auger, railcar dump pit auger, truck receiving lane conveyor No. 1, truck receiving lane conveyor No. 2, railcar receiving lane conveyor, receiving transfer conveyor No. 1, receiving transfer conveyor No. 2. The corn storage operating shall consist of receiving bucket elevator No. 1, receiving bucket elevator No. 2, distribution system with gathering hopper and fill gates, upper receiving conveyor No. 1, upper receiving conveyor No. 2, corn silo No. 1, corn silo No. 2, bin sweep No. 1, bin sweep No. 2, reclaim conveyor No. 1, reclaim conveyor No. 2, reclaim transfer conveyor and corn day bin. The corn silos shall each have a capacity of no greater than 1.0 million bushels. The corn receiving and storage fabric collector shall be cleaned using reverse air flow and shall have a rated airflow capacity of 39,000 standard cubic feet per minute (SCFM).
45. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the PM/PM10 emissions from the corn milling fabric collector shall not exceed 0.003 gr/dscf, 0.71 pound per hour and 3.10 tons in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the fabric collector associated with the corn milling operation.
46. The permittee shall keep records of the supporting calculations on a monthly basis for the total PM/PM10 emissions from the fabric collector associated with the corn milling operation to verify compliance with the total PM/PM10 emissions limitations of pounds per hour and tons in any 12-consecutive month period. Additionally, the permittee shall keep records of all stack tests reports to verify compliance with the PM/PM10 emissions limitations in gr/dscf for the fabric collector associated with the corn milling operation.
47. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the total PM/PM10 emissions limitations for the fabric collector associated with the corn milling operation in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
48. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the corn milling operation without the simultaneous operation of the corn milling fabric collector. The PM emissions from the corn milling operation shall be controlled by the fabric collector associated with the corn milling operation.
49. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, all surge bins, scalpers, feeders and hammermills associated with the corn milling operation, which are not entirely located inside a building, shall be fully enclosed.
50. The corn milling operation shall consist of grinder surge bin, rotary scalper No. 1, rotary scalper No. 2, rotary feeder No. 1, rotary feeder No. 2, rotary feeder No. 3, rotary feeder No. 4, hammermill No. 1, hammermill No. 2, hammermill No. 3, hammermill No. 4, ground corn conveyor, ground corn transfer conveyor. The hammermills shall each have a capacity of no greater than 42 tons per hour. The corn milling fabric collector shall be cleaned using reverse air flow and shall each have a rated airflow capacity of 27,500 SCFM.
51. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the total combined emission of NOx from the dryer RTOs associated with the ethanol manufacturing process shall not exceed 0.040 pound per million Btu, 7.8 pounds per hour and 34.3 tons in any 12-consecutive month period. The total combined emission of CO from the dryer RTOs associated with the ethanol process shall not exceed 13.6 pounds per hour and 59.4 tons in any 12-consecutive month period. The total combined emission of SOx, expressed as SO2, from the dryer RTOs associated with the ethanol process shall not exceed 7.0 pounds per hour and 30.6 tons in any 12-consecutive month period. The total combined emission of PM/PM10 from the dryer RTOs associated with the ethanol process shall not exceed 0.005 gr/dscf, 5.3 pounds per hour and 23.4 tons in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the dryer RTOs associated with the ethanol process. The total combined emission of VOCs from the dryer RTOs associated with the ethanol process shall not exceed 5.3 pounds per hour and 23.4 tons in any 12-consecutive month period. The emission of total combined HAPs from the dryer RTOs associated with the ethanol process shall not exceed 1.2 pound per hour and 5.3 tons in any 12-consecutive month period.
52. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emissions from the exhaust of one dryer RTO associated with the ethanol manufacturing process shall not exceed 3.9 pounds of NOx per hour, 8.1 pounds of CO per hour, 4.2 pounds of SOx per hour, 3.2 pounds of PM/PM10 per hour, 3.2 pounds of VOCs per hour and 2.0 pounds of HAPs per hour when the emissions are controlled by only one dryer RTO.
53. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, only natural gas shall be fired in each dryer RTO associated with the ethanol process and only natural gas and off-gas from the biomethanators shall be fired in each DDGS dryer.
54. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each dryer RTO shall destroy the VOC/HAP emissions ducted to it at a destruction efficiency of no less than 99% (by weight). In addition, each dryer RTO shall destroy the CO emissions ducted to it at a destruction efficiency of no less than 95% (by weight).
55. Within 120 days of achieving normal production, but no later than 180 days after initial startup, the permittee shall perform simultaneous testing on the inlet and exhaust of each dryer RTO associated with the ethanol manufacturing process to verify compliance with VOCs, CO, PM and SOx emissions limitations and the VOC/HAP and CO destruction efficiency of each dryer RTO. Additionally, the permittee shall perform tests on the inlet and exhaust of one dryer RTO associated with the ethanol manufacturing process while that specific dryer RTO is controlling the emissions to verify compliance with the emissions limitations and destruction efficiency of the dryer RTO. All testing shall be performed while the facility is operating at representative operating conditions, using EPA reference test methods, as approved by the Department. During the stack testing, the temperature of the combustion chambers of each dryer RTO shall be monitored and the temperatures shall not go below 1,550° F or above 1,650° F. Additionally, the differential pressure of the bed media of each dryer RTO shall be monitored and recorded during testing.
56. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each dryer RTO shall be equipped with instrumentation to monitor and record the temperature of the combustion chamber of each dryer RTO on a continuous basis. Each dryer RTO shall be equipped with instrumentation to monitor the differential pressure across the bed media of each dryer RTO and the monitor shall be operated on a continuous basis.
57. The permittee shall keep records of the supporting calculations on a monthly basis for the total combined CO, SOx, PM/PM10, VOC and HAPs emissions from the dryer RTOs associated with the ethanol process to verify compliance with the total combined CO, SOx, PM/PM10, VOC and HAPs emissions limitations of pounds per hour and tons in any 12-consecutive month period and the supporting calculations on a monthly basis for total combined NOx emissions from the dryer RTOs to verify compliance with the total combined NOx emissions limitations of pounds per million Btu, pounds per hour and tons in any 12-consecutive month period.
58. The permittee shall continuously record the temperature of the combustion chamber of each dryer RTO by means of temperature recorder when the respective dryer RTO is in operation. The permittee shall record the differential pressure of the bed media of each dryer RTO at least once per day when the respective dryer RTO is in operation.
59. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the total combined NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs emissions limitations for the dryer RTOs associated with the ethanol process in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
60. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the mix tank, slurry tanks, cook tubes, cook water tank, liquefaction tanks, yeast tanks, process condensate tank, beer column, side stripper, rectifier column, 190-proof condenser, whole stillage tank, molecular sieves, 200 proof condenser, centrifuges, centrate tank, thin stillage tank, evaporators, syrup tank, steam condensate tank, interconnecting conveyors and/or DDGS cooler drum associated with the ethanol manufacturing process without the simultaneous operation of the dryer RTOs, except allowed under condition No. 61 below. The permittee shall not operate DDGS dryer A and/or DDGS dryer B associated with the ethanol manufacturing process without the simultaneous operation of dryer RTO No. 1. The permittee shall not operate DDGS dryer C and/or DDGS dryer D associated with the ethanol manufacturing process without the simultaneous operation of dryer RTO No. 2. In order for each dryer RTO associated with the ethanol manufacturing process to be considered in operation, the combustion chamber of the respective dryer RTO shall achieve and maintain a temperature of at least 1,600° F. The dryer RTO operating temperature requirement may be revised based on the compliance demonstration of the destruction efficiency requirements for the dryer RTOs, as approved by the Department. The PM, CO, VOC and HAP emissions from the ethanol manufacturing process shall be controlled by the dryer RTOs.
61. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, should dryer RTO No. 1 associated with the ethanol manufacturing process be inoperable, the permittee may operate the pre-fermentation system, distillation system, separation system, and DDGS drying system, provided that the permittee does not operate DDGS dryer A and/or DDGS dryer B associated with the ethanol manufacturing process. Should dryer RTO No. 2 associated with the ethanol manufacturing process be inoperable, the permittee may operate the prefermentation system, distillation system, separation system, and DDGS drying system, provided that the permittee does not operate DDGS dryer C and/or DDGS dryer D associated with the ethanol manufacturing process. The permittee shall record the times when only dryer RTO No. 1 or dryer RTO No. 2 associated with the ethanol manufacturing process was operating and the other respective dryer RTO associated with the ethanol manufacturing process was not operating.
62. The prefermentation system shall consist of the following sources: mix tank with a 470 gallon capacity, slurry tank No. 1 with a 25,000 gallon capacity, slurry tank No. 2 with a 29,000 gallon capacity, cook tube No. 1 with a 5,200 gallon capacity, cook tube No. 2 with a 5,200 gallon capacity, flash tank with a 4,500 gallon capacity, liquefaction tank No. 1 with a 128,400 gallon capacity, liquefaction tank No. 2 with a 128,400 gallon capacity, yeast tank No. 1 with a 20,000 gallon capacity and yeast tank No. 2 with a 20,000 gallon capacity. The distillation system shall consist of the following sources: process condensate tank, beer column, side stripper, rectifier column, 190-proof condenser, molecular sieve No. 1, molecular sieve No. 2, molecular sieve No. 3, molecular sieve No. 4, molecular sieve No. 5, molecular sieve No. 6 and 200-proof condenser. The separation system shall consist of the following sources: whole stillage tank with a 180,800 gallon capacity, centrifuge No. 1, centrifuge No. 2, centrifuge No. 3, centrifuge No. 4, centrifuge No. 5, centrifuge No. 6, centrate tank with a 3,000 gallon capacity, thin stillage tank with a 374,000 gallon capacity, evaporator No. 1, evaporator No. 2, evaporator No. 3, evaporator No. 4, evaporator No. 5, evaporator No. 6, evaporator No. 7, evaporator No. 8, steam condensate tank with a 770 gallon capacity and syrup tank with a 180,000 gallon capacity. The DDGS drying system shall consist of the following sources: DDGS dryer A that is natural-gas fired with a rated burner capacity of 40.0 mmBtu/hr and a multiclone for product recovery, DDGS dryer B that is natural-gas fired with a rated burner capacity of 40.0 mmBtu/hr, a mixer, and a multiclone for product recovery, DDGS dryer C that is natural-gas fired with a rated burner capacity of 40.0 mmBtu/hr and a multiclone for product recovery, DDGS dryer D that is natural-gas fired with a rated burner capacity of 40.0 mmBtu/hr, a mixer, and a multiclone for product recovery, DDGS cooler drum with a baghouse for product recovery, and interconnecting conveyors. The DDGS drying system shall have all air cleaned by the multiclones and baghouse exhausting back to the burners of the dryer and not exhausting to atmosphere. The two dryer RTOs are natural gas fired units and each shall have a designed airflow capacity of 96,975 SCFM, burner capacity of 18 mmBtu/hr, and a flush chamber.
63. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 0.32 pound per hour and 1.40 tons in any 12-consecutive month period. The emission of CO from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 1.00 pound per hour and 4.38 tons in any 12-consecutive month period. The emission of SOx, expressed as SO2, from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 0.01 ton in any 12-consecutive month period. The emission of PM/PM10 from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 0.01 ton in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the scrubber RTO associated with the fermentation process. The emission of VOCs from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 0.15 pound per hour and 0.67 ton in any 12-consecutive month period. The emission of total combined HAPs from the exhaust of the scrubber RTO associated with the fermentation process shall not exceed 0.02 pound per hour and 0.08 ton in any 12-consecutive month period.
64. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, only natural gas shall be fired in he scrubber RTO associated with the fermentation process.
65. Within 120 days of achieving normal production, but no later than 180 days after initial startup, the permittee shall perform testing on the inlet and exhaust of the scrubber RTO associated with the fermentation process to verify compliance with VOC emissions limitations and the VOC/HAP destruction efficiency of the scrubber RTO. All testing shall be performed while the facility is operating at representative operating conditions, using test methods approved by the Department. Additionally, the test shall verify compliance with a VOC/HAP destruction efficiency of 99% for the scrubber RTO. During the stack testing, the temperature of the combustion chamber of the scrubber RTO shall be monitored and the temperature shall not go below 1,550° F or above 1,650° F. Additionally, the differential pressure of the bed media of the scrubber RTO shall be monitored and recorded during testing.
66. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the scrubber RTO associated with the fermentation process shall be equipped with instrumentation to monitor and record the temperature of the combustion chamber of the scrubber RTO on a continuous basis. The scrubber RTO associated with the fermentation process shall be equipped with instrumentation to monitor the differential pressure across the bed media of the scrubber RTO and the monitor shall be operated on a continuous basis.
67. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the scrubber associated with the fermentation process shall be equipped with instrumentation to monitor the scrubber water flow rate, differential pressure across the scrubber and pH of the scrubber water and the monitors shall be operated on a continuous basis.
68. The permittee shall keep records of: the supporting calculations on a monthly basis for the NOx, CO, VOC and HAPs emissions from the scrubber RTO associated with the fermentation process to verify compliance with the NOx, CO, VOC and HAPs emissions limitations of pounds per hour and tons in any 12-consecutive month period and the supporting calculations on a monthly basis for total combined SOx and PM/PM10 emissions from the scrubber RTO to verify compliance with the SOx and PM/PM10 emissions limitations of tons in any 12-consecutive month period.
69. The permittee shall continuously record the temperature of the combustion chamber of the scrubber RTO by means of temperature recorder when the scrubber RTO is in operation. The permittee shall record the differential pressure of the bed media of the scrubber RTO at least once per day when the scrubber RTO is in operation.
70. The permittee shall record the scrubber water flow rate, differential pressure across the scrubber and pH of the scrubber water at least once per day when the scrubber is in operation.
71. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the NOx, CO, SOx, PM/PM10, VOCs and total combined HAPs emissions limitations for the scrubber RTO associated with the fermentation process in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
72. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the scrubbing water flow rate in the scrubber associated with the fermentation process shall be no less than 40 gallons per minute at all times the scrubber is operating. Additionally, the scrubber shall only use clean water on a once-through basis.
73. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the fermentation process without the simultaneous operation of the scrubber and the scrubber RTO. For the scrubber RTO associated with the fermentation process to be considered in operation, the combustion chamber of the scrubber RTO shall achieve and maintain a temperature of at least 1,600° F. The scrubber RTO operating temperature requirement may be revised based on the compliance demonstration of the destruction efficiency requirement for the scrubber RTO, as approved by the Department. The VOC and HAP emissions from the fermentation process shall be controlled by the scrubber and the scrubber RTO.
74. The fermentation system shall consist of the following: fermenter No. 1 with a 807,000 gallon capacity, fermenter No. 2 with a 807,000 gallon capacity, fermenter No. 3 with a 807,000 gallon capacity, fermenter No. 4 with a 807,000 gallon capacity, fermenter No. 5 with a 807,000 gallon capacity, fermenter No. 6 with a 807,000 gallon capacity, fermenter No. 7 with a 807,000 gallon capacity, and beer well with a 1,080,000 gallon capacity. The fermentation scrubber is a packed gas column scrubber and shall have a designed airflow capacity of 11,000 SCFM. The scrubber RTO is a natural gas fired unit and shall have a designed airflow capacity of 18,506 SCFM, burner capacity of 8 mmBtu/hr and a flush chamber.
75. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the PM/PM10 emissions from the DDGS storage and loadout fabric collector shall not exceed 0.003 gr/dscf, 0.28 pound per hour and 1.24 tons in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the fabric collector associated with the DDGS storage and loadout.
76. The permittee shall keep records of the supporting calculations on a monthly basis for the total PM/PM10 emissions from the fabric collector associated with the DDGS storage and loadout to verify compliance with the total PM/PM10 emissions limitations of pounds per hour and tons in any 12-consecutive month period. Additionally, the permittee shall keep records of all stack tests reports to verify compliance with the PM/PM10 emissions limitations in gr/dscf for the fabric collector associated with the DDGS storage and loadout.
77. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the total PM/PM10 emissions limitations for the fabric collector associated with the DDGS storage and loadout in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
78. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the DDGS storage and loadout operation without the simultaneous operation of the DDGS storage and loadout fabric collector. The PM emissions from the DDGS storage and loadout operation shall be controlled by the DDGS storage and loadout fabric collector.
79. The DDGS storage and loadout operation shall consist of: DDGS transfer inclined conveyor, DDGS flat storage conveyor, DDGS storage pile conveyor, DDGS flat storage, DDGS reclaim hopper/conveyor, DDGS silo bucket elevator, DDGS silo storage conveyor, DDGS silo recycle conveyor, DDGS storage silo No. 1, DDGS storage silo No. 2, DDGS storage silo No. 1 loadout conveyor, DDGS storage silo No. 2 loadout conveyor, DDGS silo bucket elevator, weighing system, DDGS loadout conveyor, DDGS truck loadout and DDGS railcar loadout. The fabric collector shall be cleaned using reverse air flow and shall have a rated airflow capacity of 11,000 SCFM.
80. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the VOC emissions from the tanks storing VOC-containing material at the facility shall not exceed 0.392 pound per hour and 1.80 tons in any 12-consecutive month period.
81. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall visually inspect the internal floating roof, the primary seal and the secondary seal of the denaturant, 190-proof, 200-proof and denatured ethanol tanks prior to filling. 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 permittee shall repair the items before filling the denaturant, 190-proof, 200-proof and denatured ethanol tanks.
82. The permittee shall keep records of the supporting calculations on a monthly basis for the VOC emissions from the tanks storing VOC-containing material to verify compliance with the VOC emissions limitations of tons in any 12-consecutive month period.
83. Under 40 CFR 60.115b(a), the permittee shall keep records to verify that the denaturant, 190-proof, 200-proof and denatured ethanol tanks meet the requirements of 40 CFR Part 60, Subpart Kb. In addition, the permittee shall keep records of each inspection performed on the denaturant, 190-proof, 200-proof and denatured ethanol tanks.
84. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall keep records of the period of storage of each fill in the denaturant, 190-proof, 200-proof and denatured ethanol tanks and the maximum true vapor pressure of the materials in each fill of the denaturant, 190-proof, 200-proof and denatured ethanol tanks. The permittee shall use available data on Reid vapor pressure and maximum expected storage temperature based on the highest expected calendar-month average temperature to calculate maximum true vapor pressure for the denaturant.
85. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the VOC emissions limitations for the tanks storing VOC-containing material in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
86. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the denaturant, 190-proof, 200-proof and denatured ethanol tanks shall be equipped with a mechanical shoe primary seal and a rim-mounted secondary seal.
87. The denaturant, 190-proof, 200-proof and denatured ethanol tanks are subject to 40 CFR Part 60, Subpart Kb. The permittee shall comply with all the applicable requirements specified in 40 CFR 60.110b through 60.117b.
88. The denaturant, 190-proof, 200-proof and denatured ethanol tanks are subject to 25 Pa. Code § 129.56. The permittee shall comply with all the applicable requirements specified in 25 Pa. Code § 129.56.
89. The tanks storing VOC-containing material include the following: 190-proof ethanol tank with a 200,000 gallon capacity, 200-proof ethanol tank with a 200,000 gallon capacity, gasoline denaturant storage tank with a 200,000 gallon capacity, denatured ethanol storage tank No. 1 with a 1.5 million gallon capacity, denatured ethanol storage tank No. 2 with a 1.5 million gallon capacity, fuel additive tank with a 2,300 gallon capacity, corrosion inhibitor tank with a 6,000 gallon capacity, and diesel (No. 2 fuel oil) storage tank with a 6,000 gallon capacity.
90. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx from the ethanol loadout VBO shall not exceed 0.18 pound per hour and 0.21 ton in any 12-consecutive month period. The emission of CO from the ethanol loadout VBO shall not exceed 0.93 pound per hour and 0.96 ton in any 12-consecutive month period. The emission of SOx, expressed as SO2, from the ethanol loadout VBO shall not exceed 0.002 pound per hour and 0.002 ton in any 12-consecutive month period. The emission of PM/PM10 from the ethanol loadout VBO shall not exceed 0.101 pound per hour and 0.103 ton in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the ethanol loadout VBO. The emission of VOCs from the ethanol loadout VBO shall not exceed 2.80 pounds per hour and 2.80 tons in any 12-consecutive month period.
91. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the ethanol loadout operations for more than 2,000 hours in any 12-consecutive month period.
92. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the ethanol loadout VBO shall destroy the VOC emissions from the ethanol loadout operation at a destruction efficiency of no less than 99% (by weight).
93. Within 120 days of achieving normal production, but no later than 180 days after initial startup, the permittee shall perform testing on the inlet and exhaust of the ethanol loadout VBO to verify compliance with the VOC emissions limitations and the VOC destruction efficiency of the ethanol loadout VBO. All testing shall be performed while the facility is operating at representative operating conditions, using test methods approved by the Department. Additionally, the test shall verify compliance with a VOC destruction efficiency of 99%. During the stack testing, the temperature of the combustion chamber of the ethanol loadout VBO shall be monitored and the temperature shall not go below 1,350° F or above 1,450° F.
94. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the ethanol loadout VBO shall be equipped with instrumentation to monitor and record the temperature of the combustion chamber on a continuous basis.
95. The permittee shall keep records of: the supporting calculations on a monthly basis for NOx, CO, SOx, PM/PM10 and VOC emissions from the ethanol loadout VBO to verify compliance with the NOx, CO, SOx, PM/PM10 and VOC emissions limitations of pounds per hour and tons in any 12-consecutive month period.
96. The permittee shall continuously record the temperature of the combustion chamber of the ethanol loadout VBO by means of temperature chart recorder when the ethanol loadout VBO is in operation.
97. The permittee shall keep records of the number of hours that the ethanol loadout operates on a monthly basis to verify compliance with the operation hours restriction in any 12-consecutive month period.
98. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the NOx, CO, SOx, PM/PM10 and VOC emissions limitations for the ethanol loadout enclosed flare in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
99. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, all VOC emissions displaced from railcars and trucks being loaded with ethanol shall be collected through dedicated vapor collection lines and ducted to the ethanol loadout VBO for destruction.
100. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the truck ethanol loadout and/or the railcar ethanol loadout without the simultaneous operation of the ethanol loadout VBO. For the ethanol loadout VBO to be considered in operation, the combustion chamber of the ethanol loadout VBO shall achieve and maintain a temperature of at least 1,400° F. The VOC emissions from the ethanol loadout operation shall be controlled by the ethanol loadout VBO.
101. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the ethanol loadout operation consists of a truck ethanol loadout spout and a railcar ethanol loadout spout. The ethanol loadout VBO is a ventura burner oxidizer and the combustion chamber of the VBO shall be fully enclosed. Natural gas is used for the pilot and backup fuel supply of the ethanol loadout VBO.
102. The emergency generator is subject to the is subject to the National Emissions Standards for HAPs, 40 CFR Part 63, Subpart ZZZZ and shall comply with all applicable requirements as specified in 40 CFR 63.6580 through 63.6675.
103. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx from the fire pump shall not exceed 3.72 grams per brake horsepower-hour (g/bhp-hr), 2.46 pounds per hour and 0.3 ton in any 12-consecutive month period. The emission of CO from the fire pump shall not exceed 0.41 g/bhp-hr, 0.27 pound per hour and 0.03 ton in any 12-consecutive month period. The emission of SOx, expressed as SO2, from the fire pump shall not exceed 0.05 pound per million Btu, 0.11 pound per hour, and 0.01 ton in any 12-consecutive month period. The emission of PM/PM10 from the fire pump shall not exceed 0.16 g/bhp-hr, 0.11 pound per hour and 0.01 ton in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the fire pump. The emission of NMHC, including VOCs, from the fire pump shall not exceed 0.39 g/bhp-hr, 0.26 pound per hour and 0.03 ton in any 12-consecutive month period. The emission of total combined HAPs from the fire pump shall not exceed 0.003 pound per hour and 0.0004 ton in any 12-consecutive month period.
104. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the sulfur content of the No. 2 fuel oil or diesel fuel fired in the fire pump shall not, at any time, exceed 0.05% (by weight).
105. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the fire pump shall not be operated more than 250 hours in any 12-consecutive month period.
106. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the fire pump shall be equipped with a nonresettable meter for hours of operation prior to startup and the meter shall be operated at all times the fire pump is in operation.
107. The permittee shall keep records of the number of hours that the fire pump operates on a monthly basis to verify compliance with the operation hours restriction in any 12-consecutive month period.
108. The permittee shall keep records of: the supporting calculations on a monthly basis for NOx, CO, PM/PM10 and NMHC, including VOC, emissions from the fire pump to verify compliance with the NOx, CO, PM/PM10 and NMHC, including VOC, emissions limitations of g/bhp-hr, pounds per hour, and tons in any 12-consecutive month period; the supporting calculations on a monthly basis for SOx emissions from the fire pump to verify compliance with the SOx emissions limitations of pounds per million Btu, pounds per hour and tons in any 12-consecutive month period and the supporting calculations on a monthly basis for total combined HAP emissions from the fire pump to verify compliance with the HAP emissions limitations of pounds per hour and tons in any 12-consecutive month period.
109. The fire pump is a John Deere model JW6H-UF40 engine, which shall be rated at 300 horsepower and fired on diesel fuel (No. 2 fuel oil).
110. The Department reserves the right to require verification of emission rates from the fire pump, which may include source testing, in accordance with applicable provisions of 25 Pa. Code Chapter 139 (relating to sampling and testing) or portable exhaust gas analyzer testing approved by the Department.
111. The fire pump is subject to the New Source Performance Standards, 40 CFR Part 60, Subpart IIII and shall comply with all applicable requirements as specified in 40 CFR 60.4200 through 60.4219.
112. The fire pump is subject to the is subject to the National Emissions Standards for HAPs, 40 CFR Part 63, Subpart ZZZZ and shall comply with all applicable requirements as specified in 40 CFR 63.6580 through 63.6675.
113. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of PM/PM10 from the cooling tower shall not exceed 0.63 pound per hour and 2.74 tons in any 12-consecutive month period.
114. The permittee shall keep records of the supporting calculations on a monthly basis for the total PM/PM10 emissions from the cooling tower to verify compliance with the total PM/PM10 emissions limitations of pounds per hour and tons in any 12-consecutive month period.
115. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, each cell of the cooling tower shall be equipped with a drift eliminator. The drift eliminator located on each cell of the cooling tower shall be capable of achieving a maximum drift rate of 0.0001%. The cooling tower shall have a maximum circulating water flow rate of 3 million gallons per hour.
116. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the emission of NOx from the biomethanators candlestick-type flare shall not exceed 0.45 pound per hour and 0.15 ton in any 12-consecutive month period. The emission of CO from the biomethanators candlestick-type flare shall not exceed 2.38 pounds per hour and 0.63 ton in any 12-consecutive month period. The emission of SOx, expressed as SO2, from the biomethanators candlestick-type flare shall not exceed 0.001 pound per hour and 0.001 ton in any 12-consecutive month period. The emission of PM/PM10 from the biomethanators candlestick-type flare shall not exceed 0.001 pound per hour and 0.003 ton in any 12-consecutive month period. Additionally, there shall be no visible emissions from the exhaust of the biomethanators candlestick-type flare. The emission of VOCs from the biomethanators candlestick-type flare shall not exceed 0.33 pound per hour and 0.09 ton in any 12-consecutive month period.
117. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the main flare of the biomethanators candlestick-type flare for more than 500 hours in any 12-consecutive month period.
118. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, only natural gas and off-gas from the biomethanators shall be fired in the main flare and pilot burner of the biomethanators candlestick-type flare.
119. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the biomethanators candlestick-type flare shall be equipped with instrumentation to monitor and record the temperature on a continuous basis.
120. The permittee shall keep records of: the supporting calculations on a monthly basis for NOx, CO, SOx, PM/PM10 and VOC emissions from the biomethanators candlestick-type flare to verify compliance with the NOx, CO, SOx, PM/PM10 and VOC emissions limitations of pounds per hour and tons in any 12-consecutive month period.
121. The permittee shall continuously record the temperature of the biomethanators candlestick-type flare by means of temperature chart recorder when the main flare of the biomethanators candlestick-type flare is in operation.
122. The permittee shall keep records of the number of hours that the main flare of the biomethanators candlestick-type flare operates on a monthly basis to verify compliance with the operation hours restriction in any 12-consecutive month period.
123. The permittee shall submit reports to the Department on a semi-annual basis that include the supporting calculations to verify compliance with the NOx, CO, SOx, PM/PM10 and VOC emissions limitations for the biomethanators candlestick-type flare in any 12-consecutive month period. The semi-annual reports shall be submitted to the Department no later than March 1 (for January 1 through December 31 of the previous year) and September 1 (for July 1 of the previous year through June 30 of the current year).
124. Under BAT provisions of 25 Pa. Code §§ 127.1 and 127.12, the permittee shall not operate the biomethanators without the simultaneous operation of the biomethanators candlestick-type flare, except that the off-gas from biomethanators may be directed to the dryers of the DDGS drying system instead. In order for the biomethanators candlestick-type flare to be considered in operation, the combustion chamber of the biomethanators candlestick-type flare shall achieve and maintain a temperature of at least 1,800° F. The methane emissions from the biomethanators shall be controlled by the biomethanators candlestick-type flare and/or the dryers of the DDGS drying system.
125. The biomethanator system consists of four biomethanator modules with a total capacity of 30,000 gallons. The biomethanators candlestick-type flare uses natural gas for the pilot burner.
126. All conditions contained in existing Plan Approval 17-00063A remain in effect unless superseded or amended by conditions contained in this Plan Approval (17-00063B). If there is a conflict between a condition contained in this plan approval and a condition contained in existing Plan Approval 17-00063A, the permittee shall comply with the condition contained in this plan approval.
A copy of the plan approval application and the Department's review is available for public review between 8 a.m. and 4 p.m. at the Department's Northcentral Regional Office, 208 West Third Street, Suite 101, Williamsport, PA 17701. Appointments for scheduling a review may be made by calling the Department at (570) 327-3693. Written comments or requests for a public hearing should be directed to Muhammad Q. Zaman, Manager, Facilities Permitting Section, Department of Environmental Protection, Air Quality Program, Northcentral Regional Office, 208 West Third Street, Suite 101, Williamsport, PA 17701, (570) 327-0512.
Southwest Region: Air Quality Program, 400 Waterfront Drive, Pittsburgh, PA 15222-4745, M. Gorog and B. Hatch, Environmental Engineer Managers (412) 442-4163/5226.
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