[31 Pa.B. 6703]
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PLAN APPROVALS
Plan Approval Applications 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.
Southcentral Region: Air Quality Program, 909 Elmerton Avenue, Harrisburg, PA 17110; Contact: Ronald Davis, New Source Review Chief, (717) 705-4702.
06-05087A: Haines and Kibblehouse, Inc. (P. O. Box 196, Skippack, PA 19474) for installation of a fabric collector to control the emissions from an asphalt plant in Colebrookdale Township, Berks County. The facility is subject to 40 CFR Part 60, Subpart I--Standards of Performance for Hot Mix Asphalt Facilities.
36-03041B: County Line Quarry, Inc. (P. O. Box 99, Wrightsville, PA 17368) for construction of a cone crusher, quad deck screen and associated conveyors controlled by a fabric filter and water suppression at the Wrightsville Quarry located in Hellam Township, York County. The modification to the stone crushing facility is subject to 40 CFR Part 60, Subpart OOO--Standards of Performance for Nonmetallic Mineral Processing Plants.
36-05019E: Anvil International, Inc. (1411 Lancaster Avenue, Columbia, PA 17512) for construction of two fabric collectors at the Columbia Plant located in Columbia Borough, Lancaster County.
36-05026A: R. R. Donnelley & Sons Co. (1375 Harrisburg Pike, Lancaster, PA 17601) for construction of one heatset web offset printing press controlled by a thermal oxidizer at the Lancaster West Facility in the City of Lancaster, Lancaster County.
67-03028A: Dentsply International Trubyte Division (570 West College Avenue, P. O. Box 872, York, PA 17405-0872) for construction of a new electroplating unit controlled by a multi-stage mist eliminator at the facility in the City of York, York County. The project is subject to 40 CFR Part 63, Subpart N--National Emission Standards for Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks.
Northcentral Region: Air Quality Program, 208 West Third Street, Williamsport, PA 17701; Contact: David Aldenderfer, Program Manager, (570) 327-3637.
59-00005D: Dominion Transmission Corp. (625 Liberty Avenue, Pittsburgh, PA 15222-3199) for installation of a replacement air cleaning device (a screw-in prechamber) on a 2000 horsepower natural gas-fired reciprocating internal combustion compressor engine (Engine #7) at the Sabinsville Compressor Station in Clymer Township, Tioga County.
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.
Northeast Region: Air Quality Program, 2 Public Square, Wilkes-Barre, PA 18711-0790; Contact: James Parette, New Source Review Chief, (570) 826-2531.
48-320-012: Wheaton USA, Inc. (2400 Baglyos Circle, Bethlehem, PA 18020) for construction and operation of a heat-set printing operation consisting of two offset, sheet-fed printing presses in Bethlehem Township, Northampton County. The facility is a non-Title V (State only) facility. The operation of the heat-set printing operation will result in the emission of 6.4 tons per year of volatile organic compounds and 1.2 tons per year of particulate. The plan approval will include monitoring, reporting and recordkeeping requirements designed to keep the source operating within all applicable air quality requirements.
40-303-013A: Bartlett Materials and Construction, Inc. (East Broad Street, P. O. Box 550, Tamaqua, PA 18252) for modification of an asphalt plant by addition of a Recycled Asphalt Pavement Feed System and the replacement of existing baghouse with a newer better efficient baghouse in Tamaqua, Luzerne County. This facility is a non-Title V facility. Modification will not increase the existing emission rates for the pollutants. The modification will provide the facility to use RAP material. The company will operate the facility and maintain the system in accordance with the good engineering practices to assure proper operation of the system.
Southcentral Region: Air Quality Program, 909 Elmerton Avenue, Harrisburg, PA 17110; Contact: Ronald Davis, New Source Review Chief, (717) 705-4702.
01-05002A: MasterBrand Cabinets, Inc. (P. O. Box 5, Littlestown, PA 17340) for construction of four spray booths and installation of a regenerative thermal oxidizer in Littlestown Borough, Adams County. The facility is a Title V facility. The potential to emit volatile organic compounds (VOCs) from this modification is about 10.7 tons per year. The facility is subject to a Plantwide Applicability Limit (PAL) of 107.7 tons per year and is subject to 40 CFR Part 63, Subpart JJ--National Emission Standards for Wood Furniture Manufacturing Operations. The plan approval will include emission limitations, testing, monitoring, record keeping, reporting requirements and work practice standards designed to keep the facility within all applicable air quality requirements.
01-05032: Pella Corporation (102 Main Street, Pella, IA 50219) for construction of a window manufacturing operation at its Gettysburg Plant in Straban Township, Adams County. The facility is a non-Title V (State only) facility. The facility's potential annual emissions of VOC, PM-10 and NOx will be 76 tons, 6 tons and 3 tons, respectively. The primary sources are five wood treatment units controlled by a catalytic oxidizer. Performance testing of the catalytic oxidizer for inlet and outlet VOC emissions, capture efficiency and visible emissions will be required. A minimum catalytic oxidizer outlet temperature of 650°F will be required during operation of any of the wood treatment units. Facility emission restrictions for criteria pollutants and HAPs have been included for the facility to maintain its Synthetic Minor status. The plan approval will also contain additional work practice standards and emission restrictions, as well as monitoring, record keeping and reporting requirements.
36-03119A: Esh's Toys, LLC (343 Furnace Road, Quarryville, PA 17566) for the construction of a sealer spray booth and a topcoat spray booth in Bart Township, Lancaster County. The facility is a non-Title V (State only) facility. The operation annually emits about 7.1 tons of VOC and has a potential to emit less than 25 tons per year. The plan approval/operating permit will include emission limitations, testing, monitoring, record keeping, reporting requirements and work practice standards designed to keep the facility within all applicable air quality requirements.
36-05011A: ExxonMobil Oil Corp. (600 Billingsport Road, Paulsboro, NJ 08066) for modification to a loading rack at Lancaster Terminal, 1360 Manheim Pike, Manheim Township, Lancaster County. The modification is to incorporate a gasoline bay into the existing distillate bay and provide more flexibility to load gasoline product in the tanker trucks. The facility VOC emissions will be kept at less than 50 tons per year. The Plan Approval and administrative amendment to synthetic minor operating permit 36-05011 shall contain additional recordkeeping and operating restrictions designed to keep the facility operating within all applicable air quality requirements.
07-03034B: Fry Metals, Inc. (4100 Sixth Avenue, Altoona, PA 16602) for installation of eight new melting kettles to soft metal melting area or Casting Department at the facility in the City of Altoona, Blair County. Three kettles will be controlled by an existing Aeropulse baghouse and five will be controlled by a United Process Control baghouse to be installed under this Plan Approval. Approval of this request will increase the potential emissions from the facility by the following amounts: NOx = 2.06 tons, VOC = 0.20 ton, CO = 0.69 ton and particulate = 20.12 lbs. The plan approval will include provisions for emission testing, monitoring, recordkeeping and reporting designed to ensure compliance with the applicable requirements.
Southwest Region: Air Quality Program, 400 Waterfront Drive, Pittsburgh, PA 15222-4745; Contact: William Charlton, New Source Review Chief, (412) 442-4174.
26-00535A: Duke Energy Fayette, LLC (5400 Westheimer Court, Houston, TX 77056) for construction of the Fayette Energy Facility in German Township, Fayette County.
The proposed facility is subject to the applicable requirements of 25 Pa. Code, Chapter 127 (related to construction, modification, reactivation and operation of sources, including the nonattainment New Source Review provisions of Subchapter E), 40 CFR 52.21 (related to Prevention of Significant Deterioration), 40 CFR Part 60, Subparts Da, Dc, GG and Kb (related to standards of performance for small and large steam generating units, turbines and VOL storage tanks), 40 CFR Parts 72, 73, 75 and 77 (related to acid rain) and 25 Pa. Code §§ 123.102--123.120 (related to the NOx budget program). The Department believes that the facility will meet these requirements by complying with the following Plan Approval conditions:
1. The facility is to be constructed in accordance with the plans submitted with the application (as approved herein).
2. Upon completion of the construction of the facility, an operating permit must be obtained. Notify the Department when the installation is completed so that the facility can be inspected for issuance of an operating permit.
3. This Plan Approval authorizes Duke Energy Fayette, LLC to construct an electrical generation facility at their Fayette Energy Facility located in German Township, Fayette County. (25 Pa. Code § 127.12b)
4. The main sources at this facility will be two GE Model PG 7241 (FA) turbines. Turbines will be in combined cycle service, each equipped with its own heat recovery steam generator (HRSG), duct burners, a single condensing, reheat steam turbine generator (STG) and a surface condenser serving the STG. Overall rating for each turbine train is 310 MW nominal. (25 Pa. Code § 127.12b)
5. Turbines shall be equipped with dry low NOx combustors for use during the combustion of natural gas and water injection for use during the combustion of fuel oil. (25 Pa. Code § 127.12b)
6. Turbine exhaust gases shall be treated with selective catalytic reduction (SCR) for NOx control and oxidation catalyst (OC) for VOC and CO control. (25 Pa. Code § 127.12b)
7. Supporting equipment at this site will include an auxiliary boiler (rated at 44.1 mmBtu/hr, equipped with low NOx burners), one cooling towers with drift eliminators, four chiller cooling towers with drift eliminators, diesel engine fire pump, emergency diesel generator and two 2.45 million gallon, aboveground, fuel oil storage tanks. (25 Pa. Code § 127.12b)
8. Emission rates from each turbine, with the operation of duct burners, SCR and OC, during the combustion of natural gas, shall not exceed the following, based on a 30 day, rolling average: (25 Pa. Code § 127.12b)
Hourly Emission Rate--Gas
Pollutant ppmvd @ 15% O2 Pound/Hr NOx 2.5 23.2 CO 5.0 28.0 SO2 1.6 14.5 VOCs 5.3 11.5 PM10 N/A 34.8 NH3 5.0 18.9 9. Emission rates from each turbine, with the operation of duct burners, SCR and OC, during the combustion of fuel oil, shall not exceed the following, based on a 30-day, rolling average: (25 Pa. Code § 127.12b)
Hourly Emission Rate--Fuel Oil Pollutant ppmvd @ 15% O2 Pound/Hr NOx 6.5 68.3 CO 7.1 45.4 SO2 9.0 76.0 VOCs 6.4 28.7 PM10 N/A 61.0 NH3 5.0 22.3 10. The hourly emission limits established in Conditions 8, 9 and 34 do not apply during Startup and Shutdown. For purposes of this condition, a Startup shall be considered either a Cold Start (turbine down for more than 72 hours, startup duration 4.2 hours), a Warm Start (turbine down between 48 and 72 hours, startup duration 1.5 hours or a Hot Start (turbine down less than 48 hours, startup duration 1 hour).
11. Fuel oil combustion shall not exceed 2,000 turbine-hours per 12 consecutive month period. During the period April 1 through August 31, duct firing during fuel oil combustion shall not exceed 50% of maximum rated heat input. (25 Pa. Code § 127.12b)
12. The annual average sulfur content of the fuel oil shall not exceed 0.05 weight percent. (25 Pa. Code § 127.1)
13. Total emissions from the Fayette Energy Facility shall not exceed the following, on a 12 consecutive month rolling average basis: (25 Pa. Code § 127.12b)
Annual Emission Rate
Pollutant Combustion Turbines w/Duct Firing Auxiliary Boiler Cooling Towers Fire Pump Diesel
GeneratorFuel Oil Tanks Total Tons/Year NOx 289 2.1 0 1.55 3.1 0 296 CO 556 8.3 0 0.33 3.8 0 569 VOC 87 0.88 0 0.13 0.44 0.99 90 SO2 175 0.06 0 0.10 1.0 0 176 PM/PM10 311 0.55 1.56 0.11 0.18 0 313
14. The proposed construction is subject to 25 Pa. Code § 127.206(d)(1) and (2) and other applicable sections of 25 Pa. Code Chapter 127, Subchapter E, for nonattainment New Source Review. In accordance with 25 Pa. Code § 127.205(3), each modification to a facility shall offset in accordance with 25 Pa. Code §§ 127.201 and 127.211, the total of the net increase in potential to emit.
15. The applicable net emission increases from this facility are established at 296 tons NOx and 90 tons VOC per year. In accordance with 25 Pa. Code § 127.210, new emissions will be offset with Emission Reduction Credits (ERCs) at a ratio of 1.15:1.0.
16. Owner/operator shall secure 341 tons of NOx ERCs and 104 tons of VOC ERCs. ERCs shall be properly generated, certified by the Department and processed through the registry in accordance with 25 Pa. Code § 127.206(d)(1). Upon transfer, owner/operator shall provide the Department with documentation clearly specifying the details of the ERC transaction.
17. The combustion turbines are subject to the applicable requirements of the 40 CFR Part 60, Subpart GG--Standards of Performance for Stationary Gas Turbines.
18. The heat recovery steam generators are subject to the applicable requirements of 40 CFR 60, Subpart Da--Standards of Performance for Electric Utility Steam Generating Units for Which Construction Is Commenced After September 18, 1978.
19. The auxiliary boiler is subject to the applicable requirements of 40 CFR 60, Subpart Dc--Standards of Performance for Small Industrial-Commercial-Institutional Steam Generating Units.
20. The two 2.45 million-gallon fuel oil storage tanks are subject to the applicable requirements of 40 CFR Part 60, Subpart Kb--Standards of Performance for Volatile Organic Liquid Storage Vessels.
21. In accordance with 40 CFR 60.4, copies of all requests, reports, applications, submittals and other communications shall be forwarded to both the Environmental Protection Agency and the Department at the following addresses: Director, Air, Toxics and Radiation, Environmental Protection Agency, Region III, 1650 Arch Street, Philadelphia, PA 19103; and Department of Environmental Protection, Regional Air Quality Manager, Office of Air Quality, 400 Waterfront Drive, Pittsburgh, PA 15222-4745.
22. Owner/operator shall comply with the applicable reporting requirements of 40 CFR 60.7, 40 CFR 60.116b(d), 40 CFR 60.49a, 40 CFR 48c and 40 CFR 60.334(c).
23. In accordance with 40 CFR 60.334(a), owner/operator shall install and operate a continuous monitoring system to monitor and record the fuel consumption at all times and the ratio of water to fuel being fired in the turbines. This system shall be accurate to within +5% and must be approved by the Department.
24. Owner/operator shall monitor the sulfur content and nitrogen content of the fuel being fired in each turbine in accordance with 40 CFR 60.344(a). Upon approval from the EPA, an alternate custom fuel-monitoring program may be utilized. (25 Pa. Code § 127.12b)
25. Owner/operator shall install, certify, maintain and operate continuous emission monitoring systems in accordance with 25 Pa. Code Chapter 139, the Department's Continuous Source Monitoring Manual, 40 CFR Part 75 and applicable requirements of 40 CFR 60, Subparts Da, Dc and GG. At a minimum the systems shall measure and record the following for each turbine:
Nitrogen Oxide emissions (as NO2)
% Oxygen or Carbon Dioxide
Fuel Flow Monitor26. Prior to operation of the fuel oil-firing components of the system, the owner/operator shall install, certify, maintain and operate continuous emission monitoring systems in accordance with 25 Pa. Code Chapter 139, the Department's Continuous Source Monitoring Manual, 40 CFR Part 75 and applicable requirements of 40 CFR 60, Subparts Da, Dc and GG. At a minimum the systems shall measure and record the following for each turbine:
Opacity
Sulfur Dioxide27. Owner/operator shall record the hours of operation of each of the turbines and the amount and type of fuel consumed, on a daily basis. (25 Pa. Code § 127.12b)
28. In accordance with 40 CFR 60.334(c), owner/operator shall record daily and shall report semi-annually, in accordance with 40 CFR 60.7(c), any 1-hour period during which the average water-to-fuel ratio, as measured by the continuous water and fuel measuring system, falls below the ratio that was determined during the stack test to demonstrate compliance with NOx emission limitations. Owner/operator shall also report any period during which the actual fuel-bound nitrogen content exceeds the fuel-bound nitrogen content determined during the stack test to demonstrate compliance with the NOx emission limitations.
Substitute recordkeeping and reporting program may be utilized as an alternative to the monitoring requirements of 40 CFR 60.334(a) and 40 CFR 60.335(c)(2) upon approval from the EPA.
Owner/operator shall also report any period of fuel-oil combustion during which the actual fuel-bound sulfur content of the fuel oil exceeds 0.05 weight percent based on sampling results.
29. Compliance with the turbine emission limitations for NOx, CO, SO2, VOC, PM10 and NH3 while using both fuel oil and natural gas shall be demonstrated through performance stack testing on each turbine. (25 Pa. Code § 127.12b)
A. In accordance with 40 CFR 60.335(c)(2), the monitoring device required by 40 CFR 60.334 shall be used to determine the fuel consumption and the water-to-fuel ratio necessary to comply with turbine NOx emission limitations at 30, 50, 75 and 100% of peak load or at four points in the normal operating range of the gas turbine, including the minimum point in the range and peak load. All loads shall be corrected to ISO conditions using the appropriate equations as supplied by the turbine manufacturer.
B. Upon approval by the EPA, the following alternative testing requirement shall be used: the performance testing for nitrogen oxides shall only be required to be conducted at or near the maximum load of each turbine. The alternative is for each turbine to be monitored by a CEMS for nitrogen oxides, which is required by 40 CFR 75.
C. All stack testing shall be performed in accordance with 40 CFR 60.8 and 60.335, 25 Pa. Code Chapter 139 regulations and the most recent version of the Department's Source Testing Manual.
D. Two copies of the stack test protocol shall be submitted to the Department at least 60 days in advance of the stack test date. Stack testing shall not take place until owner/operator has received written approval of the stack test protocol.
E. Company shall notify the Department of the date and the time of the stack test at least 2 weeks prior to the tests so that an observer may be present.
F. Two copies of the stack test results shall be submitted to the Department within 60 days of completion of the test.
G. Stack testing shall be performed within 60 days of achieving maximum firing rate but no later than 180 days after the initial startup.
H. Owner/operator shall record all pertinent operating data during the stack test and include this data with the stack test results
30. The combustion turbines are subject to the Title IV Acid Rain Program of the 1990 Clean Air Act Amendments and shall comply with all applicable provisions of that Title, including the following:
40 CFR Part 72 Permits Regulations 40 CFR Part 73 Sulfur Dioxide Allowance System 40 CFR Part 75 Continuous Emissions Monitoring 40 CFR Part 77 Excess Emissions 31. The combustion turbines are subject to the applicable requirements of the NOx Budget Program established at 25 Pa. Code, §§ 123.102--123.120.
32. In accordance with 25 Pa. Code §§ 123.1--123.2, there shall be no fugitive emissions from this facility except those that arise from the use of roads. All reasonable actions shall be taken to minimize fugitive emissions that arise from use of roads. Reasonable actions shall include, but shall not be limited to paving, sweeping and application of water or other dust suppressants. In no case shall fugitive emissions arising from the use of roads be permitted to cross the property line.
33. In accordance with 25 Pa. Code § 123.31, owner/operator shall not permit the emission of any malodorous air contaminants from any source in a manner that the malodors, as determined by the Department, are detectable outside the owner/operator's property.
34. The opacity of the exhaust from all sources at this facility shall not exceed 10% at any time. Opacity shall be measured using EPA Reference Method 9, found at 40 CFR 60, Appendix A. (25 Pa. Code § 127.1)
35. The equipment at this gas turbine generating station shall be equipped with silencers and/or mufflers. The turbines, generators and gas compressors at this gas turbine generating station shall be enclosed in structures designed to minimize sound levels. (25 Pa. Code § 127.12b)
36. Per 25 Pa. Code § 127.13, if the construction is not commenced within 18 months of issuance of this Plan Approval or if there is more than an 18-month lapse in construction, a new Plan Approval application shall be submitted and the ERCs specified shall expire for use as offsets.
37. Owner/operator shall submit a Title V Operating Permit Application within 120 days of startup of the sources and/or pollution control devices. (25 Pa. Code § 127.505(a))
38. This Plan Approval authorizes the temporary operation of the sources covered by this Plan Approval provided that the following conditions are met: (25 Pa. Code § 127.12b(d))
A. The Department must receive written notice from the owner/operator of the anticipated date that sources will commence operation.
B. Operation is authorized only to facilitate the startup and shakedown of the sources, to permit operation of the sources pending the issuance of an Operating Permit or to permit the evaluation of the sources for compliance with all applicable regulations and requirements.
C. This condition authorizes temporary operation of the sources for a period of 180 days from the start of commencement of operation, provided that the Department receives notice from the owner/operator under Subpart (A).
D. Owner/operator may request an extension of this Plan Approval if compliance with all applicable regulations and Plan Approval requirements has not been established. The extension request shall be submitted in writing at least 15 days prior to the end of this period of temporary operation and shall provide a description of the compliance status of the source, a detailed schedule for establishing compliance and the reasons that compliance has not been established.
E. The notice submitted by the owner/operator under Subpart (A), prior to the expiration date of this Plan Approval, shall modify the Plan Approval expiration date. The new Plan Approval expiration date shall be 180 days from the date of the start-up.
PSD air quality modeling shows that the maximum impacts for CO, NO2 and PM10 are below the class II area significance levels. A full impact analysis to determine PSD increment consumption and compliance with the National Ambient Air Quality Standards was therefore not necessary. Class I area analyses for visibility and increment were conducted for the Otter Creek and Dolly Sods Wilderness Areas in West Virginia. Refined CALPUFF modeling shows that the project will not have significant impact on visibility or deposition in these areas.
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