Air Individual Permit Part 7 Reissuance 8516-11 Permittee: Facility name: PFB Manufacturing LLC Plasti Fab 116 Pine St S Lester Prairie, MN 55354-11 McLeod County Expiration date: July 18, 222 * All Title I Conditions do not expire Part 7 Reissuance: July 18, 217 Permit characteristics: Federal; Part 7/ Limits to avoid NSR; Limits to avoid NSR The emission units, control equipment and emission stacks at the stationary source authorized in this permit reissuance are as described in the Permit Applications Table. This permit reissuance supersedes Air Emission Permit No. 8516-4 and authorizes the Permittee to operate the stationary source at the address listed above unless otherwise noted in the permit. The Permittee must comply with all the conditions of the permit. Any changes or modifications to the stationary source must be performed in compliance with Minn. R. 77.115 to 77.15. Terms used in the permit are as defined in the state air pollution control rules unless the term is explicitly defined in the permit. Unless otherwise indicated, all the Minnesota rules cited as the origin of the permit terms are incorporated into the SIP under 4 CFR 52.122 and as such are enforceable by EPA Administrator or citizens under the Clean Air Act. Signature: for Toni Volkmeier This document has been electronically signed. Don Smith, P.E., Manager Air Quality Permits Section Industrial Division for the Minnesota Pollution Control Agency
Table of Contents 1. Permit applications table... 3 2. Where to send submittals... 4 3. Facility description... 5 4. Summary of subject items... 6 5. Limits and other requirements... 8 6. Submittal/action requirements... 21 7. Appendices... 22 Appendix A. Insignificant Activities and General Applicable Requirements... 22 Appendix B. Equipment Capacity and Maximum Contents of Materials.. 23 Page
Permit issued: July 18, 217 8516-11 Permit expires: July 18, 222 Page 3 of 23 1. Permit applications table Subsequent permit applications: Title description Application receipt date Action number Administrative Amendment 12/17/215 8516-11 Part 7 Reissuance 9/3/216 8516-11
Permit issued: July 18, 217 8516-11 Permit expires: July 18, 222 Page 4 of 23 2. Where to send submittals Send submittals that are required to be submitted to the U.S. EPA regional office to: Chief Air Enforcement Air and Radiation Branch EPA Region V 77 West Jackson Boulevard Chicago, Illinois 664 Each submittal must be postmarked or received by the date specified in the applicable Table. Those submittals required by Minn. R. 77.1 to 77.185 must be certified by a responsible official, defined in Minn. R. 77.1, subp. 21. Other submittals shall be certified as appropriate if certification is required by an applicable rule or permit condition. Send submittals that are required by the Acid Rain Program to: U.S. Environmental Protection Agency Clean Air Markets Division 12 Pennsylvania Avenue NW (624N) Washington, D.C. 246 Send any application for a permit or permit amendment to: Fiscal Services 6 th Floor Minnesota Pollution Control Agency 52 Lafayette Road North St. Paul, Minnesota 55155-4194 Also, where required by an applicable rule or permit condition, send to the Permit Document Coordinator notices of: a. Accumulated insignificant activities b. Installation of control equipment c. Replacement of an emissions unit, and d. Changes that contravene a permit term Unless another person is identified in the applicable Table, send all other submittals to: AQ Compliance Tracking Coordinator Industrial Division Minnesota Pollution Control Agency 52 Lafayette Road North St. Paul, Minnesota 55155-4194 Or Email a signed and scanned PDF copy to: submitstacktest.pca@state.mn.us (for submittals related to stack testing) AQRoutineReport.PCA@state.mn.us (for other compliance submittals) (See complete email instructions in Routine Air Report Instructions Letter at http://www.pca.state.mn.us/nwqh472.)
Permit issued: July 18, 217 8516-11 Permit expires: July 18, 222 Page 5 of 23 3. Facility description Plasti Fab is located at 116 Pine St S in Lester Prairie, McLeod County, Minnesota. Plasti Fab manufactures expanded polystyrene foam, producing custom protective foam packaging. They also manufacture commercial insulation systems for roofs. The process involves expanding polystyrene beads with steam, aging the expanded beads, and molding the beads with steam. The foam used for insulation is cut into boards with hot wires. During preexpansion, aging of expanded beads and final product, and molding, pentane and styrene monomer (both VOCs) are emitted. Plasti Fab uses a variety of beads, each releasing a different quantity of Volatile Organic Compounds (VOC). The VOCs are emitted to the atmosphere through building ventilation. Steam is provided by three boilers. Two of the boilers burn only natural gas and one burns wood chips. The wood burning boiler uses a multi-cyclone with flyash reinjection for particulate matter control.
Permit issued: July 18, 217 8516-11 Permit expires: July 18, 222 Page 6 of 23 4. Summary of subject items SI ID: Description ACTV3: All IA's COMG1: VOC and HAPs limits EQUI12: Molding Press #5 EQUI13: Molding Press #6 EQUI14: Molding Press #7 EQUI15: Molding Press #8 EQUI16: Molding Press #9 EQUI17: Molding Press #1 EQUI18: Molding Press #11 Relationshi p Type has members sends to sends to sends to sends to sends to sends to sends to Related SI ID: Description EQUI3, EQUI4, EQUI5, EQUI6, EQUI7, EQUI8, EQUI9, EQUI12, EQUI13, EQUI14, EQUI15, EQUI16, EQUI17, EQUI18, EQUI19, EQUI2 STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation SI ID: Description EQUI19: Molding Press #12 EQUI2: M & H Block Mold 25"x2' EQUI21: Boiler #1 (gas boiler) EQUI22: Boiler #2 (gas boiler) EQUI23: Boiler #3 (wood boiler) EQUI23: Boiler #3 (wood boiler) EQUI3: Pre-Puff Storage C1, C2, C3 EQUI4: Pre-Expander B- 1 EQUI5: Pre-Expander B- 2 EQUI6: Pre-Expander B- 3 #1 EQUI7: Pre-Expander B- 3 #2 Relationshi p Type sends to sends to sends to sends to sends to is controlled by sends to sends to sends to sends to sends to Related SI ID: Description (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU1: Boiler #1 stack STRU2: Boiler #2 stack STRU3: Boiler #3 stack TREA1: Multiple Cyclone w/fly Ash Reinjection- Common w/coal Boilers STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 7 of 23 SI ID: Description EQUI8: Molding Press #1 EQUI9: Molding Press #2 STRU1: Boiler #1 stack STRU2: Boiler #2 stack STRU3: Boiler #3 stack Relationshi p Type sends to sends to Related SI ID: Description (multiple points) STRU4: Building ventilation (multiple points) STRU4: Building ventilation (multiple points) SI ID: Description STRU4: Building ventilation (multiple points) STRU5: Manufacturing Including Boiler Rooms STRU6: Office and Plant STRU7: Plant and Block Mold Area STRU8: Plant TFAC1: Plasti Fab TREA1: Multiple Cyclone w/fly Ash Reinjection-Common w/coal Boilers Relationshi p Type Related SI ID: Description
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 8 of 23 5. Limits and other requirements Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation TFAC 1 8516 Plasti Fab 5.1.1 Permit Appendices: This permit contains appendices as listed in the permit Table of Contents. The Permittee shall comply with all requirements contained in Appendix A: Insignificant Activities and General Applicable Requirements and Appendix B: Equipment Capacity and Maximum Contents of Materials. [Minn. R. 77.8, subp. 2] 5.1.2 PERMIT SHIELD: Subject to the limitations in Minn. R. 77.18, compliance with the conditions of this permit shall be deemed compliance with the specific provision of the applicable requirement identified in the permit as the basis of each condition. Subject to the limitations of Minn. R. 77.18 and 717.1, subp. 2, notwithstanding the conditions of this permit specifying compliance practices for applicable requirements, any person (including the Permittee) may also use other credible evidence to establish compliance or noncompliance with applicable requirements. This permit shall not alter or affect the liability of the Permittee for any violation of applicable requirements prior to or at the time of permit issuance. [Minn. R. 77.18, (A)(2)] 5.1.3 The Permittee shall comply with National Primary and Secondary Ambient Air Quality Standards, 4 CFR pt. 5, and the Minnesota Ambient Air Quality Standards, Minn. R. 79.1 to 79.8. Compliance shall be demonstrated upon written request by the MPCA. [Minn. R. 77.1, subp. 7(A), 7(L), & 7(M), Minn. R. 77.8, subp. 4, Minn. R. 77.8, subps. 1-2, Minn. Stat. 116.7, subd. 4a, Minn. Stat. 116.7, subd. 9] 5.1.4 Circumvention: Do not install or use a device or means that conceals or dilutes emissions, which would otherwise violate a federal or state air pollution control rule, without reducing the total amount of pollutant emitted. [Minn. R. 711.2] 5.1.5 Air Pollution Control Equipment: Operate all pollution control equipment whenever the corresponding process equipment and emission units are operated. [Minn. R. 77.8, subp. 16(J), Minn. R. 77.8, subp. 2] 5.1.6 Operation and Maintenance Plan: Retain at the stationary source an operation and maintenance plan for all air pollution control equipment. At a minimum, the O & M plan shall identify all air pollution control equipment and control practices and shall include a preventative maintenance program for the equipment and practices, a description of (the minimum but not necessarily the only) corrective actions to be taken to restore the equipment and practices to proper operation to meet applicable permit conditions, a description of the employee training program for proper operation and maintenance of the control equipment and practices,
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 9 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation and the records kept to demonstrate plan implementation. [Minn. R. 77.8, subp. 14, Minn. R. 77.8, subp. 16(J)] 5.1.7 Operation Changes: In any shutdown, breakdown, or deviation the Permittee shall immediately take all practical steps to modify operations to reduce the emission of any regulated air pollutant. The Commissioner may require feasible and practical modifications in the operation to reduce emissions of air pollutants. No emissions units that have an unreasonable shutdown or breakdown frequency of process or control equipment shall be permitted to operate. [Minn. R. 719.1, subp. 4] 5.1.8 Fugitive Emissions: Do not cause or permit the handling, use, transporting, or storage of any material in a manner which may allow avoidable amounts of particulate matter to become airborne. Comply with all other requirements listed in Minn. R. 711.15. [Minn. R. 711.15] 5.1.9 Noise: The Permittee shall comply with the noise standards set forth in Minn. R. 73.1 to 73.8 at all times during the operation of any emission units. This is a state only requirement and is not enforceable by the EPA Administrator or citizens under the Clean Air Act. [Minn. R. 73.1-73.8] 5.1.1 Inspections: The Permittee shall comply with the inspection procedures and requirements as found in Minn. R. 77.8, subp. 9(A). [Minn. R. 77.8, subp. 9(A)] 5.1.11 The Permittee shall comply with the General Conditions listed in Minn. R. 77.8, subp. 16. [Minn. R. 77.8, subp. 16] 5.1.12 Performance Testing: Conduct all performance tests in accordance with Minn. R. ch. 717 unless otherwise noted in this permit. [Minn. R. ch. 717] 5.1.13 Performance Test Notifications and Submittals: Performance Test Notification and Plan: due 3 days before each Performance Test Performance Test Pre-test Meeting: due 7 days before each Performance Test Performance Test Report: due 45 days after each Performance Test The Notification, Test Plan, and Test Report must be submitted in a format specified by the commissioner. [Minn. R. 717.217, Minn. R. 717.23, subps. 1-4, Minn. R. 717.235, subps. 1-2] 5.1.14 Limits set as a result of a performance test (conducted before or after permit issuance) apply until superseded as stated in the MPCA's Notice of Compliance letter granting preliminary approval. Preliminary approval is based on formal review of a subsequent performance test on the same unit as specified by Minn. R. 717.225, subp. 3. The limit is final upon issuance of a permit amendment incorporating the change. [Minn. R. 717.225, subp. 3] 5.1.15 Monitoring Equipment Calibration - The Permittee shall either: 1. Calibrate or replace required monitoring equipment every 12
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 1 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation months; or 2. Calibrate at the frequency stated in the manufacturer's specifications. For each monitor, the Permittee shall maintain a record of all calibrations, including the date conducted, and any corrective action that resulted. The Permittee shall include the calibration frequencies, procedures, and manufacturer's specifications (if applicable) in the Operations and Maintenance Plan. Any requirements applying to continuous emission monitors are listed separately in this permit. [Minn. R. 77.8, subp. 4(D)] 5.1.16 Operation of Monitoring Equipment: Unless noted elsewhere in this permit, monitoring a process or control equipment connected to that process is not necessary during periods when the process is shutdown, or during checks of the monitoring systems, such as calibration checks and zero and span adjustments. If monitoring records are required, they should reflect any such periods of process shutdown or checks of the monitoring system. [Minn. R. 77.8, subp. 4(D)] 5.1.17 Recordkeeping: Retain all records at the stationary source, unless otherwise specified within this permit, for a period of five (5) years from the date of monitoring, sample, measurement, or report. Records which must be retained at this location include all calibration and maintenance records, all original recordings for continuous monitoring instrumentation, and copies of all reports required by the permit. Records must conform to the requirements listed in Minn. R. 77.8, subp. 5(A). [Minn. R. 77.8, subp. 5(C)] 5.1.18 Recordkeeping: Maintain records describing any insignificant modifications (as required by Minn. R. 77.125, subp. 3) or changes contravening permit terms (as required by Minn. R. 77.135, subp. 2), including records of the emissions resulting from those changes. [Minn. R. 77.8, subp. 5(B)] 5.1.19 If the Permittee determines that no permit amendment or notification is required prior to making a change, the Permittee must retain records of all calculations required under Minn. R. 77.12. For expiring permits, these records shall be kept for a period of five years from the date the change was made or until permit reissuance, whichever is longer. The records shall be kept at the stationary source for the current calendar year of operation and may be kept at the stationary source or office of the stationary source for all other years. The records may be maintained in either electronic or paper format. [Minn. R. 77.12, subp. 4] 5.1.2 Shutdown Notifications: Notify the Commissioner at least 24 hours in advance of a planned shutdown of any control equipment or process equipment if the shutdown would cause any increase in the emissions of any regulated air pollutant. If the owner or operator does not have advance knowledge of the shutdown, notification shall be made to the Commissioner as soon as possible after the shutdown. However, notification is not required in the circumstances outlined in Items A, B and C of Minn. R. 719.1,
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 11 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation subp. 3. At the time of notification, the owner or operator shall inform the Commissioner of the cause of the shutdown and the estimated duration. The owner or operator shall notify the Commissioner when the shutdown is over. [Minn. R. 719.1, subp. 3] 5.1.21 Breakdown Notifications: Notify the Commissioner within 24 hours of a breakdown of more than one hour duration of any control equipment or process equipment if the breakdown causes any increase in the emissions of any regulated air pollutant. The 24- hour time period starts when the breakdown was discovered or reasonably should have been discovered by the owner or operator. However, notification is not required in the circumstances outlined in Items A, B and C of Minn. R. 719.1, subp. 2. At the time of notification or as soon as possible thereafter, the owner or operator shall inform the Commissioner of the cause of the breakdown and the estimated duration. The owner or operator shall notify the Commissioner when the breakdown is over. [Minn. R. 719.1, subp. 2] 5.1.22 Notification of Deviations Endangering Human Health or the Environment: As soon as possible after discovery, notify the Commissioner or the state duty officer, either orally or by facsimile, of any deviation from permit conditions which could endanger human health or the environment. [Minn. R. 719.1, subp. 1] 5.1.23 Notification of Deviations Endangering Human Health or the Environment Report: Within 2 working days of discovery, notify the Commissioner in writing of any deviation from permit conditions which could endanger human health or the environment. Include the following information in this written description: 1. the cause of the deviation; 2. the exact dates of the period of the deviation, if the deviation has been corrected; 3. whether or not the deviation has been corrected; 4. the anticipated time by which the deviation is expected to be corrected, if not yet corrected; and 5. steps taken or planned to reduce, eliminate, and prevent reoccurrence of the deviation. [Minn. R. 719.1, subp. 1] 5.1.24 Application for Permit Amendment: If a permit amendment is needed, submit an application in accordance with the requirements of Minn. R. 77.115 through Minn. R. 77.15. Submittal dates vary, depending on the type of amendment needed. Upon adoption of a new or amended federal applicable requirement, and if there are more than 3 years remaining in the permit term, the Permittee shall file an application for an amendment within nine months of promulgation of the applicable requirement, pursuant to Minn. R. 77.4, subp. 3. [Minn. R. 77.4, subp. 3, Minn. R. 77.115-77.15]
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 12 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation 5.1.25 Extension Requests: The Permittee may apply for an Administrative Amendment to extend a deadline in a permit by no more than 12 days, provided the proposed deadline extension meets the requirements of Minn. R. 77.14, subp. 1(H). Performance testing deadlines from the General Provisions of 4 CFR pt. 6 and pt. 63 are examples of deadlines for which the MPCA does not have authority to grant extensions and therefore do not meet the requirements of Minn. R. 77.14, subp. 1(H). [Minn. R. 77.14, subp. 1(H)] 5.1.26 Emission Inventory Report: due on or before April 1 of each calendar year following permit issuance, to be submitted on a form approved by the Commissioner. [Minn. R. 719.3-719.31] 5.1.27 Emission Fees: due 3 days after receipt of an MPCA bill. [Minn. R. 72.5-72.95] 5.1.28 This permit establishes limits on the facility to keep it a minor source under New Source Review and NESHAPS. The Permittee cannot make any change at the source that would make the source a major source under New Source Review and NESHAPS until a permit amendment has been issued. This includes changes that might otherwise qualify as insignificant modifications and minor or moderate amendments. [Title I Condition: Avoid major modification under 4 CFR 52.21(b)(2) and Minn. R. 77.3, Title I Condition: Avoid major source under 4 CFR 52.21(b)(1)(i) and Minn. R. 77.3] 5.1.29 Equipment Labeling: The Permittee shall permanently affix a unique number to each emissions unit for tracking purposes. The numbers shall correlate the unit to the appropriate Subject Item numbers used in this permit. The number can be affixed by placard, stencil, or other means. The number shall be maintained so that it is readable and visible at all times from a safe distance. If equipment is added, it shall be given a new unique number; numbers from replaced or removed equipment shall not be reused. [Minn. R. 77.8, subp. 2] 5.1.3 Equipment Inventory: The Permittee shall maintain a written list of all emissions units. The Permittee shall update the list to include any replaced, modified, or new equipment prior to making the change. The list shall correlate the units to the Subject Item numbers used in this permit and shall include the data on GI-4, GI-5B, GI-5C, and GI-5F. The date of construction shall be the date the change was made for replaced, modified, or new equipment. [Minn. R. 77.8, subp. 2] COMG 1 GP1 VOC and HAPs limits 5.2.1 The Permittee shall limit emissions of Volatile Organic Compounds <= 24. tons per year 12-month rolling sum to be calculated by the 15th day of each month for the previous 12-month period as
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 13 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation described later in this permit. All non-combustion VOC-emitting equipment at the Facility is subject to this limit except those listed in appendix A. If the Permittee replaces any existing VOC-emitting equipment, adds new VOC-emitting equipment, or modifies the existing equipment, such equipment is subject to this permit limit as well as all of the requirements of COMG 1. Prior to making such a change, the Permittee shall apply for and obtain the appropriate permit amendment, as applicable. The Permittee is not required to complete VOC calculations described in Minn. R. 77.12, subp. 2. A permit amendment will still be needed regardless of the emissions increase if the change will be subject to a new applicable requirement or requires revisions to the limits or monitoring and recordkeeping in this permit. VOC contents for each VOC-containing material shall be determined as described under the Material Content requirement under COMG 1 of this permit. [Title I Condition: Avoid major modification under 4 CFR 52.21(b)(2) and Minn. R. 77.3, Title I Condition: Avoid major source under 4 CFR 52.21(b)(1)(i) and Minn. R. 77.3] 5.2.2 Particulate Matter <=.3 grains per dry standard cubic foot of exhaust gas unless required to further reduce emissions to comply with the less stringent limit of either Minn. R. 711.73 or Minn. R. 711.735. [Minn. R. 711.715, subp. 1(A)] 5.2.3 Opacity <= 2 percent opacity. [Minn. R. 711.715, subp. 1(B)] 5.2.4 Daily Recordkeeping: For VOC used in the EPS bead processes: On each day of operation, the Permittee shall maintain production records showing the amount of each VOC-containing material used. This shall be based on written usage logs and meter readings. For other VOC-containing materials: The Permittee shall calculate, maintain, and record monthly usage showing the quantity of each material used. This shall be based on either written usage logs or purchase/delivery records. [Minn. R. 77.8, subps. 4-5, Title I Condition: Avoid major modification under 4 CFR 52.21(b)(2) and Minn. R. 77.3, Title I Condition: Avoid major source under 4 CFR 52.21(b)(1)(i) and Minn. R. 77.3] 5.2.5 Material Content. VOC and HAPs contents in EPS beads shall be determined by a Certificate of Analysis (COA) provided by the supplier. If a COA is not available, the Permittee shall use the Safety Data Sheet (SDS) or the Material Safety Data Sheet (MSDS) provided by the supplier. If a material content range is given on the SDS or the MSDS, the highest number in the range shall be used in all compliance calculations. If there is information provided in the Regulatory Section of the SDS, the highest number in the range of that section may be used.
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 14 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation If neither a COA nor an MSDS is available or does not include the total VOC content, the Permittee shall assume that the pentane content of that shipment is 7% by weight and the styrene monomer content is.1% by weight. However, if in the preceding 12 months, EPS bead with a VOC content greater than 7.1% was used, then the Permittee shall assume that the VOC content of that shipment is equivalent to the highest VOC content used in the preceding 12 months. Other alternative methods approved by the MPCA may be used to determine the VOC, HAPs, and solids contents. The Commissioner reserves the right to require the Permittee to determine the VOC, HAP, and solids contents of any material, according to EPA or ASTM reference methods. If an EPA or ASTM reference method is used for material content determination, the data obtained shall supersede the SDS or the MSDS. [Minn. R. 77.8, subps. 4-5] 5.2.6 Material Content of Other Materials: VOC contents in other materials shall be determined by the Safety Data Sheet (SDS), Material Safety Data Sheet (MSDS) or similar document provided by the supplier for each material used. If a material content range is given on the SDS or MSDS, the highest number in the range shall be used in all compliance calculations. Other alternative methods approved by the MPCA may be used to determine the VOC contents. The Commissioner reserves the right to require the Permittee to determine the VOC contents of any material, according to EPA or ASTM reference methods. If an EPA or ASTM reference method is used for material content determination, the data obtained shall supersede the SDS or MSDS. [Minn. R. 77.8, subps. 4-5] 5.2.7 Maximum Contents of Materials: The Permittee assumed certain worst-case contents of materials when determining the short term potential to emit of units in COMG 1. These assumptions are listed in Appendix B of this permit. Changing to a material that has a higher content of any of the given pollutants is considered a change in method of operation that must be evaluated under Minn. R. 77.12, subp. 3 to determine if a permit amendment or notification is required under Minn. R. 77.115. [Minn. R. 75.1, subp. 35a] 5.2.8 Volatile Organic Compounds: Monthly Recordkeeping -- VOC Emissions. By the 15th of the month, the Permittee shall calculate and record the following: 1) The total usage of VOC-containing materials for the previous calendar month using the daily usage records. This record shall also include the VOC and solids contents of each material as determined by the Material Content requirement of this permit; 2) The VOC emissions for the previous month using the formulas specified in this permit; and 3) The 12-month rolling sum VOC emissions for the previous 12-
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 15 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation month period by summing the monthly VOC emissions data for the previous 12 months. [Minn. R. 77.8, subps. 4-5] 5.2.9 Volatile Organic Compounds: Monthly Calculation -- VOC Emissions. The Permittee shall calculate VOC emissions using the following equations: VOC (tons/month) = (A1 x B1) + (A2 x B2) + (A3 x B3) +... where: A# = amount of each VOC-containing material used, in tons/month; B# = weight percent VOC in A#, as a fraction; [Minn. R. 77.8, subps. 4-5] EQUI 21 EU1 Boiler #1 (gas boiler) 5.3.1 Particulate Matter <=.6 pounds per million Btu heat input The potential to emit from the unit is.7 lb/mmbtu due to equipment design and allowable fuels. [Minn. R. 711.51, subp. 1] 5.3.2 Opacity <= 2 percent opacity except for one six-minute period per hour of not more than 6 percent opacity. [Minn. R. 711.51, subp. 2] 5.3.3 Fuels allowed: natural gas only. [Minn. R. 77.8, subp. 2] 5.3.4 The Permittee shall keep records of fuel type used on a monthly basis. [Minn. R. 77.8, subp. 5] EQUI 22 EU2 Boiler #2 (gas boiler) 5.4.1 Particulate Matter <=.6 pounds per million Btu heat input The potential to emit from the unit is.24 lb/mmbtu due to equipment design and allowable fuels. [Minn. R. 711.51, subp. 1] 5.4.2 Opacity <= 2 percent opacity except for one six-minute period per hour of not more than 6 percent opacity. [Minn. R. 711.51, subp. 2] 5.4.3 Fuels allowed: natural gas only. [Minn. R. 77.8, subp. 2] 5.4.4 The Permittee shall keep records of fuel type used on a monthly basis. [Minn. R. 77.8, subp. 5] EQUI 23 EU3 Boiler #3 (wood boiler) 5.5.1 Particulate Matter <=.4 pounds per million Btu heat input The potential to emit from the unit is.29 lb/mmbtu due to equipment design and allowable fuels. [Minn. R. 711.515, subp. 1] 5.5.2 Opacity <= 2 percent opacity except for one six-minute period per hour of not more than 6 percent opacity. [Minn. R. 711.515, subp. 2] 5.5.3 Fuels allowed: wood only. [Minn. R. 77.8, subp. 2]
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 16 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation 5.5.4 The Permittee shall keep records of fuel type and usage on a monthly basis. [Minn. R. 77.8, subp. 5] 5.5.5 The Permittee shall operate and maintain TREA 1 any time the emission unit is in operation. [Minn. R. 77.8, subp. 2] 5.5.6 4 CFR pt. 63, subp. JJJJJJ is an Applicable Requirement under Minn. R. 77.1, subp. 7(D); however, this standard is not delegated to MPCA. [Minn. R. 77.1, subp. 7(D)] 5.5.7 Circumvention. The Permittee shall not build, erect, install, or use any article, machine, equipment, or process to conceal an emission that would otherwise constitute noncompliance with a relevant standard. Such concealment includes, but is not limited to: (1) The use of diluents to achieve compliance with a relevant standard based on the concentration of a pollutant in the effluent discharged to the atmosphere; or (2) The use of gaseous diluents to achieve compliance with a relevant standard for visible emissions. [4 CFR 63.4(b), Minn. R. 711.7] 5.5.8 The Permittee shall maintain, at a minimum, the following information in the files: --All required measurements needed to demonstrate compliance with a relevant standard; --All documentation supporting initial notifications and notifications of compliance status. [4 CFR 63.1(b)(2), Minn. R. 719.1, subp. 2(B)] 5.5.9 At all times the Permittee must operate and maintain affected boilers, including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control practices for minimizing emissions. The general duty to minimize emissions does not require the Permittee to make any further efforts to reduce emissions if levels required by this standard have been achieved. Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator that may include, but is not limited to, monitoring results, review of operation and maintenance procedures, review of operation and maintenance records, and inspection of the source. [4 CFR 63.1125(a), Minn. R. 711.755] 5.5.1 The standards in 4 CFR Section 63.1121 apply at all times the affected boilers are operating, except during periods of startup and shutdown as defined in 4 CFR Section 63.11237, during which time the Permittee must comply only with 4 CFR pt. 63, subp. JJJJJJ, Table 2. [4 CFR 63.1121(d), Minn. R. 711.755] 5.5.11 The Permittee must comply with each work practice standard, emission reduction measure, and management practice specified in Table 2 to this subpart that applies to its boiler. An energy assessment completed on or after January 1, 28 that meets or is amended to meet the energy assessment requirements in Table 2 to this subpart satisfies the energy assessment requirement. A
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 17 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation facility that operates under an energy management program established through energy management systems compatible with ISO 51, that includes the affected units, also satisfies the energy assessment requirement. [4 CFR 63.1121(b), Minn. R. 711.755] 5.5.12 Records must be in a form suitable and readily available for expeditious review. The Permittee must keep each record for 5 years following the date of each recorded action. The Permittee must keep each record on-site or be accessible from a central location by computer or other means that instantly provide access at the site for at least 2 years after the date of each recorded action. The Permittee may keep the records off site for the remaining 3 years. [4 CFR 63.1(b)(1), 4 CFR 63.11225(d), Minn. R. 711.7, Minn. R. 711.755, Minn. R. 719.1, subp. 2(B)] 5.5.13 The Permittee must conduct a performance tune-up according to 4 CFR Section 63.11223(b) and submit a signed statement in the Notification of Compliance Status report that indicates that the Permittee conducted a tune-up of the boiler. [4 CFR 63.11214(b), Minn. R. 711.755] 5.5.14 The Permittee must conduct a tune-up for EQUI23 biennially according to 4 CFR Section 63.11223 and keep records as required in 4 CFR Section 63.11225(c) to demonstrate continuous compliance. The tune-up must be conducted while burning the type of fuel that provided the majority of the heat input to the boiler over the 12 months prior to the tune-up. [4 CFR 63.11223(a), 4 CFR 63.subp. JJJJJJ(Table 2), Minn. R. 711.755] 5.5.15 The Permittee must conduct a tune-up of the boiler biennially no more than 25 months after the previous tune-up, to demonstrate continuous compliance as specified in (1) through (7) as follows: (1) As applicable, inspect the burner, and clean or replace any components of the burner as necessary (the Permittee may delay the burner inspection until the next scheduled unit shutdown, not to exceed 36 months from the previous inspection). (2) Inspect the flame pattern, as applicable, and adjust the burner as necessary to optimize the flame pattern. The adjustment should be consistent with the manufacturer's specifications, if available. (3) Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly (the Permittee may delay the inspection until the next scheduled unit shutdown, not to exceed 36 months from the previous inspection). Units that produce electricity for sale may delay the inspection until the first outage, not to exceed 36 months from the previous inspection. (4) Optimize total emissions of CO. This optimization should be consistent with the manufacturer's specifications, if available, and with any nitrogen oxide requirement to which the unit is subject. (5) Measure the concentrations in the effluent stream of CO in parts per million, by volume, and oxygen in volume percent, before and after the adjustments are made (measurements may be either on a dry or wet basis, as long as it is the same basis before and after the adjustments are made). Measurements may be taken using a
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 18 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation portable CO analyzer. (6) Maintain on-site and submit, if requested by the Administrator, a report containing the information in (i) through (iii) as follows: (i) The concentrations of CO in the effluent stream in parts per million, by volume, and oxygen in volume percent, measured at high fire or typical operating load, before and after the tune-up of the boiler. (ii) A description of any corrective actions taken as a part of the tune-up of the boiler. (iii) The type and amount of fuel used over the 12 months prior to the tune-up of the boiler, but only if the unit was physically and legally capable of using more than one type of fuel during that period. Units sharing a fuel meter may estimate the fuel use by each unit. (7) If the unit is not operating on the required date for a tune-up, the tune-up must be conducted within 3 days of startup. [4 CFR 63.11223(b), Minn. R. 711.755] 5.5.16 The Permittee must have a one-time energy assessment performed by a qualified energy assessor. An energy assessment completed on or after January 1, 28, that meets or is amended to meet the energy assessment requirements in Table 2 to 4 CFR pt. 63, subp. JJJJJJ satisfies the energy assessment requirement. Energy assessor approval and qualification requirement s are waived in instances where past or amended energy assessments are used to meet the energy assessment requirements. A facility that operates under an energy management program compatible with ISO 51, that includes the affected units, also satisfies the energy assessment requirement. The energy assessment must include: (1) A visual inspection of the boiler system; (2) An evaluation of operating characteristics of the affected boiler systems, specifications of energy using systems, operating and maintenance procedures, and unusual operating constraints; (3) An inventory of major energy use systems consuming energy from affected boiler(s) and which are under control of the boiler owner or operator; (4) A review of available architectural and engineering plans, facility operation and maintenance procedures and logs, and fuel usage; (5) A list of major energy conservation measures that are within the facility's control; (6) A list of the energy savings potential of the energy conservation measures identified; and (7) A comprehensive report detailing the ways to improve efficiency, the cost of specific improvements, benefits, and the time frame for recouping those investments. [4 CFR 63.1121(b), 4 CFR 63.subp. JJJJJJ(Table 2), Minn. R. 711.755] 5.5.17 The Permittee must submit all of the notifications in 4 CFR Sections 63.7(b); 63.8(e) and (f); 63.9(b) through (e), (g) and (h) that apply by the dates specified in those sections except as specified in 4 CFR Section 63.11225(a)(2) and (4). [4 CFR 63.11225(a)(1), Minn. R. 711.755]
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 19 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation 5.5.18 The Permittee must maintain the following records: (1) A copy of each notification and report that was submitted to comply with 4 CFR pt. 63, subp. JJJJJJ, including all documentation supporting any Initial Notification or Notification of Compliance Status that was submitted, as required by 4 CFR Section 63.1(b)(2)(xiv); (2) Records to document conformance with 4 CFR Sections 63.11214 and 63.11223 as specified as follows: (i) Records must identify each boiler, the date of tune-up, the procedures followed for tune-up, and the manufacturer's specifications to which the boiler was tuned. (ii) For each boiler required to conduct an energy assessment, the Permittee must keep a copy of the energy assessment report. (3) Records of the occurrence and duration of each malfunction of each boiler or of the associated air pollution control and monitoring equipment. (4) Records of actions taken during periods of malfunction to minimize emissions in accordance with the general duty to minimize emissions in 4 CFR Section 63.1125(a), including corrective actions to restore the malfunctioning boiler, air pollution control, or monitoring equipment to its normal or usual manner of operation. (5) Records of all inspection and monitoring data as required by 4 CFR Sections 63.11221 and 63.11222, and the information identified below for each required inspection or monitoring: (i) The date, place, and time of the monitoring event; (ii) Person conducting the monitoring; (iii) Technique or method used; (iv) Operating conditions during the activity; (v) Results, including the date, time, and duration of the period from the time the monitoring indicated a problem to the time that monitoring indicated proper operation; (vi) Maintenance or corrective action taken (if applicable). [4 CFR 63.11225(c), Minn. R. 711.755] 5.5.19 The Permittee must prepare by March 1, and submit to the Administrator upon request, a biennial compliance certification report for the previous biennial period containing the information described below. The Permittee must submit the compliance report by March 15 if the Permittee had any instance described by item 3 below. (1) Company name and address (2) Statement by a responsible official, with the official's name, title, phone number, e-mail address, and signature, certifying the truth, accuracy, and completeness of the notification and a statement of whether the source has complied with all the relevant standards and other requirements of 4 CFR pt. 63, subp. JJJJJJ. The notification must include the following certifications of compliance, as applicable, and signed by a responsible official. (i) "This facility complies with the requirements in 4 CFR Section 63.11223 to conduct a biennial tune-up, as applicable, of each
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 2 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation boiler." (ii) "This facility complies with the requirement in 4 CFR Section 63.11214(d) to minimize the boiler's time spent during startup and shutdown and to conduct startups and shutdowns according to the manufacturer's recommended procedures or procedures specified for a boiler of similar design if manufacturer's recommended procedures are not available." (3) If the source experiences any deviations from the applicable requirements during the reporting period, include a description of deviations, the time periods during which the deviations occurred, and the corrective actions taken. [4 CFR 63.11225(b), Minn. R. 711.755] 5.5.2 The Permittee must comply with the general provisions specified in 4 CFR 63, subp. JJJJJJ, Table 8. [4 CFR 63.63.11235, Minn. R. 711.755] TREA 1 CE1 Multiple Cyclone w/fly Ash Reinjection- Common w/coal Boilers 5.6.1 The Permittee shall operate and maintain TREA 1 such that it achieves a control efficiency for Particulate Matter >= 5 percent control efficiency. [Minn. R. 77.8, subp. 2, Minn. R. 711.515] 5.6.2 Pressure Drop >=.1 and <= 3. inches of water, unless a new range is set pursuant to Minn. R. 717.225, subp. 3 based on the values recorded during the most recent MPCA-approved performance test where compliance was demonstrated. The new range shall be implemented upon receipt of the Notice of Compliance letter granting preliminary approval. The range is final upon issuance of a permit amendment incorporating the change. The Permittee shall record the pressure drop at least once each operating day. [Minn. R. 77.8, subp. 14, Minn. R. 77.8, subp. 2, Minn. R. 711.515] 5.6.3 The Permittee shall vent emissions from EQUI23 to TREA 1 whenever EQUI23 operates, and operate and maintain TREA 1 at all times that any emissions are vented to TREA 1. The Permittee shall document periods of non-operation of the control equipment TREA 1 whenever EQUI23 is operating. [Minn. R. 77.8, subp. 2, Minn. R. 711.515] 5.6.4 If the Permittee replaces TREA 1, the replacement control must meet or exceed the control efficiency requirements of TREA 1 as well as comply with all other requirements of TREA 1. Prior to making such a change, the Permittee shall apply for and obtain the appropriate permit amendment, as applicable. If no amendment is needed for the replacement, the Permittee shall submit an electronic notice to the Agency using Form CR-5. The notice must be received by the Agency seven working days
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 21 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation prior to the commencement/start of replacement. [Minn. R. 77.8, subp. 2] 5.6.5 The Permittee shall operate and maintain the cyclone in accordance with the Operation and Maintenance (O & M) Plan. The Permittee shall keep copies of the O & M Plan available onsite for use by staff and MPCA staff. [Minn. R. 77.8, subp. 14] 5.6.6 On each day of operation, the Permittee shall read and record the pressure drop across the control device. [Minn. R. 717.8, subp. 4, Minn. R. 717.8, subp. 5] 5.6.7 Pressure Drop: Monitoring Equipment: The Permittee shall install and maintain the necessary monitoring equipment for measuring and recording pressure drop as required by this permit. The monitoring equipment must be installed, in use, and properly maintained when the monitored cyclone is in operation. [Minn. R. 77.8, subp. 4] 5.6.8 Annual Calibration: The Permittee shall calibrate the pressure drop monitor at least once every 12 months and shall maintain a written record of the calibration and any action resulting from the calibration. [Minn. R. 77.8, subp. 5] 5.6.9 Periodic Inspections: At least once per calendar quarter, or more frequently as required by the manufacturing specifications, the Permittee shall inspect the control equipment components. The Permittee shall maintain a written record of these inspections. [Minn. R. 77.8, subp. 14, Minn. R. 77.8, subp. 5] 5.6.1 Corrective Actions: The Permittee shall take corrective action as soon as possible if any of the following occur: - the recorded pressure drop is outside the required operating range; or - the cyclone or any of its components are found during the inspections to need repair. Corrective actions shall return the pressure drop to within the permitted range and/or include completion of necessary repairs identified during the inspection, as applicable. Corrective actions include, but are not limited to, those outlined in the O & M Plan for the cyclone. The Permittee shall keep a record of the type and date of any corrective action taken for each control device. [Minn. R. 77.8, subp. 14, Minn. R. 77.8, subp. 5] 6. Submittal/action requirements This section lists most of the submittals required by this permit. Please note that some submittal requirements may appear in the Limits and Other Requirements section, or, if applicable, within a Compliance Schedule section. Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation TFAC 1 8516 Plasti Fab
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 22 of 23 Subject Item Sec.SI.Reqt SI des:si desc Requirement & Citation 6.1.1 The Permittee shall submit an application for permit reissuance : Due 18 calendar days before Permit Expiration Date. [Minn. R. 77.4, subp. 2] 6.1.2 The Permittee shall submit a semiannual deviations report : Due semiannually, by the 3th of January and July The first semiannual report submitted by the Permittee shall cover the calendar half-year in which the permit is issued. The first report of each calendar year covers January 1 - June 3. The second report of each calendar year covers July 1 - December 31. If no deviations have occurred, the Permittee shall submit the report stating no deviations. [Minn. R. 77.8, subp. 6(A)(2)] 6.1.3 The Permittee shall submit a compliance certification : Due annually, by the 31st of January (for the previous calendar year). The Permittee shall submit this to the Commissioner on a form approved by the Commissioner. This report covers all deviations experienced during the calendar year. [Minn. R. 77.8, subp. 6(C)] 6.1.4 The Permittee shall submit an annual report : Due annually, by the 31st of January The report shall describe the changes made at the Facility during the previous calendar year using the latest MPCA application forms. The report shall include information for any new or replaced Subject Items. The report shall document the VOC 12-month rolling sum calculations for the previous calendar year. The report shall be submitted with the annual Compliance Certification required by this permit. As part of the Annual Report, the Permittee shall verify and certify that the Facility has maintained minor source status for New Source Review. [Minn. R. 77.8, subp. 2] 7. Appendices Appendix A. Insignificant Activities and General Applicable Requirements The table below lists the insignificant activities that are currently at the Facility and their associated general applicable requirements. Minn. R. Rule description of the activity General applicable requirement Minn. R. 77.13, subp. Brazing, soldering or welding equipment 3(H)(3) Minn. R. 77.13, subp. 3(I) Plasti Fab operates numerous welding units. Individual units with potential emissions less than 2 lb/year of certain pollutants Plasti Fab has hot wire cutting and small gluing operations. PM, variable depending on airflow Opacity <= 2% (Minn. R. 711.71 or 711.715) PM, variable depending on airflow Opacity <= 2% (Minn. R. 711.71 or 711.715)
Permit Issued: July 18, 217 8516-11 Permit Expires: July 18, 222 Page 23 of 23 Appendix B. Equipment Capacity and Maximum Contents of Materials The following table lists maximum equipment capacity and maximum material contents for each specified unit. These are worst-case assumptions at the time of permit issuance. Changing to a material that has a higher VOC content or increasing the capacity of an emission unit is considered a change in method of operation. Equipment Maximum VOC Maximum Capacity (EQUI) Content* 4 8 lb bead/hour 7.1 wt % 5 35 lb bead/hour 7.1 wt% 6 8 lb bead/hour 7.1 wt% 7 8 lb bead/hour 7.1 wt % 8 2 lb bead/hour 7.1 wt% 9 21 lb bead/hour 7.1 wt% 12 2 lb bead/hour 7.1 wt % 13 175 lb bead/hour 7.1 wt % 14 45 lb bead/hour 7.1 wt % 15 45 lb bead/hour 7.1 wt % 16 175 lb bead/hour 7.1 wt % 17 175 lb bead/hour 7.1 wt % 18 175 lb bead/hour 7.1 wt % 19 175 lb bead/hour 7.1 wt % 2 195 lb bead/hour 7.1 wt % *includes all VOC (e.g., pentane, styrene, etc.)