THIS FILING SUBMITTED ON RECYCLED PAPER
BEFORE THE ILLINOIS POLLUTION CONTROL BOARD
VESUVIUS USA CORPORATION,
)
)
Petitioner,
)
)
v.
)
PCB 08-____
)
(Air Permit Appeal)
ILLINOIS ENVIRONMENTAL
)
PROTECTION AGENCY,
)
)
Respondent.
)
NOTICE OF FILING
TO:
Mr. John Therriault
Division of Legal Counsel
Assistant Clerk of the Board
Illinois Environmental Protection Agency
Illinois Pollution Control Board
1021 North Grand Avenue East
100 West Randolph Street
Post Office box 19276
Suite 11-500
Springfield, Illinois 67294-9276
Chicago, Illinois 60601
(VIA ELECTRONIC MAIL)
(VIA U.S. MAIL)
(PERSONS ON ATTACHED SERVICE LIST)
PLEASE TAKE NOTICE that I have today filed with the Office of the Clerk of
the Illinois Pollution Control Board the
ENTRY OF APPEARANCE OF
KATHERINE D. HODGE, ENTRY OF APPEARANCE OF THOMAS G.
SAFLEY,
and
PETITION FOR REVIEW
on behalf of VESUVIUS USA
CORPORATION, copies of which are herewith served upon you.
Respectfully submitted,
By:
/s/ Katherine D. Hodge
Katherine D. Hodge
Dated: March 3, 2008
Katherine D. Hodge
Thomas G. Safley
HODGE DWYER ZEMAN
3150 Roland Avenue
Post Office Box 5776
Springfield, Illinois 62705-5776
(217) 523-4900
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
CERTIFICATE OF SERVICE
I, Katherine D. Hodge, the undersigned, hereby certify that I have served the
ENTRY OF APPEARANCE OF KATHERINE D. HODGE, ENTRY OF
APPEARANCE OF THOMAS G. SAFLEY, and PETITION FOR REVIEW upon:
Mr. John Therriault
Assistant Clerk of the Board
Illinois Pollution Control Board
100 West Randolph Street
Suite 11-500
Chicago, Illinois 60601
via electronic mail on March 3, 2008; and upon:
Division of Legal Counsel
Illinois Environmental Protection Agency
1021 North Grand Avenue East
Post Office Box 19276
Springfield, Illinois 62794-9276
by depositing said documents in the United States Mail, postage prepaid, in Springfield,
Illinois on March 3, 2008.
/s/ Katherine D. Hodge
Katherine D. Hodge
VESU:003/Fil/EOAs – KDH, TGS, Petition
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
BEFORE THE ILLINOIS POLLUTION CONTROL BOARD
VESUVIUS USA CORPORATION,
)
)
Petitioner,
)
)
v.
)
PCB 08-____
)
(Air Permit Appeal)
ILLINOIS ENVIRONMENTAL
)
PROTECTION AGENCY,
)
)
Respondent.
)
ENTRY OF APPEARANCE OF KATHERINE D. HODGE
NOW COMES Katherine D. Hodge, of the law firm HODGE DWYER ZEMAN,
and hereby enters her appearance in this matter on behalf of Vesuvius USA Corporation.
Respectfully submitted,
By: /s/ Katherine D. Hodge
Katherine D. Hodge
Dated: March 3, 2008
Katherine D. Hodge
HODGE DWYER ZEMAN
3150 Roland Avenue
Post Office Box 5776
Springfield, Illinois 62705-5776
(217) 523-4900
VESU:003/Fil/EOA – KDH
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
BEFORE THE ILLINOIS POLLUTION CONTROL BOARD
VESUVIUS USA CORPORATION,
)
)
Petitioner,
)
)
v.
)
PCB 08-____
)
(Air Permit Appeal)
ILLINOIS ENVIRONMENTAL
)
PROTECTION AGENCY,
)
)
Respondent.
)
ENTRY OF APPEARANCE OF THOMAS G. SAFLEY
NOW COMES Thomas G. Safley, of the law firm HODGE DWYER ZEMAN,
and hereby enters his appearance in this matter on behalf of Vesuvius USA Corporation.
Respectfully submitted,
By: /s/ Thomas G. Safley
Thomas G. Safley
Dated: March 3, 2008
Thomas G. Safley
HODGE DWYER ZEMAN
3150 Roland Avenue
Post Office Box 5776
Springfield, Illinois 62705-5776
(217) 523-4900
VESU:003/Fil/EOA – TGS
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
BEFORE THE ILLINOIS POLLUTION CONTROL BOARD
VESUVIUS USA CORPORATION,
)
)
Petitioner,
)
)
v.
)
PCB 08-____
)
(Air Permit Appeal)
ILLINOIS ENVIRONMENTAL
)
PROTECTION AGENCY,
)
)
Respondent.
)
PETITION FOR REVIEW
NOW COMES Petitioner, VESUVIUS USA CORPORATION, an Illinois
Corporation (“Vesuvius”), by and through its attorneys, HODGE DWYER ZEMAN,
pursuant to Section 40.2 of the Illinois Environmental Protection Act (415 ILCS 5/40.2)
(“Act”) and 35 Ill. Admin. Code § 105.Subpart C, and petitions the Illinois Pollution
Control Board (“Board”) for review of the Federally Enforceable State Operating Permit
(“FESOP”) issued to Vesuvius by the Illinois Environmental Protection Agency (“Illinois
EPA”) pursuant to Section 39.5 of the Act on January 28, 2008.
In support thereof, Vesuvius states as follows:
1.
Vesuvius owns and operates a ceramic manufacturing facility in
Charleston, Illinois, which operates pursuant to a FESOP.
2.
Pursuant to Section 39.5 of the Act, on December 7, 2006, Vesuvius
submitted an application to Illinois EPA to renew the FESOP for its Charleston, Illinois
facility.
3.
Thereafter, Vesuvius received a preliminary draft FESOP from Illinois
EPA for review.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
2
4.
On October 22, 2007, Vesuvius asked Illinois EPA to make changes to the
preliminary draft FESOP. Among other requests, Vesuvius asked that Illinois EPA add
language to section 5b of the draft permit requiring the seven fume incinerator
combustion chambers to operate at one of the following temperatures: (1) the
manufacturer’s recommended temperature; (2) at least 1400°F in the absence of
compliance testing; or (3) if compliance testing has been performed, at a temperature to
meet the emissions conditions of permit Section 4b. Vesuvius proposed to add this
operating temperature language to replace the combustion chamber preheating
requirements in Section 5b of the draft FESOP. That request was made in a letter sent to
Illinois EPA dated October 22, 2007. That letter is attached to this Petition as Exhibit A.
5.
On January 28, 2008, Illinois EPA issued a final FESOP for Vesuvius’s
Charleston facility. This permit is attached as Exhibit B. Section 5b of the final permit
does not contain the language requested by Vesuvius, but instead requires Vesuvius to
preheat the fume incinerator’s combustion chambers to “at least the manufacturer’s
recommended temperature but not less than the temperature at which compliance was
demonstrated in the most recent compliance test or 1400°F in the absence of a
compliance test.”
6.
Vesuvius believes that it can comply with the emissions limitations in
Section 4b without preheating the combustion chambers and therefore should not be
subject to the preheating requirements of Section 5b of the final permit.
7.
As set forth above, Illinois EPA included conditions in the FESOP that are
not required by the Act or regulations promulgated thereunder, and are not necessary to
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
3
correct, detect, or prevent noncompliance with, or to accomplish the purpose of, the Act
or regulations promulgated thereunder.
WHEREFORE, Petitioner VESUVIUS USA CORPORATION petitions the
Illinois Pollution Control Board for a hearing on the Illinois Environmental Protection
Agency’s action to issue this FESOP permit with this requirement.
Respectfully submitted,
VESUVIUS USA CORPORATION
Petitioner,
By:/s/ Katherine D. Hodge
One of Its Attorneys
Dated: March 3, 2008
Katherine D. Hodge
Thomas G. Safley
HODGE DWYER ZEMAN
3150 Roland Avenue
Post Office Box 5776
Springfield, Illinois 62705-5776
(217) 523-4900
VESU:003/Fil/Petition for Review
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
SENDER:
COMPLETE TH1S SECTION
ý COMPLETE THIS SECTfON ON DELIVERY
" Complete
items
1, 2, and 3. Also complete
item 4 if Restricted-
eAy is desired.
" Print your name and address on the reverse
so that we can return the card to you.
IIIIIII Attach this card to the back of the mailpiece,
Octobl
or on the front if space permits.
Edwin
Acting
Divisic
Illinois
1021 r
PO Bc
Spring
Re: P
ID No:
Applia
1 . Article Addressed to:
ý ýýýlowsx,,
126 r
r 9sý
5fý r
IN
7 ,e i<l
l
L
2 . Article Number
(Transfer from service lat
Dear c PS
Form 3811, August 2001
A . Signature
X
B . Received by (Printed Name)
Illinois Environmental
Proi
0 Agent
I
0 Addressee
C. Date
of Delivery
c tion An iza
D . Is delivery a
eV-ti* ite`f ,.
I`Yes
If YES, entgS4delivery address below
.:
,St o
OCT 2,5
2007
3 . Service Type
Certified Mail
0 Registered
0 Insured Mail
0
d Al
Express Ma I
Return Receipt for Merchandise
0 C.O.D.
'
i
4. Restricted Delivery? (Extra Fee)
7002 2030 0005
3853 1641
0 Yes
D omestic Return Receipt
ný.ý Fýý p
102595-02-M-1035
Vesuvius USA
respectfully requests the following
changes in the Preliminary Draft FESOP.
Page 1--change Attn: John Herring
to Attn: Joe Woodall
Page 1--change 4 Fume
Incinerators (FI-3-6) to 3 Fume Incinerators (FI-4-6) (The Brule
incinerator
(FI-3) was removed in 1999
when incinerator FI-6 was installed for the New Mix
Plant (TD-3) and the Old Mix Plant
(TD-2).)
Page 1--change Tube Dryer (TD-2)
... (FI-3) to Tube Dryer (TD-2) ... (FI-6)
Page 3 section 5a--Change the
6 to a 7 and remove "at all times" (the facility has 7 fume
incinerators/afterburners)
Page
3 section 5b--Remove the first sentence
"Fume incinerator (FI-3)..."
Page 3 section 5b--Replace the second
sentence "The other 5 Fume incinerators..." with
the following:
"The 7 fume incinerator combustion
chambers shall be operated at one of the
following temperatures:
1) the manufacturers recommended
temperature,
2) In the absence of a compliance
test, at least 1400 degrees F, or
3) if compliance testing has been
done, at a temperature to meet the conditions
of
section
4b."
Page 7 section 9a--Change 6 to 7
Page 7 section 9b--Change 6 to 7
Page 8 section 12.a.ii--Remove
the words "each day" from the sentence.
Page 8 section 12.a.ii.A--Change the
sentence to read "Daily monitoring data
of the
Incinerator/Afterburner combustion
chamber temperature."
Page 8 section 12.a.ii.B--Change
the sentence to read "A monthly log of
operating time..."
A marked up copy of the Preliminary draft
FESOP is
attached.
If You have any questions,
please contact
me at 217-345-7095 extension
277.
S incerely yours,
Jffsepph D. Woodall
Facilities Manager
Cc:
Randy Swank
David E. Haney
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
I , Xoq
SNI
UI
jT+diL
Nu°
o 6-J
'ON 1l
a
a?d
O ctober 22,2007
19A
NI
North 5.S treet
Charleston, Illinois 61920
217-345-7095
Edwin C.
Bakowski, P.E.
Acting Manager, Permit Section
Division
of Air Pollution Control
Illinois Environmental Protection
Agency
1021
North Grand Avenue East
PO Box 19506
Springfield,
Illinois 62794-9506
Re:
Preliminary Draft FESOP
ID No: 029010AAE
Application
No: 95120117
Dear
Sir.
Vesuvius USA respectfully
requests the following changes in the Preliminary Draft FESOP.
Page 1--change Attn: John Herring to Attn: Joe Woodall
Page 1--change 4 Fume Incinerators (FI-3-6) to 3 Fume Incinerators (FI-4-6) (The
Brule
incinerator (FI-3) was removed
in 1999
when
incinerator FI-6 was installed for the New Mix
Plant (TD-3) and the Old Mix Plant (TD-2).)
Page 1--change Tube Dryer (TD-2) ... (FI-3) to Tube Dryer
(TD-2)... (FI-6)
Page 3 section 5a--Change the 6 to a 7 and remove "at all times" (the
facility has 7 fume
incinerators/afterburners)
Page 3 section 5b--Remove
the first sentence "Fume incinerator (FI-3)..."
Page 3 section 5b--Replace the second
sentence
"The other
5 Fume incinerators..." with
the following:
"The 7 fume incinerator combustion
chambers
shall
be operated at one of the
following temperatures:
1) the manufacturers recommended temperature,
2) In the absence of a compliance test, at least 1400
degrees F, or
3) if compliance testing has been done,
at a
temperature to
meet
the
conditions of
section 4b."
Page 7 section 9a--Change 6 to
7
Page 7 section 9b--Change 6 to 7
Page 8 section 12.a.ii--Remove the words "each day" from the sentence.
Page 8 section 12.a.ii.A--Change the sentence to read "Daily monitoring data of
the
Incinerator/Afterbunner combustion chamber temperature."
Page 8 section 12.a.ii.B--Change the sentence to read "A monthly log of operating time..."
A marked up copy of the Preliminary draft FESOP is attached. If You have any questions, please contact
me at 217-345-7095 extension 277.
S incerely yours,
0.
1ýarZY
J sepph D. Woodall
Facilities Manager
Cc: Randy Swank
David
F. Nancy
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
ILLINOIS ENVIRONMENTAL PROTECTION AGENCY
1 021 NORTH GRAND AVENUE EAST, P.O. BOX 19506, SPRINGFIELD, ILLINOIS 62794-9506
- ( 217) 782-2113
ROD R.
BLAGOIEVICH,
GOVERNOR
DOUGLAS P. SCOTT, DIRECTOR
2 17/782-2113
FEDERALLY ENFORCEABLE STATE OPERATING PERMIT -- RENEWAL
PERMITTEE
Vesuvius
USA
A ttn: John Herring
__"C?
Lý7 ýýGýýý- L L
955 North 5th Street
Charleston, Illinois 61920
Application No.: 95120117
I.D. No.: 029010AAE
Applicant's Designation:
Date Received: December 7, 2006
Subject: Ceramic Manufacturing
Date Issued:
Expiration Date:
Location: 955
North 5th Street, Charleston
This permit is hereby granted to the above-designated Permittee to OPERATE
emission unit(s) and/or air pollution control equipment consisting of:
Advance Oven (AO-1) '
6
Baghouse
(BH-1,
BH-2,
ýBH-3,
BH-5, BH-6, BH-7)
4 Fume Incinerators (FI-a-6)
2 Bag Break Stations (BB-1 and 2) with Dust Collection (BH-1)
4 Scale Hoppers (SH-1
through 4) with Dust Collection (BH-1)
2 Barrel Tilters (BT-1 and 2) with Dust Collection (BH-2)
Batch Conveyor (BC-1)
with Dust Collection (BH-1)
Belt Sander (BS-1) with Dust Collection (BH-2)
Bickley Kiln (BK-1) with Fume Incinerator (FI-5)
Big
Blender
(MB-1)
with Dust Collection (BH-2)
Box Dumper (BD-1) with Dust Collection (BH-2)
Classifier/Hammer mill (CL-1) with Dust Collection (BH-1)
Collector Blender (CB-1) with Dust Collection (BH-1)
Electric Despatch Oven (DOE)
D rayton Kilns with Afterburners (DK-1 and 2)
5 Furfural Storage Tanks (ST-1)
1 8 Tote Bins (TB1-18) with Dust Collection (BH-1)
Keith Kiln (KK-1) with Fume
incinerator
(FI-4)
9 Econolift Elevator (EE-1-9) with Dust Collection (BH-1, BH-2, and BH-5)
Advanced Oven
(AO-1)
2 Wisconsin Ovens with Integrated Afterburners (WO-1,
WO-2)
Mixer (M-2) with
Dust
Collection (BH-1)
T ube Dryer (TD-2) with Cyclone, Baghouse, Furfural
Recovery Unit, and
Fume
Incinerator {-F-I j- F',.1.
- 6
Eirich Mixer (EM-1)
with
Dust
Collection (BH-5)
Tube Dryer (TD-3) Baghouse, Cyclone, Furfural Recovery Unit,
Afterburner
(FI-6)
3 Mold Presses
Dip Glaze (DG-1)
Flood Glaze (FG-1)
5 Grinding Stations (GR-1-5) with
Dust
Collection
(BB-3)
Holding Bin (HB-1) with Dust Collection (BH-1)
8 Holding
Hoppers
(HH-1-8) with Dust Collection (BH-2)
Small Weighment Filling Station (SWFS) with
Dust Collection
(BH-7)
P RIN1- ED
ON
R EC
Y CLED PAPER
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 2
Small Blender (SB-1)
with Dust Collection (BH-2)
5 Bulk Bag Stations (BB-1-5),with Dust Collection
(BH-7)
Pneumatic Transporter (PT-1)
with Dust Collection (BH-7)
Feedback Station (FS-1) with
Dust
Collection
(BH-6)
1 5 Bulk Bagging Stations
(BB-6-20) with Dust Collection (BH-6)
Traveling Skip (TSK-1) with Dust Collection
(BH-6)
Carrier Conveyor (CC-1)
with Dust Collection (BH-6)
Classifier (CL-3) with Dust Collection (BH-5)
2 Hammermills (HM-1-2)
with Dust Collection (BH-5)
1 Glaze Mixer with Dust
Collector
1 Makino Milling machine with
dust collector
1 Antares
Milling Machine with Dust Collector
pursuant to the above-referenced
application. This Permit is subject to
standard conditions
attached hereto and the
following special condition(s):
la. This
federally enforceable state operating
permit is issued to limit the
emissions of air pollutants
from the source to less than
major source
thresholds
(i.e., VOM to less than
100 tons/year, 10 tons/year for a
single HAP and 25 tons/year
of any combination of such HAPs).
As a result
the
source is excluded from the requirement
to obtain a Clean Air Act
Permit Program (CAAPP)
permit. The maximum emissions
of this source, as
limited by the conditions
of this permit, are described
in Attachment A.
b. Prior to issuance,
a draft of this permit has undergone
a public notice
and comment period.
c. This permit supersedes
all operating permits issued for this
location.
2a.
No person shall cause or
allow the emission of smoke or other
particulate
matter, with an opacity greater
than 30 percent, into the
atmosphere from any
emission unit other than those
emission units
subject to the requirements of
35 Ill. Adm. Code 212.122, pursuant to
35 Ill.
Adm. Code 212.123(a), except as
allowed by 35 Ill. Adm. Code
212.123(b) and
212.124.
b. No person
shall cause or allow any visible
emissions of fugitive
particulate matter
from any process, including any
material handling or
storage activity beyond
the property line of the emission source
unless
the wind speed
is greater than 40.2 kilometers
per hour (25 miles per
hour), pursuant to 35
Ill. Adm. Code 212.301 and
212.314.
c. Pursuant to 35
Ill. Adm. Code 212.321(a), no person
shall cause or
allow the emission of particulate
matter into the atmosphere
in any one
hour period
from any new process emission unit
which, either alone or
in combination with the
emission of particulate matter from all other
similar process
emission units for which construction
or modification
commenced on or after
April 14, 1972, at a source or premises,
exceeds
the
allowable emission rates specified
in subsection (c) of 35 Ill.
Adm. Code 212.321.
3.
Pursuant to 35 Ill. Adm. Code 214.301,
no person shall cause or allow
the emission of sulfur
dioxide into the atmosphere from
any process
emission source to excess 2000 ppm.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 3
4a. Pursuant
to 35 Ill. Adm. Code 215.301,
no person shall cause
or allow the
discharge of more than
3.,6 kg/hour (8
lbs/hour) of organic material
into
the atmosphere from any emission
unit, except as provided
in 35 Ill. Adm.
Code 215.302,
215.303, and 215.304
and the following exception:
If no
odor nuisance exists
the limitation of 35
Ill. Adm. Code 215 Subpart
K.
shall
apply only to photochemically
reactive material.
b.
Pursuant to 35 Ill.
Adm. Code 215.302, emissions
of organic material in
excess of
those permitted by 35
Ill. Adm. Code 215.301 are allowable
if
such emissions are
controlled by one of the following
methods:
i.
Flame, thermal
or catalytic incineration
so as either to reduce
such
emissions to 10 ppm
equivalent methane (molecular
weight 16)
or less, or to
convert 85 percent
of the hydrocarbons to carbon
dioxide
and water; or
5a.
K
ii.
Any other air pollution
control equipment
approved by the Illinois
EPA
capable of reducing by
85 percent or more the
uncontrolled
organic
material that would be otherwise
emitted to the atmosphere.
7
The,ki'Fume Incinerators/Afterburners,
6 Baghouses, and 2 Furfural
Recovery units shall be
in operation
, when the associated
emission
units are in operation
and emitting air contaminants.
b .
b'?**,
?
c
i n P r a t r, r ( E T - 3 .;_..r-emb tý.catý-c--ha
be-prý'1°tez -ed- -o--a
t
F
l -
[
o
"r s
ýý, a-ý t ,
i- h a mdSýllfý r t , i
r c
ý ý =ý
GBIF1mýI}ý-ýd-ýeFtlpý-rý-ý-13
'2--ý3ý-Tv -
1 °-ýý.zd-A
,lý L
i!'7
Z' rf
-
2.9-9-°-E-as--demo-rý-s to at-ed-i-fr-
lie-mom-t- -eee-x-t--eompýi-any-t-eý
ng .
e--
f
rV
i el- el `I
7
1 -GýBý--`ciie--c.,u-A'ýýf-t17rPrý-c
ro_
=OIRIAýIdd6G1--ýP>ýC1ýJ.Pýd-t-lý-ý2-ý3k3ý-.,-,n-=oz.r°aS-ý1a-fl
14OtT°-E'-i`ný-h-e--ýa-ýcPn
e of
a complianee--týý.
ýýWkCTl4%'/ý.
F ý
c .
The Permittee shall follow
good operating practices
for all air
pollution
control equipment covered
by this permit,
including periodic
inspection, routine
maintenance and prompt
repair of defects.
6a. Emissions and
operation of ceramic
manufacturing process
shall not
exceed
the following
limits:
Overall
Control
Max PWR
Efficiency
Emissions
Equipment
(Ton/Hr)
Pollutant
(°s)
(Lb/Hr) (Ton/Yr)
2 Wisconsin Ovens
with
Fume Incinerator (WO-1
2.00
PM
3.68
16.12
and WO-2)
(Total)
VOM
99
0.08
0.35
M ixer with Dust
3.35
PM
98
0.07
0.32
Collection
(M2)*
VOM
0
5.28 23.13
Tube
Dryer with Cyclone,
B aghouse, Furfural
3.35
PM
98
0.07
0.32
Recovery
Unit and Fume
VOM
98
3.40 14.89
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 4
Overall
Control
Max
PWR
Efficiency
Emissions
Equipment
(Ton/Hr) Pollutant
(%)
(Lb/Hr) (Ton/Yr)
Incinerator (TD2)*
Eirich Mixer
with Dust
C ollection, Condenser, &
3.65
PM
99
0.04
0.18
Afterburner (EM-1)
VOM
98
0.11
0.46
Tube Dryer with Dust
C ollection, Condenser
&
3.65
PM
99
0.04
0.18
Afterburner (TD-3)
VOM
98
4.56 19.97
Purge Air Exhaust
Value
2.50
VOM
0
2.50
10.95
(EV-1)
Bickley Kiln with Fume
0.60
PM
1.93
8.45
Incinerator (BK-1)
VOM
99
0.3
1.31
2 Drayton Kilns
with Fume
0.65
PM
2.01
8.80
Incinerator (DK-1-2)
1
,
VOM
97
1.2
5.26
(Total)*
Keith
Kiln with Fume
0.20
PM
1.07
4.69
Incinerator (KK-1)
VOM
99
0.01
0.04
5 Furfural Storage Tanks
VOM
0.6
2.64
(Total)
* Stack
Tested
T hese
limits are based on maximum process
weight rates, stack test
information and
8,760 hours of operation.
b . Emissions
and operation of natural gas combustion
shall not exceed the
following limits:
Emission
Natural Gas Usage
Factor
Emissions
P rocess
(mmscf/Mo) (mmscf/Yr) Pollutant
(Lb/mmscf)- (Lb/Mo) (Ton/Yr)
Natural Gas
100
1,000
NOX
100
10,000 50.00
Combustion
CO
84
8,400 42.00
TSP
7.6
760
3.80
VOM
5.5
550 2.75
S02
0.6
60
0.30
These limits are based
on standard emission factors (Tables 1.4-1 and
1.4-2, AP-42, Fifth Edition,
Volume I, Supplement D, July 1998) and the
maximum natural
gas usage.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 5
c .
This permit is issued
based on negligible emissions
of particulate
matte,r (PM)
from 2 Bag Break Stations
with dust collection,
2 Barrel
Tilters with dust collection,
Batch Conveyor
with dust collection, Belt
Sander
with dust collection,
Big Blender with
dust collection,
Classifier/Hammermill
with dust collection,
2 Collector Blenders
with
dust collection,
Despatch Oven Glaze Mixer
with dust collection, 5
Grinding
Stations with dust collection,
Holding Bin
with dust
collection, 8 Holding
Hoppers with dust
collection, 4 Scale Hoppers
with dust
collection, Small
Blender with dust collection,
18 Tote Bins
with Dust Collection,
Small Weighment
Filling Station with dust
collection,
5 Bulk Bag Stations
with dust collection,
Pneumatic
Transporter with
dust collection,
Feedback Station with dust
collection, 15 Bulk
Bagging Stations
with dust collection, 9 Econolift
Elevators
with dust collection,
Small Weighment
Station with dust
collection, Traveling
Skip with dust
collection, Carrier Conveyor
with
dust
collection, Classifier
with dust collection,
3 Mold Presses, and
2
Hammermills
with dust collection.
For this purpose emissions
from each
emission source, shall
not exceed nominal
emission rates of 0.05
lb/hour
and 0.22 ton/year.
d. The
emissions of Hazardous
Air Pollutants
(HAPs) as listed in
Section
112(b) of the
Clean Air Act shall
not exceed 0.9
tons/month and 9.0
tons/year of any single
HAP and 2.25
tons/month and 22.5 tons/year
of
any combination
of such HAPs.
As a result of
this condition, this
permit is issued
based on the emissions
of any HAP from this
source not
triggering
the requirement
to obtain a CAAPP permit
from the Illinois
EPA.
e. Compliance
with the annual limits
of this permit
shall be determined
on
a
monthly basis from
the sum of the data
for the current
month plus the
preceding 11
months (running
12 month total).
7a. Pursuant
to 35 Ill. Adm.
Code 201.282,
every emission source
or air
pollution control
.equipment shall
be subject to
the following testing
requirements for the
purpose of determining
the nature and quantities
of specified
air contaminant
emissions and for
the purpose of
determining ground
level and ambient
air concentrations
of such air
contaminants:
i.
Testing by Owner
or operator.
The Illinois EPA
may require the
owner
or operator of
the emission
source or air pollution control
equipment
to conduct such tests
in accordance
with procedures
adopted by the
Illinois EPA, at
such reasonable
times as may be
specified
by the Illinois
EPA and at
the expense of the owner or
operator
of the emission source
or air pollution
control
equipment.
The Illinois EPA may adopt
procedures detailing
methods
of testing and formats
for reporting
results of testing.
Such procedures
and revisions thereto,
shall not become
effective
until
filed with the Secretary
of State,
as required by the APA
Act. All such
tests shall be made
by or under the
direction of a
person qualified by
training and/or
experience in the field of
air pollution
testing. The Illinois
EPA shall
have the right to
observe all aspects
of such tests.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 6
i i. Testing by the Illinois EPA. The Illinois EPA shall have the
right
to
conduct such
tests
at
any time
at
its own
expense. Upon
request of the Illinois EPA, the owner or operator of the
emission source or air pollution control equipment shall provide,
without charge to the Illinois EPA, necessary holes in stacks or
ducts and other safe and proper testing facilities, including
scaffolding, but excluding
instruments and sensing devices,
as
may be necessary.
b. Testing required by Condition 8 shall be performed upon a
written
request from the Illinois EPA by a qualified independent testing
service.
8a
Pursuant to 35 Ill. Adm. Code 212.107, for both fugitive and
nonfugitive particulate matter emissions, a determination as to the
presence or absence of visible emissions from emission units shall be
conducted in accordance with Method 22, 40 CFR part 60, Appendix A,
except
that the length of the observing period shall be at the
discretion of the observer, but
not less
than
one minute.
This
Condition shall not apply to 35 Ill. Adm. Code 212.301.
b. Pursuant to 35 Ill. Adm. Code 212.109, except as otherwise provided in
35 Ill. Adm. bode Part 212, and except for the methods of data
reduction when applied to 35
Ill. Adm. Code 212.122 and 212.123,
measurements of opacity shall be conducted in accordance with Method 9,
40 CFR
Part 60, Appendix A, and the procedures in 40 CFR 60.675(c) and
(d), if applicable, except that for roadways and parking
areas
the
number of readings required for each vehicle pass will be three taken
at 5-second
intervals. The first reading shall be at the point of
maximum opacity and second and third readings shall be made at the same
point, the observer standing at right angles to the plume at least 15
feet away from the plume and observing 4
feet above the surface of the
roadway or parking area. After four vehicles have passed, the 12
readings
will be averaged.
c. Pursuant to
35
Ill.
Adm. Code 212.110(a), measurement of particulate
matter emissions from stationary emission units subject to 35
Ill.
Adm.
Code Part 212 shall be conducted in accordance with 40 CFR part 60,
Appendix
A, Methods 5, 5A, 5D, or 5E.
d.
Pursuant to 35 Ill. Adm. Code 212.110(b), the volumetric flow rate and
gas velocity shall be determined in accordance with
40
CFR
part 60,
Appendix A, Methods 1, 1A, 2, 2A, 2C, 2D, 3, and 4.
e. Pursuant to 35 Ill. Adm. Code 212.110(c), upon a written notification
by the Illinois
EPA, the owner or operator of a particulate matter
emission unit subject to 35 Ill. Adm.
Code
Part 212 shall
conduct the
applicable testing for particulate matter emissions, opacity, or
visible emissions at such person's own expense, to demonstrate
compliance. Such test results shall be submitted to the
Illinois
EPA
within thirty (30) days after conducting the test unless an alternative
time
for submittal
is
agreed to by the Illinois EPA.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 7
rJ
9a. The,fo" Fume Incinerators/Afterburners shall be equipped with a
continuous monitoring device, which is installed, calibrated,
maintained and operated according to vendor's specifications at all
times the incinerators/afterburners are in use.
This device
shall
monitor the afterburner combustion chamber temperature.
r
b.
The,.F1 fume incinerators/afterburners shall be
equipped
with
a
continuous temperature indicator and strip chart recorder or disk
storage for the,, fume incinerators/afterburners combustion chamber
temperature. 7
10. Pursuant to 40 CFR 63.10(b)(3), if an owner or operator determines that
his or her stationary source that emits (or has the potential to emit,
without considering controls) one or more hazardous air pollutants
regulated by any standard established pursuant to section 112(d) or (f)
of the Clean Air Act, and that stationary source is in the source
category regulated by the relevant standard,
but
that source is not
subject to the relevant standard (or other requirement established
under
40 CFR
Part 63)
because
of limitations on the source's potential
to emit or an exclusion, the owner or operator must
keep
a record of
the applicability determination on site at the source for a period of 5
years after the determination, or until the source changes its
operations to become an
affected
source,
whichever comes first. The
record of the applicability determination
must
be signed by the
person
making the
determination and include an analysis (or other information)
that demonstrates why the owner or operator believes the source
is
unaffected (e.g., because the source is an area source). The analysis
(or other information) must be sufficiently detailed to allow the USEPA
and/or Illinois EPA to make a finding
about the source's applicability
status with regard to the relevant standard or other requirement.
If
relevant, the analysis must be performed in accordance with
requirements established in relevant subparts of
40 CFR Part 63 for
this purpose for particular categories of stationary sources.
If
relevant, the analysis should be performed in accordance with USEPA
guidance materials published to assist
sources in making applicability
determinations under Section 112 of the Clean Air Act, if any. The
requirements to determine applicability
of a standard under 40 CFR
63.1(b)(3) and to record the results of that determination
under 40 CFR
63.10(b)(3) shall not by themselves create an obligation for the owner
or operator to obtain a Title V permit.
11. Pursuant to 35 Ill. Adm. Code 212.110(e),
the owner or
operator-of
an
emission unit subject to 35 Ill. Adm. Code Part
212 shall retain
records of all tests which are performed. These records shall be
retained for at least three (3) years
after the date a test is
performed.
12a. Permittee shall maintain records of the following items
so as to
demonstrate compliance
with the conditions of this permit:
Records addressing use of good operating practices for the
pollution control equipment covered under
this permit:
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 8
A.
Records for periodic inspection
of the pollution control
equipment covered under this permit with date, individual
performing
the inspection, and nature of inspection; and
B.
Records for prompt repair of defects, with identification
and description
of defect, effect on emissions, date
identified, date repaired, and nature of repair.
ii. The Permittee shall collect and record
the following information
for each Fume Incinerator/Afterburner:
i7AT
L. y nýGw1
T
L'rZ,yr
v Lý
L7/IT
M
(27F
'Tf/L
A .
AIncinerator/Afterburner
combustion chamber .M.ernýy-t- r-ý.- a-tom ;
in e rv r
/>
y-
B .
A^log of ý
'yoperating
time
for the capture system,
incinerator/afterburner, and monitoring device and the
associated
emission unit.
C. A maintenance log for the capture system, afterburner, and
monitoring device, detailing
all routine and non-routine
maintenance performed including dates and duration of any
outages.
i ii.
Natural gas usage (mmscf/month and mmscf/year);
i v. Composition of materials loaded into the mixers (lbs/batch,
lbs/month and
tons/year);
v .
Number
of batches produced per month and per year; and
vi.
Monthly and
annual CO, NO., PM, S02, VOM and HAP emissions from
the source,
with
supporting
calculations (tons/month and
tons/year).
b. All records and logs
required by this permit shall be retained at a
readily accessible location at the source for at
least five (5) years
from the date of entry and shall be made available for inspection and
copying by the Illinois
EPA
or
USEPA upon request. Any records
retained in an electronic format (e.g., computer) shall be capable
of
being retrieved and
printed on paper during normal source office hours
so as to be able to respond to an Illinois EPA or
USEPA request for
records
during
the course of a source inspection.
13. If there is an exceedance of or a deviation from the requirements of
this permit as
determined by the records required by this permit, the
Permittee shall submit a report to the
Illinois EPA's Compliance
Section in Springfield, Illinois within 30 days after the exceedance or
deviation. The report shall include
the emissions released in
accordance with the recordkeeping requirements, a copy of the relevant
records, and a description
of the exceedance or deviation and efforts
to reduce emissions and future occurrences.
14. Pursuant to 35 Ill. Adm. Code 212.110(d),
a person
planning
to conduct
testing for
particulate matter emissions to demonstrate compliance
shall give written notice to the
Illinois EPA of that intent. Such
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page
9
notification shall be given at least thirty (30) days prior to the
initiation of the test unless a shorter period is agreed to by the
Illinois EPA. Such notification shall state the specific test methods
from 35 Ill. Adm. Code 212.110 that will be used.
15. Two (2) copies of required reports and notifications shall be sent to:
Illinois Environmental Protection Agency
Division of Air Pollution Control
Compliance Section (#40)
P .O. Box 19276
S pringfield, Illinois 62794-9276
_and
one (1) copy shall be
sent
to
the Illinois EPA's regional office at
the following address unless otherwise indicated
I llinois Environmental Protection
Agency
Division of Air Pollution Control
2009 Mall
Street
Collinsville, Illinois 62234
If you have any questions on this, please
call German Barria at 217/782-2113.
E dwin C. Bakowski, P.E.
Date Signed:
Acting Manager,
Permit Section
D ivision of Air Pollution Control
ECB:GB:psj
cc: Illinois EPA, FOS Region
3
Lotus Notes
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Attachment A - Emission Summary
This attachment provides a summary of the maximum emissions from ceramic
manufacturing
operating in
compliance with the requirements of this federally
enforceable permit. In preparing this summary,
the Illinois EPA used the
annual operating scenario which results in maximum emissions from such a
plant. The resulting maximum emissions are below
the levels (e.g., 100 tons
per year of Volatile Organic Material (VOM) 10 tons per year for a single
HAP, and 25 tons per year for totaled HAP) at
which this source would be
considered a major source for purposes of the Clean Air Act Permit Program.
Actual emissions from this source will be less
than predicted in this summary
to the extent that less material is handled, and control measures are more
effective
than required in
this
permit.
E M I S S 1 0 N S (Tons/Year)
S ingle Total
Emission Unit
CO
NOX
PM
so,
VOM
HAP
HAPs
2 Wisconsin Ovens
(WO-1 and
WO-2)
16.12
0.35
Mixer (M2)
0.32
23.13
Tube Dryer (TD2)*
0.32
14.89.
Eirich Mixer (EM-1)
0.18
0.46
Tube Dryer (TD-3)
0.18
19.97
Purge Air Exhaust
Value (EV-1)
10.95
Bickley Kiln (BK-1)
8.45
1.31
2 Drayton Kilns (DK-1
and DK-2)
8.80
5.26
Keith Kiln (KK-1)
4.69
0.04
5 Furfural Storage
Tanks
2.64
2
Bag
Break
Stations
0.44
2 Barrel Tilters
0.44
Batch Conveyor
0.22
Belt Sander
0.22
Big Blender
0.22
Classifier/Hammermill
0.22
2 Collector Blenders
0.44
Despatch Oven Glaze
Mixer
0.22
5 Grinding Stations
1.10
Holding Bin
0.22
8 Holding Hoppers
1.76
4 Scale Hoppers
0.88
Small Blender
0.22
18 Tote Bins
3.96
Small Weighment
F illing Station
0.22
5 Bulk Bag Stations
1.10
Pneumatic
Transporter
0.22
Feedback Station
0.22
15 Bulk Bagging
S
tations
3.30
9 Econolift Elevators
1.98
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
E M I S S
I O N S (Tons/Year)
Single
Total
Emission Unit
CO
No.
PM
so,
VOM
HAP
HAPs
S mall Weighment
Station
0.22
Traveling Skip
0.22
Carrier Conveyor
0.22
Classifier
0.22
3 Mold Presses
0.66
2 Hammermills
0.44
Fuel Combustion
42.00 50.00 3.80 0.30
2.75
Totals 42.00 50.00
62.44 0.30 81.75
9.0
22.5
GB:
psj
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
ILLINOIS ENVIRONMENTAL PROTECTION AGENCY
1 021
N'ORTFI GRAND A VENUE EAST, P .O. Box 19506, S PRINGFIELD, ILLIN01s 62794-9506
- (
217)
782-2113
R OD R. BLAGOJEVICi I, GOVERNOR
DOUGLAS P.
SCOTT,
DIRECTOR
2 17/782-2113
FEDERALLY ENFORCEABLE STATE OPERATING PERMIT - RENEWAL
PERMITTEE
Vesuvius USA
Attn: Joe Woodall
955 North 5th Street
Charleston,
Illinois
61920
Application No.: 95120117
I.D. No.: 029010AAE
Applicant's Designation:
_Date ReReceived:
December
7, 2006
Subject: Ceramic Manufacturing
Date
Issued: January 28, 2008
Expiration Date: January 28, 2013
Location: 955 North 5th Street, Charleston
This permit is hereby granted to the above-designated Permittee
to OPERATE
emission unit(s) and/or air pollution
control equipment consisting of:
Advance Oven (AO-1)
6 Baghouse (BH-1, BH-2, BH-3, BH-5, BH-6, BH-7)
3 Fume Incinerators (FI-4-6)
2 Bag Break Stations (BB-1 and 2) with Dust Collection (BH-1)
4 Scale Hoppers (SH-1 through 4) with Dust
Collection (BH-1)
2 Barrel Tilters (BT-1 and 2) with Dust Collection (BH-2)
Batch Conveyor (BC-1) with Dust Collection (BH-1)
Belt Sander (BS-1)
with Dust
Collection (BH-2)
Bickley Kiln (BK-1) With Fume Incinerator (FI-5)
Big Blender (MB-1) with Dust Collection (BH-2)
Box Dumper
(BD-1) with Dust
Collection (BH-2)
Classifier/Hammer mill (CL-1) with Dust Collection (BH-1)
Collector Blender (CB-1) with Dust Collection (BH-1)
Electric Despatch Oven (DOE)
Drayton Kilns with Afterburners (DK-1 and 2)
5
Furfural Storage Tanks (ST-1)
1 8 Tote Bins (TB1-18)
with
Dust Collection (BH-1)
Keith Kiln (KK-1) with Fume incinerator (FI-4)
9 Econolift Elevator (EE-1-9) with Dust Collection (BH-1,
BH-2, and BH-5)
Advanced
Oven (AO-1)
2 Wisconsin Ovens with Integrated Afterburners (WO-1, WO-2)
Mixer (M-2) with Dust Collection (BH-1)
'
Tube Dryer (TD-2) with Cyclone, Baghouse, Furfural Recovery Unit, and Fume
Incinerator (FI-6)
Eirich Mixer (EM-1) with Dust Collection (BH-5)
T ube Dryer (TD-3) Baghouse, Cyclone, Furfural Recovery Unit, Afterburner
(FT-6)
3 Mold Presses
Dip Glaze (DG-1)
Flood Glaze (FG-1)
PRINTED ON RECYCLED PAPER
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 2
5
Grinding Stations (GR-1-5) with Dust
Collection (BH-3)
Holding Bin (HB-1)
with Dust Collection (BH-1)
8 Holding Hoppers (HH-1-8) with Dust Collection
(BH-2)
Small Weighment
Filling Station (SWFS) with Dust Collection
(BH-7)
Small Blender (SB-1) with Dust Collection
(BH-2)
5 Bulk
Bag Stations (BB-1-5) with Dust Collection
(BH-7)
Pneumatic Transporter
(PT-1) with Dust Collection (BH-7)
Feedback Station (FS-1)
with
Dust
Collection (BH-6)
15 Bulk
Bagging Stations (BB-6-20) with Dust Collection
(BH-6)
Traveling Skip (TSK-1)
with Dust Collection (BH-6)
Carrier Conveyor (CC-1)
with Dust Collection (BH-6)
Classifier
(CL-3) with Dust Collection (BH-5)
2 Hammermills (HM-1-2)
with Dust Collection (BH-5)
1
Glaze Mixer with Dust Collector
1 Makino Milling
machine with dust collector
1 Antares Milling
Machine with Dust Collector
pursuant
to the above-referenced application. This
Permit is subject to
standard conditions
attached hereto and the following special
condition(s):
la.
This federally enforceable state operating permit
is issued to limit
the emissions of air pollutants
from the source to less than major
source
thresholds (i.e., VOM to less than
100 tons/year, 10 tons/year
for a single
HAP and 25 tons/year of any combination
of such HAPs). As
a result the source is excluded
from the requirement to obtain a Clean
Air
Act Permit Program (CAAPP) permit. The
maximum emissions of this
source, as limited
by the conditions of this permit, are
described in
Attachment A.
b. Prior to issuance,
a draft of this permit has undergone a public notice
and comment period.
c. This permit supersedes
all operating permits issued for this
location.
2a. No person
shall cause or allow the emission of
smoke or other
particulate
matter, with an opacity greater than 30 percent,
into the
atmosphere from any emission unit
other than those emission units
subject
to the requirements of 35 Ill.
Adm. Code 212.122, pursuant to
35 Ill.
Adm. Code 212.123(a), except as allowed by 35
Ill. Adm. Code
212.123(b) and 212.124.
b. No person shall cause or allow
any visible emissions of fugitive
particulate matter from any process, including
any material handling or
storage
activity beyond the property line of the
emission source unless
the wind speed is greater than
40.2 kilometers per hour (25
miles
per
hour),
pursuant to 35 Ill. Adm. Code 212.301
and 212.314.
c.
Pursuant to 35 Ill. Adm. Code 212.321(a),
no person shall cause or
allow
the emission of particulate matter into the
atmosphere in any one
hour period from any new
process emission unit which, either
alone
or
in combination with the emission of particulate
matter from all other
similar process
emission units for which construction
or modification
commenced on or after
April 14, 1972, at a source or premises, exceeds
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 3
the allowable emission rates
specified
in subsection (c) of
35 Ill.
Adm. Code 212."321.
3. Pursuant to 35 Ill. Adm.
Code 214.301, no person shall cause or allow
the emission of
sulfur dioxide into the atmosphere from any process
emission source to excess 2000 ppm.
4a.
Pursuant to 35 Ill. Adm. Code 215.301, no person shall cause or allow
the discharge of more than 3.6 kg/hour (8 lbs/hour) of
organic material
into the atmosphere
from any emission unit, except as provided in 35
Ill.
Adm. Code 215.302, 215.303, and 215.304 and the following
exception: If no odor nuisance
exists the
limitation
of 35 Ill. Adm.
Code 215 Subpart K
shall apply only to photochemically reactive
material.
b. Pursuant to 35 Ill. Adm. Code 215.302,
emissions of organic material in
excess
of those permitted by 35 Ill. Adm. Code 215.301 are allowable if
such emissions are controlled by one of the following methods:
i.
Flame,
thermal or catalytic incineration so as either to reduce
such emissions to 10 ppm equivalent methane (molecular weight
16)
or less, or
to convert 85 percent of the hydrocarbons to carbon
dioxide
and water; or
ii. Any other air pollution
control equipment approved by the
Illinois EPA capable of reducing by 85 percent or more the
uncontrolled organic
material that would be otherwise emitted to
the atmosphere.
5a. The fume incinerators/afterburners,
baghouses,
and furfural
recovery
units shall be in
operation at all times when the associated emission
units are in operation and emitting air contaminants.
b. The fume incinerators
combustion chamber shall be preheated to at least
the manufacturer's recommended temperature but not less than the
temperature at which compliance was
demonstrated
in the most
recent
compliance test or 1400°F
in the absence of a compliance test. This
temperature
shall be maintained during operation of the emission units
associated with the fume incinerators.
c. The Permittee
shall follow good operating practices for all air
pollution control equipment covered by this permit, including periodic
inspection, routine maintenance
and prompt
repair
of defects.
6a. Emissions and operation
of ceramic manufacturing
process
shall not
exceed the following
limits:
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page
4
O verall
Control
Max PWR
Efficiency
Emissions
Equipment
(Ton/Hr)
Pollutant
(%)
(lb/Hr) (Ton/Yr)
2 Wisconsin
ovens with
Fume Incinerator
(WO-1
2
PM
3.68 16.12
and WO-2) (Total)
VOM
99
0.08
0.35
Mixer with Dust
3.35
PM
98
0.07
0.32
Collection
(M2)*
VOM
0
5.28
23.13
Tube Dryer with Cyclone,
Baghouse, Furfural
3.35
PM
98
0.07
0.32
Recovery Unit
and Fume
VOM
98
3.40 14.89
Incinerator (TD2)*
Eirich Mixer
with Dust
Collection, Condenser,
&
3.65
PM
99
0.04
0.18
Afterburner
(EM-1)
VOM
98
0.11
0.46
Tube Dryer with Dust
Collection,
Condenser &
3.65
PM
99
0.04
0.18
Afterburner (TD-3)
VOM
98
4.56 19.97
Purge Air
Exhaust Value
2.5
VOM
0
2.50 10.95
(EV-1)
Bickley Kiln
with Fume
0.6
PM
1.93
8.45
Incinerator (BK-1)
VOM
99
0.3
1.31
2 Drayton Kilns
with Fume 0.65
PM
2.01
8.80
Incinerator (DK-1-2)
VOM
97
1.2
5.26
(Total)
Keith Kiln with Fume
0.2
PM
1.07
4.69
Incinerator
(KK-1)
VOM
99
0.01
0.04
5 Furfural Storage
Tanks
VOM
0.6
2.64
(Total)
* Stack Tested
These limits
are based on maximum process
weight rates,
stack test
information and 8,760 hours
of operation.
b.
Emissions and operation
of natural gas
combustion shall
not exceed the
following
limits:
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 5
Emission
Natural Gas Usage
Factor
Emissions
P rocess
(mmscf/Mo) (mmscf/Yr)
Pollutant (lb/mmscf) (lb/Mo) (Ton/Yr)
Natural Gas
100
1,000
NO,,
100
10,000 50.00
Combustion
CO
84
8,400 42.00
TSP
7.6
760
3.80
VOM
5.5
550
2.75
S02
0.6
60
0.30
These
limits
are based on standard
emission factors (Tables 1.4-1 and
1.4-2, AP-42, Fifth Edition, Volume I, Supplement D, July 1998)
and
the
maximum natural gas usage.
c. This permit is issued based on
negligible emissions of particulate
matter (PM) from 2 Bag Break Stations with dust collection,
2
Barrel
Tilters with dust collection, Batch Conveyor with dust collection, Belt
Sander
with
dust collection,
Big Blender with dust collection,
Classifier/Hammermill with dust collection, 2 Collector Blenders with
dust collection, Despatch Oven Glaze Mixer with dust collection, 5
Grinding Stations with dust collection,
Holding Bin with dust
collection, 8 Holding Hoppers with dust collection, 4 Scale Hoppers
with dust collection, Small Blender with dust collection, 18 Tote Bins
with Dust Collection, Small Weighment
Filling Station with dust
collection, 5 Bulk Bag Stations with dust collection, Pneumatic
Transporter with dust collection, Feedback Station with dust
collection, 15 Bulk Bagging Stations
with dust collection, 9 Econolift
Elevators with dust collection, Small Weighment Station with dust
collection, Traveling Skip
with dust collection, Carrier Conveyor with
dust collection, Classifier with dust collection, 3 Mold Presses, and 2
Hammermills with dust collection. For this purpose emissions from each
emission source, shall not exceed
nominal emission rates of 0.05
lb/hour and 0.22 ton/year.
d. The emissions
of
Hazardous Air Pollutants (HAPs) as listed in Section
112(b) of the Clean Air Act shall
not exceed 0.9 tons/month and 9.0
tons/year of any single HAP and 2.25 tons/month and 22.5 tons/year of
any combination of such HAPs. As a result of this condition, this
permit is issued based on the emissions
of any HAP from this source not
triggering the requirement to obtain a CAAPP permit from the Illinois
EPA.
e. Compliance with the annual limits of this permit shall be determined on
a monthly basis from the sum of the data for the current month plus the
preceding 11 months (running 12
month total).
7 a.
requirements for the purpose
of specified air contaminant
determining ground level and
contaminants:
air
pollution control equipment shall be subject to the following testing
Pursuant to 35 Ill. Adm. Code 201.282,
every emission source, or
of determining the nature and quantities
emissions
and for the purpose of
ambient air
concentrations
of such
air
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 6
i . Testing by Owner or Operator.
The Illinois EPA may require the
owner or operator of the emission source or air pollution control
equipment
to conduct such tests in accordance with procedures
adopted by the Illinois EPA, at such reasonable times
as may be
specified
by the Illinois EPA and at the expense of the owner or
operator of the emission source or air pollution control
equipment.
The Illinois EPA may adopt procedures detailing
methods of.testing
and formats for reporting results of testing.
Such procedures and revisions thereto, shall not become
effective
until filed with the Secretary of State, as required by the APA
Act.
All
such
tests shall be made by or under the direction of a
person qualified by training and/or experience in the field
of
air pollution testing. The Illinois EPA shall have the right to
observe
all aspects of such tests.
ii.
Testing by the Illinois EPA. The Illinois EPA shall have the
right to conduct such tests at
any
time
at its own expense. Upon
request of the Illinois EPA, the owner or operator of
the
emission source or air pollution control equipment shall provide,
without charge
to the Illinois EPA, necessary holes in stacks or
ducts and other safe and proper testing facilities,
including
scaffolding,
but excluding instruments and sensing devices, as
may be necessary.
b. Testing required by Condition
8
shall
be performed upon a written
request from the Illinois EPA by a qualified independent
testing
service.
8a Pursuant to 35 Ill. Adm. Code 212.107, for both fugitive
and
nonfugitive
particulate matter emissions, a determination as to the
presence or absence
of visible
emissions
from emission units shall be
conducted in accordance with Method 22, 40 CFR part 60,
Appendix A,
except
that the length of the observing period shall be at the
discretion of the observer, but not less than one
minute. This
Condition
shall not apply to 35 Ill. Adm. Code 212.301.
b. Pursuant to 35
Ill. Adm.
Code 212.109, except
as otherwise provided in
35 Ill. Adm. Code Part 212, and except for the methods
of data
reduction when applied to 35 Ill. Adm. Code 212.122 and 212.123,
measurements of opacity
shall
be
conducted in accordance with method 9,
40 CFR Part 60, Appendix A, and the procedures in
40 CFR 60.675(c) and
(d),
if applicable, except that for roadways and parking areas the
number of readings required for each vehicle pass
will be three taken
at 5-second
intervals. The first reading shall be at the point of
maximum opacity and second
and
third
readings shall be made at the same
point, the observer standing at right angles to the plume
at least 15
feet away
from the plume and observing 4 feet above the surface of the
roadway or parking area.
After
four
vehicles have passed, the 12
readings will be averaged.
c. Pursuant to 35
Ill. Adm.
Code
212.110(a), measurement of particulate
matter emissions from stationary emission units subject to 35 Ill. Adm.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 7
Code Part 212 shall be conducted in accordance with 40 CFR part
60,
Appendix A, Methods 5,
5A,
5D, or 5E.
d. Pursuant to
35 Ill. Adm. Code 212.110(b), the volumetric flow rate and
gas velocity shall be determined in accordance
with 40 CFR part 60,
Appendix A, Methods 1, 1A, 2, 2A, 2C, 2D, 3, and 4.
e. Pursuant to 35 Ill. Adm. Code 212.110(c),
upon a written notification
by the Illinois EPA, the owner or operator of a particulate
matter
emission unit
subject to 35 Ill. Adm. Code Part 212 shall conduct the
applicable testing for particulate matter emissions, opacity,
or
visible emissions
at such person's own expense, to demonstrate
compliance. Such
test results shall be submitted to the Illinois EPA
within thirty (30) days
after
conducting the
test unless an alternative
time for submittal is agreed to by the Illinois EPA.
9a. The fume incinerators/afterburners shall
be equipped with a continuous
monitoring device, which is installed, calibrated,
maintained and
operated
according to vendor's specifications at all times the
incinerators/afterburners are in use. This device
shall monitor the
afterburner combustion chamber temperature.
b. The fume incinerators/afterburners shall be equipped
with a continuous
temperature
indicator and strip chart recorder or disk
storage for the
fume incinerators/afterburners
combustion chamber temperature.
10. Pursuant
to 40 CFR 63.10(b)(3), if an owner or operator
determines that
his or her stationary
source that emits (or has the potential to emit,
without considering controls) one or more hazardous
air pollutants
regulated
by any standard established pursuant to section 112(d) or (f)
of the Clean Air
Act, and that
stationary
source is in the source
category regulated by the relevant standard, but
that source is not
subject
to the relevant standard (or other requirement
established
under 40 CFR
Part 63) because of limitations on the source's potential
to emit or an exclusion, the owner or operator
must keep a record of
the applicability determination on site at the source
for a period of 5
years after
the determination, or until the source changes its
operations to become an affected source,
whichever comes first. The
record of the applicability determination must be
signed by the person
making the determination
and include an analysis (or other
information)
that demonstrates why the
owner
or operator
believes the source is
unaffected
(e.g., because the source is an area source).
The analysis
(or other
information) must be sufficiently detailed to
allow the
USEPA
and/or Illinois EPA to
make
a finding about
the source's applicability
status
with regard to the relevant standard or other
requirement. If
relevant, the
analysis must be performed in accordance with
requirements established in relevant subparts of
40 CFR Part 63 for
this purpose
for particular categories of stationary sources.
If
relevant, the analysis
should
be performed
in accordance with USEPA
guidance materials published to assist sources in
making applicability
determinations
under Section 112 of the Clean Air Act,
if any. The
requirements to determine
applicability
of
a standard under 40 CFR
63.1(b)(3) and to record the results of that determination
under 40 CFR
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 8
63.10(b)(3) shall not
by themselves create an obligation
for the owner
or operator
to obtain a Title V permit.
11. Pursuant
to 35 Ill. Adm. Code 212.110
(e), the owner or operator of
an
emission unit subject
to 35 Ill. Adm. Code Part
212 shall retain
records
of all tests which
are performed. These records shall
be
retained
for at least three (3) years after
the date a test is
performed.
12a. Permittee
shall maintain records of the
following items so as to
demonstrate compliance
with the conditions of this
permit:
i.
Records addressing use of good operating
practices for the
pollution control
equipment covered under
this permit:
A.
Records for periodic inspection
of the pollution control
equipment
covered under this permit
with date, individual
performing the inspection,
and nature of
inspection; and
B. Records
for prompt repair of defects,
with identification
and description of
defect, effect on emissions, date
identified, date repaired, and nature
of repair.
ii.
The Permittee shall collect and
record the following information
for each
Fume Incinerator/Afterburner:
A.
Daily monitoring data of the
Incinerator/Afterburner
combustion
chamber temperature;
B.
A monthly log of operating time
for the capture system,
incinerator/afterburner,
and monitoring
device and the
associated emission unit.
C. A maintenance
log for the capture system,
afterburner, and
monitoring device, detailing
all routine
and non-routine
maintenance performed including
dates and duration of any
outages.
iii.
Natural gas usage (mmscf/month
and mmscf/year);
iv. Composition of materials
loaded into the mixers (lbs/batch,
lbs/month
and tons/year);
v.
Number of batches produced per
month and per year;
and
vi.
Monthly and annual CO,
NO., PM, SO,, VOM and
HAP emissions from
the
source, with supporting calculations
(tons/month and
tons/year).
b. All records
and logs required by this permit
shall be retained at a
readily accessible location
at the source for at
least five (5) years
from the
date of entry and shall be
made available for inspection and
copying by the
Illinois EPA or USEPA upon
request. Any records
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Page 9
r etained in an electronic format (e.g.,
computer) shall be capable of
being retrieved
and printed on paper during normal
source office hours
so as to be able to respond to
an Illinois EPA or USEPA request for
records during the course of a source
inspection.
13. If there is an exceedance of or a deviation
from the requirements of
this permit as determined
by the records required by
this permit, the
Permittee shall submit a report
to the Illinois EPA's Compliance
Section in Springfield, Illinois within
30 days after the exceedance or
deviation.
The report shall include the emissions
released in
accordance with the recordkeeping
requirements, a copy
of
the
relevant
records, and a description of the exceedance
or deviation and efforts
to
reduce emissions and future occurrences.
14. Pursuant to 35 Ill. Adm. Code 212.110(d),
a person planning to conduct
testing for particulate matter emissions
to demonstrate compliance
shall give written notice to
the Illinois EPA of that
intent. Such
notification shall be given at least
thirty (30) days prior to the
initiation of the test unless a shorter
period is agreed to by the
Illinois EPA. Such
notification shall state the specific
test methods
from 35 Ill. Adm. Code 212.110 that
will be used.
15. Two (2) copies of
required reports and notifications shall be sent to:
Illinois
Environmental Protection Agency
Division of Air Pollution
Control
Compliance Section (##40)
P .O. Box 19276
Springfield, Illinois 62794-9276
and
one (1) copy shall be sent to the Illinois
EPA's regional office at
the following address unless
otherwise indicated:
Illinois Environmental Protection
Agency
Division of Air Pollution
Control
2009 Mall Street
Collinsville, Illinois 62234
If you have any questions on this, please
call German
Barria at 217/782-2113.
Edwin C. Bakowski, P.E.
Acting Manager, Permit Section
Division of
Air Pollution Control
ECB:GB:jws
Date Signed:
0;ý"
CC: Illinois EPA, FOS Region 3
Lotus Notes
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
Attachment A - Emission Summary
This attachment provides a summary of the maximum emissions from ceramic
manufacturing operating
in compliance with
the requirements of this federally
enforceable permit. In preparing this summary, the Illinois EPA used the
annual operating scenario which results in maximum emissions from
such
a
plant. The resulting maximum emissions are well below the levels (e.g., 100
tons per year of Volatile Organic Material (VOM) 10 tons per year for a
single HAP, and 25 tons per
year for totaled HAP)
at which this source would
be considered a major source for
purposes
of the Clean Air Act Permit
Program. Actual emissions from this source will be less than predicted in
this summary to the
extent that less material
is handled, and control
measures are more effective
than required
in this permit.
E M I S S I O N S (Tons/Year)
S ingle Total
Emission Unit
CO
NO,,
PM
S02
VOM
HAP
HAPs
2 Wisconsin Ovens
(WO-1 and WO-2)
16.12
0.35
Mixer (M2)
0.32
23.13
Tube Dryer (TD2)*
0.32
14.89
Eirich Mixer (EM-1)
0.18
0.46
Tube Dryer (TD-3)
0.18
19.97
Purge Air Exhaust
Value (EV-1)
10.95
Bickley Kiln (BK-1)
8.45
1.31
2 Drayton Kilns (DK-1
& DK-2)
8.80
5.26
Keith Kiln (KK-1)
4.69
0.04
5 Furfural Storage
Tanks
2.64
2 Bag Break Stations
0.44
2 Barrel Tilters
0.44
Batch Conveyor
0.22
Belt Sander
0.22
Big Blender
0.22
Classifier/Hammermill
0.22
2 Collector Blenders
0.44
Despatch Oven Glaze
Mixer
0.22 '
5 Grinding Stations
1.10
Holding Bin
0.22
8 Holding Hoppers
1.76
4 Scale Hoppers
0.88
Small
Blender
0.22
18 Tote Bins
3.96
Small Weighment
F illing Station
0.22
5 Bulk Bag Stations
1.10
Pneumatic Transporter
0.22
Feedback Station
0.22
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
E M I S S I O N S (Tons/Year)
S ingle
Total
Emission Unit
CO
N_Ox
_PM
_so,
VOM
HAP
HAPs
15 Bulk
Bagging
S tations
3.30
9 Econolift Elevators
1.98
Small
Weighment
Station
0.22
Traveling Skip
0.22
Carrier Conveyor
0.22
Classifier
0.22
3
Mold Presses
0.66
2 Hammermills
0.44
Fuel Combustion
42.00 50.00
3.80 0.30
2.75
_----
Totals
42.00 50.00 62.44 0.30
81.75
9.0
22.5
GB: jws
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION AGENCY
DIVISION
OF AIR POLLUTION CONTROL
P.O. BOX 19506
SPRINGFIELD, ILLINOIS 62794-9506
S TANDARD CONDITIONS
FOR
OPERATING PERMITS
May, 1993
The Illinois Environmental Protection Act (Illinois Revised Statutes, Chapter 111-1/2,
Section
1039) grants the Environmental Protection Agency authority to impose conditions on permits
which it
issues.
The following
conditions
are
applicable
unless superseded
by special permit conditions(s).
1. The issuance of this permit does not release the Permittee from
compliance with state
federal regulations which are part of the Illinois State Implementation
Plan, as well as
other applicable statues and regulations of the United States
or the State of Illinois or
applicable local laws, ordinances and regulations.
2.
and
with
with
The Illinois EPA has issued this permit based upon the information
submitted by the Permittee
in the permit application. Any misinformation, false
statement or misrepresentation in
the
application shall
be
ground
for
revocation under 35 Ill. Adm. Code 201.166.
3. a. The Permittee shall not authorize, cause, direct or allow any modification,
as defined in
35 Ill. Adm. Code 201.102, of equipment, operations
or practices which are reflected
in
the permit application as submitted
unless a new application or request for
revision of
the existing permit is filed with
the
Illinois
EPA and unless a new permit
or revision of
the existing permit(s) is issued for such modification.
b.
4 .
This permit only covers emission sources and control equipment
while physically present
at
the indicated plant location(s). Unless the permit
specifically provides for equipment
relocation, this permit is void for an item
of equipment on the day it is removed
from the
permitted
location(s)
or if all
equipment is removed, notwithstanding the
expiration date
specified on the permit.
The Permittee shall allow any duly authorized agent of the
Illinois EPA, upon the presentation
of credentials, at reasonable times:
a. To
enter the
Permittee's
property where actual or potential effluent,
emission or noise
sources are located or where any activity is to be conducted pursuant
to this permit;
b. To have access to and to copy
any records required to be kept under
the terms and
conditions of this permit;
c. To inspect, including during any hours of operation
of equipment constructed or
operated
under this permit, such equipment and any equipment
required to be kept,
used, operated,
calibrated and maintained under this permit;
d.
e.
To obtain and remove samples of any discharge or emission of pollutants;
and
To enter and utilize any photographic,
for the purpose of preserving, testing,
emission authorized by this permit.
5. The
issuance of this permit:
recording, testing, monitoring or
other equipment
monitoring
or recording any activity,
discharge or
a. Shall not be considered as in any manner affecting
the title of the premises
upon which
the permitted facilities are located;
I L 532-0224
090-005
APC 161 Rev. March, 2001
P RINTED ON RECYCLED PAPER
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
b. Does not release the Permittee
from any liability for_ damage to person
or property caused
by or resulting from the construction,
maintenance, or operation of the facilities;
c. Does not take into consideration
or_ attest to the structural stability
of any unit or part
of the project; and
d. In no manner implies or
suggests that the Illinois EPA (or its
officers, agents, or
employees) assumes any liability,
directly or indirectly, for any loss
due to damage,
installation, maintenance, or operation of
the proposed equipment or facility.
6. The
facilities covered by this permit shall
be operated in such a manner that the disposal
of
air contaminants
collected by the equipment shall
not cause a violation of the Environmental
Protection Act or regulations
promulgated thereunder.
7.
The
Permittee shall maintain all equipment
covered under this permit in such a
manner that the
performance of
such equipment shall not cause a
violation of the Environmental Protection Act
or regulations promulgated thereuner.
8.
The Permittee shall maintain a maintenance
record on the premises for each
item of air
pollution
control equipment. This records shall be
made available to any agent of the
Environmental Protection
Agency at any time during normal
working hours and/or operating hours.
As a minimum, this record
shall show the dates of performance
and nature of preventative
maintenance activities.
9.
No person shall cause or allow continued operation
during malfunction, breakdown or startup
of
any
emission source or related air pollution control
equipment if such operation would cause a
violation of an applicable
emission standard or permit
limitation. Should a malfunction,
breakdown or startup occur
which results in emissions in excess
of any applicable standard or
permit limitation, the Permittee
shall:
a.
Immediately report the incident to the
Illinois EPA's Regional Field Operations Section
Office by
telephone, telegraph, or other
method as constitutes the fastest available
alternative,
and shall comply with all reasonable directives
of the Illinois EPA with
respect to the incident;
b. Maintain the following records for
a period of no less than two (2) years:
i. Date and duration
of malfunction, breakdown,
or startup,
ii. Full and detailed explanation of
the cause,
iii. Contaminants emitted and an estimate
of quantity of emissions,
iv. Measures taken to
minimize the amount of emissions
during the malfunction, breakdown
or startup, and
v. Measures taken to reduce future occurrences
and frequency of incidents.
10. If the permit
application contains a compliance
program and project completion schedule, the
Permittee shall submit
a project completion status report
within thirty (30) days of any date
specified in the compliance
program and project completion
schedule or at six month intervals,
whichever is more frequent.
11. The Permittee shall submit an Annual Emission
Report as required by 35 Ill.
Adm.
Code 201.302
and
35 Ill. Adm. Code Part 254.
Electronic Filing - Received, Clerk's Office, March 3, 2008
* * * * * PCB 2008-048 * * * * *
