### •

## • • 

## Sialeof IIIil10is 

# ENVIRONMENTALPROTECTIONAGENCY
Mary A. 

### Gade, Director 217/782-2113 

### P
.O
.Box 

### 19506, Springfield, IL 6279,1 -9506
OPERATING PERMIT FOR HARD CHROME ELECTROPLATING OPERATION NESHAP SOURCE PE:RtHTTE£ 

### Empire H ard Chrome, Inc
. Attn : Steve Hallin 

### 1615 South Kastner A venue Chicago, Illinois 60623**Applicat~on** No .: 73032100 Applicant ' s Designation ; 90-997 Subject : Hard chrome Electroplating Date Issued : Harch 21 , 1996 Location : 1615 South Kastner Avenue, 1
. 0
. No.: 031600CUQ Date Received : January 5, 1996 Expiration Date: March 21, 2001 Chicago 

### This 

### permit is hereby granted to the above-designated Permittee to OPERATE emission source(s) and/or air pollution control eqUipment consisting of t welve hard chrome electroplating tank(s) A-4

- A-a, A-123, 8-1, B-7, 8-2, 8-5, 8-6, and 8-34 controlled by packed bed scrubbers, three gas fired air makeup units, and three sandblast units controlled by dust collector as described in the above-referenced application. Thi s permit is subject to standard conditions attached hereto and the following special condition(s) : la

. Air pollution control equipment associated with a hard chrome electroplating tank(s) shall be operated at all times during the operation of the tank. b. Hard chrome electroplating tank(s) shall not exceed the following limits, pursuant to 40 CFR 63.342(c) (1) : Hard ChromiUm Plating Tanks Existing Large Tank(s) Chrom ium Emissions mg/dscm



### 0
. 015 This limit is the National Emissions standard for Hard Chromium Electroplating Tanks, 40 CFR Part 63 Subpart N and based on the maximum annual cumulative rectifier capacity of the hard chrome electroplating tanks being greater than 60 million amp - hrs/year

. An electroplating tank(s) installed before December 16, 1993, is considered as existing t ank (s). Compliance with the limit shall be determined from initial performance testing and ongoing compliance monitoring requirements, as =equired by Conditions of this permit.
c . FailUre to operate in accordance with operating parameter value, determined during initial performance testing shall be considered a violation of the above limit, pursuant to 40 CFR 63 Subpart N
. d

. The Permittee shall be in compliance with 40 CFR Part 63 Subpart N

- National Emission Standard for hard chrome tank (s) on or before January 25, 1997
. 

# /Page 2
2. The operation and maintenance practices required by 40 CFR 63.342(f) shall be implemented for control systems used on hard chrome plating tanks, including: The following operation and maintenance procedure for packed-bedscrubber(PBS)

. a. A quarterly visual inspection of packed-bed scrubber to ensure there is proper drainage, no chromic acid buildup on the packed beds, and no evidence of chemical attack on the structural integrity of the devices. b. A quarterly visual inspection of back portion of the chevronblade mist eliminator to ensure that it is dry and there is no breakthrough of chromic acid mist.
c. A quarterly visual inspection of duct work from the tank(s) to the control device to ensure there are no leaks. d. Add fresh make-up water to the top of the packed bed whenever makeup is added. 3a. The Permittee shall develop and implement an operation and maintenance (0 

### & M) plan for hard chrome plating tanks which shall include at least the following, pursuant to 40 eFR 63.342(f) (3): i. Description of the control devices and monitoring equipment in use. ii. A checklist to document the operation and maintenance of the equipment. iii. Required operation and maintenance procedures, pursuant to 40 CFR 63.342(f) (Condition 2). iv. Procedure to follow to ensure that equipment or process malfunctions due to poor maintenance or other preventable conditions do not occur.
v. Procedure for identifying malfunctions and for implementing corrective actions. b. The Permittee may use any Standard Operating Procedure (SOP) manuals, Occupational Safety and Health Administration (OSHA) plans or other existing plans as part of operation and maintenance plan, as long as they meet all the criteria of Condition 3(a). 4. Hard chrome electroplating tank(s) shall complete an initial performance test to demonstrate compliance pursuant to 40 CFR 63.343(b). Emissions tests shall be conducted during conditions which are representative of maximum emissions, i.e. at maximum rated rectifier capacity of all tanks. The initial performance test shall be performed by July 24, 1997. oPage 3
5. The following methods and procedures shall be used for performance testing: Refer to 40 CFR 63, Appendix A, for USEPA test methods. Location of sample Points Gas Flow and Velocity Chromium USEPA Method 1 USEPA Method 2 USEPA Method 306 & 306A 6a. Prior to carrying out these tests, the Bureau of Air shall be notified in writing a minimum of sixty (60) calendar days prior to the scheduled date of these tests with the exact date, time and place of these tests, to enable the Agency to observe these tests, pursuant to 40 CFR 63.347(d). Illinois Environmental Protection Agency Bureau of Air Compliance Unit (#39) P.O. Box 19276 Springfield, Illinois 62794-9276 Illinois Environmental Protection Agency Division of Air Pollution Control

- Regional Office Eisenhower Tower 1701 First Avenue Maywood, Illinois 60153 b. If the scheduled date for the test is changed for unforeseen reason, the Permittee shall inform the Agency within 5 calendar days of the originally scheduled test date and must specify the date of the rescheduled test. Observation of the performance test by the Agency is optional. 7a. During testing, the site specific "operating parameter value", Le., range of pressure drop data across the scrubber will be established to demonstrate continuous compliance, pursuant to 40 CFR 63.343(c). Pressure drop range can be established from the highest and lowest value during the multiple performance testing or 

### ± 1 inch of H 20 column about the average pressure drop measured during the three compliant test runs. b. During testing, the site specific "operating parameter value", Le., a range of velocity pressure drop data across the system inlet will be established to demonstrate continuous compliance, pursuant to 40 CFR 63.343(c) (2). Velocity pressure drop range can be established from the highest and lowest value during the multiple performance testing or 

### ± 10 percent about the average velocity pressure drop measured during the three compliant test runs.
c. Two (2) copies of the Final Report(s) for emission tests and compliance status shall be submitted to the Agency within 90 days after the performance test. If testing is not required, report shall be submitted no later than 30 days of compliance date. i. General information, i.e., date of test, testing peraonnel and observers, if any. ii. A summary of results and compliance status.

### Page 4
iii. Description of test method(s), including description of sampling points, sampling train, analysis equipment, and test schedule. iv. Detailed description of test conditions, including: A. Process information, i.e., models) of operation, process weight rate, e.g. raw material consumption, rectifier operating rate. B.**~ontrol** 

### equipment record of: 1. Pressure drop range across the system to demonstrate continuous compliance. 2. Range of velocity pressure at system inlet to demonstrate continuous compliance.
c. A discussion of calibration procedure.
v. Data and calculations, including copies of all raw data sheets and records of laboratory analyses, sample calculations, and data on equipment calibration. vi. An explanation of any discrepancies among individual tests or anomalous data. vii. Quality assurance procedure and result. viii. Any additional information required by the test method. d. Submittals of information shall be made as follows: i. Notices of Test

- one copy to the Regional Office, and one copy to compliance unit. ii. Final Report

- one copy to the Regional Office, and one copy to Compliance Unit. Illinois Environmental Protection Agency Bureau of Air compliance Unit (#39) P.O. Box 19276 springfield, Illinois 62794-9276 Illinois Environmental Protection Agency Division of Air Pollution control

- Regional Office Eisenhower Tower 1701 First Avenue Maywood, Illinois 60153Page 5
8. The Permittee shall keep the records required by 40 eFR 63.346, to demonstrate compliance: including the following:
a. Records of monitoring data required by 40 eFR 63.343(c). i. Pressure drop across the packed bed scrubber, determined daily. ii. Velocity pressure at system inlet, determined daily. b. Records of all maintenance performed on the chrome plating tanks, as related to emissions, the associated control system and monitoring equipment.
c. Records of the occurrence, duration, and cause (if known) of each malfunction of the chrome plating process, associated control system and monitoring equipment. d. Records of actions taken during periods of malfunction when such actions are inconsistent with the operation and maintenance plan.
e. Records, which may take the form of checklists, necessary to demonstrate consistency with the operation and maintenance plan required by 40 eFR 63.342{f) (3). f. Copies of test reports documenting results of all performance tests and all measurements as may be necessary to determine the conditions of performance tests, including measurements necessary to determine compliance with the special compliance procedures of 40 eFR 63.344(e). g. Records of monitoring data required by 40 eFR 63.343(c) that are used to demonstrate compliance with the standard including the date and time the data are collected. h. The specific identification (i.e., the date and time of commencement and completion) of each period of excess emissions, as indicated by monitoring data. Records of excess emissions that occurs during malfunction of the process, control or monitoring equipment. i. The specific identification (i.e., the date and time of commencement and completion) of each period of excess emissions, as indicated by monitoring data. Records of excess emissions with that occurs during periods other than malfunction of the subject chrome plating tanks and associated control devices. j. Records for the total process operating time of the affected chrome plating tank(s) during the reporting period.Page 6
k. Records demonstrating the maximum cumulative rectifier capacity if hard chrome plating is less than 60 million amphrs per year or of the actual cumulative rectifier capacity of hard chromium electroplating tank(s) at a facility expended during each month and the total capacity expended to semiannually. 1. Copies of the notifications and reports required by 40 CFR Part 63.9, 63.10 and 63.347 (Condition 9 

### & 10) with supporting documentation.
m.**~l** records shall be retained for a period of five years, pursuant to 63.10(b) (1). 9. The Permittee shall comply with the compliance reporting requirements of 40 CFR 63.347 including the following: A notification of compliance status, signed by the responsible official who shall certify its accuracy, attesting to whether the affected source has complied with Subpart N, pursuant to 40 CrR 63.347(e). The notification shall list the following:
a. The applicable emission limitation and the methods that were used to determine compliance with this limitation. b. The performance test report documenting the results of the performance test, which contains the elements required by 40 CFR 63.344(a), including measurements and calculations to support the special compliance provisions of 40 CFR 63.344(e) if these are being followed.
c. The type and quantity of hazardous air pollutants emitted by the source reported in mg/dscm or mg/hr if the source is using the special provisions of 40 CFR 63.344(e) to comply with the standards. lOa. The Permittee shall submit ongoing compliance status report documenting the ongoing compliance status to the Agency every six months. If the Permittee exceeds the emission limits as indicated during performance testing, ongoing compliance status shall be submitted on every quarter. b. The ongoing compliance report shall contain the following: i. The company name and address of the source performing hard chrome plates. ii. 

### An identification of the operating parameter(s) that are monitored for compliance determination. iii. The relevant emission limitation for the source, and the operating parameter value, or range of values, that correspond to compliance with this emission limitation as specified in the notification of compliance status.Page 7
iv. The beginning and ending dates of the reporting period.
v. A description of the type of process performed in the source. vi. The total operating time of the source during the reporting period. vii. The capacity cumulative rectifier actual expended during the reporting period, on a month-by-month basis, if the Permittee limits the maximum cumulative rectifier capacity less than 60 million amp-hr/yr. viii. A summary of operating parameter values, including the total duration of excess emissions during the reporting period as indicated by those values, the total duration of excess emissions expressed as a percent of the total source operating time during that reporting period, and a breakdown of the total duration of excess emissions during the reporting period into those that are due to.process upsets, control equipment**~alfunctions,** other known causes, and unknown causes. ix. A certification by a responsible official that the work practice standards followed in accordance with the operation and maintenance plan for the source.
x. If the operation and maintenance plan was not followed, an explanation of the reasons for not following the provisions, an assessment of whether any excess emission and/or parameter monitoring exceedances are believed to have occurred, and a copy of the report(s) documenting that the operation and maintenance plan was not followed. xi. A description of any changes in monitoring processes, or controls since the last reporting period. xii. The name, title, and signature of the responsible official who is certifying the accuracy of the report. xiii. The date of the report.
c. The Permittee shall report the results for each monitoring device. However, when one monitoring device is used as a backup for the primary monitoring device, the Permittee shall only report the results from the monitoring device used to meet the monitoring requirements. If both devices are used to meet these requirements, then the owner or operator shall report the results from each monitoring device for the relevant compliance period. 11. All notification and reports required by this permit shall be sent to the following address, unless otherwise indicated: Illinois EPA Bureau of Air Compliance Unit (#39) P.o. Box 19276 Springfield, Illinois 62794-9276Page 8
12a. Emissions and operation of air makeup units shall not exceed the following limits: Gas Consumption (rnmftJ/Mo) (rnrnftJ /Year) 1.90 22.76 NOx Emissions (Lb/Mo) (Ton/Year) 190 1.14 These limits are based on maximum gas consumption and emissions are determined based on standard emission factor. b. Compliance with annual limits shall be determined from a running total of 12 months of data.
c. Natural gas shall be the only fuel used in air makeup units. 13. This permit is issued based on negligible emissions of PM from sandblasting units. For this purpose emissions shall not exceed nominal emissions rate of 0.1 lb/hr and 0.44 ton/yr. 14. The Permittee shall also maintain gas consumption record (rnrnftJ/mo and rnrnftJ/yr) for at least three years. If you have any questions on this permit, please call Joydeb Majumder at 217/782-2113.

Donald E. sutton, P.E. Manager, Permit section Division of Air Pollution Control 

### (\M I

. /JA

____ DES:JM:jar

### f1P'~ cc: Region 1 IEPA, Compliance Unit 

# COpy OriginalSigned 

# by Uonald 

# E. Sutton, 

# P.E.

### July I, 1985 STATE OF ILLINOIS ENVIRONMENTAL PROTECTION AGENCY DIVISION OF AIR POLLUTION CONTROL 2200 CHURCHILL ROAD SPRINGFIELD. ILLINOIS 62706



### STANDARDCONDITIONS FOR OPERATING PERMITS

The Illinois Environmental Protection Act (Illinois Revised Statutes, Chapter 111-1/2, 

### Section 1039) grants the EnvironmentalProtection Agency authority to impose conditions on permitswhich itissues. Thefollowing conditions are applicable unless superseded by special permitcondition(s). 1. The issuance ofthis permit does not release the permittee from compliance with stateand federal regulations whicharepartoftheIllinoisStateImplementationPlan,aswellaswithotherapplicablestatutesandregulations oftheUnited Statesorthe StateofIllinoisorwith applicablelocal laws, ordinances andregulations. 2. The Agency has issued this permit based upon the information submitted by the permittee in the permit application. Any misinformation, false statement or mispresentation in the application shall be grounds for revocation under35 Ill. Adm. Code 201.207. 3. a. The permittee shall not authorize, cause, director allow any modification, as defined in 35 Ill. Adm. Code 201.102, ofequipment, operations or practices which are reflected in the permit application as submitted unless a new application orrequestfor revision ofthe existingpermitis filed withtheAgency andunlessa new permitor revision ofthe existingpermit(s) is issued for suchmodification. b. This permit only covers emission sources and control equipment while physically present at the indicated plantlocation(s). Unless thepermitspecifically providesfor equipmentrelocation, thispermitisvoidfor an itemofequipmenton the day it is removed from the permitted location(s) or ifall equipment is removed, notwithstanding the expiration date specified on the permit. 4. The permittee shall allow any duly authorized agent of the Agency, upon the presentation ofcredentials, at reasonable times:

a. toenterthepermittee'sproperty whereactualor potentialeffluent,emissionornoise sources arelocatedor where any activity is to be conductedpursuant to this permit, b. tohaveaccess to and to copy any recordsrequired to be keptunderthe terms andconditionsofthispermit,
c. to inspect, including duringany hours ofoperationofequipmentconstructed oroperatedunderthispermit, suchequipmentandanyequipmentrequiredtobekept,used,operated,calibratedandmaintainedunderthis permit, d. 

### toobtain andremove samplesofany discharge or emission ofpollutants, and
e. toenter and utilize any photographic, recording, testing, monitoring or otherequipmentfor thepurpose of preserving, testing, monitoring orrecording any activity, discharge oremission authorizedby thispermit. 5. Theissuance ofthis permit:
a. shall not be 

### considered as in any manner affecting the title of the premises upon which the permitted facilities arelocated, b. doesnotreleasethepermitteefrom anyliabilityfor damagetopersonorpropertycausedbyorresultingfrom the construction, maintenance.oroperation ofthe facilities,

IL 532-0224 09G-005 APe 161 Rev. MaY-93**Print~**on Recycled Piper