CITY OF PHILADELPHIA 

DEPARTMENT OF PUBLIC HEALTH 

AIR MANAGEMENT SERVICES 

RACT PLAN APPROVAL 

Effective Date: August 1, 2000 

Amended Date: October 7, 2002, February 19, 2014 

Expiration Date: None 

Replaces Permit No. None 

In accordance with provisions of the Air Pollution Control Act, the Act of January 8, 1960, P.L. 

2119, as amended, and after due consideration of a Reasonably Available Control 

Technology (RACT) proposal received under the Pennsylvania Code, Title 25, Chapter 

129.91 thru 129.95, of the rules and regulations of the Pennsylvania Department of 

Environmental Protection (PADEP), Air Management Services (AMS) approved the RACT 

proposal of the Facility below for the source(s) listed in section 1.A. Emission Sources of the 

attached RACT Plan Approval. 

Facility: 

Owner: 

Location: 

Mailing Address: 

SIC Code(s): 

Plant ID: 

Facility Contact: 

Phone: 

I 
Permit Contact: 


Phone: 


Responsible Official: 

I 
 Title: 
 ,c,, I ); .. 

c(:~c~l .. ~~·~· 

Philadelphia Energy Solutions Refining and Marketing LLC 

(PES) 

Philadelphia Energy Solutions Refining and Marketing LLC 

Girard Point Processing Area located at 3001 Penrose Ave 

Point Breeze Processing Area located at 3144 Passyunk Ave 

3144 Passyunk Ave., Philadelphia, PA 19145 

2911 

1501 and 1517 

Charles Barksdale 

(215) 339-2074 

Charles Barksdale 

(215) 339-2074 

Nithia Thaver and James Keeler 

Vice Presidents and General Managers 

1 

, ; /, i ~ . 

Ed~ra Wiener, Chief of Source Registration Date I

I 

i 

I 

2/19114 
RACT PLAN APPROVAL 	 PES Page 2 

The RACT plan approval is subject to the following conditions: 

I. 	 The purpose ofthis Plan Approval is to establish Nitrogen Oxides (NOx)lVolatile Organic Compound (VOC) Reasonably 

Available Control Technology (RACT) for PES Girard Point Processing Area and Point Breeze Processing Area. This 

includes the following emission sources and control equipment: 

A. 	 Emission Sources 

(I) 	 Process Heaters: Unit 137: FI heater (415 MMBTU!hr) 


F2 heater (155 MMBTU/hr) 


F3 heater (60 MMBTU/hr) 


Process heaters FI and F2 bum refinery fuel gas or refinery fuel oil. Heater F3 bums refinery fuel oil. 

(2) 	 Process Heater: Unit 231: B-1 0 1 heater Heater fires refinery fuel gas. 

(3) 	 Process Heater: Unit 433: H-I heater (243 MMBTU/hr) Heater fires refinery fuel gas. 

(4) 	 Process Heaters: Unit 1332: H·400 heater (186 MMBTUlhr) 


H-401 heater (233 MMBTUlhr) 


H 600 neater (21.3 MMBTU/hr) 


H 601 heater (48 MMBTUlnr) 


H 602 heater (49 MMBTUlnr) 


H 1 heater (45 MMBTU/nr) 


H-2 heater (60 MMBTUlhr) 


H 3 heater (43 MMBTUlhr) 


These heaters bum refinery fuel gas. 

(5) 	 Process Heater: Unit 1232: B-104 heater (70 MMBTU/hr) Heater fires refinery fuel gas. 

(6) 	 Boiler House #3: Boiler #37 (495 MMBTUlhr) 


Boiler #38 (495 MMBTU/hr) 


Boiler #39 (495 MMBTUlhr) 


Boiler #40 (660 MMBTUlhr) 


These boilers fire refinery fuel gas or refinery fuel oil. 

(7) 	 Sludge iRciReratar 8832: URil was 44 MMBTU/hr aRd bUrRed refiRery fuel gas or refiRery fuel oil. 

(8) 	 Sulfur Recovery URit 532: S02 incinerator was 16 MMBTWhr. URit bUrRed refiRer)' fuel gas. 

(9) 	 1232 FCCU CO Boiler: CO '....aste gas combustion unit (580 MMBTU/hr) bl:lRls I"roeess waste gas, refinery fuel 

gas and refiRery fuel oil. 

( I 0) Asphalt Heater: 	 HI (12.8 MMBTU/hr) 


H2 02.8 MMBTu/hr) 


H3 (\2.8 MMBTWhr) 


H5 (12.8 MMBTU/hr) 


These heaters burned fire refinery fuel gas. 

(II) 	 Crude Unit 210: Section A HTR HI 01 


Section B HTR H20 I 


Section C HTR 13HI (235.4 MMBTU/hr) 


These heaters above fire refinery fuel gas. 

(12) Hydrocracker Unit 859: HTR I HI (76 MM BTu/hr) Unit fires refinery fuel gas and retinery fuel oil. 

2/19114 
RACT PLAN APPROVAL 	 PES Page 3 

HTR 1H2 (70 MMBTU/hr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR I H3 (211 MMBTU/hr) Unit tires refinery fuel gas and refinery fuel oil. 

HTR I H4 (19 MMBTU'hr) Unit tires refinery ftlel gas. 

(13) 	 Reformer Unit 864: HTR PH3 (80 MMBTU/hr) 

HTR PHS (90 MMBTU!hr) 

HTR PHI (80 MMBTU.'hr) 

HTR PH2 (45 MMBTWhr) 

HTR PH4 (57 MMBTUihr) 

HTR PH7 (45.5 MMBTu/hr) 

HTR PHIl (74 MMBTU/hr) 

HTR PHI2 (85.1 MMBTUihr) 

These heaters fire refinery fuel gas and refinery fuel oil. 

(14) Hydrogen Plant 861: 	 HTR 3H I S (123 MMBTUihr) 

HTR 3HIN (125 MMBTU/hr) 


These heaters burned refinery fuel gas. 


(IS) Distillate HDS Unit 865: HTR II HI 

HTR 11 H2 HTR I IH2 

These heaters fire refinery fuel gas. 

(16) Gas Oil HOS Unit 866: 	 HTR 12HIHeater fires refiflery fuel gas. Gas-Oil HDS Unit 866: HTR 12H 1Heater 

fires refinery fuel gas (17) 	 22 Boiler House: Boiler #1 (169 MMBTU/hr) 

Boiler #2 (169 MMBTUIhr) 

Boiler #3 (203 MMBTU/hr) 

These three boilers burn only refinery fuel gas or natural gas and are equipped with Ultra Low NOx 

Burners. 

(18) 	 Reformer Unit 860: HTR 2H3 (174.67 MMBTU/hr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H5 (155 MMBTUihr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H I (49 MMBTu/hr) Unit fires refinery fuel gas ans refiner)' f1:lel oil. 

HTR 2H2 (69.78 MMBTU/hr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H4 (99.44 MMBTU/hr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H6 (36.7 MMBTUihr) Unit fires refinery f1:lel gas ana refinery f1:lel oil. 

HTR 2H7 (59 MMBTU/hr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H8 (49.6 MMBTUihr) Unit fires refinery fuel gas ans retinery fuel oil. 

Boiler 2H9 (165 MMBTU/hr) Unit fires refinery fuel gas or natural gas. 

(19) 	 868 FCCU HTR 8HlO I (49.5 MMBTUihr) Unit fires refiflery fuel gas. 868 FCCU HTR 8H 1 0 1 Unit fires refinery 

fuel gas 

(20) 	 868 FCCU Catalyst Regenerator 

(21) 	 867 81:11fur Reco't'ery Unit Incinerator 

(22) 	 Emergency Flares 

(23) 	 Cooling towers 

(24) 	 Fugitive leaks: valves, tlanges, compressors, pumps, pipes. 

B. 	 Control Eguipment 

(1) 	 Ultra-low NOx burner (ULNB) systems are installed on the following sources to control NOx emissions: 

Unit 433 H- J heater 

Unit 1232 B-104 heater 

2119/14 
RACT PLAN APPROVAL 	 PES Page 4 

#3 Boiler House boilers #37, #38, #39. and #40. 

Unit 210 H20 I heater 

2. 	 This approval requires and authorizes: 

A. 	 The installation of the Ultra Low NOx Burners on 433 H-I heater, 1232 B-104 heater, #3 Boiler House boilers #37. 

#38, #39, and #40, and 210 H20 I heater to comply with RACT requirements. The installation ofthe burners has been 

completed. 

i. 	 The installation of Ultra Low NOx Burners on 231 BIOI heater and 865 IIHI heater to comply with RACT 

requirements after the issuance of Plan Approval No. 12195. 

B. 	 PES will use combustion tuning to comply with RACT requirements for the following heaters: 

Unit 137: FI heater, F2 heater, F3 heater 

Unit 231: B 101 heater 

Unit 1332: H-400 heater, H-40 I heater, H-2 heater 

Crude Unit: 21 OA HTR H10 I, 210C HTR 13HI 

Hydrocracker Unit 859: HTR IHI, HTR I H2, HTR I H3 

Reformer Unit 864: HTR PH3, HTR PH5. HTR PHI, HTR PH2, HTR PH4, HTR PHil, HTR PHI2 

Hydrogen Plant 861: HTR 3HIS, HTR 3HIN 

Distillate HDS Unit 865:HTR IIHI, HTR IIH2 

Reformer Unit 860: HTR 2H3, HTR 2H5, HTR 2H4, HTR 2H2. HTR 2H7 

Gas Oil HDS Unit 866: HTR 12Hl Gas Oil HDS Unit 866: HTR 12HI, 

Unit 868: HTR 8HIOI 

C. 	 All fuel burning sources will be capped at the heat input specified in the table below. [f PES desires to raise the cap, a 

RACT evaluation will have to be performed at that new heat input. The economic evaluation will be made using cost 

of living increases. Changes will require a resubmission as revision to the PA State Implementation Plan. The 

applicant shall bear the cost of public hearing and notification required for EPA approval as stipulated in 25 PA Code 

§ 129.9(h). Modifications or changes may require additional controls or more strict emission limits depending on the 

applicable regu I' atlOn trtggere . d as a resu Itotf h e mo d'fi I lcafIOn or change, 

Process Unit 

Unit 137: 

Unit 433: 

Unit 1332: 

Unit 1232: 

Boiler House #3: 

Hydrocracker Unit 859: 

Reformer Unit 864: 

Source 

FI heater 

F2 heater 

H-I heater 

H-400 heater 

B-I04 heater 

Boilers #37, #38, #39 

Boiler #40 

HTRIH! 

HTRIH2 

HTR PH3 

I HTR PH5 

HTRPH2 

Heat Input 


Cap 


(MMBTUlhr) 


415 


155 


741 


186 


70 


495 


660 


76 

70 

80 

90 

45 

HTR PH4 57 

Hydrogen Plant 861: HTR3HIS 123 

HTR 3HIN 125 

D. 	 PESsha11 monitor all fuel input to all heaters and boilers with BTU limitations on a daily basis to insure capacity limits 

are not exceeded or PES shall install fuel limiting devices on the heaters or boilers to keep capacities below allowable. 

The compliance method must be in place by June 30th 2000. 

E. 	 All fuel combustkm sources with heat input equal to Of greater than 20 MMBTUlhr and less than ~1i.tU 

oomplj' with applicable presumptive RACT requirements of25 Pi\' Code I 29.93(b)(2) (5). All fuel combustion sources 

wtth-heat input less than 20 MMBTUlhr shall comply with presumptive RACT reqttirements 0[15 PA Code 129.93(c). 

2/19/14 
RAeT PLAN APPROVAL 	 PES Page 5 

F. 	 RACT for 22 Boiler House: Boiler # I, Boiler #2, and Boiler #3 is combustion tuning. 

G. 	 RACT for Reformer Unit 860 HTR 2H9 is combustion tuning. 

H. 	 The 868 FCCU NOx emissions shall be limited to 569 tons per year calculated on a 365 day rolling average basis. 

PES shall follow good combustion practices controlling the level of excess oxygen and CO promoter in the 

regenerator to minimize NOx emissions from the regenerator. 

J. 	 PES shall utilize an inspection and maintenance/monitoring program for VOC fugitive emissions from cooling 

towers. 

K. 	 PES shall utilize a fugitive emissions leak detection and repair program (LDAR) for all valves, pumps, flanges, and 

compressors in VOC service. All applicable equipment shall be tagged by May 31, 1995. Monitoring of components 

shall begin by July 3 L 1995 and shall be conducted on a quarterly basis (gaseous service) and an annual basis (liquid 

service) for all sources not covered under an existing LDAR program. 

The 1232 FCCU CO Boiler: CO waste gas comet:lstioA t:lAit (580 MMBTUihr) shall comply with the presumptive RACT 

reqHirements of 25 PA Code 129.93(c)('I), 'Ilhich is iflstallation, maintenance aAd operation of the source in accordance 

with mant:lfactt:lrers specifications. 

3. 	 RACT Implementation Schedule 

A. 	 Upon issuance of this approval, PES shall begin immediate implementation of the measures necessary to comply with 

the approved RACT proposal. 

B. 	 Sources proposing combustion tuning to comply with RACT requirements of25 PA Code 129.91({) shall perform the 

annual combustion tuning by December 31 H of each year not to exceed 12 months between tunings. 

C. 	 Sources applicable to presumptive RACT requirements of 25 PA Code 129.93(b)(2) shall complete the annual 

adjustment or tune-up by December 31 51 of each year not to exceed 12 months between tunings. 

D. 	 Sources proposing installing Ultra Low NOx Burners to comply with RACT requirements of 25 PA Code 129.91({) 

shall perform combustion tuning annually by December 31 st of each year not to exceed 12 months between tunings. 

E. 	 The installation of Ultra Low NOx Burners on 231 BIOI heater and 865 I1Hl heater to comply with RACT 

requirements within 18 months after the issuance of Plan Approval No. 12195. The 231 B101 heater shall be limited 

to 91 MMBTU/hr and 0.122 Ibs NOxlMMBTU until the burners are installed. The 865 II HI heater shall be limited 

to 72.2 MMBTU/hr and 0.113 lbs NOxlMMBTU until the burners are installed. The 0.030 Ibs/MMBTU NOx 

emission limit listed below for each unit will not become applicable until the burners are installed. 

4. 	 Testing Requirements and Stack Emission Limitations 

A. 	 For units installing ULNB, PES shall conduct performance tests for NOx. The results of these tests have been 

submitted to AMS. 

B. 	 The final NOx RACT emission limits for the #3 Boiler House boilers, 137 Unit FI heater, #22 Boiler House boilers: 

# I, 2, & 3, Unit 210 H20 I heater, and the 860 unit Boiler 2H9 have been established through the use of Department 

approved Continuous Emission Monitoring System (CEMS). Compliance with the limitations listed below will be on 

a 30-day rolling average based on hourly averages ofCEM data, except for the Unit 210 H201 heater, which will be 

on a 365 -d ay ro 	ll'mg average based h I on ouny averages 0 f CEM d a t a.

Source Limitation 

Boiler House #3 boilers #37, #38, #39, and #40 0.330 Ibs. NOx/MMBTU 

! 137 Unit F I heater 0.230 Ibs. NOxiMMBTU 

Rdormer Unit 860 Boiler 2H9 0.20 Ibs. NOXlMMBTU 

1122 Boiler House - boilers #1, #2. and #3 0.20 Ibs. NOxlMMBTU 

Unit 210 H201 heater • 0.030 Ibs. NOx/MMBTU 

C. Compliance With emISSion lImIts for combustion sources listed below shall be determIned by quarterly stack sampling 

with a portable NOx analyzer. After one year sampling, PES may petition AMS for semi-annual monitoring. AMS 

2/19/14 
RACT PLAN APPROVAL 	 PES Page 6 

may, at any time, require three one-hour stack tests per fuel type for each unit where fuels can be tired separately. 

AMS may, at any time, require three one-hour stack tests for dual-fuel type combustion sources where both fuels must 

be fired at the same time and compliance with emission limits will be through the use of one set of three one-hour 

stack tests 

Limitation (Ibs. NOx/MMBTU) 

Source Gas Oil 

Process Heater Unit 433 H-l heater 0.060 NiA 

Process Heater Unit 1332 H-400 heater 0.156 N/A 

Process Heater Unit 1332 H-40 I heater 0.156 N/A 

Crude Unit 210A HTR H101 0.089 

Crude Unit 210C HTR 13HI 0.104 0.4 

Hydrocracker Unit 859 HTR I H3 0.134 0.4 

Hydrogen Plant 861 HTR3HIS 0.133 N/A 

Hydrogen Plant 861 HTR3 HI N 0.133 N/A 

F-2@ 137 Unit 0.257 0.4 

F-3 @ 137 Unit N/A 0.4 

B-IOI@ 231 Unit (until ULNB installed) 0.122 N/A 

B-IOI(a) 231 Unit (after ULNB installed) 0.03 N/A 

H-2 (a) 1332 Unit 0.300 N/A 

B-I04 @ 1232 Unit 0.177 N/A 

I H-I (jj) 859 Unit 0.123 0.4 

1 H-2 (a) 859 Unit 0.123 0.4 

PH-3 @ 864 Unit 0.284 0.4 

PH-5 (a) 864 Unit 0.283 0.4 

PH-I (a) 864 Unit 0.167 0.4 

PH-4 (jj) 864 Unit 0.102 0.4 

PH-II @ 864 Unit 0.145 0.4 

PH-12 @ 864 Unit 0.119 0.4 

II H-I @ 865 Unit (until ULNB installed) 0.113 

IIH-l (a) 865 Unit (after ULNB installed) 0.113 N/A 

2H-3 @ 860 Unit 0.163 0.4 

2H-5 @ 860 Unit 0.163 0.4 

2H-2 @ 860 Unit 0.350 0.4 

2H-4 @ 860 Unit 0.270 0.4 

2H-7 (jj) 860 Unit 0.157 0.4 

Unit 865 II H2 heater 0.113 N/A 

Unit 866 12HI heater 0.113 N/A 

Unit 868 8H I 0 I heater 0.113 N/A .. D. 	 All annual combustIOn tunIng shall at a mInImum meet the requIrements set forth In 129.93 (b)(2) through (5). 

E. 	 At least thirty (30) days prior to a performance NOx test, PES shall inform AMS of the date and time of the scheduled 

test. 

F. 	 PES shall conduct performance tests to determine compliance with the Ibs NOx/MMBTU emission limits of this plan 

approval for the following heaters: 

1. 	 Within 180 days of the installation of ULNBs for the Unit 23 I B I 01 Heater and the Unit 865 II H I Heater. 

11. 	 Within 180 days of the issuance of Plan Approval No. 12195 forthe Unit 210 HI 0 I Heater, Unit 865 II H2 

Heater, Unit 866 12H I Heater, and Unit 868 8H I 0 I Heater. 

111. 	 Testing shall be conducted in accordance with 25 Pa. Code Chapter 139 

G. 	 The Unit 210 H20 I Heater shall be equipped with continuous monitors and recorders for NOx and O2. The 

continuous monitors and recorders shall meet the requirements of25 Pa. Code Chapter 139. 

2/\9/14 
RACT PLAN APPROVAL 	 PES Page 7 

H. 	 Each heater listed belo\\< shall be limited to the following rolling 365-day heat input limits: 

I. Lnit 231 B 101 Heater shall not exceed 915,420 MMBTU on a rolling 365-day basis. 


Ii. Unit 865 II H I Heater shall not exceed 764,748 MMBTU on a rolling 365-day basis. 


iii. Unit 865 II H2 Heater shall not exceed 562,392 MMBTU on a rolling 365-day basis. 

iv. Unit 210 HI 0 I Heater shall not exceed 1,681,920 MMBTU on a rolling 365-day basis. 

v. Unit 210 H20 IAiB Heater shall not exceed 2,225,040 MMBTU on a rolling 365-day basis. 

vi. Unit 866 12H I Heater shall not exceed 536,112 MMBTU on a rolling 365-day basis. 

1. Unit 868 8H 101 Heater shall not exceed 525,600 MMBTU on a rolling 365-day basis 

5. 	 Recordkeeping and Reporting Requirements 

A. 	 The permittee shall maintain a file containing all the records and other data that are required to be collected to 

demonstrate compliance with NOx/VOC RACT requirements of25 PA Code 129.91 - 129.94. 

B. 	 The records shall provide sufficient data and calculations to clearly demonstrate that the requirements of §129.91­

129.94 are met. 

C. 	 Data or information required to determine compliance shall be recorded and maintained in a time frame consistent 

with the averaging period of the requirement. 

D. 	 Records shall be retained for at least two years and shall be made available to the Department on request. 

6. 	 The operatioR of the aforemeRtioRea seurees shall Rot at aR)' time result in the emissioA of visible air contaminants in 

excess of the limitations specified in 8eetion 123 AI, particulate matter ift excess of tAe limitations speeified in Section 

123.11 or sulfur oxides ift e){eess oftAe limitatiofts specified in Section 123.22, all Sections of Chapter 123 of ArtieIe 1Il of 

tAe Rules and Regulations of the Department of EW/ironmental Resources, or in the emission of any of these or any other 

type of air contamiftaftt 1ft exeess of the limitations speeified in, or established pursuant to, any other applicable rule or 

regulatioft eofttaifted ift Artiele Ill. 

7. 	 The company shall not impose conditions upon or otherwise restrict the Department's access to the aforementioned 

source(s) and/or any associated air cleaning device(s) and shall allow the Department to have access at any time to said 

source(s) and associated air cleaning device(s) with such measuring and recording equipment, including equipment 

recording visual observations, as the Department deems necessary and proper for performing its duties and for the 

effective enforcement of the Air Pollution Control Act. 

8. 	 Revisions to any emission limitations incorporated in this RACT Approval will require resubmission as revision to the PA 

State Implementation Plan. The applicant shall bear the cost of public hearing and notification required for EPA approval 

as stipulated in 25 PA Code § 129.9(h). 

,VOTE: Wording witll sIFikell"ough /Ollt is NOT beillg submitted/or SIP approval. 

2/19114