1 PRELIMINARY DETERMINATION.

ANALYSIS, PRELIMINARY DETERMINATION AND DRAFT PERMIT

FOR

THE RENEWAL OF OPERATION PERMIT NUMBER 122049950

- P02

FOR

SCOT INDUSTRIES, INC

LOCATED AT

810 NEBRASKA

MUSCODA,

GRANT COUNTY, WISCON SIN

ON THE OPERATION S OF

EXISTING

CHROM IUM PLATING

, HONING

, AND METAL CLEANING

This review was performed by the Wisconsin Department of Natural Resources in accordance with Se c tions 285.60

to 285.66, Wis. Stats. and Chapter NR 407, Wis. Adm. Code. This review is for a Part 70 source located in an area

which is designated attai n ment/unclassified for all criteria pollutants.

Air Pollution Control Operation Permit:

Air Pollution Control CONOP: 122049950

- P10

Analysis, Preliminary Determin a tion

and Draft Permit prepared by: /s/ Yonggang (Y.) Su Date: 1 2 / 2 1 /2005

Approval Element Initials and Date

Preliminary Determination Document (including ca l

culations) /s/ YSu for BNP 12/21/05

Applicable Requirement /s/ YSu for BNP 12/21/05

Compliance Documentation Methods

(compliance inspector co ncurrence) /s/ YSu for MaH 12/21/05

Compliance Plan and Schedule /s/ YSu for MaH 12/21/05

Federal Enforceability of Permit Conditions

(synthetic minor conditions) /s/ TJR

Approved for Public Review and Co m ment: /s/ Thomas Roushar Date: 12/21/05

c c: WDNR BAM (AM/7) Files

– FOP Renewal

Muscoda Public Library, 206 N. Wisconsin Ave., Muscoda, WI 53573

- 0038

Maria Hill / Files

– WDNR South Central Region Air Program, Dodgeville Service Center**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 2**  **of 22** 

2 1

. Introduction INTRODUCTION

Sources which are not exempt fro m the operation permit requirements under Section 407.03, Wis. Adm. Code, that

were issued an operation permit from the Department of Natural Resources, are required to obtain a renewed air

pollution control operation permit. Sources subject to the requir ements must submit a permit renewal application to

the Department by the date set forth in Sections 285.66(3)(a), Wis. Stats., and NR 407.04(2), Wis. Adm. Code. The

renewal application is then reviewed following the provisions set forth in Sections 285.62 , 285.63 and 285.64, Wis.

Stats., and Chapter NR 407, Wis. Adm. Code.

Subject sources are to be reviewed for their air pollution control technology and for their impact upon the air quality.

This is to insure compliance with all applicable rules and stat utory requirements. The review will show why the

source(s) operation should be approved, conditionally approved, or disapproved. It will encompass emission

calculations and air quality analysis using US EPA models, if applicable. Emissions from volatil e organic

compound (VOC) sources and small sources whose emissions are known to be insignificant are normally not

modeled. As a precautionary note, the emission estimates may be based on US EPA emission factors (AP

- 42) or

theoretical data and can vary fro m actual stack test data.

This review is based on information contained within the renewal application submitted for an air pollution control

operation permit. A renewed operation permit may be issued if the criteria set forth in sections 285.63, 284.64 and

285.66, Wis. Stats., are met.

A final decision on the renewal will not be made until the public has had an opportunity to comment on the

Department's analysis, preliminary determination and draft permit. The conditions proposed in the draft permit ma y

be revised in any final permit issued based on comments received or further evaluation by the Department.

2

. General Application Information

GENERAL APPLICATION INFORMATION

Owner/Operator: Scot Industries

810 Nebraska Street

Muscoda

, WI 53573

Responsible Official: Robert B Anderson

, Plant Manager

608

- 739

- 3171

Application Contact Person: Tim J. DeB r uin , P rojec t Manager

608

- 739

- 3171

Application Submitted By:

Date of Administratively Complete Application: May 30, 2003

Dates of Submittal: May 1, 1997; J uly 1, 1998; December 1, 1998, and May 30, 2003

3

.**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 3**  **of 22** 

3 SOURCE DESCRIPTION

Scot Industries, Inc. (Scot) manufactures honed a n d hard chromium (Cr) plated steel tubing as well as hard

chromium plated steel bar to serve the hydraulic and pneumatic industries. I ts main operations and processes are

chromium plating, honing, and metal cleaning.

All the chromium plating, honing and metal cleaning will initially be housed in three different buildings. Scot

Industries plans to eventually house the chromium plating an d honing operations in two new buildings (Phase II

building and Phase III building) which have been constructed. The phase II building will contain 10 hard chromium

plating tanks and will exhaust emissions from plating tanks to two exhaust stacks (five tan ks per stack). Each stack

will exhaust 25,000 CFM. The Phase III building will contain 23 hard chromium plating tank s and will be

ex hausted through a single stack.

VOC fugitive emissions will be generated from 16 honing machines. There will be a small area for hand cleaning

steel tubes which have been honed.

The maximum theoretical emissions of chromium compounds is above the major source definition listed pursuant to

section 112(b) of the Clean Air Act, but the applicant has elected permit conditions restricting potential emissions

rates to less than the major source definition in NR 407.02(4)(a) , Wis. Adm. Code

.

The existing and previous air permits #122049950

- P02, #122049950

- P01, and #98

- GDB

- 906 for this facility were

issued in 1999. These three p ermits covered operations of 35 hard chromium plating tanks, 16 honing machines,

one boiler, and one metal cleaning process . The construction permit #98

- GDB

- 906 was issued as both an after

- the

fact (AtF) construction permit (CO) for then

- exist ing units an d an initial construction permit for then

- to

- be

constructed units

. During the 10/18/2005 s i te meeting w it h Tim Debruin and Robert Anderson from Scot Industries,

Maria Hill and Y. Su from WDNR, the following main changes occurred since 1999 hav e been recog nized and

c l arified :

1

. In Phase I building, t he significant emissions unit S12/P12 (S02/P02 in OP #122049950

- P02) has been

removed and phased out

. Another significant emissions unit S11/P11 (S06/P06 in OP #122049950

- P02) is

still in operation cu r rently , bu t w ould be removed and phased out eventually in futur e

.

2

. Two new Boilers S01/B01 (S15/B15 in 5/2003 submitted Application Forms, 0.085 MMBtu/hr, Natural Gas

Fueled Only, Uncontrolled, installed 1/18/2001) and S03/B03 (S35/B35 in 5/2003 Application, 0.3

MMB tu/hr, Natural Gas Fueled Only, Uncontrolled, installed 1/7/2002) and two fugitive processes S14/F14

- Metal Cleaning (S04/P04 in 5/2003 Application) and S33/F33

- Honing (S33/P33 in 5/2003 Application)

were not included in the 1999 issued #122049950

- P01/#98

- G DB

- 906/#122049950

- P02 , but have been

constructed and are currently in operation

.

3

. Th e twenty

- seven (27) Hard Chromium Plating Tanks, P20

- P24, P25

- P27, P30

- P46, P50, and P52 we r e

included in the 1999 issue d #122049950

- P01/#98

- GDB

- 906 and #122049950

- P02 . A nd

, their installation

have been completed and are currently in operation

.

4

. Six Processes P28, P29, P47, P48, P49, and P51

- Hard Chromium Plating Tanks were included in the 1999

issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02

. T heir installation

, howeve r, has not been

completed ye t as of the 10/18/2005 site meeting

.

5

. After 1999, the revised ch. NR 445, Wis. Adm. Code has been effective since July 1, 2004. Also, US

- EPA’s

National Emission Standards for Hard and Decorative Chromium Electroplating and Chro mium Anodizing

Tanks; Final Rule; a mendments we r e promulgated on Federal Register, Vol. 69, No. 137, July 19, 2004. As

such, a n e w hazardous air pollutant (HAP) emissions r e view is needed for this renewal.

Most parts in t his renewal review and prelimin ary determination (PD) will focus only on the

change/update/revisions fr om the 1998/1999 review and their documents for the air permits #122049950

-

P02/#122049950

- P01/#98

- GDB

- 906

. Additionally

, several administrative revisions will be made for this PD and

DP (draft permit) , e.g., d e l e t ing overlapp ed parts and a CP format to an OP one b a sed o n the availabl e documents

and the 10/18/2005 site meeting

. Other than the changes, m an y p a r ts contained in the previous documents for air

permits #122049950

- P02/#122049 950

- P01/#98

- GDB

- 906 may remain unchanged and/or un

- presented fo r th e

re vi ew of this renewal.**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 4**  **of 22** 

4 The following sections will present a detailed description of this r e view and its results

.

SIGNIFICANT EMISSIONS UNITS

BOILERS AND PROCESSES FOR CHROMIUM PLATI NG, HONING, AND METAL CLEANING

Stack/Process No.

(Based on Existing Documents and

10/2005 #122049950

- P10 Meeting ) Process Description Emission Controls Remarks

#122049950

- P10 *

(2003 Form 102A #122049950

-

P02

01. S01/B01

(S15/B15) (Not included

i n

- P02) Cast Iron Hot Water Boiler (<1

MMB tu) None

NR 406.04(1)(a)5. &

407.05(4)(c)10,

W.A.C. 02. S02/B02

(S25/B25) E. S01/B01 Hot Water Boiler (4 MMBtu ) None

03. S03/B03

(S35/B35) (Not included

in

- P02) Cast Iron Hot Water Boiler (<1

MMBtu ) None

A . S11/P11 A. S06/P06 Hard Chromium Plating (Tank?) C11: 4

- Stage

Composite Mesh Pad

Scrubber

B . S13/F13

Fugitive C. S03/P03

Fugitive Honing Operations None

C . S14/F14 S04/P04 (?) Metal Cleaning Not found in

- P02.

D. S21/P20, P21,

P22, P 23, P24 B. S21/P20,

P21, P22, P23,

P24 Hard Chromium Plating

Processes / Tanks 4

- Stage Composite

Mesh Pad Scrubbers

for each tank , then

vented to a common

HEPA filter C 0 1 and

Stack S21

D . S22/P25, P26,

P27 B. S22/P25

-

P29 Hard Chromium Plating

Processes / Tanks 4

- Stage Composite

Mesh Pad Scrubbers

for each tank , then

vented to a common

HEPA filter C02 and

Stack S22 P28 and P 29 have

NOT been install ed

yet

.

E . S31/P30

- P35,

P36

- P50, P51 , and

P52 B. S31/P31 Hard Chromium Processes /

Tanks A 4

- Stage Compo site

Mesh

- Pad

- Scrubber

(C31), followed by a

HEPA filter (C03). P 47, P48, P49, and

P51 ha v e NOT been

installed yet

.

F . S33/F33

Fugitive S33/P33

Fugitive Honing None Not found in

- P02.

G . S34/F34 D. S34/P34 Metal Cleaning None

N otes:

* The numbering in the documents for this PD (Preliminary Determination) and enclosed DP (Draft Permit) is

based on the facility’s request

.

The significant emissions sources at Scot Industries, Inc. are listed in the above table. De t a il ed parame te rs for the

boilers and pro c e sses in the permit application are summarized in the follow ing :**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 5**  **of 22** 

5 01

. STACK INFORMATION

Stack Identification Number: S01 (S15 in 5/2003 Application Forms)

Exhausting Unit(s): B01 (B15 in 5/2003 Application Forms)

This stack has an actual exhaust poi nt: YES

A. Emission Unit Information

Process number : B01 (B15 in 5/2003 Application Forms)

Unit description: Cast Iron Hot Water Boiler, fired with natural gas only

Maximum heat continuous ratin g: 0.085 mm BTU/hr

Control technology status: Uncontrol led

Date of construction or last modification: 1 /1 8 /2001

Construction Permit (CP): Exempted under s. NR 406.04(1)(a)5, Wis. Adm. Code

Fuel and firing conditions: (based on 5 /200 3 Renewal Application Form 4530

- 104, Item 11.)

Primary Fuel Back up Fuel

Fuel name/type Natural Gas None

Higher heating value 1,050 BTU/CF

Maximum sulfur content (wt. %) Negligible

Maximum ash content (wt. %) Negligible

Excess combustion air (% O 2 ) 15%

Moisture content (as fired) (%) 8.4%

Maximum hourly cons umption 50 therms

Actual yearly consumption Unknown

02 . STACK INFORMATION

Stack Identification Number: S02 (S25 in 5/2003 Application Forms or S01 in 1999

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Exhausting Unit(s): B02 (B25 in 5/2003 Applicatio n Forms or B01 in 1999

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

This stack has an actual exhaust point: YES

A. Emission Unit Information

Process number : B02 (B25 in 5/2003 Application Forms or B 01 in 1999 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Unit description: Hot water boiler

, fired with natural gas only

Maximum heat continuous ratin g: 4 mm BTU/hr ( shown in 5/2003 Application Form 104

, and clarified

by Scot Industries during the 10/18/2005 site meeting, but sh o wn with

5.0 MMBtu/hr in 19 99 issued #122049950

- P02 /

- P01/#98

- GDB

- 906

. )

Control technology status: Uncontrolled

Date of construction or last modification: 4/5/2001

Construction Permit (CP): Exempted under s. NR 406.04(1)(a)5, Wis. Adm. Code

Fuel and firing conditions: (based on 5 /200 3 Renewal Application Form 4530

- 104, Item 11.)

Primary Fuel Backup Fuel

Fuel name/type Natural Gas None

Higher heating value 1,050 BTU/CF

Maximum sulfur content (wt. %) Negligible

Maximum ash content (wt. %) Negligible

Excess combu stion air (% O 2 ) 15%**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 6**  **of 22** 

6 Primary Fuel Backup Fuel

Fuel name/type Natural Gas None

Moisture content (as fired) (%) 8.4%

Maximum hourly consumption 50 therms

Actual yearly consumption Unknown

03. STACK INFORMATION

Stack Identification Number: S 03 (S35 in 5/2003 Application Forms)

Exhausting Unit(s): B03 ( B35 in 5/2003 Application Forms)

This stack has an actual exhaust point: YES

A. Emission Unit Information

Process number : B 03 (B35 in 5/2003 Application Forms)

Unit description: Cast Iron Steam or Hot Water Boiler, fired with natural gas only

Maximu m heat continuous ratin g: 0.3 mm BTU/hr

Control technology status: Uncontrolled

Date of construction or last modification: 1 /7/2002

Construction Permit (CP): Exempted under s. NR 406.04(1)(a)5, Wis. Adm. Code

Fuel and firing conditions: (based on 5 /200 3 Renewal Application Form 4530

- 104, Item 11.)

Primary Fuel Backup Fuel

Fuel name/type Natural Gas None

Higher heating value 1,050 BTU/CF

Maximum sulfur content (wt. %) Negligible

Maximum ash content (wt. %) Negligible

Excess combustion air (% O 2 ) 15%

Moisture content (as fired) (%) 8.4%

Maximum hourly consumption 50 therms

Actual yearly consumption Unknown

4

. * STACK INFORMATION

Stack Identification Number: S11 (S11 in 5/2003 Application Forms or S06 in 1999

#122049950

- P01/# 98

- GDB

- 906/#122049950

- P02)

Exhausting Unit(s): P11 (P11 in 5/2003 Application Forms or P06 in 1999 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

This stack has an actual exhaust point: Yes

Discharge height above ground level (ft): 25

Inside dimension s at outlet (ft): Circular

- 2

Exhaust flow rate (ACFM) : 7,7 00 (Normal)

Exhaust gas temperature (Normal) ( 0 F): 90

Exhaust gas discharge direction: Up

Stack equipped with any obstruction: No

A. Emission Unit Information

Process number: P11 (P11 in 5/ 2003 Application Forms or P06 in 1999 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02) Comment [ BNP 1 ]: These numbers are based

on general outline formatting and are not

intended to correlate to the stack number.**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 7**  **of 22** 

7 Unit description: Hard chromium plating tank

Control technology status: Controlled

Maximum continuous rating: 10,000 amps (for P06 in the 12/1998 signed PD for 199 9 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02, but 32,000 amps in

5/2003 Application Form 126 enclosure for P11?)

Date of construction or last modification: 12/1996 ( but 1972 in the 12/1998 signed PD for 1999 issued

#122049950

- P01/#98

- GDB

- 906/#1220499 50

- P02 )

Construction Permit: #98

- GDB

- 906

a. Control devices associated with this emissions unit

Emission unit controlled: P 11

Control device number: C 11

Date of installation: 12/96

Description of device: 4 Stage composite mesh pad scrubber

Pollutant(s) controlled Chromic acid mist

Efficiency (%) 99.9

Pressure drop:

5 . S1 2/P12 (S1 2/P12 in 5/2003 Application Forms or S0 2 /P0 2 in 1999 #122049950

- P01/#98

- GDB

906/#122049950

- P02 , but this process has been removed according to a clarifi cation from Sco t

Industries’ Tim DeBruin d uring the 10/18/2005 site meeting with DNR staff )

6 . STACK INFORMATION

Stack Identification Number: S 1 3 (S13 in 5/2003 Application Forms or S03 in 1999

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Exhausting Unit(s): F13 (F13 in 5/2003 Application Forms or P03/04 in 1999

issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

This stack has an actual exhaust point: NO

A. Emission Unit Information

Process number : F13 (F13 in 5/2003 Application Forms or P03 in 1999 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Unit description: Honing operation

Control technology status: Uncontrolled

Date of construction or last modification: 1 /30/2000

Construction Permit: #98

- GDB

- 906

Diesel Fuel (coolant) Usage: 5,32 0 (Average) / 6,84 0 (Ma ximum) gal/yr.

S ul furized Lard Oil (coolant) Usage: 852 (Average) / 1, 0 95 (Maximum) gal/yr.

Honed Stee l Tubing Products : 8,000 (Average) / 14, 0 00 (Maximum) Ft. / wk

.

7 . STACK INFORMATION

Stack Identification Number: S 1 4 (S1 4 in 5/2003 Application Forms or S0 4 in the 12/1998 signed

PD for 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Exhausting Unit(s): F1 4 (F1 4 in 5/2003 Application Forms or P0 4 /0 5 in the 12/1998 signed

PD for 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

This stack has an actual exhaust point: NO

A. Emission Unit Information

Process number : F1 4 (F1 4 in 5/2003 Application Forms or P0 4 /0 5 in the 12/1998 signed

PD for 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Unit description: M anual cleaning of m etal par ts with shop rags and m in eral spirits

Control technology status: Uncontrolled

Date of construction or last modification: 0 / 0 / 197 0

Construction Permit (CP): Exempt from the CP requirement since the construction date

was before the effective date of the air pollution control permit program in 1980.**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 8**  **of 22** 

8 Min eral Spirits Usage: 2

, 16 0 (Average) / 2

, 7 0 0 (Maximum) lb. / yr

.

8 . STACK INFORMATION

Stack Identification Number: S21

Exhausting Unit(s): P20, P21, P22, P23, P24

This stack has an actual exhaust point: Yes

Discharge height above ground level (ft): 22

Inside dimensions at outlet (ft): Circular

- 3.33

Exhaust flow rate (Normal) (ACFM): 25,000

Exhaust gas temperature (Normal) ( **°** F): 90

Exhaust gas discharge direction: Up

Stack equipped with any obstruction : No

A. Emission Unit Information

Process numbers: P20, P21, P22, P23, P24

Unit description: Five Hard Chromium Plating Tanks

Control technology status: Controlled

Date of construction or last modification: 8/27/ 2002 ( 5/2003 Application Form 1 09 for P 20

- P24 )

Construction Permit: #98

- GDB

- 906

Maximum inst a ll ed rectifier capacity: 19 8

, 0 00 amps (5/2003 Form 126 Enclosure for P20

- P24)

a. Control devices associated with this emissions unit

Emission unit s controlled: P2 0

- P2 4

Control device number: C2 0

- C2 4 for P20

- P24 respectively

, then C 0 1 for all P20 /C20

- P24 /C24

combined

Date of installation: Unknown

Description of device: C2 0

- C2 4

– Five 4

- Stage composite mesh pad scrubber s

, C01

- HEPA filter.

Pollutant(s) controlled Chromic acid mist

Scrubber Ef ficiency (%) 99.9 9

Pressure drop: Not provided

9 . STACK INFORMATION

Stack Identification Number: S22

Exhausting Unit(s): P25, P26, P27

This stack has an actual exhaust point: Yes

Discharge height above ground level (ft): 22

Inside dimension s at outlet (ft): Circular

- 3.33

Exhaust flow rate (Normal) (ACFM): 25,000

Exhaust gas temperature (Normal) ( **°** F): 90

Exhaust gas discharge direction: Up

Stack equipped with any obstruction: No

A. Emission Unit Information

Process numbers: P25 th rough P29

Unit description: Five Hard Chromium Plating Tanks

Control technology status: Controlled

Date of construction or last modification: Between 1998 and 10/18/2005

, except uninstalled yet P28 and

P29, accor ding to Tim DeBruin ’s clarifi cation durin g the

10/18/2005 meeting at Scot Industries

Construction Permit: #98

- GDB

- 906

Maximum installed rectifier capacity: 180,000 amps (5/2003 Form 126 Enclosure for P25

- P29)

a. Control devices associated with this emissions unit

Emission unit s controlled: P25 through P29

Control device number: C25

- C29 for P25

- P29 respectively, then C02 for all P25/C25

- P29/C29

combined

Date of installation: Unknown**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 9**  **of 22** 

9 Description of device: C25

- C29

– Five 4

- Stage composite mesh pad scrubber s

, C02

- HEPA filter.

Pollutant(s) co ntrolled Chromic acid mist

Scrubber Efficiency (%) 99.9 9

Pressure drop: Not provided

10

. STACK INFORMATION

Stack Identification Number: S31

Exhausting Unit(s): P30 through P52

This stack has an actual exhaust point: Yes

Discharge height above ground level (ft): 2 9 (but 2 5 ft in the 12/1998 signed PD for 1999 issued

#122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Inside dimensions at outlet (ft): Circular

- 3.00

Exhaust flow rate (Normal) (ACFM): 15,000

Exhaust gas temperature (Normal) ( **°** F): 90

Exha ust gas discharge direction: Up

Stack equipped with any obstruction: No

A. Emission Unit Information

Process number: P3 0 through P52

Unit description: 23 Identical Hard Chromium Plating Tank s

Control technology status: Controlled

Date of construc tion or last modification: between 1998 and 10/18/2005, except P47, P48, P49, and P51

that were not instal led yet, according to Tim DeBruin’s

clarification during the 10/18/2005 meeting at Scot Industries

Maximum installed rectifier capacity: 68,000 amps ( 5/2003 Form 126 Enclosure for P30

- P52)

a. Control devices associated with th e s e emissions unit s

Emission unit controlled: P3 0

- P52

Control device number: C31

Date of installation: 1 2/2001

Description of device: 4

- Stage composite mesh pad scrubber

Pollutan t(s) controlled Chromic acid mist

Scrubber Efficiency ( C31 ) 99.9 9 % for Cr (VI)

Pressure drop:

b. Con trol devices associated with the s e emissions unit s

Emission unit controlled: P30

- P52

Control device number: C 0 3

Date of installation: 12/2001

Descr iption of device: HEPA Filter

Pollutant(s) controlled Chromic acid mist

HEPA Filter Efficiency ( C03 ) 9 9.97 % for Cr (VI)

Pressure drop:

11 . STACK INFORMATION

Stack Identification Number: S 3 3 (S 3 3 in 5/2003 Application Forms or S03 in 1999

#12204 9950

- P01/#98

- GDB

- 906/#122049950

- P02)

Exhausting Unit(s): F 3 3 (F 3 3 in 5/2003 Application Forms or P 3 3/ 3 4 in 1998

signed PD, but not in 1999 issued #122049950

- P01/#98

- GDB

906/#122049950

- P02)

This stack has an actual exhaust point: NO**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 10**  **of 22** 

10 A. Emission Unit Inf ormation

Process number : F 3 3 (F 3 3 in 5/2003 Application Forms or P 3 3/ 3 4 in 1998 signed PD, but not in

1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

Unit description: Honing operation

Control technology status: Uncontrolled

Date of construction or last modification: 1 /2/2000

Construction Permit: #98

- GDB

- 906

Diesel Fuel (coolant) Usage: 13,50 0 (Average) / 17,20 0 (Maximum) gal/yr.

S ul furized Lard Oil (coolant) Usage: 1,800 (Average) / 2,30 0 (Maximum) gal/yr.

Honed Stee l Tubing Products : 27,000 (Average) / 40, 0 00 (Maximum) Ft. / wk

.

12 . STACK INFORMATION

Stack Identification Number: S34

Exhausting Unit(s): P34

This stack has an actual exhaust point: NO

A. Emission Unit Information

Process number : F 34 (F 34 in 5/2003 Application Forms or P 3 4 in 1999 issued #122049950

-

P01/#98

- GDB

- 906/#122049950

- P02)

Unit description: M anual cleaning of m etal parts with shop rags and m in eral spirits

Control technology status: Uncontrolled

Date of construction or last modification: 3/ 1 5/2002

Construction Perm it: #98

- GDB

- 906

Min eral Spirits Usage: 3,240 (Average) / 4, 0 50 (Maximum) lb. / yr

.

Stack Parameter Summary.

Stack ID Actual Exhaust

Point or Fugitive Circular or

Rectangular Diameter or

Width (if

rect.) Length (if

rect.) Discharge

Direction Exhaust

Obs tacle Height Temp. Normal

Flow Rate Maximum

Flow Rate

ft (m) ft (m) U, D, H True/False ft (m) **°** F ACFM ACFM

S01/B01

(S15/B15) Yes Circular 1 ft. Up Yes 22.75 ft. 196

S11/P11 Yes Circular 2 ft. Up No 25 ft. 90 7700 7700

S13/F13 No Room

S1 4/F14 No Room

S02/B02

(S25/B25) Yes Circular 1.67 ft. Up Yes 44 ft. 196

S21/

P20

- P24 Yes Circular 3.33 ft. Up No 22 ft. 90 25000 25000

S22 /

P25

- P29 Yes Circular 3.33 ft. Up No 22 ft. 90 25000 25000

S31 /

P30

- P52 Yes Circular 2.33 ft. Up No 29 ft. 90 8000 8000

S33/F33 No Room

S34/F34 No Room

S03/B03

( S35/B35 ) Yes Circular 0.67 ft. Down No 10 ft. 196

INSIGNIFICANT EMISSION UNITS (IEUs)

Group 1 IEU s , which were listed in the 2003 Renewal Application Form 102B:

Maintena nce of Grounds, Equipment, and Bld g

. Boiler, T urbi n e, a nd H V A C Syste m Mai n ten a nce

Pollution Control Equipment Maintenance

Int Comb Eng Used for Warehouse and Mat Trans

Fire Control Equipment

Janitorial Services

Office Activities**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 11**  **of 22** 

11 Convenience Water Heat ing

Convenience Space Heating ( < 5 mil BTU/hr )

Sani tary sewer and plumbing venting

Group 2 IEU , which wa s listed in the 12/8/1998 signed PD for #122049950

- P01 a nd a lso clarified by Scot

Industries’ Tim DeBruin during the 10/18/2005 site meeting , but N OT listed in the 2003 Renewal Application Form

102B :

Boiler clean operation

Group 3 IEU s , which are new insignificant emission units verified in the following Section of SOURCE

SPECIFIC APPLICABLE REQUIREMENTS AND EMISSION CALCULATIONS

01. Boiler B01/S01 (B15/S15 in Scot Industries’ 5/2003 Application) , 0.085 MMBtu/hr, Natural Gas

Fueled Only, Uncontrolled, installed 1/18/2001; :

0 2 . Boiler B0 2 /S0 2 (B 2 5/S 2 5 in Scot Industries’ 5/2003 Application and B01/S01 in WDNR’s 1999 issued

#122049950

- P01/#9 8

- GDB

- 90 6 /# 122049950

- P0 2 / ), 4 MMBtu/hr, Natural Gas Fueled Only,

Uncontrolled, installed 4 / 5 /2001;

0 3 . Boiler B0 3 /S0 3 (B 3 5/S 3 5 in Scot Industries’ 5/2003 Application), 0. 3 MMBtu/hr, Natural Gas Fueled

Only, Uncontrolled, installed 1/ 7 /2001

.

4

. Cross Media Impacts

Material from the chromium ( Cr ) plating tanks is process ed by a filter press and the sediment is disposed of off site. CROSS MEDIA IMPACTS

LATEST PERMIT HISTORY

May 19, 1999: An op eration permit (OP) of #122049950

- P01 and a construction permit (CP) of 98

- GDB

- 906 were

issued by the Wisconsin DNR.

August 2 , 1999: #122049950

- P02, a Revision to #122049950

- P01, was issued

. A nd the initial OP #122049950

- P01

was superseded immediately at the issuance of #122049950

- P02. Two changes were made with this revision: 1. The

cover page of #122049950

- P01 was revised for a clarification; 2. A missing page of permit conditions relating to

reporting and compliance c e rtification was adde d into the OP #122049950

- P02. The OP #122049950

- P02 would

expire on Ma y 19 , 200 4.

Ma y 30 , 2003: Th e DNR received Sc o t Industries ’ Air Control Operation Permit Renewal Application.

Febr u ary 1 0, 2004: The DNR’s NSR

- Exemption

- Letter #03

- POY

- 133 determin ed that Scot Industries ’ proposed

construction of chrome plating tanks was exempted from the Air Control Construction Permit r equ ir e men t s per s.

NR 406.04(1)(rm), Wis. Adm. Code. This is based on that the facility is an area source, which is defined in s. NR

460.02(5) , Wis. Adm. Code, for federal hazardous air pollutants and that the project only involves the construction

of the chromium electroplating tanks.

October 18 , 200 5 : A site meeting participated by Tim Debruin and Robert Anderson from Scot Industries, Maria

Hill and Y. Su from WDNR

. During t he meeting

, Mr. Robert Anderson gave a presentation on Scot Industries

. Then other three c larified main changes happened since the 1999 issuance of #122049950

- P01/ 98

- GDB

- 906 and

#122049950

- P02

, and discussed th e strategi es for this renewal review.

October 1 9 , 2005: WDNR’s Maria Hill distributed a summary for the 10/18/2005 site meeting.

December 8, 2005: The DNR’s NSR

- Exemption

- Letter #05

- POY

- 337 determined that Scot Industries’ proposed

construction of two chrome elec troplating tanks “is exempt from construction permit requirements as per s. NR

406.04(1)(rm), Wis. Adm. Code. This is based on that your facility is an area source for federal hazardous air

pollutants and that the project only involves the construction of the chromium electroplating tanks. Your f a cility

may proceed with the construction.

Although this project has been determined to be exempt under ch. NR 406, Wis. Adm. Code, it is still subject to all

applicable requirements in NR 400

– 499, Wis. Adm. Cod e and any other applicable federal, state or local

regulations. In addition, please note that you are required by s. NR 407.04(1)(b)3., Wis. Adm. Code, to submit an**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 12**  **of 22** 

12 operation permit application covering these emissions units prior to commen c ing constructio n, if you have not done

so a l ready. ”

EXISTING PERMITS ( #122049950

- P02 )

Sc o t Industries has an existing Air Control Operation Permit #122049950

- P02 , which was issued by the DNR on

08/0 2 / 1999

.

EXISTING PERMITS ACTIONS

The following permit actions will be done concurrently with the issuance of this operation permit renewal, in

addition to the administrative changes for an operation permit renewal format:

A CON/OP permit # 98

- GDB

- 90 6

- OP will be issued. This will be done so that the construction permit # 9 8

- GDB

90 6 can be converted into an operation permit, with several needed changes per s. NR 407.07(3)(c), Wis. Adm.

Code

.

When the 

### operation permit renewal #122049950

- P10 is issued, all t he permit s 

### # 98

- GDB

- 90 6

- OP

, 

### #122049950

- P02

, #122049950

- P01

, a nd # 98

- G DB

- 90 6 will be incorporated/carried over into the integrated



### operation permit #122049950

- P10 and be superseded/expired immediately upon the issuance of th is



### renewal

. As such, #122049950

- P10 will become the only effective air permit for this facility after its

soon

- coming issuance until the next renewal or Scot Industries applies for another air permit/revision in

future

.

Most of the limitations included in the permits # 98

- GDB

- 90 6 / #122049950

- P01 / #122049950

- P02 will be kept

unchanged and just be incorpora ted into the integrated operation permit renewal #122049950

- P10 , except several

typos, facility updates, permit language upgrading, integrating/reorganizing, and already completed construction

permit requirements. Also, several items contained in the exis ting/previous air permits may be moved into Part II

GENERAL PERMIT CONDITIONS, as applied.

SOURCE SPECIFIC APPLICABLE REQUIREMENTS AND EMISSION CALCULATION S

Boilers: S01/B01, S02/B02, and S03/B03 : Natural Gas Fueled Only, Uncontrolled.

The primary crit eria pollutant emissions from these bo i ler s are nitrogen oxides and carbon monoxides emissions.

The natural gas criteria pollutant emissions a re calculated using emission factors from the Fifth Edition of AP

- 42,

1

. 4 Natural Gas Combustion . The following table s in this s ection list the emission factors used a nd the calculated

criteria pollutant emissions.

Natural gas, the only fuel combusted in Boilers: S01/B01, S02/B02, and S03/B03

, is considered Group 1 Virgin

Fossil fuel as defined by s. NR 445.02(18) , Wis. Adm. Code. Per s. NR 445.0 7 ( 5 ) (a) , Wis. Adm. Code t he

emissions of hazardous air pollutant s from the Group 1 Virgin Fossil fuel combustion , including n atural gas

, are

exempt from the requirements of the regulatory chapter NR 445, Wis. Adm. Code. T herefore no further NR 445

review is necessary for the emissions from Natural Gas combust ion in Boilers: S01/B01, S02/B02, and S03/B03

.

S01/B01

– Boiler, Rated @ 0.085 MMBtu /hr

, Natural Gas F u eled Only, Uncontrolled : (S15 /B15 in 5/2003

submitted Applicati on Forms , but not in 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02 )

Natural Gas (NG) Combustion Only : 85,000 B tu /hr / 1050 B tu /cf / 1,000,000 = 0. 000081 cf6/hr

EF FUEL USE RATES POLLUTANT EMISSION RATES

CF

max CF

aa Actual MTE PTE

P ollutant lb/cf6

burned Max. Fuel

Use cf6/hr Actual Fuel

Use cf6/yr ACT h

lb/hr ACT

a TPY MTE h

lb/hr MTE

a TPY PTE h

lb/hr PTE

a TPY**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 13**  **of 22** 

13 SO2 0.6 0. 000081 Unknown 0.00 0.0 0 0.00 0.0 0

NOx 100 0. 000081 Unknown 0. 01 0 .0 44 0. 01 0 .0 44

CO 84 0. 000081 Unknown 0. 0 07 0. 03 0. 0 07 0. 03

VOC 5.5 0. 000081 Unknown 0.00 0. 00 0.0 0 0. 00

PM 7.6 0. 000081 Unknown 0.0 0 0. 00 0.0 0 0. 00

NG: ACT h = EF x CF

max ACT

a = EF x CF

aa MTE h = EF x CF

max MTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

PTE h = EF x CF

max PTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

S02/B02

– Boiler, Rated @ 4.0 MMBtu /hr

, Natural Gas F u eled Only, Uncontrolled : (S 25/B2 5 in 5/2003

submitted Application Forms, o r S01/B01 with 5.0 MMBtu/hr in 1999 issued #122049950

- P01/#98

- GDB

906/#122049950

- P02 . During the 10/18/2005 meeting, Scot Industries’ Tim DeBruin clarified this boiler as

S02/B02, Rated @ 4.0 MMBtu/hr . The following table has used the updated data to update and revise the

corresponding part in the 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02 for this renewal OP

. )

Natural Gas (NG) Combustion Only : 4 ,000,000 B tu /hr/1050 B tu /cf / 1,000,000 = 0.00 381 cf6/hr

EF FUEL USE RATES POLLUTANT EMISSION RATES

CF

max CF

aa Actual MTE PTE

Pollutant lb/cf6

burned Max. Fuel

Use cf6/hr Actual Fuel

Use cf6/yr ACT h

lb/hr ACT

a TPY MTE h

lb/hr MTE

a TPY PTE h

lb/hr PTE

a TPY

SO2 0.6 0.00 381 Unknown 0.00 0.01 0.00 0.01

NOx 100 0.00 381 Unknown 0. 38 1

. 67 0. 38 1

. 67

CO 84 0.00 381 Unknown 0. 32 1 .4 0 0. 32 1 .4 0

VOC 5. 5 0.00 381 Unknown 0.0 21 0. 09 2 0.0 21 0. 09 2

PM 7.6 0.00 381 Unknown 0.0 29 0. 1 2 7 0.0 29 0. 1 2 7

NG: ACT h = EF x CF

max ACT

a = EF x CF

aa MTE h = EF x CF

max MTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

PTE h = EF x CF

max PTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

S03/B03

- Boiler, Rated @ 0. 3 MMBtu /hr

, Natural Gas F u eled Only, Uncontrolled : (S 3 5 /B35 in 5/2003

submitted Appl ication Forms , but not in 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02 )

Natural Gas (NG) Combustion Only : 300 ,000 B tu /hr/1050 B tu /cf / 1,000,000 = 0. 000 2 8 6 cf6/hr

EF FUEL USE RATES POLLUTANT EMISSION RATES

CF

max CF

aa Actual MTE PTE

Pollutant lb/cf6

burned Max. Fuel

Use cf6/hr Actual Fuel

Use cf6/yr ACT h

lb/hr ACT

a TPY MTE h

lb/hr MTE

a PTE h

lb/hr PTE

a TPY**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 14**  **of 22** 

14 TPY

SO2 0.6 0. 000 2 8 6 Unknown 0.00 0.0 0 0.00 0.0 0

NOx 100 0. 000 2 8 6 Unknown 0. 02 86 0

. 125 0. 0 286 0

. 125

CO 84 0. 000 2 8 6 Unknown 0. 0 24 0. 1 0 5 0. 0 24 0. 1 0 5

VOC 5.5 0. 000 2 8 6 Unknown 0.00 2 0. 00 7 0.0 0 2 0. 00 7

PM 7.6 0. 000 2 8 6 Unknown 0.0 0 22 0. 0 1 0.0 0 22 0. 0 1

NG: ACT h = EF x CF

max ACT

a = EF x CF

aa MTE h = EF x CF

ma x MTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

PTE h = EF x CF

max PTE

a = EF x CF

max x 8,760 hr/yr x 1 ton/2000 lb

Emissions Summary from Facility Wide Boilers

- S01/B01, S02/B02, and S03/B03

Sub

- Total Air Criteria Pollutants Emissions f rom Facility Wide Boilers

- S01/B01, S02/B02, and S03/B0 3

Air pollutant Actual

emissions Maximum theoretical

emissions (MTE) Potential to emit

(PTE) Maximum

allowable 5 times NR 407

inclusion level

TPY TPY TPY TPY TPY

Sulfur di oxide 0.01 0.01 0.01 5.0

Nitrogen oxides 1.84 1. 84 1. 84 5.0

Carbon Monoxide 1.54 1.54 1.54 5.0

VOCs 0

. 1 0. 1 0

. 1 5.0

Particulate matters (PMs) 0.14 0.1 4 0.1 4 5.0

The Table above shows that MTEs of all the Criteria Pollutants Emissions from all the bo i ler s within the enti re

facility are less than 5 times the corresponding inclusion levels specified in Table 2 or Table 3 in s. NR 407.05, Wis.

Adm. Code. Therefore, no further discussion for all the Criteria Pollutants Emissions from all the boilers within the

entire facilit y will be required, under s. NR 407.05(4)(c)10, Wis. Adm. Code. A l s o

, no further NR 445 review is

necessary for the emissions from Natural Gas combust ion in Boilers: S01/B01, S02/B02, and S03/B03 since all

t hese boilers fire natural gas only a nd natural g as i s a Group 1 Virgin Fossil fuel . As such, Boilers: S01/B01,

S02/B02, and S03/B03 will be listed as insignificant sources in th e Section of INSIGNIFICANT EMISSION

UNITS

.

Honing Operations

Air Pollutant Emissions from S13/ F 13 (Based on Scot Industr ies’ 5/2003 Renewal Application Form 128 for

S13/F13)

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 6.76 25.308 6.76 25.308 25.308**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 15**  **of 22** 

15 Air Pollutant Emissions from S 3 3/F 3 3 (Based on Scot Industries’ 5/200 3 Renewal Application Form 128 for

S33/F33)

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 17.00 63.64 17.00 63.64 63.64

Sub

- Total Air Pollutant Emissions from Honing Operation s within the entire facili ty (Based on Scot

Industries’ 5/2003 Renewal Application Form 128 s for S13/F13 and S33/F33 )

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 23 .76 88

. 94 8 23 .76 88.948 88.948

Hard Chromium Electroplating Processes (in Tanks)

The electroplating plating process es use chromium (VI), water soluble compound. The process is subject

to the MACT standard which limits emission of total chromium to 0.015 milligrams of total chromium per

dry standard cubic meter (mg/dscm)(6.6 x 10

- 6 grain per dry standard cubic foot [gr/dscf]) of ventilation air.

The flow rates for the electroplating stacks which are the basis of calcu lating the emission rates of

chromium (VI), water soluble compound, were taken from the permit a pplication. The moisture content is

assumed to be 4.0%.

Along with the 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02, all the emission calculations

including the principles and methods for all the electroplating processes within the entire facilit y have been

reviewed and commented by the public/facility and approved by the DNR. They cover ed and included all the

electroplating processes in this renewal review, plus the already

- removed S12/P12

- Hard Chromium Electroplating

Process (i.e., S0 2 /P0 2 in 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02)

. A s such

, the emission

calculations for the electroplating processes will not be re

- reviewed and re

- presented in detail again in this renewal

review. Please refer to the preliminary determination fo r air permits #122049950

- P01/#98

- GDB

- 906/#122049950

- P02 for a detailed description of the emission calculations for all the electroplating processes within the entire

facility.

But, m a ny emission re sults will be presented in this renewal review for furthe r applicable limitation/requirements

establishing and regulatory analyzing for this preliminary determination (PD)

.

S 11 / P11 Hard Chromium Electroplating Process Tank * ( i.e., S06/P06 in 1999 issued #122049950

- P01/#98

-

GDB

- 906/#122049950

- P02)

Pollutant A ctual Emissions Maximum Theoretical PTE

Total Chromium 0.0058954 mg/dscm 1.483175 TPY 0.11 lb/yr

Chromium VI (water

soluble) 0.401693 TPY 0.03 lb/yr

Notes:

* Data in the table are based on Scot Industries’ 5/2003 Renewal Application Form 126

.

S21/P20

- P24

, Five (5) Hard Chromium Electroplating Tanks *

Pollutant Actual Emissions Maximum Theoretical PTE

Total Chromium ** 9.1770143 TPY 0.07 lb/yr

Chromium VI (water

soluble) 2.485476 TPY 0.02 lb/yr**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 16**  **of 22** 

16 Notes:

* Data in the table are based on Scot Industries’ 5/2003 Renewal Application Form 126.

** To be determined with compliance test. Maximum stack emissions must be less than 0.015 mg/dscm to be

compliance with 40 CFR Parts 9 and 63.

S22/P25

- 29

, Five (5) Hard Chromium Electroplatin g Tanks *

Pollutant Actual Emissions Maximum Theoretical PTE

Total Chromium ** 8.342857 TPY 0.06 lb/yr

Chromium VI (water

soluble) 2.259524 TPY 0.02 lb/yr

Notes:

* Data in the table are based on Scot Industries’ 5/2003 Renewal Application Form 126.

** To be determined with compliance test. Maximum stack emissions must be less than 0.015 mg/dscm to be

compliance with 40 CFR Parts 9 and 63.

S31/P30

- P52

- Hard Chromium Plating Process * (S31/P31

- Hard Chromium Plating Tank in #122049950

- P02

, whose specifications were intended to include P30

- P52 in #122049950

- P10)

Pollutant Actual Emissions Maximum Theoretical PTE

Total Chromium ** 3.151746 TPY 0.000142 lb/yr

Chromium VI (water

soluble) 0.8535979 TPY 0.000038 lb/yr

Notes:

* Data in the table are based on Scot Industries’ 5/2003 Renewal Application Form 126.

** To be determined with compliance test. Maximum stack emissions must be less than 0.015 mg/dscm to be

compliance with 40 CFR Parts 9 and 63.

Sub

- Total Air Pollutant Em issions from Scot Industries’ All Hard Chromium Plating Processes

– S11/P11,

S21/P20

- P24, S22/P25

- P29, and S 31/P30

- P52 *

Pollutant Actual Emissions Maximum Theoretical PTE

Total Chromium ** 22 .15 4 7 923 TPY 0. 24 0142 lb/yr

Chromium VI (water

solub le) 6. 0 002 9 0 9 TPY 0.0 7 0038 lb/yr

Notes:

* Data in the table are based on Scot Industries’ 5/2003 Renewal Application Form 126s.

** To be determined with compliance test. Maximum stack emissions must be less than 0.06 mg/dscm ( 0.015

mg/dscm x 4 Stacks ) to be compliance with 40 CFR Parts 9 and 63.

Manual Metal Parts Cleaning

- S14/F14 and S34/P34 :

Air Pollutant Emissions from S1 4 /F1 4 (Based on Scot Industries’ 5/2003 Renewal Application Form 128 for

S14/F14 , which was constructed or last modified in 1970 according to their 5/2003 Renewal Application Form 109 )

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 0.36 1.35 0.36 1.35 1.35

Air Pollutant Emissions from S34/P34 (Based on Scot Industries’ 5/200 3 Renewal Application Form 128 for

S34/F34 , which was constructed or last modified in 3/15/20 0 2 according to their 5/2003 Renewal Application Form

109 )**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 17**  **of 22** 

17 Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 0.54 2.0 268 0.54 2.0268 2.0268

Sub

- Total Air Pollutant Emissions from Manual Metal Parts Cleaning within the entire facility (Based on Scot

Industries’ 5/2003 Renewal Application Form 128s for S14/F14 and S34/F34)

Pollutant Actual Emissions Maximum Theoret ical PTE

lb/hr TPY lb/hr TPY TPY

VOC 0.90 3.37 8 0.90 3.37 8 3.37 8

VOC Description: Mineral Spirits (CAS 8052

- 41

- 3)

Density: 7.2 lb/gal

Usage: 5,400 lb./yr (Average) and/or 6,750 lb./yr (Maximum) in 5/2003 Form 109s. (2,160

lb./yr (Aver age) and/or 2,700 lb./yr (Maximum) for S14/F14 and 3,240 lb./yr (Average) and/or 4,050 lb./yr

(Maximum) for S34/F34 ) ( but 470 gal/yr in the 12/8/1998 signed PD for the 1999 issued #122049950

-

P01/#98

- GDB

- 906/#122049950

- P02)

Operating Schedule in 5/2003 Fo rm 109s: 24 hr/day

6 days/week

312 days/year ( but 300 days/year in the 12/8/1998 signed PD)

7488 hr/yr

Average VOC Emission Rate: 6,750 lb/yr / 7488 hr/yr = 0.90 lb/hr

0.9014 lb/hr x 24 hr/day = 21.6 lb/day

The honed tubes are cleaned with mineral spirit s. The 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02 covered only one Manual Metal Parts Cleaning process line, S34/P34. The emission rate of mineral spirits from

S34/P34 was 0.47 lb/hr and 11.28 lb/day. Therefore, S34/P34 was exempt from the req uirements of chap. NR 424

per s. NR 424.03(1)4., Wis. Adm. Code.

This renewal review covers both of the current S14/F14 in Phase Building 1 and S34/F34 in Phase Building 3.

Since they separately process/manufacture product s at two different buildings

, a further investigation to each of

current / renamed S14/F14 and S34/F34 is needed as follows

.

Process S14/F14

- Manual Metal Parts Cleaning was constructed or last modified in 1970 according to their 5/2003

Renewal Application Form 109 . Therefore, the cur rent S 1 4/ F1 4 i s exempt from the requirements of chap. NR 424

per s. NR 424.03(1)1., Wis. Adm. Code.

The above calculation shows that the maximum theoretical mineral spirits emissions from process S34/F34

- Manual

Metal Parts Cleaning are 0.54 lb/hr and /or 12.96 lb/day. Th i s is lowe r t h an 15 pounds in any day, an exemption

threshold under s. NR 424.03(1)4., Wis. Adm. Code. Therefore, the current S34/F34 is exempt from the

requirements of chap. NR 424 per s. NR 424.03(1)1., Wis. Adm. Code.

The above analy sis shows that the VOC is the only criteria air pollutant emitted from S14/F14 & S34/F34

- Manual

Metal Parts Cleaning

. General Limitations for VOC emissions in s s

. NR 419.03 and NR 419.0 4 , Wis. Adm. Code

, however, still apply to both of S14/F14 & S34/F34

- Manual Metal Parts Cleaning

. And the General Limitations for

VOC emissions have been in cluded in Permit Part II.C. 2.d.

- e.

, September 6, 2005 version, therefore, will not been

included in the Draft Permit Part I.

MAXIMUM AVAILABLE CONTROL TECHNOLOGY (M ACT) and NATIONAL EMISSION

STANDARDS for 

### HAZARDOUS AIR POLLUTANTS (NESHAPs)**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 18**  **of 22** 

18 Chromic acid is used in the hard chromium electroplating plating process es . Chromic acid contains 27% chromium

(VI), water soluble compound. The hard chromium electroplating tan ks are required to meet US

- EPA’s MACT

standard s for hard chromium plating. Th ose standard s include a requirement to limit emissions of total chromium to

0.015 mg/dscm for each affected exhaust source per 40 CFR Part 63, Subpart N, 63.342(c)

. The l a te s t MA CT and

National Emission Standards for Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks;

Final Rule; amendments were promulgated on Federal Register, Vol. 69, No. 137, July 19, 2004.

WISCONSIN HAZARDOUS AIR POLLUTANT ( HAP / NR 44 5) REVIEW

Stoddard Solvent (Mineral Spirits) Emissions from M anual Metal Parts Cleaning

- S14/F14 and S34/ F

34 :

Hazardous Air Pollutant Emissions from Manual Metal Parts Cleaning

- S14/F14 and S34/F34

Pollutant Stack No. Maximum

Theoretical (MTE) Potenti al to

Emit (PTE) NR 445 **de minimus** Values

(Table A)

lb/hr / tpy TPY < 25 ft 25 to

<40 ft 40 to

<75 ft **≥** 75 ft Unit (Lb/hr or

Lb/yr)

Stoddard solvent

(Mineral spirits,

CAS# 8052

- 41

- 3) S14/F14 0.36 lb/hr /

1.35 TPY 1 .3 5 TPY

30.8 Lb/hr

S34/F34 0

. 54 lb/hr /

2.0268 TPY 2.0268 TPY Lb/hr

Sub

- Total 0.90 lb/hr /

3.37 8 TPY 3.37 8 TPY Lb/hr

The facility’s 2003 Application Form 109s for Processes F14 and/or F34 indicate that mineral spirits ( S toddard

solvent, CAS 8052

- 41

- 3) is the only raw material used for these two manual metal cleaning processes. Mineral

spirits is not a Federal regulated HAP. But the current NR 445, Wis. Adm. Code, which started to be effective on

July 1, 2004, lists in its Table A de minimis level for Stoddard solvent (mineral spirits) of 30.8 lb/hr for stacks less

than 25 feet in height (either S14 or S34 has NO an actual stack exhaust point, but serves to identify fugitive

emissions only)

. Scot Industries’ 5/2003 Renewal Application Form 128s, however, listed the MT E (maximum

theoretical emissions) rate for facility wide mineral spirits as 0.90 lb/hr (0.36 lb/hr from S14/F14 and 0.54 lb/hr from

S34/F34), which is less than the de minimis value in Table A. Therefore, no further analysis for Stoddard solvent

(mineral spirits) within this facility is required under NR 445, Wis. Adm. Code.

Combined with and b ased on the analyses and conclusions in the above paragraph for HAPs and at the end of above

Section of SOURCE SPECIFIC APPLICABLE REQUIREMENTS AND EMISSION CALCULA TION S for

VOC, the only criteria air pollutant, for S14/ F14 and/or S34/F34

- manual metal cleaning processes , no s pecial

limitation(s) are needed to be included in the Draft Permit Part I for this renewal. On e of the reason s for this is that

the General L imitations for VOC and HAP emissions included in the enclosed Permit Part II are good enough for

these two manual metal cleaning processes

.

Chromium Emissions from all Hard Electroplating Tanks within the Entire Facility :

Since Scot Industries’ hard chro mium electroplating tanks are required to meet US

- EPA’s MACT standard s, their

NR 445 review and analysis are NOT needed per s. NR 445.01(1)(b), Wis. Adm. Code.

CONTROL TECHNOLOGY REVIEW

Hard Chrome Electrop lating Tanks

The hard chromium electroplating tanks are required to meet the MACT standard for hard chromium plating. That

standard includes a requirement to limit emissions of total chromium to 0.015 mg/dscm for each affected exhaust

source . The following table summarizes emission c alculations from the SOURCE SPECIFIC APPLICABLE

REQUIREMENTS AND EMISSION CALCULATIONS section of this preliminary determination (PD) . Th e

table demonstrates that stack s S 1 1 /P11

, S21/P20

- P24

, S22/P25

- P29 and S31/P30

- P52 will meet the 0.015 mg/dscm

limitation.**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 19**  **of 22** 

19 Comparison o f Total Chromium PTE and Code Allowable Rate

Stack/ P r o cess * EF * CE ** A

max V std ** ACT

mg ** * MACT

Stan d ard

mg/hr/amp %/100 Amp

- hr dscfm/m mg/dscm mg/dscm

S11/P11 (S06/P06) 4.8 0.999 10000 **

(32000 *) 132.9 0.00 60 0.015

S21/P20

- P24 4.8 0.99975 198 000 * 664.6 0

. 005 9 6 0.015

S22/P25

- P29 4.8 0.99975 18 0000 * 664.6 0.00542 0.015

S31/P3 0

- P52 4.8 0.99975 68 000 * 398.8 0 .0 03 4 1 0.015

Notes:

* Based on Scot Industries’ 5/2003 Renewal Application. The numbering in parentheses is based on the

12/8/1998 signed PD for the 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

- P02.

** Based on WDNR’s 12/8/1998 signed PD for the 1999 issued #122049950

- P01/#98

- GDB

- 906/#122049950

-

P02.

* ** Based on the following formula in WDNR’s 12/8/199 8 signed PD for the 1999 issued #122049950

-

P01/#98

- GDB

- 906/#122049950

- P02 :

ACT

mg = EF x (1

- CE) x A

max **÷** (V std x 60 min/hr)

Control equipment for all tanks in the Phase II building will consist of ten individual 4 stage composite mesh pad

scrubbers for e ach tank. Tanks P20

- 24 and P25

- 29 will be vented thorough individual four stage composite mesh

pad scrubbers (C 20

- C 24 and C 25

- C 29 ), and t he n b e passed through HEPA filters C01 and C02 respectively. I n the

Phase III building

, Tanks P30

- 52 will be vented th orough a 4

- Stage Composite

- Mesh

- Pad

- Scrubber (C31), and

followed by a HEPA filter (C03). Th e s e are considered to be T

- BACT (Toxic Best Available Control Technology).

Honing Operations (16 machines)

The facility includes 16 honing machines which hone th e inside of the steel tubes prior to plating with chromium.

Kerosene is used as a lubricant to hone 20 foot lengths of pipe. For regulatory purposes it is assumed that 100% of

the kerosene used is emitted as VOC. Based on emission estimates contained in t he Source Specific Emission Limit

Calculation section of this preliminary determination

, VOC emissions from this operation are greater than the de

minimis amount that would subject this operation to regulation under NR 424, Wis. Adm. Code. The emission rat e

for each honing machine is 370 lb VOC/day. Each machine emits 0.81 lb of VOC/hr. NR 424 requires sources to

meet 85% control, or if 85% control is infeasible to meet LACT. The infeasibility of meeting 85% control is

demonstrated by the low PTE 3.4 tons/ year/machine) and the impractical nature of collecting emissions from 40 foot

long honing machine. LACT for this case is limiting use of kerosene to no more than 1914 gallons per month in

average and not using any other lubricant

.

5

. Facility Emissions FACI LITY EMISSIONS

Actual emissions are the total emissions generated by the emission sources identified below over the specified time

period taking into account any reductions made by a control device or technique. Maximum theoretical emissions

are the quant ity of air contaminants that theoretically could be emitted by the emissions sources identified below,

without considering emission control devices, based on the design capacity of the source. Potential to emit is the

maximum capacity of the emission sourc es identified below to emit any air contaminant under its physical and

operational design. Any physical or operational limitation on the capacity of a source to emit an air contaminant

shall be treated as part of its design if the limitation is Federally e nforceable.

A

. Stack Emissions.

Honing Operations

Sub

- Total Air Pollutant Emissions from Honing Operations within the entire facility (Based on Scot

Industries’ 5/2003 Renewal Application Form 128s for S13/F13 and S33/F33)**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 20**  **of 22** 

20 Pollutant Actual Emissions Maxi mum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 23.76 88.948 23.76 88.948 88.948

Hard Chromium Electroplating Processes (in Tanks)

Sub

- Total Air Pollutant Emissions from Scot Industries’ All Hard Chromium Plating Processes

- S11/P11,

S21/P20

- P24, S22/P25

- P29, and S31/P30

- P52 *

Pollutant Actual Emissions Maximum Theoretical PTE

Total Chromium ** 22.1547923 TPY 0.240142 lb/yr

Chromium VI (water

soluble) 6.0002909 TPY 0.070038 lb/yr

Notes:

* Data in the table are based o n Scot Industries’ 5/2003 Renewal Application Form 126s.

** To be determined with compliance test. Maximum stack emissions must be less than 0.06 mg/dscm (0.015

mg/dscm x 4 Stacks) to be compliance with 40 CFR Parts 9 and 63.

Manual Metal Parts Cleaning

- S14/F14 and S34/P34 :

Sub

- Total Air Pollutant Emissions from Manual Metal Parts Cleaning within the entire facility (Based on Scot

Industries’ 5/2003 Renewal Application Form 128s for S14/F14 and S34/F34)

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY TPY

VOC 0.90 3.37 8 0.90 3.37 8 3.37 8

B. Facility Emissions Summary.

I. Criteria Air Pollutants Emissions *

Pollutant Actual Emissions Maximum Theoretical

Emissions (MTE) Potential to Emit (PTE)

Lb/hr TPY Lb/ hr TPY Tons per Year

VOC 92.33 92.33 92.33

Notes:

* The data come from Scot Industries’ 5/2003 Renewal Application Form 129.

II. Hazardous Air Pollutant Emissions

Pollutant Stack No. Maximum

Theoretical (MTE) Potential to

Emit (PTE) NR 445 **de minimu s**  Values

(Table A)

tpy lb/yr < 25 ft

(c) 25 to

<40 ft (d) 40 to

<75 ft **≥** 75 ft

(f) Unit (Lb/hr or

Lb/yr)

Stoddard

solvent (Mineral

spirits, CAS#

8052

- 41

- 3) S14/F14 0.36 lb/hr /

1.35 TPY +

0.54 lb/hr /

2.0268 TPY 0.90 lb/hr *

(0.36 lb/hr

(S14) + 0.54

lb/hr (S34))

/ 3.378 TPY 30.8 Lb/hr

S34/F34

Sub

- Total 0.90 lb/hr /

3.378 TPY 0.90 lb/hr /

3.378 TPY 30.8 Lb/hr

Total Chromium

(Cr) S11/P11 1.483175 TPY 0.110142

lb/yr * Lb/hr

S31/P30

- 52 3.151746 TPY Lb/hr**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 21**  **of 22** 

21 S21/P20

- 24 9.1 770143 TPY 0.13 lb/yr * Lb/hr

S22/P25

- 29 8.342857 TPY Lb/hr

Sub

- Total 22.1547923 TPY 0.240142

lb/yr Lb/hr

Chromium VI

(water soluble

, CAS# 744 0

- 4 7

-

3 ) S11/P11 0.401693 TPY 0.030038

lb/yr * 5.84 Lb/yr

S31/P30

- 52 0.8535979 TPY

S 21/P20

- 24 2.485476 TPY 0.04 lb/yr * 1.42 Lb/yr

S22/P25

- 29 2.259524 TPY

Sub

- Total 6.0002909 0.070038

lb/yr Lb/yr

Notes:

* The PTEs are combined and grouped for each contaminant for all stacks within each of the 4 stack categories

for compa rison with the threshold rates in column (c) or (d) in the NR 445 Table A per s. NR 445.07(6)(b), Wis.

Adm. Code. Also, the PTE data are based on Scot Industries’ 5/2003 Renewal Application Form 126s.

III. Facility Summary

Pollutant Actual Emissions Maximum Theoretical PTE

lb/hr TPY lb/hr TPY

VOC 92.3 3 92.3 3 92.3 3 TPY

Total Chromium * 22.155 TPY 0.240142 lb/yr

Chromium VI (water

soluble) 6.0003 TPY 0.070038 lb/yr

** To be determined with compliance test. Maximum stack emissions mus t be less than 0.06 mg/dscm (0.015

mg/dscm x 4 Stacks) to be compliance with 40 CFR Parts 9 and 63.

AIR QUALITY REVIEW

Based on the above review and analyses, VOC emissions are the only significant criteria air pollution emitted from

this facility. T her e are currently no approved and reliable dispersion modeling programs for VOCs , however, so this

criteria pollutant cannot be accurately modeled for its impact on air quality. VOCs are precursors to ozone

formation. VOCs are difficult to model because th ey interact with other substances in the atmosphere in the

presence of sunlight to produce ozone. While it is known that this reaction occurs in the atmosphere and sunlight

acts as a catalyst, scientists are not currently able to predict the amount of ozo ne that will be created under specific

conditions.

Stoddard solvent (Mineral spirits, CAS# 8052

- 41

- 3) is listed in Table A and has a de minimis value of 30

. 8 lb/ h r for

stacks less than 25 feet ( both S14 and S34) in height

. Based on the above review and analyses, 0.90 lb/hr

, the

potential to emit (PTE) of m ineral spirits from S14 (0.36 lb/hr) and S34 (0.54 lb/hr) combined a re less than the

corresponding NR 445 T able A threshold value of 30

. 8 lb/h r . Therefore, a modeling analysis for Scot Industries’

Sto ddard solvent (Mineral spirits, CAS# 8052

- 41

- 3) emissions is NOT needed.

Chromium VI water soluble compound is listed in Table A and has a de minimis value of 5.84 lb/yr for stacks

equal to 25 feet (S11) or more, but less than 40 feet (S31) in height or 1.42 lb/yr for stacks less than 25 feet (S21

and/or S22) in height. The potential to emit (PTE) of chrome VI water soluble compound from S11 and S31 is

0.030038 lb/yr pound per hour, based on MACT standard of 0.015 milligrams of total chromium per dry st andard

cubic meter (mg/dscm). Similarly, the potential to emit (PTE) of chrome VI water soluble compound from S21 and

S22 is 0.04 lb/yr pound per hour, based on MACT standard of 0.015 milligrams of total chromium per dry standard

cubic meter (mg/dscm). Each of these PTEs is less than the corresponding NR 445 Table A threshold values and

thus no modeling is necessary. For the total Chromium, the situation is the same since the PTEs for the total

Chromium are less than the corresponding NR 445 Table A thr eshold values for Cr

- VI (water soluble) only

, i.e.,

0.110142 lb/yr < 5.84 lb/yr for (S11 + S31) and 0.13 lb/yr < 1.42 lb/yr for (S21 + S22) respectively . Here, we hav e

used a reasonable assumption that a NR 445 T able A threshold value for Cr

- VI ( water sol uble ) should be less than**Preliminary D etermination, FID No. 122049950, Permit No. 122049950** 

**- P10**  **Page 22**  **of 22** 

22 the corresponding NR 445 T able A threshold value for total Chromium , which is the sum of the NR 445 T able A

threshold value for Cr

- VI ( water soluble ) plus the corresponding NR 445 T able A threshold value for total

Chromium other t han Cr

- VI ( water soluble ). The current NR 445 Table A, however, has not listed yet the

corresponding NR 445 Table A threshold value for either annual total Chromium emissions (lb/yr) or annual total

Chromium emissions other than Cr

- VI (lb/yr).

A s such , a modeling analysis is NOT needed for either criteria air pollutant emissions or hazardous air pollutant

(HAP) emissions for Scot Industries

.

6

. The results of the modeling analysis demonstrate that all applicable air quality standards will be satisfied, assu ming the emission rates and stack parameters given in the attached source table. Facility Status Under Part 70

FACILITY STATUS UNDER PART 70

The permit issued pursuant to this analysis and determination will be a Part 70 permit because all chromium plating

operations are defined as Part 70 sources per s. NR 407.02(6) (b ) 7

. , Wis. Adm. Code

. The maximum theoretical

emissions of particulate matter, sulfur dioxide, carbon monoxide, nitrogen oxides, and volatile organic compounds

, however, are less than 100 tons per year.

COMPLIANCE DEMONSTRATION MONITORING METHODS

I n th is r e newal, the allowable operating parameter for the chrome scrubbers ha s been changed from + or

- 1 inch to

+ or

- 2 inches of water column from the base value measured during the stack test

. The range of + or

- 2 inches is

t he most recent and governing versions of the Chromium MACT standards.

Ot he r details can be seen in the enclosed DP (draft permit).

FACILITY COMPLIANCE STATUS

The Department finds that:

1. The source will meet app licable emission limits and other requirements.

2. The source will not cause nor exacerbate a violation of an ambient air quality standard or ambient air increment.

7

. Determination

PRELIMINARY DETERMINATION

The Wisconsin Department of Natural Resources (WDNR) has reviewed the permit application and o ther materials

submitted by Scot Industries, Inc. and hereby makes a preliminary determination that an operation permit may be

issued with the following Draft Applicable Limits and Draft Permit Conditions.