}J' Page: 1 of 65 Pennit Number: 199600451 

### Expiration Date: June 2, 2004



## STATE OFMICmGAN RENEWABLE OPERATING PERMIT IS HEREBY ISSUED TO 

### Deco' Plate Manufacturing Company SRN: N1863 LOCATED AT 395 Demille Road Lapeer, MI 48446 Pennit**Numb~r:** 

### 199600451

Effective Date: June 2, 1999 Expiration Date: June 2, 2004

This permit is issued 

### in accordance with and subject to Part 5506(3) ofArticle II, Chapter 1, Part 55 (Air 

### Pollution Control) ofP.A. 451 of 1994. Pursuant to 

### AirPollution Control Rule 336.1210(1), this pennit constitutes the permittee's authority to operate the major stationary source identified above 

### in accordance with the general conditions, special conditions and attachments contained herein. Operation ofthe major stationary source and all emission unit/process groups listed 

### in the permit are subject to all future or amendedrules andregulations pursuant to P.A. 451. This permit does notrelieve the permittee from the responsibilityto obtain the necessarypermits to install pursuant to Air Pollution Control Rule 336.1201 for new or modified process or process equipment. 

## In addition, issuance ofthis renewable operating pennit does not obviate the necessity of obtaining such permits orapprovals from otherunits ofgovernment as required by law.

Michigan Department ofEnvironmental Quality

Michael J. Koryto, District Supervisor Air QualityDivision, Shiawassee District Office; r 

### Page: 2 of 65 

## Table ofContents A. GENERAL REQUIREMENTS EnforceabiUty 

### GENERAL CONDITIONS Recordkeeping and Reporting CompUance Reporting and Certification PermitSbield Stratospberic Ozone Protection RiskManagement Plan Emission Trading 

### B. SOURCE-WIDE REQUIREMENTS C. EMISSION UNIT/PROCESS GROUP SUMMARYTABLE D. FLEXIBLE GROUPINGS SUMMARY TABLE E. EMISSION UNIT/PROCESS GROUP REQUIREMENTS

TABLE E-l.l EGPAINTLINE#l TABLE E-l.2 EGPAINTLINE#2 TABLE E-l.3 EG-CHROMETANKJ2 TABLE E-l.4 EG-COPPERTANKS TABLE E-l.S EG-ACTIVATORTANKS TABLE E-1.6 EG-NEUTRALIZERTANKS TABLE E-l. 7 EG-CHROMEETCH 

### F. FLEXIBLE GROUPING REQUIREMENTS

TABLE F-l.1 FG-CHROMEPROCESS TABLE F-l.2 FG-COLDCLEANER 

### G. NON-APPLICABLE REQUIREMENTS APPENDICES Permit Nwnber: 19960045I Expiration Date: June 2. 2004



## 4 4 

## 4 6 7 7 

### 8 

### 8 9 

## 9 10 10 11 12 

### 16 20 

### 24 26 

### 28 30 

## 32 33

. 3S 

## 37 37; II 

### Page: 3 of 

### 65 

### Appendix 1. Abbreviations Used in This Permit Appendix 2. Schedule ofCompliance Appendix 3. Monitoring Requirements Appendix 4. Recordkeeping Appendix 5. Testing Procedures Appendix 6. Voided Permits Appendix 7. Emission Calculations Appendix 8. Reporting Appendix 9. Preventive Maintenance Plan-Air Exhaust Equipment Pennit Number: 199600451 Expiration Date: June 2, 2004 

### 37 37 37 38 42 42 43 

### 52 64Page: 4 of 65 

### A. General Requirements Pennit Number: 199600451 Expiration Date: June 2, 2004

For the purpose ofthis Renewable Operating (RO) pennit, the 

### permittee is defined as any person who owns or operates an emission unit/process group at a stationary source for which a RO pennit has been issued. This pennit is issued to Deco' Plate Manufacturing Company, hereinafter the pennittee for this RO pennit. The department is defined in R 336.1104(d) as the Director ofthe Department ofEnvironmental Quality or his or her designee. 

### Enforceability All conditions in this pennit are both federally enforceable and state enforceable unless otherwise noted. Those requirements which are enforceable by the state only are designated by an asterisk. (R336.1213(5» 

## General Conditions
I. A challenge by any person, the Administrator ofthe EPA, or the department to a particular condition or a part ofthis RO pennit shall not set aside, delay, stay, or in any way affect the applicability or enforceability ofany other condition or part of this RO pennit. (R 336.1213(1)(f) 2. Except as provided in subrules 2, 3, and 4 ofR 336.1301, a person shall not cause or pennit to be discharged into the outer air from an emission unit/process group a visible emission ofa density greater than the most stringent ofR 336.1301(a) or (b) unless otherwise specified in this RO pennit. The grading of visible emissions shall be determined 

### in accordance with R 336.1303. (R 336.1301(1) in pertinent part) a) A 6-minute average of20% opacity, except for one 6-minute average per hour ofnot more 

### than 27% opacity. b) A limit specified by an applicable federal new source perfonnance standard. 3. Anycollected aircontaminants shall be removed as necessary to maintain the equipment at the required operating efficiency. The collection and disposal of air contaminants shall be perfonned in a manner so as to minimize the introduction of contaminants to the outer air. Transport of collected air contaminants in Priority I and II areas requires the use ofmaterial handling methods specified in R 336.1370(2). (R 336.1370) 4. Any air cleaning device shall be installed, maintained, and operated in a satisfactory manner and in accordance with the Michigan Air Pollution Control rules and existing law. (R 336.19I0) 5. The department may require the owner or operator ofany source ofan air contaminant to conduct acceptable perfonnance tests, at the owner's or operator's expense, in accordance with R 336.2001 and R 336.2003, under any ofthe conditions listed in R 336.2001. (R 336.2001) 6. A change in ownership or operational control of a stationary source covered by a RO pennit shall be made pursuant to R 336.1216(1). (R 336.1219(3» 7. Operation ofany emission unit/process group at this stationary source shall not result in the emission ofan air contaminant in quantities which cause injurious effects to human health or safety, animal life, plant life ofsignificant economic value, or property, orwhich cause unreasonable interference with the comfortableenjoyment oflife and property.· (R 336.190I) 8. Approval of this RO pennit does not exempt the pennittee from complying with any 

### future regulations which may 

### be promulgated under Act451 of 1994, as amended, Part 55, (Air Pollution Control) andlor the CAA. (R 336.1217(2)(a)(i) and (ii» 9. The pennittee shall comply with all conditions of this RO pennit. Any pennit noncompliance constitutes a violation of Act45I of 1994, as amended, Part 55, (Air Pollution Control) and is grounds for enforcement action, for pennit revocation or revision, or for denial of the renewal of the RO pennit.

. Notwithstanding the compliance detennination methods which the

. owner or operator of a stationary source is authorized to use under Act 451 of 1994, as amended, Part 55 (Air Pollution Control), the department may use anyrelevant information or appropriate method to detennine a stationary source's compliance with applicable emission limitations. All terms and conditions ofthis RO pennit that are designated as federally enforceable are enforceable by the Administrator ofthe EPA and by citizens under the provisions ofthe CAA. Any terms and conditions based on applicable requirements which are defined as "state only" are not enforceable by the EPA or citizens pursuant to the CAA. (R 336.1213(1)(a»Page: 5 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 10. It shall not be a defense for the permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity in orderto maintain compliance with the conditions ofthis RO permit. (R336.1213(1)(b» II. This RO permit may be modified, revised, or revoked for cause. The filing ofa request by the permittee for a permit modification, revision, or termination, or a notification ofplanned changes or anticipated noncompliance does not stay any pennit condition. Pursuant to R 336.1215 and R 336.1216 the permittee may make changes at a stationary source at his/her own risk. (R 336.1213(1)(c» 12. The permittee shall furnish to the department, within a reasonable time, any information the department may request, in writing, to determine whether cause exists for modifying, revising, or revoking the RO permit or to determine compliance with this RO permit. Upon request, a person shall also furnish to the department copies ofanyrecords that are required to bekept as a termorcondition ofthis RO permit. (R 336.1213(1)(e» 13. The permittee shall allow the department, or an authorized representative ofthe department, to enter at reasonable times, this stationary source orotherpremises, have access to and copy any records that must be kept under the conditions ofthis RO permit, and inspect, sample, or monitor emission unit/process groups at this stationary source. (Act 451 Part 5526(1)(b) and R 336.1213(l)(d» 14. The permittee shall pay fees consistent with the department fee schedule and requirements pursuant to Part 5522 of Act 451, P.A. 1994. (R 336.1213(l)(g» 15. This RO permit does not convey any property rights orany exclusive privilege. (R 336.1213(1)(h» 16. For renewal ofthis RO permit, an administratively complete application shall be considered timely ifit is received by the department not morethan 18 months, butnot less 

### than 6 months, before the expiration date ofthe RO permit. (R 336.1210(7» 17. Formodifications to this RO permit, an administratively complete application shall be considered timely ifit is received by the department in accordance with the time frames specified in R 336.1216. (R336.1210(9» 18. For changes to any emission unit/process group covered by this RO permit which do not require a revision of the RO permit, the permittee must provide written notification to the department and the Administrator of the EPA as specified in R 336.1215(2) and R 336.1215(3)(c) andkeep records as specified in R 336.1215(3)(d). 19. An RO permit shall be reopened prior to the expiration date and revised by the department under any ofthe following circumstances: a) 

### Ifadditional requirements become applicable to this stationary source with three ormore years remaining in the term of the permit. (R 336.1217(2)(a)(i» b) Ifadditional requirements pursuant to Title IV ofthe CAA become applicable to this stationary source. (R 336.l217(2)(a)(ii» c) If the department determines the permit contains a material mistake, that information required by any applicable requirement 

### was omitted, or that inaccurate statements were made in establishing emission limits orthe terms or conditions ofthepermit. (R 336.1217(2)(a)(iii» d) Ifthe department determines the permit must berevised to ensure compliance with the applicable requirements. (R 336. 12I7(2)(a)(iv» 20. Any required testingprotocol shall conform to a format acceptable to the AQD. (R 336.2003(1» 21. Any required test results which must be submitted to the AQD shall conform to a format acceptable to the AQD. (R 336.2001(4»

# , Page: 6 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 

### Recordkeeping and Reporting 22. The permittee shall use all emissions monitoring and analysis procedures or test methods required by the applicable requirements, including any procedures and methods promulgated pursuant to Section 504(b) ofTitle V or Section I 14(a)(3) of Title I ofthe CAA. (R 336.1213(3)(a)(i» 23. Where an applicable requirement does not require periodic testing or instrumental or noninstrumental monitoring, the permittee shall use periodic monitoring as required in this RO permit, sufficient to yield reliable data from the relevant time period that are representative ofthe stationary source's compliance with the permit as specified in R 336.1213(3)( a)(ii). 24. Records of any periodic emission or parametric monitoring required by this RO permit, shall include the information specified in R 336. 1213(3)(b)(i) unless the details for suchrecords are otherwise specified in this RO permit. (R 336.l213(3)(b» 25. AIl required documents, monitoring data, support information and all reports, including reports ofall instances ofdeviation from permit requirements, shall be kept and made readily available for a period of not less than 5 years from the date of generation ofthe document, data, report, or information. Support information includes all calibration and maintenance records and all original strip-chart recordings, or other original data records, for continuous monitoring instrumentation and copies of all reports required bythe RO permit. (R 336. 1213(3)(b)(ii), R 336. 1213(I)(e» 26. Semi-annually for the term of the permit as detailed in the requirement tables, or more frequently if specified in an applicable requirement in this RO permit, the permittee shall submit certified reports of any required monitoring to the appropriate District Office ofthe AQD. All instances ofdeviations from permit requirements during the reporting period shall be clearly identified in the reports. 

### (R 336. 1213(3)(c)(i» 27. Thepermittee shall promptlyreport any deviations from permit requirements and certify the reports. The prompt reporting of deviations from permit requirements is defined in R 336. 1213(3)(c)(ii) as follows, unless otherwise described in this RO permit: (R336. 1213(3)(c» a) For deviations that exceed the emissions allowed under the RO permit, prompt reporting means reporting consistent with the requirements ofR 336.1912 as detailed in Condition 29. All reports submitted pursuant to this paragraph shall be promptlycertified as specified in R 336.1213(3)(c)(iii). b) For deviations which exceed the emissions allowed under the RO permit and which are not reported pursuant to R 336.1912 due to the duration ofthe deviation, prompt reporting means the reporting ofall deviations in the semi-annual reports required by R 336. 1213(3)(c)(i). The report shall describe reasons for each deviation and the actions taken to minimize orcorrect each deviation. c) For deviations that do not exceed the emissions allowed under the RO permit, prompt reporting means the reporting of all deviations in the semi-annual reports required by R336.1213(3)(c)(i). The report shall describe the reasons for each deviation and the actions taken to minimize orcorrect each deviation. Forreports required pursuant to R 336.l213(3)(c)(ii), prompt certification ofthe reports is described in R 336.1213(3)(c)(iii) as follows:

d) Submitting a certification by a responsible official with each report which states that, based on information and belief formed after reasonable inquiry, the statements and information inthe report are true, accurate, and complete. e) Submitting, within 30 days following the end of a calendar month during which one or more prompt reports of deviations from the emissions allowed under the permit were submitted to the department pursuant to R 336.12l3(3)(c)(ii), a certification by a responsible official which states that, based on information and beliefformed after reasonable inquiry, the statements and information contained in each ofthe reports submitted during the previous month were true, accurate, and complete. The certification shall include a listing ofthe reports that are being certified. Any report submittedpursuant' to R336.1213(3)(c)(ii) that will be certified on a monthly basis pursuant to this paragraph shall include a statement that certification ofthe report will be provided within 30 days following the end ofthe calendar month. 28. Any document required to be submitted to the department as a term or condition of this RO permit shall contain a certification by a responsible official which states that, based on information and belief formed after reasonable inquiry, the statements and information in the document are true, accurate, and complete. (R 336.1213(3)(c»

### Page: 7 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004
29. The permittee shall provide notice ofan abnonnal condition, start-up, shutdown, or malfunction that 

### results in 

### emissions ofa hazardous or toxic air pollutant which continue for more than 

### one hour in excess of any applicable standard or limitation, or emissions ofany aircontaminant continuing for more than two hours in excess ofan applicable standard orlimitation, as required 

### in R336.1912, to the appropriate District Office ofthe AQD. The notice shall be

### provided not later than 

### two business days after startup, 

### shutdown, or discovery of the abnormal condition 'or malfunction. Written reports, if 

### required, 

### must be filed with the appropriate District Supervisorwithin 10 days afterthe start-up orshutdown occurred, within 10 days after the abnonnal conditions or malfunction has been corrected, or within 30 days ofdiscovery ofthe abnormal conditions or malfunction, whichever is first The written reports shall include all ofthe information required in R336.1912(5) and shall be certifiedby aresponsible official. 30. On an annual basis, the permittee shall report the emissions, or the information necessary to determine the emissions, of each regulated air pollutant actually emitted for each emission unit/process group utilizing the emissions inventory forms provided by the department as specified in R 336.1212(7). 

### Compliance Reporting and Certification 31. The responsible official shall certify to the appropriate District Office ofthe AQD and the EPA, whether the stationary source is and has been in compliance with all terms and conditions contained in the RO permit except for deviations that have been reported to the appropriate District Office of the AQD pursuant to Condition 27. This certification shall be in 

### an acceptable written format as specified in R 336.12I 3(4)(c)(i) through (v) and shall state that, based on information and belief formed after reasonable inquiry, the statements and information in 

### the certification are true, accurate, and complete. The EPA address is: US EPA, Air Compliance Data

- Michigan, Air and Radiation Division, 77 West Jackson Boulevard, Chicago, IL, 60604. (R336.1213(4)(c» 32. The certification ofcompliance shall be submitted annually for the term ofthis RO permit as detailed in the requirement tables, ormore frequently ifspecified in an applicable requirement in this RO permit. (R 336.1213(4)(c» 

### Permit Shield 33. A permit shield is in place for any applicable requirements which are included and specifically identified in this RO permit as ofthe date ofpermit issuance. Compliance with each condition ofthis permit shall be deemed compliance with the specific applicable requirements identified with that condition. Any requirements identified in Part G ofthis RO permit have been identified as non-applicable to this RO permit and are included in 

### the permit shield. (R 336.12I 3(6)(a}(i) and (ii» 

### 34. Nothing in this RO permit shall alter or affect any ofthe following: a) The provisions of Section 303 ofthe CAA, emergency orders, including the authority ofthe EPA under Section 303 of the Act. (R 336.l213(6)(b)(i» b) The liability ofthe owner or operator ofthis stationary source for any violation ofapplicable requirements prior to or at the time ofthis permit issuance. (R 336.1213(6)(b)(ii» c) The applicable requirements ofthe acid rain program, consistentwith Section 408(a) ofthe CAA. (R 336.1213(6)(b)(iii» d) The ability ofthe EPA to 

### obtain information from a source pursuant to Section 114 ofthe CAA. (R 336. 1213(6)(b)(iv» 35. The permit shield shall not apply to provisions incorporated into this permit through procedures for any ofthe following: a) Changes for operational flexibility made pursuant to R 336.1215. (R 336.1215(5» b) Administrative amendments made pursuant to R336.l216(l)(a)(i-iv) until the changes have been approved by the 

### department. (R 336. 1216(1)(b)(iii» c) Administrative amendments made pursuant to R336.1216(1)(a)(v) until the amendment has been approved by the department. (R 336. 1216(l)(c)(iii» d) Minorpermit modifications made pursuant to R336.1216(2). (R 336.I216(2)(f)Page: 8 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 e) State-only modifications made pursuant to R 336.1216(4) until the changes have been approved by the department. (R 336. 1216(4)(e» 36. Expiration ofthis RO pennit results in the loss ofthe permit shield. Ifa timely and administratively complete application for renewal is submitted not more than 18 months, but not less than 6 months before the expiration date ofthe RO permit, but the department fails to take action before the end ofthe permit term, the existing RO permit does not expire until the renewal is approved or denied, and the pennit shield shall extend beyond the original permit term until the department takes final action. (R 336.1217(1)(c), R 336.1217(1)(a» 

## Stratospheric Ozone Protection 37. Ifthe pennittee services, maintains, orrepairs appliances except for motor vehicle air conditioners (MV AC), ordisposes of appliances containing refrigerant, including MVAC and small appliances, or if the permittee is a refrigerant reclaimer, appliance owner or a manufacturer of appliances or recycling and recovery equipment, the permittee shall comply with all standards for recycling and emissions reduction pursuant to 40 CFR Part 82, Subpart F. 38. If the permittee perfonns a service on motor (fleet) vehicles when this service involves refrigerant in the MVACt the pennittee is subject to all the applicable requirements as specified in 40 CFR Part 82, Subpart B, Servicing ofMotor Vehicle 

### Air Conditioners. The term "motor vehicle" as used in Subpart B does not include a vehicle in which final assembly ofthe vehicle has not been completed by the original equipment manufacturer. The term MVAC as used in Subpart B does not include the air-tight sealed refrigeration system used for refrigerated cargo or an air conditioning system on passenger buses using HCFC-22 refrigerant. 

## Risk Management Plan 39. If subject to Section 112(r) ofthe CAA and 40 CFR Part 68, the permittee shall register and submit to the appropriate regulatory agency, a risk management plan (RMP) for reducing the probability of accidental releases of any regulated substances listed pursuant to Section I 12(r}(3) ofthe CAA as amended in 68.130. The RMP shall be submitted in a method and format as specified by EPA. The list ofsubstances, threshold quantities, and accident prevention regulations promulgated under Part 68 do not limit in any way the general duty provisions under Section 112(r)(l). 40. Ifsubject to Section I 12(r) ofthe CAA and40 CFR Part 68, the permittee shall comply with the requirements ofPart 68 no later than the latest ofthe following dates as provided in 68.10(a):

a) June 21, 1999, b) Three years afterthe date on which a regulated substance is first listed under 68.130, or c) The date on which a regulated substance is first present above a threshold quantity in an emission unit. 41. Ifsubject to Section 112(r) ofthe CAA and 40 CFR Part 68, the permittee shall submit any additional relevant information requested by any regulatory agency necessary to ensure compliance with the requirements of40 CFR Part 68. 42. If subject to Section 112(r) of the CAA and 40 CFR Part 68, the permittee shall annually certify compliance with all requirements ofSection Il2(r), including the registration and submittal ofan RMP, as detailed in Conditions 31 and 32 ofthis RO permit. (40 CFR Part 68)Page: 9 of 65


### Emission Trading P ennit Number: 199600451 Expiration Date: June 2, 2004

43

. The use ofEmission Reduction Credits for purposes ofcompliance with emission standards or limitations contained in this pennit is allowed, provided that such usc is in compliance with Michigan's Part 12 Emission Averaging alld Emission Reduction Credit Trading rules (R 336.220I-R 336.2218). Any changes consistent with these rules do not require a revision to this RO Penni!.· (R 336. 12 I5(2)(b), R 336.2204(7), R 336.2211(3»



## B

. Source-Wide Requirements
At the time of RO pennit issuance, the AQD has det emlincd that there are no additional specific source-wide applicable requirements which apply to all emission unit/pr ocess groups at this source. Ther efore, the pennillee is subject to the General Requirements in Part A and any other tenns and conditions contained in this RO penni!.Page : 10 of 65 

### C. 

### Emission UnitlProcess Group Summary Table

UnltlGroup ID Emission Uliit/PrOCHI Group

### l\1**od ~~** **~tion** EG-PAINTLlNE# I Plastic 

### ; 1121199' parts cOllting line consisting offive dry filter {or equivalent control) spray booths and two bake ovens.

EG·PAINTLlNEI#2 Plastic 

### ; !12I199' pans coating line consisting ofsix dry filter (or equivalent control ) spray booths and one oven.

# ~

# ~ ",,,iii 1711990

1**,, ~**  

### .,opp" m ik' " "k ("''') 7 /1990 and five bright acid copper I

### ,,,k ,W15 , ,#19i.

# I~~~**VATORTANKS** 1

### 0", , ctank

.!"7), 0", 

### 1 711990 accelerator tank (#9), and one electroless coppertank 

### 1(# 11)

. EG· One neutralizer tank (#5) nnd 711990 NEUTRALIZERTANKS 

### Itank (li3'9)

. and nickel strip EG·CHROMEETCH One tank (# I) and 711990 one etch tank (#2).



### 1& 12 s"" H , 

## An" 1979



### D. Flexible Groupings Summary Table Permit Number: 199600451 Expiration Date: June 2, 2004

Control De\icc Stac

. k/Vcnt ID T.bl,N • . 

# :. '

. 

# , 1

# ~~:~~:~~~**~~ ;:**  1E
- l.l equivalent SY· LN1BOOTH3, control) SV· LNIBOOTH4, SV-LNIBOOTH5, SY· LNIOVENI, 1SV- LNI filters (or 

### I

## ~V-**N2. OO** **~~ ~:**  1E
- !.'

equivalent SV

-LN2-BOOTH3, control) SY·LN2·BOOTH4 , SV·LN2-BOOTH5, SV·LN2·BOOTH6,

# ~**Is~** ISV, I E· 1.3

I

# ~~p~:a~~o~e SVCHRMEX HSYS2 E-1.4 , F·Ll 

# IPacked Bed 

# "" IE-1.5, Scrubber F-1.1

1

### P"k,d B,d SVCHRMEXHSYS4 E-I.6, Scrubber F·Ll Dry mesh pad SYCHR.t\lEXHSYS5 E-1.7 scrubber on 

### I

# ~**~:;~** May 

### NA NA F-1.2

Flexible Grouping ID Eminion UnitIProcess Groups Requirement Included in Flexible Groupint: Table No. FG·CHROMEPROCESS EG·COPPERTANKS F·l.l EG-ACfIYATORTANKS EG-NEUTRALIZERTANKS FG-COLDCLEARNERS EG-COLDCLEANERI & 2· F·i.2Page: 11 of 65 

## E. Emission UnitlProcess Group Requirements Permit Number: 199600451 Expiration Date: June 2, 2004

The tables in Part E outline the applicable requirements for each emission unit/process group listed in the Emission UnitIProcess Group Summary Table. The permittee is subject to the requirements for each emission unit/process group in addition to the General Requirements in Part A and any other terms and conditions contained in this RO permit. Each emission unit/process group shall meet the design parameters, material usage/emission limitations, monitoring, recordkeeping, reporting and testing requirements, operational parameters, and any other requirements listed in Tables E-l.l through E-1.7 as well as other terms and conditions specified in this RO permit to assure compliance with all applicable requirements. The permittee shall comply with all specific details in the special conditions and the underlying applicable requirements cited in the tables. The underlying applicable requirements for the material usage/emission limitations, monitoring, recordkeeping, reporting and testing requirements, operational parameters, and any other requirements 

### are identified in parentheses. Ifa specific requirement type does not exist for the emission unit/process group, NA (not applicable) has been used in the table. Those requirements which are enforceable bythe state only are designated by an asterisk.Page: 12 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.l EGPAINTLINE#l EMISSION UNITIPROCESS GROUP REQUIREMENTS EMISSION GROUP EGPAINTLINE#I Plastic exterior automotive parts coating Jine consisting offive dry filter (orequivalentcontrol) spraybooths and two bake ovens. Flenble Groupine ID NA 

### I. DESIGN PARAMETERS A. Pollution Control Exhaust filters (orequivalent control) on each spraybooth forparticulate control. Equipment B. Stack/Vent Parameters 

## I Exhaust gases shall be discharged unobstructed vertically upwards unless otherwise noted. Stack/Vent a. Minimum b. Maximum Exhaust Co Temperature d. Air Flow AppUcable ID Height (feet) Dimension (incheSl (oF)**Rate-.lacfm~** Requirement 1. SV-LNIBOOTHI 36 36 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.120l(3)) 2. SV -LNIBOOTH2 36 36 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.120l(3)) 3. SV-LNIBOOTH3 36 36 NA NA (paragraph 8.A, ConsentOrder No. 6-1995, R336.120U3)) 4. SV-LNIBOOTH4 36 36 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.1201(3» 5. SV-LNlBOOTH5 36 36 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.110l(3)) 6. SV-LNIOVENI 36 36 NA NA (paragraph 8.A, Consent Order No. 6-1995, R336.1201(3)) 7. SV-LNIOVEN2 36 36 NA NA (paragraph B.A, Consent Order No. 6-1995, R336.1201(3» C. OtherDesign Parameters NA 

### II. MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usaee Rate NA NA B. Pollutant Manmum Emission LImit Volatile Organic Compounds 1. 25.2 poundslhour, 2. 604 pounds/calendar day, 3. 3.73 ton/calendar month. (VOC) «Paragraph 8.B.l, Consent Order No. 6-1995, R336.1701) 4. For coating exterior glastic automotive garts-high bake coatings as sgecified in Rule 632 (20):**1.2.4.~** a). Prime-Flexible Coating Category4.5 Ibs. VOC/gal. ofcoating (minus water) as applied. b). Prime-Non Flexible Category 3.5 lbs. VOC/gal. ofcoating (minus water) as applied. c). Topcoat-Basecoat Category 4.3 Ibs. VOC/gal. ofcoating (minus water) as applied. d). Topcoat-Clearcoat Category 4.0 lbs. VOC/gal. ofcoating (minus water) as applied.Page: 13 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004


## TABLE E-l.l EGPAINTLINE#l EMISSION UNITIPROCESS GROUPREQUIREMENTS e). Topcoat-Non-BasecoatlClearcoat Category 4.3 lbs. VOC/gal. ofcoating (minus water) as applied. (Paragraph 8.8.2, Consent Order No. 6-1995, R336.1702(d» 5. Forcoatingexteriorplastic automotive parts-airdried coatings as specified in Rule 632**~1.J**•••5 a). Prime Coating Category 4.8 Ibs. VOClgal. ofcoating(minus water) as applied. b). Topcoat-Basecoat Category "lilbs. VOCIgal. ofcoating (minus water) as applied. c). Topcoat-Cleareoat Category Ulbs. vec/gal. ofcoating (minus water) as applied. d). Topcoat-Non-BasecoatlClearcoat Category 5.0 Ibs. VOC/gal. ofcoating (minus water) as applied. (Paragraph 8.8.2, Consent Order No. 6-1995, R336.1702(d» 6. Fortouch-up and repair ofexteriorplastic automotive parts as specified in Rule 632 (20): 3,5 5.2 lbs. VeC/gal ofcoating (minus water) as applied. (Paragraph 8.8.2, Consent Order No. 6-1995, R336.1702(d» 

### 7. For coating automotive parts using resist coatingsCNote: Resist coatings exempt from Rule 632 (20) under Rule 632(l5)(d)): 3,5 6.3 Ibs. VOC/gal ofcoating (minus water) as applied. (Paragraph 8.B.2, Consent OrderNo. 6-1995, R336.1702(a» 

# ---------------------------------------------_._-_._---- I Forred andblack coatings, the emission limitation shall be detcnnined by multiplying the appropriale limit table

by 1.15. 2When method 24 is used todetermine the volatile organic compound content ofa coating, the applicable

emission limitation shall be determined by adding 0.5 to the appropriate limit. 3 When method 24 is used to determine the volatile organic compoundcontent ofa coating, the applicable

emission limitation shall be determinedby adding 0.1 to the appropriate limit. 4 Air-dricd coating means a coating that is dried by the usc ofairor forced warm at temperatUreSup to 90cIcgrees

Celsius (194 degrees Fahrenheit)-abovc this tempcratun: would be considered a high baked coating

, Limits arc based on a calendardayaveraging period-the limits arc volume weighted bycategory. 

### ill. 

### COMPLIANCEEVALUATION Records ofall ofthe following shaD bemaintained on rue for a period of5 yean. (R336.1213(3)(b)(U))



### 1. Continuous Emission Monitoring (CEM)System and Recordkeeplng 2. Process Monitoring System and Recordkeeping 3. OtherMonitoring and/or Recordkeeping 

### A. MONITORINGIRECORDKEEPING (R336.1213(3» InAddition To General Requirements in PartA NA

NA I. Identification ofthe applicable coating category for each coating: daily records. (Paragraph 8.B.4, Consent OrderNo. 6-1995, R336.201(3» 2. Hours ofoperation: daily records. (Paragraph 8.B.4, Consent OrderNo. 6-1995, R336.201(3» 3. Gallons ofcoating/reducerused: daily records. (Paragraph 8.8.4, Consent Order No. 6-1995,**R336.2041~** 4. vec content: daily records ofthe VOC content ofeach coating/reducer in pounds/gallon as applied. (Paragraph 8.8.4, Consent Order No. 6-1995, R336.2041) 5. IfVOC content is detennined from manufacturer's formulation data, Pennittee shall record the mixing ratio ofeach coating and reducer: daily record. (Paragraph 8.B.4, Consent OrderNo. 6-1995 R336.201(3))Page: 14 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004


## TABLE E-l.l EGPAINTLINE#l EMISSION UNITIPROCESS GROUP**RE~UlREMENTS**

1. Parameterto be TestedlRecorded 2. Method/Analysis 3. Frequency and Schedule ofTestfng/RecordkeeJ)ing 

### IV. REPORTING Reports and Schedules 6. The VOC content ofall solvent based coatings used as applied shall be determined using Federal Reference Test Method 24. Upon prior approval ofthe District Supervisor, Air Quality Division, the VOC content may alternativelybe determined from manufacturer's formulation data. Water based coatings may utilize batch certifications for determination of the

## vec content. (Paragraph 8.A, Consent Order No. 6-1995, R336.2040(S)(a» 7. IfVOC content is determined from manufacturer's formulation data, Permittee shall maintain current listing ofthe manufacturer's formulation data for each coating/reducer.

. (Paragraph S.A, Consent Order No. 6-1995, R336.201(3» 8. Cleanup solvents: monthly records ofthe amount in gallons/month andVOC content in pounds/gallon ofall purge and/or cleanup solvents used and reclaimed. (Paragraph 8.A, Consent Order No. 6-1995, R336.201(3) 9. Condition ofexhaust filters: Daily visible check ofthe condition ofexhaust filters. (R336.1213(3» 1 

### O. 

## vec Emissionrates shall be calculated according to the method outlined in Appendix 7. (R336.201(3» See Appendix 4 and 7 B. TESTINGIRECORDKEEPING (R336.1213(3»

In Addition to General Requirements in Part 

### A NA NA NA

1. Prompt reporting ofdeviations pursuant to Condition 27 ofPart A. (R336.1213(3)(c)(il» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPartA. Due March 15 for reporting period July 1to December 31 and September 15 for reporting period January I to June 30. (R336.1213(3)(c)(I» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart A. Due March 15, 2000 for calendar year 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4)(c» 4. Within 30 days following the end ofeach calendar quarter, the Permittee shall submit a summary of the coating usage records using the format in Appendix 8 or an equivalent method approved by the AQD Shiawassee District Supervisor. (Paragraph 8.B.5, ConsentOrder No. 6-1995, R336.1201(3» See Appendix 8

I. Permittee shall not operate the paint spray booths unless all exhaust filters are in place and operatingproperly. (paragraph 8.B.8, Consent OrderNo. 6-1995, R336.1910) 2. The disposal ofcollected dry filters and/or paint sludge shall be performed in a manner which minimizes the introduction of

### Page: 15 of 65


## TABLE E-l.l EGPAINTLINE#l Pennit Number: 199600451 Expiration Date: June 2, 2004



## EMISSION UNITIPROCESS GROUP REQUIREMENTS aircontaminants to the outer air. (Paragraph 8.A, 

### Consent OrderNo. 6-1995, R336.1702) 3. 

### Solvent based coatings shall be applied utilizing HVLP applicators and/or an electrostatic spray system or equivalent technology with a comparable transfer efficiency. All coating applicators shall be properly installed, maintained and operated according to manufacturer's specifications. (Paragraph 8.8.9, 

### Consent OrderNo. 6-1995, R336.1702) 4. 

### All purge solvents and paints from all manual coating applicators used 

### in the coating line shall be captured and stored in 

### closed containers and disposed ofin an acceptable manner in compliance with all applicable rules and regulations. (Paraeraph 8.A•• 

### Consent OrderNo.**6-199~** 

### R336.1702) 

### VI. OTHERREQUIREMENTS NA 

## *This requirementis state enforceable only.Page: 16 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.l EGPAINTLINE#l EMISSION UNITIPROCESS GROUP REQUIREMENTS EMISSION GROUP EGP AINTLINE#2 Plastic exterior automotive parts coating line consisting ofsix dry filter spray (or equivalent control) booths and one oven. Flenble Grouping ID NA 

### I. DESIGN PARAMETERS A. PoUudon Control Exhaust filters (or equivalent control) on each spray booth for particulate control. Equipment B. Stack/V ent Parameters 

## I Exhaust gases shall be discharged unobstructed vertically

### llItwards unless otherwise noted. Stack/Vent 

### a. Minimum b. Manmum Exhaust c. Temperature d. Air Flow AppUcable ID Heieht (feet) Dimension (inches) (oF) Rate (acfm) Requirement 1. SV-LN2BOOTH 1 44.5 30 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.120l(3}) 2. SV-LN2BOOTH2 44.5 30 NA NA (paragraph 8.A, Consent Order No. 6-1995, R336.1201(3)) 3. SV-LN2BOOTH3 44.5 30 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.1201(3)) 4. SV-LN2BOOTH4 44.5 30 NA NA (Paragraph 8.A, ConsentOrder No. 6-1995, R336.120113}l 5. SV-LN2BOOTH5 44.5 30 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.1201(3)) 6. SV-LN2BOOTH6 44.5 30 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.1201(3» 7. SV-LN20VEN 40 34 NA NA (Paragraph 8.A, Consent Order No. 6-1995, R336.1201(3)) C. OtherDesign Parameters NA 

### II. MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usaee Rate NA NA B. PoUutant Maximum Emission Limit Volatile Organic Compounds 1. 52 poundslhour, 

### 2. 1248 pounds/calendar day, 3. 8.3 tonlcalendar month. (VOC) (Paragraph 8.C.l, Consent OrderNo. 6-1995, R336.1702) 4. For CQIUing exleriQuinterior nlastjc automQ!ive**nart~-bigh** hake coatings as sl'lecifjed in Rule 632 (20);1,2,4,5 a). Prime-Flexible Coating Category 4.5 lbs. VOC/gal. ofcoating (minus water) as applied, b). Prime-Non Flexible Category 3.5 lbs. VOC/gal. ofcoating (minus water) as applied. c). Topcoat-Basecoat Category 4.3 Ibs. VOC/gal. ofcoating (minus water) as applied. d). Topcoat-Clearcoat Category 4.0 lbs. VOC/gal. ofcoating (minus water) as applied.Page: 17 of 65 Pennit Number: 199600451 Expiration Date: June 2. 2004


## TABLE E-l.2 EGPAINTLINE#2 EMISSION UNITIPROCESS GROUPREQUIREMENTS e). Topcoat-Non-BasecoatlClearcoat Category 4.3 Ibs. VOC/gal. ofcoating (minus water) as applied. 5. For coating exteriorplastic automotive parts-air dried coatings as specified in Rule 632 (20): 1,3.4.' a). Prime Coating Category 4.8 Ibs. VOCIgai ofcoating (minus water) as applied. b). Topcoat-BasecoatCategory 5.0 Ibs. VOCIgal ofcoating(minus water) as applied. c). Topcoat-Clearcoat Category 4.5 Ibs. VOC/gal ofcoating (minus water) as applied. d). Topcoat-Non-BasecoatlClearcoat Category 5.0 Ibs. VOC/gal ofcoating (minus water) as applied. 6. Fortouch-up and repair ofexteriorplastic automotive parts as mecified in Rule 632 (20):: 305 5.2 lbs. VOCIgal ofcoating (minus water) as applied. ( Forred and black coatings, the emission limitation shall be detc:nnined by multiplying the appropriate limit table

by 1.15. 2When method 24 is used to determine the volatile organic compound content ofa coating, the applicable

emission limitation shall be determined byadding 0.5 to the appropriate limit 1 When method 24 isused to determine the volatile organic compound content ofacoating, the applicable

emission limitation shall be detennined byadding 0.1 to the appropriate limit 4 Air-driecl coating means a coating that is dried by the usc ofairorfcm:ed warm attemperatures up to 90 degrees

Celsius (194 degrees Fahrenheit)-above this temperatun:would be considered a highbaked coating S Limits are based on a calendarday averaging period-the limits arc volume weiglUed bycategory. (paragraph 8.C.2,Consent OrderNo. 6-1995 R336.1702(d)) 

### UI. COMPLIANCE EVALUATION Records ofaD ofthe (oDowina shaD be maintained on me for a period of5 yean. (R336.1213(3)(b)(U»

I. Continuous Emission Monitoring (CEM) System and Recordkeeping 2. Process MonitoringSystem and Recordkeeplng 3. OtherMonitoring and/or Recordkeeping A. MONITORINGIRECORDKEEPING (R336.1213(3» InAddition To General Requirements inPartA 

### NA
NA 1. Identification ofthe applicable coating category for each coating: daily records. (paragraph 8.B.4, Consent OrderNo. 6-1995, R336.201(3» 2. Hours ofoperation: daily records. (Paragraph 8.B.4, Consent OrderNo. 6-1995, R336.201(3» 3. Gallons ofcoating/reducerused: dailyrecords. (Paragraph 8.8.4, Consent Order No. 6-1995, R336.2041) 4. VOC content: daily records ofthe 

## voe content ofeach coating/reducerin pounds/gallon as applied. (Paragraph 8.8.4, Consent OrderNo. 6-1995, R336.2041) 5. IfVOC content is determined from manufacturer's formulation 

### data. Pennittee shall record the mixing ratio ofeach coating and reducer: daily record. (Paragraph 8.8.4, Consent Order No. 6-1995, R336.201(3»

6. The VOC content ofall solvent based coatings used as applied shall bedetermined using Federal Reference Test Method 24. Uponprior approval ofthe District Supervisor, Air Quality Divisio1l. the VOC content may alternativelY be determined from manufacturer'sPage: 18 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004


## TABLE E-l.2 EGPAINTLINE#2 EMISSION UNITIPROCESS GROUP REQUIREMENTS

1. Parameterto be TestedIRecorded 2. Method! Analysis 3.Frequency and Schedule ofTestine/R.ecordkeepin2 

### IV. REPORTING Reports and Schedules formulation data. Water based coatings may utilize batch certifications for determination of the VOC content. (Paragraph 8.A, ConsentOrder No. 6-1995, R336.2040(5)(a» 7. IfVOC content is detennined from manufacturer's formulation data, Permittee shall maintain current listing ofthe manufacturer's formulation data for each coating/reducer. (Paragraph 8.A, Consent OrderNo. 6-1995, R336.201(3» 8. Cleanup solvents: monthly records ofthe amount in gallons/month and VOC content in pounds/gallon ofall purge andlor cleanup solvents used and reclaimed. (Paragraph 8.A, Consent Order No. 6-1995, R336.201(3) 9. Condition ofexhaust filters: Daily visible check ofthe condition ofexhaust filters. (R336.12J3(3» 

### 1 O. VOC Emission rates shall be calculated according to the method outlined in Appendix 7. (R336.201(3» See Appendix 4 and 7 8.TESTINGIRECORDKEEPING (R336.1213(3»

InAddition to General Requirements in Part A NA NA NA

1. Prompt reporting ofdeviations pursuant to Condition 27 ofPartA. (R336.1213(3)(c)(U» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPartA. Due March 15 for reporting period July 1to December 31 and September 15 for reportingperiodJanuary 1 to June 30. (R336.1213(3)(c)(i» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart A. Due March 15, 2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.12J3(4)(c» 4. Within 30 days following the end ofeach calendar quarter, the Permittee shall submit a summary of the coating usage records using the format in Appendix 8 or an equivalent method approved by the AQD Shiawassee District Supervisor. (Paragraph 8.C.4, Consent Order No. 6-1995, R336.1201(3» SeeAppendix 8 

# v. OPERATIONAL PARAMETERS 1. Permittee shall not.operate the paint spraybooths unless all exhaust filters are in place and operatingproperly. (Paragraph 8.8.4, ConsentOrder No. 6-1995, R336.1910) 2. The disposal ofcollected 

### dry filters andlor paint sludge shall beperformed in a manner which minimizes the introduction of aircontaminants to the outer air. (Paragraph 8.8.4, Consent Order No. 6-1995, R336.1201(3» 3. Solvent based coatings shall be applied utilizing HVLP applicators andlor an electrostatic spray system orequivalent technology with a comparable transfer efficiency. All coating applicators shall be properly installed, maintained and operated according to manufacturer's specifications. (Paragraph 8.8.4, Consent OrderNo. 6-1995, R336.1702) 4. All purge solvents and paints from all manual coating applicators used in the coatin&line shall be captured and stored inPage: 19 of 65


## TABLE E·l.2 EGPAINTLINE#2 Permit Number: 199600451 Expiration Date: June 2, 2004



## EMISSION UNITIPROCESS GROUPREj2UIREMENTS closed containers and disposed of

### in an acceptable manner 

### in compliance with all applicable rules and regulations. (paralraph 

### 8.0.4, ConsentOrderNo. 6-1995, R336.1702) 

## VI. OTHER REQUIREMENTS NA 

## * This requirement 

### is state enforceable only.: 

### Page: 20 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.3 EG-CHROMETANK32 EMISSION UNITIPROCESS GROUPREQUIREMENTS EMISSION GROUP EG-CHROMETANK32 Existing decorative chromium electroplating tank 

### #32. Exhaust also includes negligible emissions from one soak cleanertank (#42), and one electroclean tank 

### (#43).) Emission UnitlProcess Groups EG-CHROMETANK32 

### I. DESIGN PARAMETERS A. 

### Pollution Control Use ofa wetting agent for fume suppression and one mesh pad mist eliminator. Equipment B. StackIVent Parameters 

## I Exhaust gases shan be discharged unobstructed vertically upwards unless otherwise noted. StacklVent a. Minimum b. Maximum Exhaust c. Temperature d. Air Flow Applicable 

## m Height (feeft Dimension**(Inche~.** 

### .(DF) Rate (acfm) Requirement 1. SV-CHREXHSYS 1 50 32 NA NA R336.120 1(3» C. OtherDesign Parameters NA 

### D. MATERIAL USAGEIEMISSION LIMITS A. Material Maximum Usage Rate NA NA B. Pollutant Maximum Emission Limit Hexavalent Chromium 1. 2.9 micrograms percubic meter, corrected to 70 0 

### F and 29.92 inches Hg. (Emissions from EG-CHROMEETCH are included under this limituntil May 1,1999.) (R336.1901(a))* 

### UL COMPLIANCE EVALUATION Records ofan oftbe fonowlne shall be maintained on mefor a period of5 years. (R336.1213(3}(b)(Ii)) A. 

### MONITORINGIRECORDKEEPING (R

### 336.1213(3» InAdditionTo General R!!(Iuirements In PartA 1. Continuous Emission NA MOnitoring (CEM) System and**Recordkeepin~** 

### 2. Process Monitoring System I. The surface tension (dynes/cm) shall be measured once every 4 hours (except as and Recordkeeping outlined below) during operation ofeach tank with a stalagmometer or tensionmeter as described in 40 CFR 63 Subpart N 63.343(c)(5). 

### (40 CFR 63 SubpartN 63.343(c)(S)(ll)(A» 2. The Permittee shall follow procedures specified ASTM Method D 1331-0, Standard Test Methods for Surface and Interfacial Tension ofSolutions ofSurface Active Agents for proper use ofthe tensionmeter. (40 CFR 63 SubpartN63 Appendix A, Method 306B) 3. The time between monitoring can be increased ifthere have been no exceedances. The surface tension shall be measured once every 4 hours oftank operation for the first 40 hours oftank 

### operation after the compliance date. Once there are no exceedances during 40 hours oftank operation, surface tension measurement may be conducted once every 8hours oftank 

### operation. Once there are no exceedances during 40 hours oftank operation, surface tension measurement may be conducted once every 40 hours oftank operation on an ongoing basis, until an exceedance occurs. The minimum frequency ofmonitoring

. allowed is once every40 hours oftank 

### operation. (40 CFR 63 Subpart N 63.343(c)(S)(ii)(B»

4. Once an exceedance occurs as indicated through surface tension monitoring, the original monitoring schedule ofonce every 4 hours must be resumed. A subsequent decrease in

### Page: 21 of 65 Permit Nwnber: 199600451 Expiration Date: June 2, 2004


## TABLE E-l.3 EG-CHROMETANlOl EMISSION UNITIPROCESS GROUP REOUIREMENTS frequency shall follow the schedule outlined in the previous paragraph ofthis section. (For example, ifan owner or operator had been monitoring an affected source once every 40 hours and an exceedance occurs, subsequent monitoring would take place once every 4 hours oftank operation. Once an exceedance does not occur for40 hours oftank 

### operation, monitoring can occuronce every 8hours oftank 

### operation. Once an exceedance does not occur for 40 hours oftank 

### operation on this schedule, monitoring can occur once every40 hours oftank

### operation.)(40 CFR 63 SubpartN 63.343(c)(5)(U)(C» 5. Once a tankbath solution is drained from a affected tank 

### and anew solution added, the original monitoring schedule ofonce every 4 hours mustbe reswned. with a decrease in monitoring frequency allowed following the procedures ofprevious paragraphs. (40 CFR63 SubpartN 63.343(c)(5)(ill» 6. Records ofall maintenance performed on the chrome tanks and the tensionmeter. (40 CFR 63 SubpartN 63.346(b)(1» 7. Records ofall maintenance performed on mesh pad mist eliminator. (R336.1l13(3» 8. Records ofthe occurrence, duration, and cause (ifknown) ofeach malfunction of the process and the tensionmeter. (40 CFR 63 SubpartN 63.346(b)(3» 9. Records ofthe occurrence, duration, and cause (ifknown) ofeach malfunction ofthe mesh pad mist eliminator. (R336.1l13(3» 1 O. 

### Records ofactions taken during periods ofmalfunction when such actions are inconsistentwith the operation and maintenance plan. (40 CFR 63 SubpartN 63.346(b)(4» 11. Other records, which may take the form ofchecklists, necessary to 

### demonstrate consistency with the provisions ofthe operation and maintenance plan. (40 CFR 63 SubpartN63.346 (b) (5» 

### 12. Records ofmonitoring data that are used to demonstrate compliance with the standard including the date and time the data are collected.(40 CFR 63 SubpartN63.346(b)(8» 13. The specific identification (i.e., the date and time ofcommencement and completion) ofeach period ofexcess emissions, as indicated by monitoring data, that occurs during malfunction ofthe process ormonitoring equipment. (40 CFR 63 Subpart N63.346(b)(9» 14. The specific identification (Le., the date and time ofcommencement and completion) ofeach period ofexcess emissions, as indicated by monitoring data, that occurs during periods other than malfunction ofthe process or monitoring equipment. (40 CFR 63 SubpartN 63.346(b)(10» 15. (factions taken by the Permittee during periods ofmalfunction are inconsistentwith the procedures specified in the operation and maintenance plan, the Pennittee shall record the actions taken for that event and shall report by phone such actions within 2working days after commencing actions inconsistent with the plan. This report shall be followed by a letter within 7working days after the end ofthe event. (40 CFR 63 Subpart N63.341(t)(3)(E)(iv» 16. The total process operating time ofthe chrome plating tank 

### during the reporting period. (40 CFR 63 Subpart N 63.346(b)(1l»Page: 22 of 65 PennitNumber: 199600451 Expiration Date: June 2, 2004


## TABLE E-l.3 EG-CHROMETANlOl EMISSION UNITIPROCESS GROUPREQUIREMENTS 17. Records ofthe date and time that fume suppressant wetting agents are added to the tanks. (40 CFR 63 SubpartN 63.346(b}(13» See Appendix 4 3. Other Monitoring and/or 1. Inspect for properoperation ofthe tensionmeter orstalagmometer at least once a quarter Recordkeeping following manufacturers recommendations. The inspection record shall take the fonn ofa checklist and shall identifY the device inspected, the date ofinspection, a briefdescription ofthe working condition ofthe device during the inspection, and any actions taken to correct deficiencies found during the inspection. (40 CFR 63 SubpartN 63.346(b)(I» 2. Permittee shall monitor and record pressure drop across each mesh pad mist eliminator on a weekly basis.

.(R336.1213(J» B. TESTINGIRECORDKEEPING (R 336.1213(3»

In Addition to General Requirements in Part A 

### 1. Parameterto be NA TestedlRecorded 2. Method/Analvsis NA 3. Frequency and Schedule NA ofTestinwRecordkeeping 

### IV. REPORTING Reports and Schedules 1. Prompt reporting ofdeviations pursuant to Condition 27 ofPartA. (R336.1213(3)(c}(U» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPartA. Due March 15 forreportingperiod July 1to December 31 and September 15 for reportingperiod January 1 to June 30. (R336.1213(3)(c:)(l» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart A. Due March 15, 2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4)(c» The following is a summary ofadditional reporting requirements pursuant to 40 CFR 63 Subpart N. 4. Notification ofconstruction orreconstruction. (40 CFR 63 SubpartN 63.345(b» 5. Notification ofcompliance status. (40 CFR 63 Subpart N 63.347(e» 6. Compliance status reports for major sources. (40 CFR 63 Subpart N 63.347(g) See Appendix 8 

### V. OPERATIONAL PARAMETERS 1. Surface tension in each of the decorative chromium electroplating 

### tank baths shall not exceed 45 dynes/cm during 

### tank operation. (40 CFR 63 SubpartN 63.342(d)(2» 2. At all times, including periods ofstartup, shutd0"!'1l, and malfunction, owners oroperators shall operate and maintain any affected source, including associated monitoring equipment, in a manner consistent with good airpollution control practices, consistent with the operation and maintenance plan. (40 CFR 63 Subpart N 63.342(1)(1)(1» 3. Pennittee shall not operate the decorative chrome plating tanks unless the mesh pad mist eliminators are installed and operatingproperly. (R336.1910) 4. Malfunctions shall be corrected as soon as practical aftertheir occurrence in accordance with the operation and maintenance

### Page: 23 of 65


## TABLE E-l.3 EG-CBROMETANK32 EMISSION UNITIPROCESS GROUPREQUIREMENTS Pennit Number: 199600451 Expiration Date: June 2, 2004

plan. (40 

### CFR 63 

### Subpart N63.342 (I) 

### (1)(ii» 

### 5. Pennittee shall not operate this emission unit unless the mesh pad mist eliminator is operating properly with apressure drop across the eliminatorwithin the ranR;e detennined under VI. OTHERREQUIREMENTS. 0036.1910) 

### VI. OTHERREQUIREMENTS 1. Pennittee shall implement the Operation and Maintenance Plan which waS 

### submitted on June II, 1997. Any changes made to the Malfunction Abatement Plan dated June II, 1997 must have prior approval by the Shiawassee District Supervisorprior to implementation. (40 

### CFR 63 

### SubpartN63.342 (I) 

### (3» 

### 2. The Operation and Maintenance Plan shall include the following elements: (a) The plan shall specify the operation and maintenance criteria for the affected source, the aircontrol method, and the process monitoring equipment (tensionmeter), and shall include a standardized checklist to document the operation and maintenance ofthis equipment. (b)

### The following workplace standard shall be incorporated into the plan: (i) Follow manufacturers recommendations for calibration/use ofthe tensionmeter (calibrate priorto each use). (c) The plan shall specify procedures to 

### be followed to 

### ensure that equipment orprocess malfunction due to poor maintenance orotherpreventable conditions do not occur. (d) The plan shall include a systematic procedure for identifying malfunction ofprocess equipment, monitoring equipment and for implementing corrective actions to address such malfunctions.(40 

### CFR SubpartN 63.342(1)(3)(1) 

### 3. Ifthe Operation and Maintenance Plan fails to address or inadequately addresses an eventthat meets the characteristics ofa malfunction at the time the plan is initially developed, the owneroroperator shall revise the Operation and Maintenance Plan within 4S 

### days after such an event occurs. The revised plan shall include procedures for operating and maintaining the process equipment, ormonitoring equipment during similarmalfunction events, and aprogram for corrective action for such events. (40 

### CFR 63 

### SubpartN 63.342(1)(3)(ii» 

### 4. The Pennittee shall implement aPreventative Maintenance Plan which requires inspection and maintenance ofvarious system components related to air emissions. See Appendix 9. (R336.1911) 

### 5. Pennittee shall determine the properpressure drop operating range for the mesh pad mist eliminator and submitresults to the AQD District Supervisor within 30 days ofthe issuance date ofthis RO pennit. (R336.1213(3» 

## *This requirementis state enforceable only./. Page: 24 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.4 EGwCOPPERTANKS EMISSION UNITIPROCESS GROUP**RE~UIREMENTS** EMISSION GROUP EG-COPPERTANKS One copper strike 

### tank (#14) and five bright acid coppertanks (#15 through#19). Flexible Groupine ID FG-CHROMEPROCESS I. DESIGN PARAMETERS A. Pollution Control 6 Cyclone separators EQwDment B. StackIV ent Parameters 

## I Exhaust gases shall bedischarged unobstructed vertically upwards unless otherwise noted. Stack/Vent 

### a. Minimum b. Maximum Exhaust Co Temperature d.AirFlow Applicable ID Heieht (feet) Dimension (inches) _eF) Rate (acfm) ReQuirement 1. SVCHREXHSYS2 25 42 NA NA 0036.1201(3» C. Other Desil!D Parameters NA 

# n. MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usajte Rate NA NA B. Pollutant Maximum Emission Limit SulfuricAcid See FG-CHROMEPROCESS. In. COMPLIANCE EVALUATION Records ofall ofthe followin!! shall be maintained on flIe for a Deriod of5 -'years.**~R** 336.1213{3}{1)l{U» A. MONITORINGIRECORDKEEPING (R336.1213(3» In Addition To General Requirements in Part A I. Continuous Emission NA Monitoring (CEM) System and Recordkeepine 2. Process Monitoring System 1. Permittee shall measure and record the bath surface tension in each 

### tank on a weekly and Recordkeeping basis. (R336.1213(3» 2. Pennittee shall determine and record the bath composition 

### in each 

### tank on a weekly basis. (R336.1213{3» 3. Permittee shall measure and record the bath density in each 

### tank on a weekly basis. 0036.1213(3)) 3.OtherMonitoring andlor 1. Weeklyrecords of sulfuric acid emission calculations 

### in 

### milligrams percubic meter. Recordkeeping SeeAppendix 7. (R336.1213(3» 2. Permittee shall monitor and record fan motor electric current for each cyclone on a weekly basis. (R336.1213(3» B. TESTINGIRECORDKEEPING (R336.1213(3»

In Addition to General Requirements in PartA 1. Parameterto be NA TestedlRecorded 2. Methodl Analysis NA 3. Frequency and Schedule NA ofTestine/Recordkeepine IV. REPORTING Reports and Schedules 1. Prompt reporting ofdeviations pursuant to Condition 27 ofPart

### A. (R336.1213(3)(c)(U» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPart A. Due March 15 for reporting period July I to December31 and September 15 for reporting periodJanuary 1 to June 30. (R336.1213(3)(c)(i»

3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart 

### A. Due

### Page: 25 of 65


### TABLE E-l.4 EG-COPPERTANKS EMISSION UNITIPROCESS GROUP REQUIREMENTS Pennit Number: 199600451 Expiration Date: June 2, 2004

March 15. 2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4)(c» See A»endix 8 

### V. 

### OPERATIONAL PARAMETERS 1. Pennittee shall not operate this emission unit unless each cyclone is operating properly with fan motor electric current within the ranSte determined under VI. OTHERREQUIREMENTS. (R336.1910) 

### VI. OTHERREQUIREMENTS I. Permittee shall determine the fan motorelectric current range for each cyclone and submit results for approval to the AQD District Supervisorwithin 30 dayS 

### ofthe issuance date 

### ofthis RO permit (R336.1213(3» 

## * This requirement is 

### state enforceable only.Page: 26 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.5 EG-ACTIVATORTANKS EMISSION UNITIPROCESS GROUPREQUIREMENTS EMISSION GROUP EG·ACTIV ATORT ANKS One activatortank (#7), one acceleratortank (#9), and one electroless coppertank (#II). Flexible Groupin2 ID FG·CHROMEPROCESS 

### I. DESIGN PARAMETERS A. Pollution Control Packed bed scrubber Equipment B. Stack/V ent Parameters 

## I Exhaust gases shall 

### be discharged unobstructed vertically upwards unless otherwise noted. Stack/Vent 

### a. Minimum b. Maximum Exhaust Co Temperature d. Air Flow AppUcable ID Height (feeft Dimension Jinches) (oF) Rate(acfm) Requirement 1. SVCHREXHSYS3 25 30 NA NA
..{R336.1201(3)) C. Other Desilln Parameters NA 

### II. MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usage Rate NA NA B. Pollutant Maximum Emission Limit Hydrochloric Acid See FG·CHROMEPROCESS Fonnaldehyde See FG·CHROMEPROCESS 

### ill. 

### COMPLIANCE EVALUATION Records ofall ofthe followln£ shall be maintained on me for a period of

### 5 years. (R336.1213(3}(b)(bl) A. MONITORINGIRECORDKEEPING (R336.1213(3» In AdditionTo General Requirements In PartA I. Continuous Emission NA Monitoring (CEM) System and**Recordket!pin~** 2. Process Monitoring System 1. Permittee shall measure and record the bath surface tension in each 

### tank on a weekly and Recordkeeping basis. (R336.1213(3» 2. Pennittee shall detennine and record the bath composition in each tank on a weekly basis. (R336.1213(3» 3. Permittee shall measure and record the bath density 

### in each 

### tank on a weekly basis. (R336.1213(3» 3. Other Monitoring and/or 1. Weekly records of hydrochloric acid emission calculations in milligrams percubicmeter. Recordkeeping Hydrochloric acid emissions from this process and EG·NEUTRAlLIZERT ANKS will be combined in order to determine compliance with hydrochloric acid limit specified in FG· CHROMEPROCESS. See Appendix 7. (R336.1213(3» 2. Weekly records offormaldehyde emission calculations in milligrams percubic meter. See Appendix 7. (R336.1213(3» 3. Pennittee shall monitor and record pressure drop across the packedbed scrubberon a weekly basis. (R336.1213(3» B. TESTINGIRECORDKEEPING (R336.1213(3»

In Addition to General Requirements in PartA 1. Parameter to be NA TestedIRecorded 2. Method/Analysis NA 3. Frequency and Schedule NA ofTestinWRecordkeeping 

### IV. REPORTING Reports and Schedules 1. Prompt reporting ofdeviations pursuant to Condition 27 ofPart A. (R336.1213(3)(c)(ll»

### Page: 27 of 65


### TABLEE-l.5 EG-ACTIV ATORT ANKS EMISSION UNITIPROCESS GROUP REQUIREMENTS Pennit Number: 199600451 Expiration Date: June 2, 2004

2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPart A. Due March 15 for reporting period July I to December 31 and September 15 for reporting period January 1 to June 30. (R336.1213(3)(c)(i» 

### 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart A. Due March 15, 2000 for calendaryear 1999 and each March 15 for the previous calendar year thereafter. (R336.1213(4)(c» 

### See Appendix 8 

### V. OPERATIONALPARAMETERS I. Pennittee shall not operate this emission unit unless the packed bed scrubber is operating properly with apressure drop across the scrubberwithin the range determined under VI. OTHER REQUIREMENTS. (al36.1910) 

### VI. OTHERREQUIREMENTS 1. Pennittee shall detennine the properpressure drop operating range for the packed bed scrubber and submit results for approval to the AQD District Supervisorwithin 30 days ofthe issuance date ofthis RO pennit. (R336.1l13(3» 

### * This requirementis state enforceable only.Page: 28 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



## TABLE E-l.6 EG-NEUTRALIZERTANKS EMISSION UNITIPROCESS GROUP REQUIREMENTS EMISSION GROUP EG-NEUTRAIUZERT ANKS One neutralizertank (#5) and one copper and nickel strip tank_(#391 Flexible Grouping ID FG-CHROMEPROCESS 

### I. DESIGN PARAMETERS A. Pollution Control Packed bed scrubber Equipment B. Stack/Vent Parameters 

## I Exhaust gases shall be discharged unobstructed vertically upwards unless otherwise noted. Stack/Vent a. Minimum b. Maximum Exhaust Co Temperature d. Air Flow AppUcable ID Heieht (feet) Dimension (Inches) (oF) Rate (acfm) Requirement 1. SVCHREXHSYS4 25 30 NA NA 0036.1201(3» C. Other Desian Parameters NA 

### ll. MATERIAL VSAGElEMISSION LIMITS A. Material Maximum Usaee Rate NA NA B. Pollutant Maximum Emission Limit Hydrochloric Acid See FG·CHROMEPROCESS 

### III. COMPLIANCE EVALUATION Records of

### aU ofthefollowing shall be maintained on me for a**~eriod** of5**~ean.** (R336.1213(3)(b)(b,» A. MONITORINGIRECORDKEEPING (R336.1213(3» In Addition To General Requirements In PartA 

### 1. Continuous Emission NA Monitoring (CEM) System.and Recordkeeping 2. Process Monitoring System I. Permittee shall measure and record the bath surface tension in each tank on a weekly and Recordkeeping basis. (R336.1213(3» 2. Permittee shall determine and record the bath composition in each tank on a weekly basis. (R336.1213(3» 3. Permittee shall measure and record the bath density in each 

### tank on a weekly basis. (R336.1213(3» 3. OtherMonitoring and/or I. Weekly records of hydrochloric acid emission calculations in milligrams percubic meter. Recordkeeping Hydrochloric acid emissions from this process and EG-ACTIVATORTANKS will be combined in orderto determine compliance with hydrochloric acid limit specified in FGCHROMEPROCESS. See Appendix 7. (R336.1213(3» 2. Permittee shall monitor and record pressure drop across the packed bed scrubber on a weekly basis. (R336.1213(3)) B. TESTINGIRECORDKEEPING (R336.1213(3»

In Addition to General Requirements In PartA 1. Parameter to be NA TestedlRecorded 2. Method/Analysis NA 3. Frequency and Schedule NA ofTestina/Recordkeepine 

### IV. REPORTING Reports and Schedules 1. Prompt reporting ofdeviations pursuant to Condition 27 ofPart A. (R336.1213(3)(c)(ii» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPartA. Due March 15 for reporting period July I to December 31 and September 15 for reporting period January 1 to June 30. (R336.1213(3)(c)(i» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPart A. DuePage: 29 of 65


## TABLE E-l.6 EG-NEUTRALIZERTANKS EMISSION UNITIPROCESS GROUP REQUIREMENTS PermitNwnber: 199600451 Expiration Date: June 2, 2004

March 15, 2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4}(c» SeeAppendix 8 

### V. OPERATIONALPARAMETERS I. Pennittee shall not operate this emission unit unless the packedbed scrubber is operating properly with a pressure drop across the scrubberwithin the range determined under VI. OTHERREQUIREMENTS. (R336.1910) 

### VI. OTHERREQUIREMENTS 1. Pennittee shall detennine the properpressure drop operatingrange for the packed bedscrubber andsubmitresults for approval to the AQD District SlJPer!isor within 30days ofthe issuance date ofthis RO permit. (R336.1213(3)) 

## * This requirementis state enforceable only.

### Page: 30 of 65 PennitNumber: 199600451 Expiration Date: June 2, 2004



### TABLE E-t.' EG-CHROMEETCH EMISSION UNITIPROCESS GROUPREQUIREMENTS EMISSION GROUP EO-CHROMEETCH One pre-etch tank (#1) and one etch tank (#2). Flexible Grouping ID NA 

### I. DESIGN PARAMETERS A. 

### PoUutlon Control Dry

### mesh pad scrubberon or afterMay I, 1999. Equipment Mist eliminatorbefore May I, 1999. B. Stack/Vent Parameters 

## I Exhaust gases shall be discharged unobstructed vertically upwards unless otherwise noted. Stack/Vent a. Minimum b. Maximum Exhaust c. Temperature d.AirFlow AppUcable ID Height (feet) Dimension (inches) (oF) 

### Rate (acfm) Requirement 1. 

### SVCHREXHSYS5 25 26 NA NA (R336.1201(3» C. Other DesiRn Parameters NA 

### D. 

### MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usatte Rate NA NA B. PoUutant Maximum Emission Limit Hexavalent Chromium 1. 

### a) On and after May I, 1999: 11.5 micrograms percubic meter, corrected to 70 0 

### Fand 29.92 inches Hg. (R336.1224, R336.1225»* b) Before May I, 1999: See EO-CHROMETANK32. Sulfuric Acid 2. a) On and afterMay I, 1999: 6.05 milligrams per cubic meter, corrected to 70 0 

### Fand 29.92 inches Hg. (R336.1224, R336.1225»* b) Before May 1 1999: See FO-CHROMEPROCESS. 

### UI. COMPLIANCE EVALUATION Records ofaU ofthe foUowlnR shall be maintained on file for a period of5yean. (R336.1213(3J(DJ(im A. 

### MONITORINGIRECORDKEEPING (R336.1213(3» In Addition To General Requirements In PartA 1. Continuous Emission NA Monitoring (CEM) System and RecordkeeJ)intt 2. Process Monitoring System 1. Pennittee shall measure and record the bath surface tension in each tank

### on a weekly and Rec:ordkeeping basis. (R336.1213(3» 2. Permittee shall detennine and record the bath composition in each tank 

### on a weekly basis. (R336.1213(3» 3. Pennittee shall measure and record the bath density in each tank 

### on aweekly basis. (R336.1213(3» 3. OtherMonitoring and/or 1. Weekly records of sulfuric acid emission calculations in milligrams per cubic meter. See Rec:ordkeeping Appendix 7. (R336.1213(3» 2. Weekly records of hexavalent chromiumemission calculations in micrograms per cubic meter. See Appendix 7. R336.1213(3» 3. Pennittee shall monitor and record pressure drop across the two stage mist eliminator on a weekly basis. (R336.1213(3» B. TESTINGIRECORDKEEPING (R336.1213(3»

In Addition to General Requirements in PartA I. Parameterto be NA TestedlRecorded 2. Method/Analysis NA 3. Frequency and Schedule NA ofTestiniVRecordkeepinR 

### IV. REPORTINGPage: 31 of 65


## TABLE E-l.7 EG-CHROMEETCH EMISSION UNITIPROCESS GROUP REQUIREMENTS Permit Number: 199600451 Expiration Date: June 2, 2004

Reports and Schedules I. Prompt reporting ofdeviations pursuant to Condition 27 ofPart A. (R336.1213(3)(c)(U» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPart A. Due March IS for reporting periodJuly I to December 31 and September IS for reporting periodJanuary I to June 30. (R336.1213(3)(c)(I» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPartA. Due March 15,2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4)(c» See Appendix 8 

### V.OPERATIONALPARAMETERS I. On and after May I, 1999, Permittee shall not operate this emission unit unless the 

### dry mesh pad scrubberis operating properly with a pressure drop across the eliminatorwithin the range determined under VI. OTHERREQUIREMENTS. (R336.1910) 

### VI. OTIlERREQUIREMENTS 1. The Pennittee shall implement a Preventative Maintenance Plan which requires inspection and maintenance ofvarious system components related to airemissions. SeeAppendix 9. (R336.1911) 2. Pennittee shall determine the properpressure drop operating range for the 

### dry mesh pad scrubber and submit results for**~roval** to theAOD District**S~ervisor** by June I, 1999. (R336.1213(3» 

## * This requirementis state enforceable only.

### Page: 32 of 65


### F. Flexible Grouping Requirements Pennit Number: 199600451 Expiration Date: June 2, 2004

The tables in Part F outline the applicable requirements for each flexible grouping listed in the Flexible Groupings 

### Summary Table. The permittee is subject to the requirements for each flexible grouping in addition to the General Requirements in Part A and any other tenns and conditions contained in this RO permit. Each flexible grouping shall meet the design parameters, material usage/emission limitations, monitoring, recordkeeping, reporting and testing requirements, operational parameters, and any other requirements listed in Tables F-l.l through F-1.2 as well as other tenns and conditions specified in this RO pennit to assure compliance with all applicable requirements. The permittee shall comply with all specific details in the special conditions and the underlying applicable requirements cited in the tables. The underlying applicable requirements for the material usage/emission limitations, monitoring, recordkeeping, reporting and testing requirements, operational parameters, and any other requirements are identified in parentheses. If a specific requirement type does not exist for the flexible grouping, NA (not applicable) has been used in the table. Those requirements which are enforceable bythe state only are designated by an asterisk.Page: 33 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



### TABLE F-l.l FG-CHROMEPROCESS FLEXIBLE GROUPING REQUIREMENTS FLEXIBLE GROUPING FG-CHROMEPROCESS Non chrome electroplating processes. Emission UnitlProeess Groups EG-COPPERTANKS EG-ACTIVATORTANKS EG-NEUTRALIZERTANKS 

### I. DESIGN PARAMETERS A. PoUution Control Equipment B. StaekIV ent Parameters 

## I Exhaust gases shall be discharged unobstructed vertically upwards unless otherwise noted. StacklVent a. Minimum b. Maximum Exhaust Co Temperature d. Air Flow AppUcable ID Height (feet) Dimension (inches) (oF) Rate (aerm) Requirement NA NA NA NA NA NA C. Other Desl2n Parameters NA 

### II. MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usa2e Rate NA NA B. Pollutant Manmum Emission Limit Sulfuric acid 1. 4.65 milligrams per cubic meter, corrected to 70 OF and 29.92 inches Hg. (R336.1901(a))* Hydrochloric acid 2. 4.65 milligrams per cubic meter, corrected to 70 OF and 29.92 inches Hg. (R336.901(a))* Fonnaldehyde 3. 1.02 milligrams per cubic meter, corrected to 70 OF and 29.92 inches Hg. (Tank#11 only.) (R336.1901(a»* 

### IlL COMPLIANCE EVALUATION Records ofall oftbe foUowin2 sball bemaintained on me for a period of5 Yean. (R336.1213(3)(b)(U)) A. MONITORINGIRECORDKEEPING (R336.1213(3» InAddition To General Requirementsin Part A 1. Continuous Emission NA Monitoring (CEM) System and Recordkeepin2 2. Process Monitoring System NA and Recordkeepin2 3. Other Monitoring and/or NA Recordkeepin2 B. TESTINGIRECORDKEEPING (R 336.1213(3» In Addition to General Requirements in Part A 1. Parameter to be NA TestedlRecorded 2. Metbod/Analysis NA 3. Frequency and Schedule NA ofTesting/Recordkeepin2 

### IV. REPORTING Reports and Schedules 1. Prompt reporting ofdeviations pursuant to Condition 27 ofPart A. (R336.1213(3)(c)(U» 2. Semi-annual reporting ofdeviations pursuant to Condition 26 ofPart A. Due March 15 for reporting period July 

### I to December 31 and September 

### IS for reporting period January 

### I to June 30. (R336.1213(3)(e)(i»

3. Annual certification ofcompliancepursuant to Conditions 31 and 32 ofPart A. Due

### Page: 34 of 65


## TABLE F-l.l FG-CHROMEPROCESS FLEXIBLE GROUPING REQUIREMENTS Pennit Number: 199600451 Expiration Date: June 2, 2004

March 15, 2000 for calendar

### year 1999 and each March 15 for the previous calendar

### year thereafter. (R336.1213(4)(c» 

### See Appendix 8 

### V. OPERATIONALPARAMETERS NA 

### VI. 

### OTHERREQUIREMENTS l. 

### The Pennittee shall implement a Preventative Maintenance Plan which requires inspection and maintenance ofvarious system components related to air

### emissions. See Appendix 9. (R336.1911) 

## * This requirement is stateenforceable only.Page: 35 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004



### TABLE F-l.lFG-COLDCLEANER FLEXIBLE GROUPING REQUIREMENTS FLEXIBLE GROUPING FG-COLDCLEANER- All new coldcleaners (placed into operation after 7/1179) that are exempt from NSR pennitting by R336.1281 (b) orR336.128S (r)(iv) and not required to 

### be in compliance with the Halogenated Solvent CleanerMACT standard. Emission UnitlProcess Groups EGCOLDCLEANERI&EGCOLDCLEANERl 

### I. DESIGN PARAMETERS A. Pollution Control NA Equipment NA B. StackIV ent Parameten INA StacklVent a. Minimum b. Maximum Exhaust c. Temperature d. Air Flow AppUeable 

### ID Heieht (feet) Dimension (inches) 

### fl1 Rate (aefm) Requirement NA NA NA NA NA NA C. Otber Design Parameters 1. Equipment must meet one ofthe following parameters: (a) Cold Cleanerwith air/vaporinterface of 10 square feet or less. (R336.1281(h» (b) Equipment for the cleaning ofmetal which 

### has process emissions released only into the general in-plant environment. (R336.128S(r)(iv» 2. A cover shall 

### be installed and the cover shall be closed wheneverparts are not beinghandled in the cleaner. (R336.1707(3)(a» 3. A device shall 

### be available for draining cleaned parts. (R336.1707(3b» 4. The cover shall be mechanically assisted ifthe Reid vaporpressure ofthe solvent is more than 0.3 psis, the solvent is agitated or the solvent is heated. (R336.1707(3)(a)) 

### U. 

### MATERIAL USAGElEMISSION LIMITS A. Material Maximum Usaee Rate NA NA B. Pollutant Maximum Emission Limit NA NA 

### IlL COMPLIANCE EVALUATION Records ofaU oftbe following shall be maintained on me for a period of5 yean. (R336.1213(3)(b)(U) A. MONITORINGIRECORDKEEPING (R336.1213(3» In Addition To General Requirements in PartA 1. Continuous Emission NA Monitoring (CEM)System and Recordkeepin2 2. Process Monitoring System NA and Recordkeepin2 3. OtberMonitOring and/or 1. The name, make/model, size, description, date ofinstallation and air/vapor interface area Recordkeeping ofthe machine(s) and type ofsolvent (including VOC content and Reid vapor pressure) shall be maintained for each cold cleaner. (R336.1213(3» 2. Ifthe solvent is heated, as noted in R336.1707(2), monitor and record the solvont temperature on a monthly basis, during peak operating conditions. (R336.1213(3» 3. Option chosen to comply with R336.l707(2) (as noted in Operational Parameters Section), ifapplicable. (R336.1213(3» B. TESTlNGIRECORDKEEPlNG (R 336.1213(3»

In Addition to General Requirements In PartAPage: 36 of 65


## TABLE F-l.2FG-COLDCLEANER FLEXIBLE GROUPING REQUIREMENTS 1. Parameterto be NA TestedlRecorded 2. Method/Analysis NA 3. Frequency and Schedule NA ofTesting/Recordkeepina 

### IV. REPORTING Pennit Number: 199600451 Expiration Date: June 2, 2004

Reports and Schedules 1. Prompt reporting ofdeviationspursuant to Condition 27 ofPartA. (R336.1l13(3)(c)(il» 2. Semi-annual reporting ofdeviations pursuant tQ Condition 26 ofPart A. Due March 15 forreportingperiod July 1 to December 31 and September 15 for reporting period January 1 to June 30. (R336.1213(3)(c)(i» 3. Annual certification ofcompliance pursuant to Conditions 31 and 32 ofPartA. Due March 15, 2000 for calendaryear 1999 and each March 15 for the previous calendaryear thereafter. (R336.1213(4)(c» See Appendix 8 

### V.OPERATIONALPARAMETERS 1. Waste solvent shall be stored only in closed containers, unless the stored solvent is demonstrated to a safetyhazard and is disposed so 

### that not more than 20%, byweight, is allowed to evaporate into the atmosphere. (R336.1707(3)(c» 2. A person responsible for the provisions ofthis rule shall develop writtenprocedures for the operation ofsuch provisions, and suchprocedures shall beposted in an accessible, conspicuous location near the coldcleaner. (R336.1707(4» 3. Parts shall be drained not less than 15 seconds oruntil dripping ceases. (R336.1707(3)(b» 4. The cold cleaner shall notbe operated using a solvent having a Reid vaporpressure ofmore 

### than 0.6 psia orheated above 120 degrees Fahrenheit, unless atleast one ofthe following is met: (R336.1707(2» (a) The cold cleaner is designed such that the ratio ofthe freeboard height to the width ofthe cleaner is equal to orgreater than 0.7. (R336.1707(2)(a» 

### (b) The solvent bath is coveredwith water ifthe solvent is insoluble and has a specific gravity ofmore than 1.0. (R336.1707(2)(b» (c) The coldcleaner is controlled by a carbon adsorption system, condensation system. orothermethod ofequivalentcontrol approved bythe AQD. (R336.1707(2)(c» 5. Each cold cleaning machine shall be properly maintained. (R336.1213(3» 

### VI. OTHERREQUIREMENTS 1. The provisions of R336.1707 do not apply to cold cleaning machines that are requiredto be in compliance with 40 CFR Part 63 SubpartT (National Emission Standards for Halogenated Solvent Cleaning (MACT Standard)). (R336.1707(S» 

## * This requirement is state enforceable only.Page: 37 of 65 

## G. Non-Applicable Requirements Pennit Number: 199600451 Expimtion Date: June 2, 2004

At the time of RO pennit issuance, the AQD has detennined that no non-applicable requirements have been identified for incorpomtion into the pennit shield provision set forth in Part A (Conditions 33 through 36) ofthis RO permit pursuant to R 336. 1213(6)(a)(ii). 

## Appendices Appendix 1. Abbreviations Used in This Permit The following is an alphabetical listing ofall abbreviations/acronyms used in this RO pennit. acfin AQD 

### CAA CEM CFR DEQ EPA of HCFC HVLP ID MVAC NA 

### RMP RO 

### SRN Actual cubic feet perminute Air Quality Division Fedeml Clean 

### AirAct Continuous Emission Monitor(ing) Code ofFedeml Regulations Michigan Department ofEnvironmental Quality United States Environmental Protection Agency Degree Fahrenheit Hydrochlorofluorocarbon High Volume LowPressure Identification (Number) Motorvehicle airconditioner Not applicable Risk Management Plan Renewable Operating State Registmtion Number 

## Appendix 2. Schedule ofCompliance The permittee has certified that this source is in compliance with all applicable requirements as ofthe date ofissuance ofthis RO permit and the pennittee shall continue to comply with all applicable requirements listed in this RO pennit. A detailed Schedule ofCompliance is not required. (R 336.12I3(4)(a), R 336.1119(a)(ii» 

## Appendix 3. Monitoring Requirements Specific monitoring requirement procedures, methods or specifications are detailed in Part A or the appropriate Requirement Tables. Therefore, this appendix is not applicable.

### Page: 38 of 65 

## Appendix 4. Recordkeeping Permit Number: 19960045 I Expiration Date: June 2, 2004

The permittee shall use the following approved formats and procedures for the recordkeeping and/or reporting requirements referenced in Tables E-1.l, E-l.l, 

### aod F-l.l. 

### I. For EG-I.I and EG-I.2 (separate records shall be kept for each line), the Permittee shall record the following infonnation: On a daily basis: I. Record the identification ofthe applicable coating category for each coating used; 2. Record the number of hours ofoperation; 3. Record the number ofgallons ofeach coating/reducer used; 4. Record the VOC content ofeach coating batch is pounds pergallon (plus water) as applied. (This will be generated from on site U.S. EPA Method 24 testing ofcoating batches.) 5. Record the VOC content ofeach coating batch is pounds pergallon (minus water) as applied. (This will be generated from on site U.S. EPA Method 24 testing ofcoating batches.) 6. Record the daily volume-weighted average VOC contentin pounds per gallon, minus water, as applied, for each coating category; 7. The VOC emission rate in pounds per hour and pounds percalendarday: and 8. IfVOC content in pounds pergallon (Plus water and minus water) as applied is determined from Manufacturer's formulation data then the following additional data must be maintained: a) Current listing ofthe formulation data for each. b) Mixing ratio ofeach coating and reducer. c) VOC content in pounds pergallon ofcoating (minus water) as received and as applied for each coating used. d) VOC content in pounds pergallon ofcoating (Plus water) as applied, for all waterbased coatings. On a monthly basis: 9. Record the amount in gallons/month and VOC content ofall purge solvent and/or cleanup solvents used and reclaimed. 2. For FGCHROMETANKS, the Permittee shall use the Fume Suppressant Monitoring Data Record Form, and the Daily Process Operations Record form.

### Page: 39 of 65 Pennit Number: 199600451 Expimtion Date: June 

### 2, 2004 

## FUME SUPPRESSANT MONITORING DATA RECORD This InfonnatJon is required byArticle II, Part

### 55 (AirPollution Control) ofP.A. 

### 451 of

### 1994, as amended, and the Federal Clean AirAct of1990. Failure to provide this Infonnatfon mayresultIn penalties and/orImprisonment. Applicable Rule: 40 CFR Part 63, Subpart N-National Emission Standards for Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks. NOTE: Use this form to document the additions offume suppressants (i.e., wetting agents and foam blankets) and the measurements of surface tension and foam blanket thickness. Records must be maintained on file for five years and made available upon request for inspection by the Michigan Department of Environmental Quality. /1. Plant Name 

# 12. Plant LocaUon

Fume Suppressant Addition ofWetting Agent or Foam Surface Tension Measurement (dynes/cm) or Foam Blanket Thickness (wetting agent or foam blanket) Blanket Cinches) 1 Date TIme

1 Surface tension and foam depth measurements must be initially taken once every 4 hours and every hour,

respectively. Once 40 hours of measurements have passed without any exceedances from the appropriate standard (Le., surface tension 

## s 45 dynes/cm or minimum foam blanket thickness of 1 inch), measurements can be reduced to 8 hours and 4 hours, respectively. Following another 40 hours of compliance, measurements can be reduced to 40 hours and 8 hours for surface tension and foam depth, respectively. THIS IS

### A MASTER COPY. PLEASEMAKE COPIES FROM THIS MASTER COPY.Page: 40 

### of 65 Pennit Number:199600451 Expiration Date: June 2, 2004


### 3. EXCESS EMISSIONS. Record date,**be~inninR** and**endin~** time of each period of emissions exceedinR emission limit Excess emissions occur when the surface tension exceeds 45 dynes/cm if using wetting agents or when the foam blanket thickness is less than 1 inch. Describe the corrective actions taken durin!l periods of excess emissions. Date 

# IStarting Time 

# IEnding Time 

# IInitials Date 

# I Starting Time 

# I Ending Time

# J Initials Corrective Action Taken: Corrective Action Taken:

Date 

# IStarting Time 

# IEnding Time 

# I Initials Date 

# 1 Starting Time

# T Ending Time 

# IInitials Corrective Action Taken: Corrective Action Taken:

Date 

# I Starting Time 

# IEnding Time 

# IInitials Date 

# I Starting Time 

# IEnding Time 

# IInitials Corrective Action Taken: Corrective Action Taken:

Date 

# I Starting Time 

# IEnding Time 

# IInitials Date 

# 1 Starting Time

# 1 Ending Time 

# IInitials Corrective Action Taken: Corrective Action Taken:

### Page: 41 of 6S 

# DEQ • Pennit Number: 199600451 Expiration Date: June 2. 2004

MICHIGAN DEPARTMENT OF ENVIRONMENTAL QUAlllY, AIR QUALIlY DIVISION 

## DAILY PROCESS OPERATIONS RECORD This in(onnaUon Is requiredbyArticle II, Part55 (AirPollution Control) 

### o(P.A. 451 

### o( 1994, 

### as amended, and the Federal Clean AirActo( 1990. Failura toprovide this in(onnation mayresultin penalUes and/orimprisonment. Applicable Rule: 40 CFR Part 63, Subpart N-National Emission Standards for Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks. All affected facilities must maintain records ofthe amount of time each affected tank is in operation. If an affected facility is using a nonresettable ampere-hr meter to demonstrate that it is a small, hard chromium electroplating facility, records of the actual rectifier usage (amp-hrs) must be maintained. Records must 

### be maintained on file for fIVe years and made available upon request for inspection by the Michigan Department of Environmental Quality. 1. Plant Name and Location
Tank 10# Date Hours ofOperation



### THIS ISA MASTER COPY. PLEASEMAKE COPIES FROM THIS MASTER COPY..

EQP 5711 (04/97)

### Page: 42 of 65 

### Appendix S. Testing Procedures Permit Number: 199600451 Expiration Date: June 2, 2004

Specific testing requirement plans, procedures, and averaging times are detailed in the appropriate Requirement Tables. Therefore, this appendix is not applicable. 

### Appendix 6. Voided Permits Except as provided in Section 91(2) ofAct 306 ofthe Public Acts of 1969, as amended, being §24.291(2) ofthe Michigan Compiled Laws, and known as the Administrative Procedures Act, the Permits to Install and Permits 

### to Operate listed below shall be void as of the effective date of this RO permit. A petition on this RO permit may be filed pursuant to the Administrative Procedures Act, as provided in Section 5506(14) of Act 451 of the Public Acts of 1994, amended, being §324.5S06(14) ofthe Michigan Compiled Laws, and known as the Natural Resources and Environmental Protection Act. If such petition involves conditions from one or more ofthe aforementioned Permits to Install andlor Permits to Operate, said permits remain in effect until final action is taken by the DEQ at the conclusion ofthe appeals process. At the point where said permits are voided, all processes and process equipment at this stationary source will be covered by and subject to the requirements ofthis RO permit.

Pennltto Corresponding Emission Unit InstaUlOperate Description ofEquipment or Number FledbIeGroupin2

## m lO53-90A Exterior automotive plastic parts coating line. EO-PAINTLINE#1 157-94 Exterior automotive plastic parts coating line. EO-PAINTLINE#2 177-90A Decorative chromium plating process. EO-CHROMETANK32. FO-CHROMEPROCESS

### Page: 43 of 65 

## Appendix 7. Emission Calculations Pennit Nwnber: 199600451 Expiration Date: June 2, 2004

The permittee shall use the following calculations in conjunction with monitoring. testing or recordkeeping data to detennine compliance with the applicable requirements referenced in Tables E-l.l,E-1.2, E-l.3, E-l.4, E-l.5, E-l.6,E-1.7 

### and F-l.l 

### For E-l.l and E-1.2 VOC, less water, less exemptsolvent (lbs/gal, as appUed). Calculation using 

### U.S. EPA Method

### 24: 

## rooo - % Wt. Solids

- %Wt. Water

- %Wt. Exempt Solvent> xDensity ofcoating] 100-[( 

### %Wt. Water 

### + %Wt. Exempt Solvent ) x Density ofCoating] Density ofWater Density ofExempt Solvent Where: %

Wt. Solids is obtained from Method 24 %Wt. Water is obtained from Method 24 %Wt. Exempt solvent from fonnulation 

### as applied Density ofExempt Solvent from literature Density ofWater from literature Density ofcoating from U.S. EPA Method 24 VOC, plus water (lbs/gal as appUed). Calculation using 

### U.S. EPA Method 

### 24: (100%

- 

### %Wt. Nonvolatile) x Density ofCoating Where: %Wt. Nonvolatile is obtained from Method 24 Density ofcoating from u.S. EPA Method 2 Dally volume-weighted average VOC contentin pounds per gallon, minus water, as appUed, for each coating category:

i-n W= :rcV 

### x

## Yli ;-1 

### LVi ;"1 where: W 

# = Daily volume weighted average pounds ofVeC per gallon of coating (minus water), as applied. V 

# = Gallons ofcoating (minus water), as applied, used during the averaging period (ie. one day). Y 

# = Pounds ofvec per gallon ofcoating (minus water), as applied. i 

# = Individual coatings applied during the averaging period. 

### VOC Emission Rate Calculation (lbs/day): Pounds VeC/day 

### = = where: V 

### = Gallons ofcoating(minus water), as applied, used during the reported day. Y 

# = Pounds ofVOC per gallon of coating (minus water), as applied, used during the reported day. i 

# = Individual coatings applied during the averaging period. 

### VOC Emission Rate Calculation (Ibs/hr): Pounds VOC/hour

# = Ibs VeC/1 day x 1 day/(Actual daily hours of operation)



### VOC Emission RateCalculation (tons/month): .i-m

### Page: 44 of 65 Tons VOe/month 

# =[L(lbs VOClday);] x 1tonl2000 Ibs ';-1 

### Where: 

### j 

### = The dayofthe month m 

# =Number ofdays during the reported month. For E-1.3, E-I.4, E-1.5, E-1.6, E-1.7 and F-l.l PennitNwnber: 199600451 Expiration Date: June 2, 2004

Weekly Sulfuric Acid, Hydrochloric Acid, Formaldehyde, and HexavalentChromium Emission Compliance Calculations: 

### 1) Measure surface tension on a weekly basis from tanks #1, #2, #14, #15, #16, #17, #18, and #19. 2) Measure Specific Gravity ofsolution on a weekly basis from tanks #1, #2, #14, #15, #16, #17, #18, and #19. 3) Record concentration ofsulfuric acid solution on aweekly basis from tanks #I, #2, #14, #15, #16, #17, #18, and #19. 4) Record concentration ofhydrochloric acid solution on a weekly basis from tanks #5, #7, and #9. 5) Record concentration offormaldehyde solution on a weeklybasis from tank

### #II. 6) Record concentration ofchromic acid solution on a weekly basis from tanks #1, #2. 7) Input the above data into following spreadsheets in orderto calculate weekly emissions. Note: Sulfuric acid emission from tanks #1, #2, #14, #15, #16, #17, #18, and#19 are due to 1) electrical current loss, and 2) air agitation. Since the process cathode efficiency is approximately 98%, current loss is negligible; consequently sulfuric acid mist emissions due to electrical current loss is considered to be negligible. Mist generated due to air agitation can be estimated using Equation 4, AP-42, Section 12.20.2. Hydrochloric acid and formaldehyde emissions can be estimated using the same equation. Chromium (VI) emissions from the etch tanks are mainly due to air agitation (or air sparging). No electrical current is passed through these tanks and gassing caused by current loss is not a factor. Calculations is started first by calculating the chromic acid (cr03) 

### emissions using the approach described for sulfuric acid. Cr(VI) emissions are then calculated by multiplying the cr03 

### emission rate by the ratio ofthe chromic acid and Cr (VI) molecular weights.

### Page: 45 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004 FOR Fe-CHROME PROCESS-SULFURIC ACID CALCULATIONS:


### a = (3.60335"-5*62.4*S.G.*32.2*R"2)/o 

### E2 = 

### (1.9*olR)*«(1-2*a+9*a"2),,0.5+(a-1

# »/«1+3*a)-(I-2*a+9*a"2)"O.5»"0.5

Tank#14

SurfaceTension

## = Bubble Radius = Mixing Air Rate

# = TankSurfaceArea = S.G. ofSolution = Conc. of H 1SO

.. = Outputs:



### a= E2= Mist Emissions

## = Density ofSolution = (InputJ dynes/em IJlbf7ft 

### 0.25 in 0.35 eu ftlmin

- sq ft



### 54 sq ft (InputJ (InputJ Ib/gal 

### ( Joz.lgal


## [] [ ] grainS/cu ft 

### [ ] grains/min [ ] Ib/cu ft [] Ib/gal 

### [] wt. % [ ] grains/min 

### [ Jpounds/min

Total Uncontrolled 

### H 1S04 Emissions Emaust Air Flow UncontroUed H1SO

.. Emaust Conc.
Cyclone Control Efficiency Controlled H2 SO.. Emissions from tanks #14

- #19 Tanks#15 through #19

SurfaceTension = Bubble Radius = Air Rate

## = TankSurface Area

# = S.G. ofSolution

# = Conc. ofH1SO

..

## =
Outputs:



### a= E2= Mist Emissions = Density ofSolution =

For all five tanks = 

### [ ] pounds/min 26080 scrm, corrected to 70 F 

### 26080 actin, @ T = 

### 70 F 

### [ ] pounds/cu ft [] mglml 

### 40% (Inputl dynes/em IJlbf7ft 

### 0.25 in 0.35 eu ftlmin

- 

### sq ft



### 54 

### sq ft [InputJ (Inputllb/gal 

### ( Joz.lgal



### [ ] 

### [ ] grains/cu ft 

### [ ] grains/min [ ] Ib/cu ft [] Ib/gal []wt.% 

### [ ] grainslmin 

### [ J pounds/min [ ]pounds/minPage: 46 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004

FOR EG-CHROMEETCH-SULFURIC ACID CALCULATIONS: Tank#1

Surface Tension

## = BubbleRadius

### == MixingAir Rate

# = TankSurface Area

# = S.G. ofSolution

# = Cone. ofH2 SO

.. = Outputs:

a= E2= Mist Emissions

# = Density ofSolution 

### == Weight 

### % H2SO

..

# = HzSO

.. Emissions

# =

ExhaustAir Flow (Input) dynes/cm 1)lbfjlft 0.25 in 0.35 cu 

### ftlmin

- sq ft

45 sq ft (Input) (Input) Ib/gal 

### ( ) gil () N 

## [] [ ] grainslcu ft [] grains/min [ ] Ib/cu ft [ ] Ib/gal 

### []wt.% [ ] grains/min [ ] pounds/min

Exhaust Demister Control Efficiency Controlled 

### HzSO.. Emissions from Tanks#1 and #2 

### Permit Limit Tank#2

SurfaceTension 

### == Bubble Radius = Air Rate

## = TankSurfaceArea = S.G. ofSolution

## = Cone. ofH2SO

.. = Outputs:

a= E2= Mist Emissions = Density ofSolution

# =
Weight 

### % H2SO

.. = H2SO

.. Emissions

## =

[ ] pounds/min 13800 scfin, @ T 

### == 70 F [ ] pounds/cu 

### ft [] mglm3 

### 97%



### 6.05 109! 103 (Input) dynes/cm Illbfjlft 0.25 in 0.35 cu 

### ftlmin

- sq ft 85.5 sq ft (Input) (Input) Ib/gal 

### ( ) gil ()N 

### [ ] [ ] grains/cu ft [ ] grains/min [ ] Ib/cu ft [ ] Ib/gal []wt.% [ ] grains/min [ ] pounds/minPage: 47 of 65

FOR FG-CHROMEPROCESS

- HYDROCHLORIC ACID EMISSIONS CALCULATIONS: Pennit Number: 199600451 Expiration Date: June 2, 2004

E2 = (1.9*0'1R)·«(1-2·a+9·a"2)"0.5+(a-1»/«1+3·a)-(1-2·a+9·a"2)"0.5»"0.5

a = (3.60335"-5*62.4·S.0.·32.2·R"2)/0'

SurfaceTension

# = Bubble Radius

## = Mixing Air Rate

## = Tank SurfaceArea= S.G. ofSolution

## = Conc. ofHCI = Outputs:



### a= 

### E2= Mist Emissions

# = Density ofSolution = Weight % HCl HCI Emissions

Total HCl Emissions ExhaustAir Flow Tank#7

[Inputl dynes/em 

### [Ilbflft 0.25 in 0.35 eu ftlmin

- sq 

### ft

45 sq 

### ft [Input) (Input) Ib/gal 

### [ ) gil [) N
( ) ( ) grains/eu 

### ft 

### ( I grains/min ( )Ib/eu

### ft ( ] lb/gal [) wt. % 

### [ I grains/min 

### (I pounds/min

Packed Bed ScrubberControl Efficiency

Controlled HCI Emissions FromTanks#7 

### & #9 Tank #f)

Surface Tension

# = Bubble Radius

# = AirRate

# = TankSurface Area = S.G. ofSolution = ConCo ofHCI = Outputs:

a= 

### E2= Mist Emissions = Density ofSolution

## = Weight%HCI HCI Emissions



### [) mgfmin 11158 sefiD. @ T = 70 F 12000 aefiD. @ T = 110 F 95 % 

### (I mgfmin [Input) dynes/em 

### ()lbflft 0.25 in 0.35 eu ftlmin

- sq 

### ft 22.5 sq ft (Input) [Input] Ib/gal [) %v/v

[ ) 

### II grains/eu 

### ft ( ] grains/min [)Ib/eu

### ft [ lib/gal ()wt.% [ ) grains/min 

### [ I pounds/minPage: 48 of 65

SurfaceTension = Bubble Radius = Mixing Air Rate = TankSurfaceArea = S.G. ofSolution = Cone. ofHCI = Outputs: Tank #5

(Inputl dynes/em [ Ilbflft 0.25 in 0.35 eu ftlmin

- sq 

### ft 22.5 sq 

### ft (Inputl (Inputllb/gal 

### [ ] gil 

### (] N



### a = 

## (I E2 = [ 

### I grains/eu ft Mist Emissions

## = I ] grains/min Density ofSolution

## = [I Ib/eu ft [] Ib/gal Weight 

### % HCI 

### [I wt. % HCI Emissions 

## II grains/min 

## [ I pounds/min [] mg/min

ExhaustAirFlow 10759 selin, @ T = 70 F Permit Number: 199600451 Expiration Date: June 2, 2004

11368 aelin, 

### @ T = 100 

### F Packed Bed Scrubber 95 

### % Control Efficiency Controlled HCI Emissions 

### II mg/m3

Overall Exhaust air flow Overall Emission Overall Concentration Permit Limit 21917 

### scfin mg/min 

### II mglm3 4.65 mglm3 (Combine Exhaust from Tanks #5, #7, 

### & #9) (Combine Tanks #5, #7, & #9)

### Page: 49 of 65

FOR FG-CHROMEPROCESS EMISSIONS CALCULATIONS: FORMALDEYHDE 

### Pennit Number: 199600451 Expiration Date: June 2, 2004

E2 

### =(l.9*alR)*(((1-2·a+9·a"2)"O.5+(a-1

# »/«I+3*a)-(1-2*a+9*8"2)"0.5»,,0.5 

### a = (3.60335"-5*62.4*S.G.*32.2*R"2)1a

SurfaceTension

### = BubbleRadius

### = Mhlng AirRate

## = TankSurface Area

## = S.G. ofSoludon = Conc. ofRCRO

## =
Outputs:

a= E2= MistEmissions

## = Density ofSoludon =
Weight % RCRO RCRO Emissions

TotalRCRO Emissions ExhaustAir Flow RCRO ExhaustConc. Tank#11

Packed Bed Scrubber Control Effidency
Controlled HCRO Emissions
Emission Limit (Input) dynes/em 

### () Ibflft 0.25 in 0.35 eu ftlmin

- sq 

### ft

45 sq 

### ft [Input) () Ib/gal () gil


### (I 

### (I grains/eu 

### ft 

### (I grains/min 

### (I Ib/eu ft 

### (I Ib/gal 

### (I wt. % ( ] grains/min 

### ( Jpounds/min 

### (I pounds/min 11158 selin, @ T

### =70 F 12000 aelin, @T= 110 F [ ] pounds/cu ft 

### (I mglm 3
95%Page: 50 of 65

FOR FG-CHROMEPROCESS

- HEXAVALENT CHROMIUM EMISSIONS CALCULATIONS: PennitNumber: 199600451 Expiration Date: June 2, 2004

E2 = (l.9*0'/R)*«(1-2*a+9*aI\2)"0.5+(a-l»/(1+3*a)-(I-2*a+9*aI\2)"0.5»A0.5 a = (3.603351\-5*62.4*8.0.*32.2*RI\2)/0' Tank#1

SurfaceTension = Bubble Radius = MixingAir Rate= TankSurfaceArea = S.G. ofSolution = Cone. ofCr03 = [Inputl dynes/em ( Ilbflft 0.25 

### in 0.35 eu ftlmin

- sq ft

45 sq 

### ft [Inputl (Input) Ib/gal ( I oz.lgal Tank#2

Surface Tension = Bubble Radius = Air Rate = TankSurfaceArea = S.G. ofSolution = Cone. ofCr03 = (Input) dyneslem Illbflft 0.25 in 0.35 cu ftlmin

- sq ft 85.5 sq 

### ft [Input) Iinputllb/gal II oz.lgal Outputs: Outputs:

a= [ I E2= ( I grains/eu 

### ft Mist Emissions = ( I grains/min Density ofSolution = ( I Ib/eu 

### ft ( ) Ib/gal Weight % Cr03 = II wt. % Cr03 Emissions = [ I grains/min ( I pounds/min CrEmissions = II pounds/min Total CrEmissions ExhaustAir Flow CrExhaust Cone

ExhaustDemisterControl Efficiency Controlled CrEmissions EG-CHROMEETCH Emission Limit 

### a = 

### (I E2 = [ ) grains/eu ft Mist Emissions

## = Density ofSolution = Weight 

### % Cr03 = CrOJ Emissions =

CrEmissions= pounds/min 13800 selin, @ T = 70 F 9046 aefin, @ T = 135 F [ I pounds/eu 

### ft 

### [) l1g1m3 97% II grains/min [ ) Ib/eu 

### ft ( lib/gal [I wt. % II grains/min [ ) pounds/min ( I pounds/minPage: 51 of 65 I'ennll Numoer: JYYOUV4:> J Expiration Date: June 2, 2004

FOR EG-CHROMETANK32

- HEXAVALENTCHROMIUM EMISSIONS CALCULATIONS: For surface tensions at orbelow 45 dynes/em, the chromium (VI) emission fact (1.2 • 10-6gr/dscO published inthe "Compilation ofAirPollutant Emission Factors, AP-42, Fifth Edition, Volwne I: Stationary Point and Area Sources" (tlAP_ 42"), Chapter 12, Table 12.20-1 applies. Cr(VI) Emissions =(1.2 • 10-6 gr/dscf) • (453.6 • 106 J,lgl7000 gr). (I 

### ft3 /O.0283m3 )=2.75 J,lglm3 The rated control efficiency for the mesh pad is 99%. Assuming 97%. the controlled CR (VI) emissions are equal to: =2.75 J,lg/mJ • (1-0.97)=0.082 J.lglm 3

The emission limit for EG-CHROMETANK32=2.9 J,lglm3Page: 52 of 65 

### Appendix 8. Reporting A. Annual and Deviation Certification Reporting l"ermn Numoer: 1YYOUUlt:> 1 Expiration Date: June 2, 2004

The Permittee shall use the attached Report Certification fonn (EQP5736) and Deviation Report fonn (EQP 5737) for the annual and deviation certification reporting referenced in Section IV and described in Rules 336.l213(4)(c) and 336.1213(3)(c)(i). Alternative fonnats must be approved by the AQD District Supervisor. 

### B. Other Reporting For E-I.l, and E-1.2 Example Format: 

### Line: Mix Mixed Date Product Used 1101199 45.25 1102/99 1103/99



### Line: Mix Mixed Date Product Used 

### 1101199 17.75 1102199 1/03/99

For 

### E-l.3: Mask Line (Line I) Gal Gal VOCs Paint used Solvent Used Produced

22.11 21.88 251.7



### Line Total: 251.7



### Tons VOC: 0.12

A Line (Line 2) Gal Gal VOCs Paintused Solvent Used Produced

8.7 8.7 

### 99.4



### Line Total: 99.4



### Tons VOC: 0.05 Hours In Use

24

Hours In Use 8 VOCs per Hour

10.5

VOCs per Hour

14.

Pennittee shall use the NOTIFICATION OF CONSTRUCTIONIRECONSTRUCTION REPORT FORM and the ONGOING COMPLIANCE STATUS REPORT FORM as appropriate.

### Page: 53 of 65 t'enrut Numoer: I !:I!:IOUU4:> I 

### Expiration Date: June 2, 2004 

# Diet MICHIGAN DEPARTMENT OF ENVIRONMENTAL QUALITY AIR QUALITY DIVISION 

### RENEWABLE OPERATING PERMIT REPORT CERTIFICATION Authorizedby 1994 P.A. 451, as amended. Failure toprovide this infonnatlon may resultIn civil and/orcriminalpenalties. Reports submitted pursuant to R 336.1213 (Rule 213), subrulea (3)(c) andlor (4)(c), of Michigan's Renewable Operating (RO) Pennlt program must be certlfled by a responsible official. Additional Information regarding the reports and documentaUon listed below must be kept on file for at least 5 years, as described In General Condition No. 25 in the RO Permit and be made available to the Department of environmental Quality, Air Quality Division upon request.

Source Name County

________ _ Source Address City AQD Source 10 (SRN) RO Permit No. RO Permit Section No. (General Condition No. 31 and No. 32 ofthe RO Permit) Reporting period (provide inclusive dates): From To



### 1. During the entire reporting period, this source was in compliance with ALL terms and conditions contained in the RO Permit, each term and condition of which is identified and included by this reference. The methodes) used to determine compliance islare the method(s) specified in the RO Permit. 2. During the entire reporting period this source was in compliance with all terms and conditions contained In the RO Permit, each term and condition of which Is identified and included by this reference, EXCEPT for the deviations Identified on the enclosed deviation report(s). The method used to determine compliance for each term and condition is the method specified in the RO Permit, unless otherwise indicated and described on the enclosed deviation report(s).
Seml·Annual (or More Frequent) Report Certlflcatlon (General Condition No. 26 ofthe RO Permit)

Reporting period (provide inclusive dates): From To

1. During the entire reporting period, ALL monitoring and associated recordkeeplng requirements in the RO Permit were met and no deviations from these reqUirements orany otherterms orconditions occurred. 2. During the entire reporting period, all monitOring and associated recordkeeping requirements in the RO Permit were met and no deviations from these requirements or any other terms or conditions occurred, EXCEPT for the deviations identified on the enclosed deviation report(s).
Other Report Certification

Reporting period (provide Inclusive dates): From To Additional monitOring reports orother applicable documents required by the RO Permit are attached as described:

I certify that. based on information and belief formed after reasonable inquiry, the statements and information in this report and the supporting enclosures are true. accurate and complete, and that any observed, documented or known Instances of noncompliance have been reported as deviations, including situations where a different or no monitoring method is specified by the RO Permit.

Name of Responsible Official (print ortype) Title Phone Number Signature of Responsible Official DatePage: 54 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 

# DEe

MICHIGAN DEPARTMENT OF ENVIRONMENTAL QUALITY AIR QUALITY DIVISION 

### RENEWABLE OPERATING PERMIT DEVIATION REPORT Authorizedby 1994 PA 451. as amended. Failure to provide this information mayresultin civilandlorcriminalpenalties. This form may be submitted in conjunction with the Renewable Operating Permit Report Certification form (EQP 5736) to report deviations from all general conditions and special conditions In the Renewable Operating (RO) Permit for which deviations required to be reported by Rule 213(3)(c) have occurred. Additional information regarding the reports and documentation listed below must be kept on file forat least 5 years, as described In General Condition No. 25 In the RO Permit and be made available to the Department of Environmental Quality, Air Quality Division, upon request. Items 1 • 8 must be completed for all deviations being reported. Source Name County

________________ __ Source Address City AQD Source 10 (SRN) RO Permit No. RO Permit Section No. RO Permit Section Contact Contact Phone No. Reporting Period (provide inclusive dates): From to Report Type: D Annual D Semi Annual 

## 0 Other (Describe) 1. Group or 2. Table/Condition No. 3. Date(s) ofOccurrence 4. Previously reported? 5. Duration of Source Wide 10 DYes D No Deviation IfYes, Date 6. Method Used to Determine Compliance Status 7. Description of Deviation (ifdifferent from method specified in RO Permit) 8. Reason for Deviation and Description ofCorrective Action Taken

1. Group or 2. Table/Condition No. 3. Date(s) ofOccurrence 4. Previously reported ? 5. Duration of Source Wide 10 DYes D No Deviation IfYes, Date 6. Method Used to Determine Compliance Status 7. Description of Deviation (ifdifferent from method specified in RO Permit)
8. Reason for Deviation and Description of Corrective Action Taken

1. Group or 2. Table/Condition No. 3. Date(s) ofOccurrence 4. Previously reported? 5. Duration of Source Wide 10 DYes 

## 0 No Deviation IfYes, Date 6. Method Used to Determine Compliance Status 7. Description of Deviation (if different from method specified in RO Permit)
8. Reason for Deviation and Description of Corrective Action TakenPage: 55 of 65 Pennit Number: 199600451 Expiration Date: June 2. 2004 

### INSTRUCTIONS FORCOMPLETINGTHE RENEWABLE OPERATING PERMIT REPORT CERTIFICATION A Renewable Operating (RO) Pennit Report Certification form (EQP 5736) shall be submitted with each report required to be certified by a responsible official for the pertinent section ofthe RO Pennit. Additional information regarding the reports and documentation listed below must be kept on file for at least 5 years, as described in General Condition No. 25 in the RO Permit, and be made available to the Department ofEnvironmental Quality, Air Quality Division, upon request. A single certification form may be used for multiple reports, ifsubmittal dates coincide. (Forexample, a semi-annual and an annual report with coinciding reporting dates can be reported using the same fonn.) Before completing theform, make additional photocopies as needed. Source Name COUDtyName Source Address City AQD Source ID (SRN) RO PermitNo. RO PermitSection No. Provide the name ofthe source as it appears in the RO Permit. Provide the name ofthe county in which the permitted source is located. Provide the address for the physica1location ofthe source or source section as it appears in the RO Permit. Provide the name ofthe city in which the permitted source is located. Provide the source's AQD Source Registration Number (SRN). Provide the source's RO PermitNumber as it appears in the permit. Ifapplicable, provide the RO PermitSection Number. Note: MostROPermits will haveonlyonesection. Forpermits with multiplesections. a responsible official mustsign aROPermitReport Certification formfor his/herrespective section(s). Annual Com Hance Certification General Conditions No. 31 and No. 31 ofthe RO Permit This box should be selected ifinformation is being submitted to satisfy the annual compliance certification requirements as described in General Conditions No. 31 and No. 32 ofthe RO Permit. Enter the starting and ending dates ofthe reporting period in the space provided. The reporting period for annual compliance certification is January 1to December 31, unless an alternate reporting period is specified by the RO Permit special conditions. Select Box I, ifDQ deviations have occurred from any ofthe general conditions or special conditions ofthe applicable section(s) ofthe RO Permit at any point during the above stated reporting period. Ifthis box is checked, no other forms or attachments are necessary. Note: The method(s) usedto determine compliance l11H:f1 be the method(s) specifiedin the ROPermit. OR Select Box 2, ifone or more deviations have occurred from any ofthe general conditions or special conditions ofthe RO Permit during the above stated reporting period. A description ofeach deviation must be included with this report using the Renewable Operating Permit Deviation Report form (EQP 5737), unless an alternate deviation reporting format has received prior approval from the appropriate AQD District Supervisor. Note: A copy of the report andanysupporting documentation mustalso besentto the USEPA at the address statedin General Condition No. 31 of the RO Permit. Semi-Annual orMore Fr**~ent** Re ort Certification General Condition No. 16oUhe RO Permit This box should be selected ifinformation is being submitted to satisfy the semi-annual (or more frequent ifspecified in an applicable requirement ofthe RO Permit) certification requirements as described in General Condition No. 26 ofthe RO Permit. Enterthe starting and ending dates ofthe reporting period in the space provided. The reporting periods for semi-annual certification are January 1to June 30 and July 1 to December 31, unless an alternate reporting period is specified by the RO Permit special conditions. Select Box I, ifall monitoring and associated recordkeeping requirements have been met and if!lQ deviations have occurred from these or any ofthe other general or special conditions ofthe RO Permit at any point during the above stated reporting period. Ifthis box is checked, no additional forms or attachments are necessary. OR Select Box 2, if one or more deviations has occurred from any monitoring or recordkeeping requirement or any of the other general conditions or special conditions ofthe RO Permit during the above stated reporting period. A description ofeachdeviation must be included with this report using the Renewable Operati!lg Permit Deviation Report form (EQP 5737), unless an alternate deviation n;porting format has received prior approval from the appropriate AQD District Supervisor.Page: 56 of 65 Other Report Certification Pennit Number: 199600451 Expiration Date: June 2, 2004

This box should be selected ifinfonnation is being submitted to satisfy RO Pennit reporting requirements other than the annual compliance or semi-annual (or more frequent) report certification requirements described above. Enter the starting and ending dates ofthe reporting period in the space provided. Also, give a description ofthe infonnation that is being submitted in the space provided. Otherreports required by the RO Permit may include, but are not limited to, the following:

• Prompt reporting ofdeviations 

### as described in General Condition No. 27 ofthe RO Permit. • Material usage records, operating schedule records, and calculated emission data. • CEMorothermonitoring data. • Sampling or stack testing data andresults. • Calibration and maintenance data for process monitoring equipment. • Records ofrequired preventative maintenance ormalfunction abatementactivities. • Any other reports required by the special conditions listed in Sections B, E, orF ofthe RO Permit.
Signature ofResponsible Omdal: The Renewable Operating Pennit Report Certification form must be signed by a responsible official for the applicable section(s) ofthe RO Pennit. In accordance with the federal Clean Air Act, federal Credible Evidence Rule (62 FR 8314, 

### February 24, 1997) and US EPA White Paper Number 2 (Lydia Wegman to Regional Air Directors, March S, 1996). the responsible official for the facility must certify that all observed. documented. or known instances ofnoncompliance were reported 

### as deviations, including situations where a different or no monitoring method is specified by the RO Permit. The completed Renewable Operating Permit Report Certification form and any attachments should be submitted to the attention of the appropriate Air QualityDivision District Supervisor orthe Wayne County Renewable Operating Program Manager.Page: 57 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 

## INSTRUCTIONS FORCOMPLETING THE RENEWABLE OPERATING PERMIT DEVIATION REPORT This fonn may be submitted for deviations required to be 

### reported pursuant to Rule 213(3)(c)(i) ofMichigan's Renewable Operating (RO) Pennit program. The permittee is required to promptly report any deviations from RO Permit requirements during the reporting period. A Renewable Operating Permit Report Certification form (EQP 5736) must accompany all deviation reports. Before compledng the form, make addJdonaJ photocopies as needed. The prompt reporting ofdeviations from RO Permit requirements must be reported consistent with General Condition No. 27 ofthe RO Permit, which states: • Deviations that exceed the emissions allowed under the RO Permit must be reported consistent with the requirements ofRule 912. • Deviations that exceed the emissions allowed under the RO Permit but were not required to be reported pursuant to Rule 912 due to the duration ofthe deviation must be reported on the semi-annual report, orother report as required in the RO Permit. • Deviations that did not exceed the emissions allowed under the RO Permit must be reported on the semi-annual report, ormore frequently ifrequired by the RO Permit. Note: Submittal of the Deviation Reportdoes notnecessarilyconstitute a written report underRule 912(5).
Source Name Provide the name ofthe source as it appears in the RO Permit. County Source Address City AQD Source ID (SRN) RO PermJt No. RO Permit Seedon No.

Seedon Contact Contact Phone Number Provide the name ofthe county in which the permitted source is located. Provide the address for the physical location ofthe source orsource section as it appears in the RO Permit. Provide the name ofthe city in which the permitted source is located. Provide the source's AQD Source Registration Number (SRN). Provide the source's RO PermitNumber as it appears in the RO Permit Ifapplicable, provide the RO Permit Section Number. Note: Most RO Permits will have only one section. For RO Permits with multiple sections, a responsible official must sign an RO Permit Report Certificationform for hislherrespective section(s). Provide the name ofthe contact person identified in the RO Permit Application for the RO Permit Section to which this report applies. Provide the phone number ofthe Section Contact. Reporting Period Enter the starting and ending dates of the reporting period. The reporting period for annual reporting will

Report Type typically be January I to December 31, unless an altemate reporting period is specified by the RO Permit special conditions. The reporting periods for semi-annual report certification will typically be January I to June 30 and July I to December 31, unless an alternate reporting period is specified by the RO Permit special conditions. The starting date for the fnldal report(s) should be the date ofissuance ofthe RO Permit.
Note: 

### If thisform is being used for more than one reportingperiod. list the datesfor the longestperiod. For example. 

### if theform is used for the annual andsemi-annual report. the reportingperiodforthe annual reportshouldbe used. Select the report type for which this report is being submitted. The RO Permit may require reporting other than annually or semi-annually. Describe the report type ifnot annual or semi-annual. Other reports required by the RO Permit may include, but are not limited to, the following:
• Prompt reporting ofdeviations as described in General Condition No. 27 ofthe RO Permit. • Material usage records, operating schedule records and calculated emission data. • CEM orother monitoring data. • Sampling or stack testing data and results. • Calibration and maintenance data for process monitoring equipment. • Records ofrequired preventative maintenance ormalfunction abatement activities. • Any other reports required by the special conditions listed in Sections B. E orF ofthe RO Permit.Page: 58 of 65 Commete Items 1-8 for each deviadon. Pennit Number: 199600451 Expiration Date: June 2, 2004

I. Enter the Emission Group or Flexible Group 10, as it appears on the RO Permit, for which the deviation has occurred. Ifthis is a deviation from a Source Wide requirement, "Table B"is the Source Wide 10. 2. Enter the Table number and RO Permit condition number ofthe requirement for which the deviation has occurred. Ifthe deviation applies to a general condition. enter "NA" in place ofthe Table number. See Attachment A for an example ofthe current numbering system. Ifthere is an "A" in the "Pollution Control Equipment" box. as indicated bythe arrow in this example, then the RO Permit uses the current numbering system. Ifthe RO Permit is not labeled in this manner, describe the RO Permit condition in detail or contact the appropriate Air Quality Division District or Wayne Countyoffice for instruction on the numbering protocol ofyour RO Permit 3. Enter the date(s) on which the deviation occurred or time period covered by a referenced monitoring or compliance report(s). (For example: 1101198 to 1104/98) 4. Indicate whether this deviation 

### was previouslyreported to the Air QualityDivision. Ifso, provide the date on which it was reported. Note: Previously submittedinformation shouldhave includedthe Source Name. City. AQD Source ID. RO PermitNumber andROPermit Section Number. S. Indicate the duration ofthe deviation. (Forexample: 2 hours, 4 days, etc.) 6. Describe the compliance method used to determine the compliance status. Ifthe compliance method used was the same as specified in the RO Permit, then this box may be left blank. Note: This is the only box that may be left blanlc. 7. Describe the deviation in sufficient detail to showhow the deviation differs from the requirement. 8. Explain the reason for the deviation and describe the actions taken to correct the deviation. 9. Provide additional supporting information for Items 6, 7, & 8, as needed. If submitting additional information. please give a brief description in the appropriate box(es) and note that additional supporting information is being submitted.
Write in the page numbering at the bottom ofthepage. For example, "Page 3 of6",

### Page: 59 of 

### 65 

# DIQ Permit Number: 199600451 Expiration 

### Date: June 2, 2004

MICHIGAN DEPARTMENT OF ENVIRONMENTAL QUAliTY, AIR QUALITY DIVISION 

## NOTIFICATION OF CONSTRUCTION/RECONSTRUCTION REPORT This information is requiredbyArticle II, Part

### 55 (AIrPollution Control) ofP.A. 

### 451 of

### 1994, as amended, andthe Federal Clean Air Actof1990. Failure to provide this Information mayresultInpenalties and/orimprisonment. Applicable Rule: 40 CFR Part 63, Subpart N-National Emission Standards for Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks. NOTE: All affected facilities must complete and submit this report to the Michigan Department of Environmental Quality prior to the construction or reconstruction of chromium electroplating or chromium anodizing tanks. Please complete and send to the appropriate office listed on the last page ofthis report. Please printortype al/lnfonnatlon. 

### 1. COMPLETE THIS SECTION FOR EACH PLANT IN WHICH A CHROMIUM ELECTROPLATING ANDIOR CHROMIUM ANODIZING TANK IS BEING CONSTRUCTED OR RECONSTRUCTED. OWNERIOPERATOR NAME AND TITLE PLANT NAME STREETADDRESS PLANTTELEPHONE AREA CODE & NUMBER CITY 

# I STATE 

# I ZlPCODE PLANT CONTACT NAME AND TITlE PLANT STREETADDRESS (ifdifferent Ihan Owner/Operator's) CITY 

# I STATE 

# I ZlPCODE



### 2. COMPLETE THIS SECTION FOR EACH TANK FOR WHICH CONSTRUCTION OR RECONSTRUCTION IS PLANNED. If additional space is needed, make copies ofthis page. Expec:ted Expected Estimaled Total Type of Control Chromium Tank Type of Tank Beginning Dale Completion Date Anllcipated Control System Emissions After 10# for Construction! for Construction! Startup Date Technique to be 10# Reconstruction Reconstruction Used 1 Control Is Applied 2

1 Attach deSign information from vendor, including design drawings and deSign capacity. 2 Attach engineering calculations to support estimate. These calculations may be from the vendor. Emissions estimates should be

expressed in units consistent with the emission limits in the regulation. EXAMPLE RESPONSE' 

# . Expected Expected Estimated Total Type of Control Chromium Tank Type ofTank Beginning Date Completion Dale Anticipated Control System Emissions After 10# for Construction! for Constructionl Startup Date Technique to be 10# Reconstruction Reconstruction Used 1 Control Is Applied 2 1 Hard chrome 10/94 1195 1/95 CompoSite mesh- 5 0.01mgJdscm plating pad system 2 Decorative 2195 6195 6/95 Wetting-agent NlA Will meet 45 chrome plating fume suppressant dynes/em 

### 3. This form is being completed because a chromium electroplating and/or chromium anodizing tank is being: 

### 0 Constructed 

### 0 Reconstructed 4. After construction/reconstruction occurs, tanks will be located at a facility which is a: 

### 0 Major Source (emits greater than 

### 10 tons per year of any 

### 0 Area Source (all sources which are one hazardous air pollutant [HAP] or 25 tons per year of not Major Sources) multiple HAP's. NOTE: The major/area source determination is based on all HAP emission points inside the facility fenceline, not justlhe chromium electroplating and anodizing tanks.

# .. Page: 60 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004 5. If hard chromium electroplating tanks are being operated, check all boxes that apply. The maximum cumulative potential rectifier capacity ofthe hard chromium electroplating tanks (Total installed Rectifier Capacity [amperes] X 8400 HoursJYrX .70 for Each Tank) is: 

## o greater than orequal to 60 million amp-hr/yr 

### 0 less than 60 million amp-hr/yr 

## o Records show that the facility's previous 12-month cumulative current usage for the hard chromium electroplating tanks was less than 60 million amp-hr. 

## o The facility wishes to accept a federally-enforceable limit of less than 60 million amp-hr/yr on the maximum cumulative tential rectifier ca aci ofthe hard chromium electro lati tanks. 6. Attach a brief description of the proposed emission control technique(s), including design drawings, design capacity. and emissions estimates with supporting calculations. 7. If reconstruction isto occur, attach a briefdescription ofthe source and the components to be replaced. B. Complete the following if reconstruction is to occur and the facility believes that there are economic or technical limitations to prevent the facility from complying with all relevant standards or requirements. A. Attach a discussion ofany economic or technical limitations ofcomplying with the relevant standards or reqUirements. The discussion must be sufficiently detailed to demonstrate how these limitations will affect the facility's abilitv to comply. B. Provide an estimate of the fixed capital cost of the replacements and of constructing a comparable entirely new source: Replacements $ ; New source $,

____ _ C. Provide the estimated life ofthe source after the replacements:

____ _ NOTE: The NOTIFICATION OF CONSTRUCTIONIRECONSTRUCTION REPORT does not replace the Permit to Install requirement identified in Rule 201 of the Michigan Administrative Rules for Air Pollution Control (or the Installation Permit required by the Wayne County Air Pollution Control Ordinance). Permits to Install (or Installation Permits) are to be obtained prior to a facility installing. constructing, reconstructing. relocating. altering or modifying any process or process equipment. including control equipment, that emits air contaminants. The purpose of the permit requirements is to ensure that new or modified sources ofaircontaminants will operate in compliance with all applicable state and federal requirements. 9. Print ortype the name and title ofthe Responsible Official for the plant: (Name) (Title) A Responsible Official can be:

• The preSident, vice-president, secretary, ortreasurerofthe company who owns the plant; • The owner ofthe plant; • The plant engineer orsupervisor; • A govemment official ifthe plant is owned by the Federal. State, City. orCounty government; or • A ranking military officer ifthe plant is located on a military base. I Certify the Information Contained in this Report to be Accurate and True to the Best of my Knowledge. (Signature of Responsible Official) (Date)" 

# .. Page: 61 of 65 Permit Number: 199600451 Expiration Date: June 2. 2004 

# Dlt\ MICHIGAN DEPARTMENT OF ENVIRONMENTAL QUALllY, AIR QUALllY DIVISION 

## ONGOING COMPLIANCE STATUS REPORT This Information Is required byArticle II. Part55 (AirPollution Control) ofP.A. 451 of1994, 

### as amended, and the Federal Clean Air Act of 1990. Failure toprovide this information mayresultinpenalties and/orimprisonment. Applicable Rule: 40 CFR Part 

### 63. Subpart N-National Emission Standards for Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks. NOTE: This report is used to demonstrate ongOing monitoring ofthe operating parameter established during the performance test. Affected facilities must begin monitoring on and after the date of their performance test. Major sources must submit this report to the Michigan Department of Environmental Quality. Please complete and send to the appropriate office listed on the last page ofthis report. Pleaseprintortype allinfonnation. 1. COMPLETE THIS SECTION FOR EACH PLANT IN WHICH CHROMIUM ELECTROPLATING ANDIOR CHROMIUM ANODIZING OPERATIONS ARE PERFORMED. OWNER/OPERATOR NAME AND TITLE PLANT NAME STREET ADDRESS PLANT TELEPHONE AREA COCE & NUMBER CITY 

# I STATE 

# I ZIP CODE PLANT CONTACT NAME AND TITLE
PLANT STREET ADDRESS (Ifdifferent than Owner/Operator'S) CITY 

# I STATE 

# I Z1PCOCE

2. COMPLETE THIS SECTION. Ifadditional space is needed, make copies of this page. Operating Acceptable Tank Applicable Type of Control Control System Parameter Value or Range Total Operating Type ofTank Monitored to of Values for Time During 10# Emission Limit Technique 10# Demonsllate Monitored Reporting Compliance Parameter(s) Period

EXAMPLE RESPONSE,' 

# . Operating Acceptable Tank Applicable Type ofControl Control System Parameter Value or Range Total Operating Type ofTank Monitored to of Values for Time During 10# Emission Limit Technique 10# Demonstrate Monitored Reporting Compliance Parameter(s) Period 1 Hard chrome plating 0.015 mg/dscm Composite 10 pressure drop 7 in. w.c. ± 1 in. 1,040 hr. mesh-pad sYStem 2 Chrome anodizing 45dyneslcm Wetting agent N/A surface tension S45 dynes/ern 1,040 hr. fume sUPllressant 3 Hard chrome plating 0.015 mg/dscm CompoSite 10 pressure drop 7 in. w.c. ± 1 in. 1,040 hr. mesh-pad SYStem 3. IDENTIFY THE BEGINNING AND ENDING DATES OF THE REPORTING PERIOD, Beginning Date: 

# I Ending Date:" Page: 62 of 65 Pennit Number: 199600451 Expiration Date: June 2. 2004 4. COMPLETE THIS SECTION FOR THIS REPORTING PERIOD FOR HARD CHROMIUM ELECTROPLATING TANKS THAT ARE LIMITING THEIR MAXIMUM CUMULATIve RECTIFIER CAPACITY IN ACCORDANCE WITH 40 CFR 63.342 (C) (2). Ampere-Hours Consumed By Month Total Ampere-Hours Tank Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Consumed During Reporting 10# Period

Total For All Tanks EXAMPLERESPONSE Ampere-Hours Consumed By Month Total Ampere-Hours Tank Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Consumed During Reporting 10# Period 1 400,000 400,000 400,000 200,000 200,000 200,000 1,800,000 3 300,000 300,000 300,000 300,000 300,000 300,000 1,800,000 Total 700,000 700,000 700,000 500,000 500,000 500,000 3,600,000 For All Tanks 

### 5. Attach all MONITORING DATA RECORDKEEPING FORMS for the reporting penod. Based on the data on excess emissions and the data on operating times, calculate the following hours:
Duration of excess emissions caused by: Process upsets Control equipment malfunctions Other known causes Unknown causes Total duration of excess emissions Percent oftotal Hours operating time

6. In accordance with the OPERATION AND MAINTENANCE PLAN for this source, during this reporting period the work practices identified in 40 CFR 63.342(f) were: 

### D Followed 

### D Not Followed 7. Ifthe OPERATION AND MAINTENANCE PLAN was not followed during the 

### reporting period, please provide an explanation of the reasons for not following the proviSions in the plan, an assessment of whether any excess emissions and/or parameter monitoring exceedances are believed to have occurred, and a copy of the appropriate records documenting that the operation and maintenance plan was not followed. Please state whether or not the plan 

### is being revised accordingly.t. 

### Page: 63 of 65 Permit Number: 199600451 Expiration Date: June 2, 2004 8. Please describe anychanges in monitoring, processes, or controls since the last reporting period.

9. Print or

### type the name and title ofthe Responsible Official for the plant: (Name) (Title) A Responsible Official can be:

• The president, vice-president, secretary, or treasurer ofthe company who owns the plant; • The owner ofthe plant; • The plant engineer or supervisor; • A government official ifthe plant is owned bythe Federal, State, City, or County government; or • A ranking military officer ifthe plant is located on a military base. I Certify The Information Contained In This Report To Be Accurate And True To The Best OfMy Knowledge.
(Signature of Responsible Official) (Date) NOTE: Major sources are required to submit the ONGOING COMPLIANCE STATUS REPORT to the Michigan Department of Environmental Quality. Air Quality Division, semi-annually. 

### If exceedances occur, the report must be completed and submitted quarterly. Area sources are required to complete this report annually, retain the report on site, and make the report available to the Michigan Department of Environmental Quality, Air Quality Division, upon request. If exceedances occur, the report must be completed semi-annually. Area sources must keep the reports on file forfive years. Majorsources must submit the ONGOING COMPLIANCE STATUS REPORT to the Michigan Department of Environmental Quality, Air Quality Division.I. .,



# • Page: 64 of 65 

## Appendix 9. Preventive Maintenance Plan-Air ExhaustEquipment Permit Number: 199600451 Expiration Date: June 2, 2004

The supervisoryperson responsible for inspection and repair ofall aircleaning devices shall be the "Maintenance Manager". A listing ofeach aircleaning device to be inspected and repaired is as follows: I. CHROME MIST ELIMINATOR

This system has one blowerwith two eliminators, one for the sidearm chrome tank. This system has a programmable timer that runs five minutes each weekend or when a shutdown has lasted more than 10 hours to spraywateron the mist eliminator media.

Ourinspection and service shall consist of: a. Visual inspection ofblowerbelts (3) and shives. b. Visual inspection ofblower, bearings and shafts. c. Visual inspection ofwaternozzles. d. Visual inspection ofelectric motor. Parts to be kept in stock will be: a. 3 belts. b. Spray nozzles. 2. NITRIC WET AIR SCRUBBER This system has one airblower and a pump to supply a constant source ofspray over the fume collection media. Ourinspection ofthis scrubber will consist of: a. Visual inspection ofblower belts (3) and shives. b. Visual inspection ofblower, bearings and shafts. c. Visual inspection ofwater nozzles. d. Visual inspection ofelectric motor. e. Visual inspection ofpump. Parts tobe kept in stockwill be: a. 3 belts. b. Spray nozzles. c. Water spraypump. NOTE: A constant feed of2 gpm ofcity water is flushing the waterreservoir. 3. ETCH MIST ELIMINATOR This system consists ofa cry scrubberpowered with a blower and manually washed down (with a spray nozzle system) media. This media is washed down once per week for three minutes. Ourinspection ofthis system will consist of: a. Visual inspection of belts. b. Visual inspection ofblower, bearings and shaft. c. Visual inspection ofspray nozzles. d. Visual inspection ofelectric motor. Parts to be kept in stock will be: a. 3 belts. b. Spray nozzles

. 4. PREPLATE WET SCRUBBER This system is identical to the nitric wet scrubber and will be serviced and stocked the same.Page: 65 of 65 Pennit Number: 199600451 Expiration Date: June 2, 2004 5. ACID COPPER DRY MIST ELIMINATOR This system depends only on the movement ofcopper fumes to collect on the fume media (walls) at the outside of the chamber and gravity drain down in to a waste treatment collectionpit. No water is used on this fume collection system. Our inspection ofthis system will consist of: a. Visual inspection of belts. b. Visual inspection ofblower, bearings and shaft. c. Visual inspection ofelectric motor. Parts to be kept in stockwill be: a. Belts. The two wet air scrubbers (Nitric, Preplate) variables will be detennined by the water spray nozzles and blower/motorbelts. 1. Forthe Nozzles: A full "fan" cone-shaped spray that meets the nozzle spray next to it or overlaps is considered "OK". 

### Ifthey don't meet oroverlap they mustbe repaired. 2. Forthe BlowerlMotorBelts: A timing strobe will beused to observe the belt slippage. As long as belt slippage is less than one foot per 15 seconds the RPM ofthe bloweris sufficient to move the rated air flow. Our aim will be 

### "0" belt slippage however. For the Chrome Mist Eliminators, we will use blower belt slippage as the variable to detennine the proper function ofthe air blower. Our goal will be zero slippage. However, twelve inches per fifteen seconds 

### (12"/155) is the point after which air volumes will begin to be affected and will be used as the unacceptable limit. The spray nozzles for the three chrome mist eliminators (1 main line, 1 side 

### arm. 1 etch) are operated by time (mainline, sidearm) and by hand (etch). While operating, we will observe the spray pattern to be sure all media is being completely covered. Any deviation outside these variables will be repaired. For the Acid Copper Dry Mist Eliminator, the blower belts are the only item that has operational variables, as there are no nozzles 

### in this unit. The same variables apply here as in the ahove units. The goal is to have zero belt slippage, however, the maximum allowable slippagebefore blower volume is appreciably affected is twelve inches in fifteen seconds (12"/15s). Again a strobetiming scope will beused to check this. Anything over this variable will be repaired. All reasonable, necessary repair parts such as belts, pumps and nozzles are kept in stock to be used immediately to affect repairs. All large and more costly items such as motors, shafts, etc. are available within a fifty mite radius and are stock items with our suppliers. Therefore, we will not stock these seldomneeded items. All checks and service will be done by the maintenance department. The checks will be on a BI-WEEKLY basis and repairs will be done upon detennination ofa problem.