Chemical Products Corporation - Best Available Retrofit Technology Eligible Emissions Units (BART-Eligible Source) [Revised November 11, 2008]

Table A-1. Chemical Products Corporation BART-Eligible Source Potential-to-Emit

Coke

Stack ID 

No. a 

Emissions 

Unit ID No. 

a

Emission Unit Description a Construction

Date a

Maximum 

Rated Heat 

Input, 

(mmBtu/hr) a

Natural Gas 

Consumption, 

(cfh) a, b

Propane 

Consumption, 

(gph) a, b

Used Oil 

Consumption, 

(gph) a, b

No. 2 Fuel Oil 

Consumption, 

(gph) a, b

Coke 

Consumption, 

(tph) a

Maximum Hourly 

Input Rate,

(tph) a

Georgia Rule (d)

PM10 Emissions

Permit Limit, 

(lb/hr)

Georgia Rule (e)

PM10 Emissions

Permit Limit, 

(lb/hr)

Georgia Rule 

(g)

Fuel Sulfur

Permit Limit, 

Coke Sulfur 

Content, (%) c

SO2 

Emissions

Factor, Mass 

Balance, 

NOx Emissions

Factor, AP-42 ,

1.4-1, (lb/mmscf)

SO2 Emissions

Factor, AP-42 ,

1.4-2,

(lb/mmscf)

NOx Emissions

Factor, AP-42 1.5-1, 

(lb/mgal)

SO2 Emissions

Factor, AP-42 1.5-1, 

(lb/mgal) d

Fuel Oil

Type

NOx Emissions

Factor, TV-02-0, 

Condition 6.2.6, 

(lb/mgal)

SO2 Emissions

Factor, AP-42 1.3-1 or 

1.11-2, (lb/mgal)

PM10, Potential

 Emissions Rate, (lb/hr) 

e

NOx, Potential

Emissions Rate, (lb/hr) 

f, g

SO2, Potential

Emissions Rate, (lb/hr) 

f

Chemical Products Corporation, Title V Permit No. 2819-015-0008-V-02-0/-1

BCZ1 BC01 South Rotary Calciner 1969 24.00 23,301 262 0 179 -- 5.50 -- 12.85 2.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 12.848 3.582 63.582

BDZ1 BD01 Rotary Dryer 1964 8.89 8,631 97 0 66 -- 4.00 -- 10.38 2.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 10.379 1.327 23.552

BDZ3 BD03 South Spray Dryer 1968 5.85 5,680 64 0 44 -- 3.50 -- 9.49 2.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 9.491 0.873 15.498

BDZ4 BD04 Barium Chloride Rotary Dryer 1976 4.50 4,369 49 0 34 -- 3.00 -- 8.56 2.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 8.560 0.672 11.922

BKZ1 BK02 East Rotary Kiln 1966 10.20 9,903 111 69 76 1.00 6.00 -- 13.62 2.5 15.50 619 100 0.6 13 0.01000 Used Oil 19.00 147S 13.619 8.900 646.442

GBZ1 GBX1 B&W Process Steam Boiler 1973 100.00 97,087 1,092 0 746 -- -- 15.81 -- 3.0 -- -- 100 0.6 13 0.01000 No. 2 (> 100mmBtu/hr) 24.00 157S 15.811 17.910 351.493

Notes: PTE (tpy) PM NOx SO2

a. Stack and emissions unit identification, construction date, maximum rated heat input, fuel consumption rates, petroleum coke consumption and design capacity determined from Title V Permit No. 2819-015-0008-V-02-0/-1 and Title V Application No. 16069. Maximum hourly input rate of East Rotary Kiln increased from 5 tph to 6 tph to include both 1 tph of petroleum coke and 5 tph of barite ore processed. South Rotary Calciner 56.27 15.69 278.49

b. Maximum hourly fuel consumption determined from maximum rated heat inputs divided by the heating values for each fuel provided in the Title V application; 91,547 Btu/gal propane; 134,000 Btu/gal No. 2 fuel oil; 1,030 Btu/cf natural gas; 148,000 Btu/gal used oil. Rotary Dryer 45.46 5.81 103.16

c. Chemical Products Corporation will propose to accept a federally enforecable permit limitation of 15.5 percent sulfur, by weight, in coke processed in the East Kiln through permitting action. South Spray Dryer 41.57 3.82 67.88

d. SO2 emissions factor for processing of petroleum coke determined from sulfur content in coke with 100% conversion to SO2; (64.06, MW of SO2)/(32.06, MW of S)*(2000 lb/hr coke processed)*(15.5 lb sulfur per 100 lb coke processed). Propane SO2 emissions factor is 0.1*S where "S" is assumed to be 0.1 grains per 100 cubic feet (typical). Barium Chloride Dryer 37.49 2.94 52.22

e. PM10 potential-to-emit determined from Georgia Rules (d) and (e). East Rotary Kiln 59.65 38.98 2831.42

f. NOx and SO2 potential-to-emit determined from maximum hourly emissions rates resulting from combustion of natural gas, propane, or fuel oil as applicable. SO2 emissions rate for the East Rotary Kiln includes estimated SO2 from processing coke. B&W Boiler 69.25 78.45 1539.54

g. The East Kiln NOx equipment emissions cap specified in Condition 3.2.1 of TV-02-1 is proposed to be revised to 8.9 lb/hr NOx from 42 tpy NOx per twelve consecutive month period (charcoal process). BART-Eligible Source Total 309.70 145.70 4872.70

Natural Gas Propane No. 2 and Used Fuel Oil

g. The East Kiln NOx equipment emissions cap specified in Condition 3.2.1 of TV-02-1 is proposed to be revised to 8.9 lb/hr NOx from 42 tpy NOx per twelve consecutive month period (charcoal process). BART-Eligible Source Total 309.70 145.70 4872.70

Table A-2. Chemical Products Corporation BART-Eligible Source Maximum 24-hr Actual Emissions Rates (Potential-to-Emit, Proposed 0.5% Fuel Oil Sulfur Content, AP-42, Proposed Daily SO2 Limit East Kiln)

Coke

Stack ID 

No. a 

Emissions 

Unit ID No. 

a

Emission Unit Description a Construction

Date a

Maximum 

Rated Heat 

Input, 

(mmBtu/hr) a

Natural Gas 

Consumption, 

(cfh) a, b

Propane 

Consumption, 

(gph) a, b

Used Oil 

Consumption, 

(gph) a, b

No. 2 Fuel Oil 

Consumption, 

(gph) a, b

Coke 

Consumption, 

(tph) a

Maximum Hourly 

Input Rate,

(tph) a

Georgia Rule (d)

PM10 Emissions

Permit Limit, 

(lb/hr)

Georgia Rule (e)

PM10 Emissions

Permit Limit, 

(lb/hr)

Proposed

Fuel Sulfur

Permit Limit, 

(%) c

Coke Sulfur 

Content, (%) c

SO2 

Emissions

Factor, Mass 

Balance, 

NOx Emissions

Factor, AP-42 ,

1.4-1, (lb/mmscf)

SO2 Emissions

Factor, AP-42 ,

1.4-2,

(lb/mmscf)

NOx Emissions

Factor, AP-42 1.5-1, 

(lb/mgal)

SO2 Emissions

Factor, AP-42 1.5-1, 

(lb/mgal) d

Fuel Oil

Type

NOx Emissions

Factor, TV-02-0, 

Condition 6.2.6, 

(lb/mgal)

SO2 Emissions

Factor, AP-42 1.3-1 or 

1.11-2, (lb/mgal)

PM10, Potential

 Emissions Rate, (lb/hr) 

e

NOx, Potential

Emissions Rate, (lb/hr) 

f, g

SO2, Potential

Emissions Rate, (lb/hr) 

f

Chemical Products Corporation, Title V Permit No. 2819-015-0008-V-02-0/-1

BCZ1 BC01 South Rotary Calciner 1969 24.00 23,301 262 0 179 -- 5.50 -- 12.85 0.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 12.848 3.582 12.716

BDZ1 BD01 Rotary Dryer 1964 8.89 8,631 97 0 66 -- 4.00 -- 10.38 0.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 10.379 1.327 4.710

BDZ3 BD03 South Spray Dryer 1968 5.85 5,680 64 0 44 -- 3.50 -- 9.49 0.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 9.491 0.873 3.100

BDZ4 BD04 Barium Chloride Rotary Dryer 1976 4.50 4,369 49 0 34 -- 3.00 -- 8.56 0.5 -- -- 100 0.6 13 0.01000 No. 2 20.00 142S 8.560 0.672 2.384

BKZ1 BK02 East Rotary Kiln 1966 10.20 9,903 111 69 76 1.00 6.00 -- 13.62 0.5 15.50 619 100 0.6 13 0.01000 Used Oil 19.00 147S 13.619 8.900 624.824

GBZ1 GBX1 B&W Process Steam Boiler 1973 100.00 97,087 1,092 0 746 -- -- 15.81 -- 0.5 -- -- 100 0.6 13 0.01000 No. 2 (> 100mmBtu/hr) 24.00 157S 15.811 17.910 58.582

Notes: PTE (tpy) PM NOx SO2

a. Stack and emissions unit identification, construction date, maximum rated heat input, fuel consumption rates, petroleum coke consumption and design capacity determined from Title V Permit No. 2819-015-0008-V-02-0/-1 and Title V Application No. 16069. Maximum hourly input rate of East Rotary Kiln increased from 5 tph to 6 tph to include both 1 tph of petroleum coke and 5 tph of barite ore processed. South Rotary Calciner 56.27 15.69 55.70

b. Maximum hourly fuel consumption determined from maximum rated heat inputs divided by the heating values for each fuel provided in the Title V application; 91,547 Btu/gal propane; 134,000 Btu/gal No. 2 fuel oil; 1,030 Btu/cf natural gas; 148,000 Btu/gal used oil. Rotary Dryer 45.46 5.81 20.63

c. Chemical Products Corporation will propose to accept a federally enforecable permit limitations of 15.5 percent sulfur, by weight, in coke processed in the East Kiln and 0.5% sulfur, by weight, in fuel oils combusted through permitting action. South Spray Dryer 41.57 3.82 13.58

d. SO2 emissions factor for processing of petroleum coke determined from sulfur content in coke with 100% conversion to SO2; (64.06, MW of SO2)/(32.06, MW of S)*(2000 lb/hr coke processed)*(15.5 lb sulfur per 100 lb coke processed). Propane SO2 emissions factor is 0.1*S where "S" is assumed to be 0.1 grains per 100 cubic feet (typical). Barium Chloride Dryer 37.49 2.94 10.44

e. PM10 potential-to-emit determined from Georgia Rules (d) and (e). East Rotary Kiln 59.65 38.98 2736.73

f. NOx and SO2 potential-to-emit determined from maximum hourly emissions rates resulting from combustion of natural gas, propane, or fuel oil as applicable. SO2 emissions rate for the East Rotary Kiln includes estimated SO2 from processing coke. B&W Boiler 69.25 78.45 256.59

g. The East Kiln NOx equipment emissions cap specified in Condition 3.2.1 of TV-02-1 is proposed to be revised to 8.9 lb/hr NOx from 42 tpy NOx per twelve consecutive month period (charcoal process). BART-Eligible Source Total 309.70 145.70 3093.67

Table A-3. Chemical Products Corporation BART-Eligible Source CALPUFF Modeling Input Parameters and PM10 Specication

Organic Condensable (OC)

Proposed Sulfur Limits Natural Gas Propane No. 2 and Used Fuel Oil

Chemical Products Corporation, Title V Permit No. 2819-015-0008-V-02-0/-1 PM056 PM081

BCZ1 BC01 South Rotary Calciner d 34.1509 84.7861 16 1118.285 -572.130 45 213 65 708.66 216.00 400 49.86 2.26 12.716 3.582 12.848 0 100 50 50 6.424 6.424

BDZ1 BD01 Rotary Dryer d 34.1509 84.7860 16 1118.296 -572.126 48 213 65 708.66 216.00 300 12.78 2.00 4.710 1.327 10.379 0 100 50 50 5.190 5.190

BDZ3 BD03 South Spray Dryer d 34.1508 84.7862 16 1118.279 -572.143 48 213 65 708.66 216.00 300 34.93 1.35 3.100 0.873 9.491 0 100 50 50 4.745 4.745

BDZ4 BD04 Barium Chloride Rotary Dryer 34.1509 84.7863 16 1118.270 -572.133 30 213 65 708.66 216.00 250 11.41 1.67 2.384 0.672 8.560 0 100 50 50 4.280 4.280

BKZ1 BK02 East Rotary Kiln 34.1506 84.7854 16 1118.352 -572.148 195 213 65 707.68 215.70 400 33.16 4.00 624.824 8.900 13.619 0 100 50 50 6.809 6.809

GBZ1 GBX1 B&W Process Steam Boiler 34.1505 84.7852 16 1118.374 -572.161 55 213 65 705.41 215.01 500 80.70 3.00 58.582 17.910 15.811 0 100 50 50 7.906 7.906

Notes:

a. Lambert Conformal Conic (LCC) coordinates determined from conversion from latitude and longitude coordinates determined from Google Earth and stack locations provided by Chemical Products Corporation.

b. Base elevations in the ASCII CALPUFF control files obtained from GA EPD from 2006 12km BART exemption modeling performed by VISTAS were determined to be incorrect; the original base elevations reflected the release height (approximated 705 feet plus stack height).

b. Base elevations provided in Table A-3 were determined by processing the USGS Digital Elevation Model (7.5' DEM 30m) file for Cartersville, Georgia (34084B7) in AERMAP; please refer to the "AERMAP.srf" provided.

b. Stack height and diameter, exhaust temperature, and exit velocity have been verified with Chemical Products Corporation and are consistent with previous data supplied to GA EPD.

c. Particulate matter speciation performed in accordance with "Procedure for Speciation of Emissions for VISTAS BART Modeling", July 18, 2006, example 3.(1) available at http://www.vistas-sesarm.org/documents/SpeciationMemo_July182006.pdf.

d. Vertical discharge of stacks BCZ1 (South Rotary Calciner) and BDZ1 (Rotary Dryer) have been verified to be obstructed by means of a rain protection device. The South Spray Dryer vents horizontally to the atmosphere through emissions points BDZ3. For this reason, FMFAC will be set to "0" in the CALPUFF input file. The remaining stacks will be set to "1".

e. All stack heights have been verified to not exceed good engineering practice (GEP) stack height as defined in 40 CFR §51.100(ii); all stack heights, measured from the ground-level elevation at the base of the stack, are less than 65 m (213 feet).

Stack ID 

No.

Emissions 

Unit ID No. Emission Unit Description

Organic Condensable (OC)

Assumed Fraction of PM10 c

0.625 - 1.0 m, (%) 0.5 - 0.625 m, (%)

Base

Elevation,

(ft) b

NOx, (lb/hr) PM10, (lb/hr)

Base

Elevation,

(m) b

Stack

Height, (ft) b

Organic Condensable (OC)

 c

0.625 - 1.0 m, (lb/hr) 0.5 - 0.625 m, (lb/hr)

PM10 Particle Speciation (Unknown) c

Filterable, (%) Condesable, (%)

SO2, (lb/hr)

Location a

Latitude Longitude Zone

Location LCC a

Easting, (km) Northing, (km)

GEP Stack 

Height, (m) e

GEP Stack 

Height, (ft) e

Exhaust

Temp., t

(

o

F) b

Exit

Velocity,

(fps) b

Stack

Diameter, 

(ft) b

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Appendix A ChemProdBARTSource Page 1 of 1