p. 1



# OAR Box 1413 Prepped by Ollie Stewart



### Document

Number: 

# 29 ) 11-1-2 9

Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:21 PM

Sheet 29 of 114P. 2 

### w . 

# T

EXA S AI RCONTROL BOAR 1212 4 PAR K3 3 CIRCLE

. U'STl. V TEXAS ~«"5.'

. 512"9ns-l»Ki 

# D

DICKVVHITTISCTON.rE CHMRMAX BOB C BAILE D VICECHAIRMAS fTE\'E \ \ fl-AVV

. PE EXECUTIXT

DIRECTOR 

# j&& ICH N L 3 1 -:\ \ 5 -i.SNEi.! . ' s •- : : M- •*- *n '•'•".:!A\: H •_?• . •'•-*. -

' • \A\_ \ . . • • • -

Novembe r 5 , 199 1

Mr . Thoma s D . Walczy k Plan t Enginee r COMPOSIT E TECHNOLOG Y 100 5 Blu e Moun

d Roa d For t Worth , Texa s 7613 1
Re : Permi t No . 1942 4 Fiberglas s Production Facilit y Blu e Mound , Tarran t Count y Accoun t I D No . TA-0573- N Dea r Mr . Walczyk : A permi t for you

r ne w facilit

y i s enclosed . W

e appreciat e you

r cooperationi

nsendin

g us th e informatio

n necessary

t o evaluat a your proposal . The permi t contain s severa l genera l an d specia l provision s that * defin e th

e leve l of operatio nan d allowabl e emissions . I n addition , th

e constructio

nan d operatio

no f th e facilitie s mus t b e a s represented i nth e application . Than k yo u for you

r cooperatio

nan d interes t inai r pollutio n control . Sincerely , \^JLMJHJrUA^JtfaJ

JbatJZf Lawrenc e E . Pewitt , P.E . Director , Permit s Progra m Enclosure s

cc : Mr . Melvi nLewis , Regiona l Director , For t Wort h Mr . Gen e Rattan , Supervisor , Environmenta l Qualit y Section , Publi c HealthDepartment , For t Wort h Th e Honorabl e A . R . Perkins , Mayor , Cit y o f Blu e Moun

d



### Texans ivorkingfor

clean airP. 3

GENERAL PROVISION S 1942 4

1 . Equivalency

o f Method s - I t shal l b e th e responsibility

o f the holde r o f thi s permi t t o demonstrat e o r otherwis e justif

y the equivalency

o f emissio ncontro l methods , samplin g o r other emissio ntestin

g method s an

d monitorin

g method s propose

d a s alternative s t o method s indicate d i n th e provision s o f thi s permit . Alternativ e method s shal l b

e applie

d for i

nwritin

g an d shal l b

e reviewed an

d approve

d b y th e Executiv

e Director prio r t o thei r us e i nfulfillin g an y requirement s o f thi s permit . 2 . Samplin

g Requirement s - I f samplin g of stack s or proces s vent s i s required , th

e holde r o f thi s permi t mus t contac t the Qualit y Assuranc e Divisio no f th e Texa s Ai r Contro l Boar d (TACB ) prio r t o sampling t o obtai nth e prope r dat a form

s an d procedures . Th

e holde r o f thi s permi t i s als o responsibl e for providin

g samplin

g facilitie s an

d conductin

g the samplin

g operation s at hi s ow nexpense . 3 . Appea l - Thi s permi t ma y b e appeale

d pursuan t t o Rul e 103.8 1 o f th e Procedura l Rule s o f th e TACB an

d Sectio

n382.03 2 of the Texa s CleanAi r Act . Failur e t o tak e suc happea l constitute s acceptanc e b

y th e applican t of al l term s of th e permit . 4 . Constructio

nProgres s - Star t o f construction , constructio n interruption s exceedin g 4 5 day s an

d completio

no f constructio

n shal l b e reporte

d t o th e appropriat e regiona l offic e of th e TACB no t later tha n1 0 workin

g days after occurrenc e o f th e event . » 5 . Recordkeepin

g - Informationan d dat a concernin

g production , operatin

g hours , sampling an d monitorin

g data , i f applicable , fue l typ e an

d fue l sulfur content , i f applicable , shal l be maintained i

na fil e a t th

e plan t site an

d mad e availabl e a t th e reques t o f personne l fro m th e TAC B or an

y loca l ai r pollutio

ncontro l progra

m havin g jurisdiction . The fil e shal l b e retained fo

r at leas t tw

o year s followin

g the dat e tha t the informatio

nor dat a i s obtained . 6 . Maintenanc e o f EmissionContro l - Th e facilitie s covere d b y thi s permi t shal l no t be operate d unles s al l ai r pollutio n emissio ncaptur e equipmen t an d abatement equipmen t ar e maintained i

ngoo d workin g orde r an

d operatin

g properl y

durin g norma l facilit

y operations .



# 2

_P. 4

SPECIA L PROVISION S 1942 4 EMI88I0 M

8TANDARD8 , FUE L SPECIFICATION S AM D WOR KPRACTICE * 1 . Thi s permi t cover s onl y thos e source s o f emission s liste d i n th e attache d tabl e entitle d "Emissio

n Source s - Maximu m Allowabl e EmissionRates, " an d thos e source s ar e limite d t o th e emissionlimit s an d other condition s specified intha t attache d table . Th e annua l rate s ar e base d o nan y consecutiv

e 12-monthperiod . 2 . The temperatur e inth e retentio

nchambe

r o f th e therma l oxidize r shal l b e continuously monitore

d an d recorded t o ensure i t i s maintained a t 1400* F o r greater . 3 . In-stack concentrationo f volatil e organi c compound s (VOC ) wil l b e continuousl y measure

d a s tota l hydrocarbo n(THC ) an

d reporte d a s styrene . Th

e TH C measured i

n th e therma l oxidize r stac k shal l no t exceed 5 0 part s pe r millio nb y volum e (ppmv) , average d ove r a one-hou

r period . An

y upse t condition s tha t caus e th e 5 0 ppm

v hourly averag e t o b

e exceede

d shal l b

e reporte d t o th

e TAC B a s require

d b y TAC B Genera l Rule s an d shal l b e reviewed b y th e TACB o na case-by-cas e basi s t o determine whethe r th e exceedanc e wa s beyon d th e contro l o f th

e company . 4 . VOC emission s fro m th e fiberglas s productio nprocesse s inth

e facilit y shal l b e capture

d a t th e sourc e an d routed t o a therma l oxidize r capabl e of achievin g a t leas t 9 5 percen t destructio

nefficiency . I f th e therma l oxidizer fail s t o mee t th e requirement s o f Specia l Provisio nNo . 3 (above) , al l VO C producin

g fiberglas s productio nwil l b

e terminated , * a s follows : Th e mixin g an d Hetrolac coatin

g operation s shal l b e immediately

shut down . N

o ne w liqui d resins shal l be adde d t o th e pane l lin

e o r pultrusio

nline an

d th e lin e shal l b

e ru n only unti l the existin g liquid resin s ar e boun d int o the panel . Inth e even t on e portio

no f th

e collectio

nsystem

s malfunction s an

d i s unabl e t o collec t an d rout e the emission s t o th e oxidizer , th

e VO C producin

g processe s associate d wit h tha t portio

no f th e collectio

nsyste m wil l b e terminate

d unti l th e VOC s ca

nb e properl y

route d t o th e therma l oxidizer . 5 . Supplementa l fue l use d i nth e therma l oxidize r shal l b e limite d t o pipeline qualit y swee t natura l gas . 6 . Opacit

y o f emission s fro

m th e therma l oxidizer stac k mus t no t excee d 5 percen t average d over a 6-minut e period , excep t for thos e period s described i nTACB Rul e 111.111(a)(1)(E) .



# 3P. 5

SPECIA L PROVISION S 1942 4 Pag e 2

7 . Therma l oxidize r operating instruction s shal l b e established an d mus t be posted o nor near th e therma l oxidizer . Th e therma l oxidize r shal l be operate d i naccordanc e withthes e instructions . Therma l oxidize r operator s mus t b e trained prio r t o operatin

g th e therma l oxidize r an d record s o f initia l an d recurrin

g trainin

g mus t b

e kept . 8 . Durin

g al l VOC emittin

g operations , al l buildin g door s wher e thes e operation s take plac e wil l remai nclose d except for th e ingress/egres s o f personnel , ra w material s an

d finishe

d products . A

negativ

e ai r flo

w indicatin

g syste m shal l b e installe

d t o indicat e the directio no f airflo

w t o ensur e ai r i s flowin

g fro m th e buildin

g int o th

e enclosure s fo

r the mixin g room , pane l line an d Hetrola c booth s durin g al l VO C producin

g operations . 9 . Al l VO C containin g compound s outsid e o f the enclose

d area s unde r negativ

e pressur e shal l b

e kept i

nclose d container s a t al l times . 10 . Al l handlin

g an d cleanu

p o f spill s shal l be don e i nsuc ha wa y a s t o minimiz e an

y possibl e fugitiv

e emissions . 11 . Al l cuttin

g an d grindin

g operation s shal l b e controlle

d b y a dus t collectio

nsystem . Particulate s trappe d inth

e dus t collectio

nsystems/baghouse s shal l b e bagge d an d dispose

d o f i na manne r tha t wil l preven t visibl e emissions . 12 . Al l exhaus t filter s i nthe spra y booths wil l b

e inspected* o

n a regula r schedul e an d replace

d whenever a hol e i s detecte d o r wheneve r th

e pressur e drop , a s measure d b y a manometer-o r other suitabl e device , increase s t o a maximu m of 0. 5 inche s o f water . Fabri c bag s i

nthe baghous e wil l be inspecte d weekl y

fo r hole s an d moisture/oi l buildu p an d wil l b

e replace

d a s necessary . Pressur e drop s acros s th e fabri c bag s shal l b e measure

d b y a magneheli c gaug e o r othe r suitabl e devic e suc htha t the revers e je t puls e cleanin g syste m ca nb e monitore

d for prope r operation . I f the pressur e dro p increase s t o a maximu m o f 3 inche s o f water , th e cleanin

g syste m shal l b

e inspecte

d an d repaired . 13 . Permitte e shal l provide publi c notic e pursuan t t o Sectio

n 116.1 0 fo r al l change s inoperations , modification s an d expansion s for whicha permi t i s require d under Sectio

n 116. 1 o r a permi t amendment i s require d under Sectio

n116. 5 i f the amendment (a ) make s change s t o the permi t "maximu m allowabl e emissio nrates " table s b y increasin

g th e maximu

m permi t allowabl e emission s rat e b y an y amount o

r addin g t o th e tabl e an y ne v ai r contaminant , o r (b ) change s an y o f the specia l permi t conditions . Copie s o f al l amendmen t request s t o th e TAC B vil l b e mailed directl y t o th e Mayo

r o f Blu

e Mound .P. 6 

# r SPECIA L PROVISION S 1942 4 Pag e 3


### 14 . Th e holde ro f

thi s permi tshal l physicall y identif y and mar k i n aconspicuou s locatio n al l equipmen ttha tha s th e potentia l o f emittin g ai rcontaminant s a s follows : A . Th e facilit y identificatio n numbers (FIN) a s submitte d t o th e Emission s Inventor y Sectio n o f th e TACB

. B . Th e emissio n poin tnumbers a s liste d on th e Maximu m Allowabl e Emissio n Rate s table . 8TAC KSAMPLIN

G 15 . Upo

n reques to f

th e TACB

, th e holde ro f

thi s permi tshal l perfor m stac ksamplin g an d othe rtestin g a s require d t o establis h th e actua l patter n an d quantitie s o f

ai r contaminant s bein g emitte d int o th e atmosphere : 

### from th e facility . Th

e testin g require d b y thi s Specia l Provisio n fo r VO C shal l b e use d t o determin e complianc e wit h th e pound pe r hou rlimi to f

th e Maximu

m Allowabl e Emissio n Rate s Table , TH C concentratio n i n th e stac klimitatio n i n Specia l Provisio n No . 3 an d th e VO

C destructio n efficienc y specifie d i n Specia l Provisio n No . 4 . Samplin g mus tb e conducte d i n accordanc e wit h appropriat e procedure s o f th e TAC

B Samplin q Procedure s Manua l an d i n accordanc e vit h EP A Referenc e Metho

d 1 8 fo rVOC

. Th e holde ro f

thi s permi ti s responsibl e fo rprovidin g samplin g an

d testin g facilitie s an d conductin g th e samplin g an d testin g operatio n a thi s expense . A . Th e TAC

B regiona l offic e i n For tWort h shal l b e contacte d a s soo n a s testin g i s schedule d bu tno tles s tha n 4 5 day s prio rt o samplin g t o schedul e apretes tmeeting . Th e notic e shal l include : 1 . Dat e fo rpretes tmeeting . 2 . Dat

e samplin g wil l occur . 3 . ~ Nam

e o f fir m conductin g sampling . 4 . Typ

e o f samplin g equipmen tt o b e used . 5 . Metho

d o rprocedur e t o b e use d i n sampling . Th e purpos e o f

th e pretes tmeetin g i s t o revie w th e necessar y samplin g an d testin g procedures , t o provid e th e prope rdat aform s fo rrecordin g pertinen tdat aan d t o revie w th e forma tprocedure s fo rsubmittin g th e tes t reports . A writte n propose d descriptio n o f any deviatio n fro m samplin g procedure s specifie d i n permi tprovision s o r TAC B o rU.S . Environmenta l Protectio n Agenc y (EPA ) samplin g procedure s shal l b e mad e availabl e t o th e TAC B prio rt o th e pretes tmeeting . Th e Regiona l Directo ro r th e Directo ro f

th e Qualit y Assuranc e Divisio n shal l approv e o rdisapprov e o f an y deviatio n from specifie d samplin g procedures .

• • ' - 5P. 7

SPECIA L PROVISION S 1942 4 Pag e 4

Request s t o waiv e testin g fo r an

y pollutan t specifie d i n B o f thi s provisionshal l b e submitted t o th e TAC B Permit s Program . Tes t waiver s an d alternate/equivalen t procedur e proposal s fo r Ne w Sourc e Performanc e Standar d testin g whic hmus t hav

e EP A approva l shal l b e submitte d t o th e TAC B Qualit y

Assuranc e Divisio

ninAustin . B . Ai r contaminant s emitte d fro m th e therma l oxidize r stack t o b e tested fo r include , bu t are no t limite d to , styren

e methy l methacrylat e an d toluene . C . Samplin

g port s an

d platform

s shal l b

e incorporated int o th e desig no f the therma l oxidizer stack accordin g t o th e specification s se t forthi nth e attachmen t entitle d "Chapter 2 , -Stac

k Samplin

g Facilities. " Alternat e samplin g facilit y

design s ma

y b e submitte

d fo r approva l b y th e Executiv

e Director o f th

e TACB . D . Samplin

g shal l occu

r withi n9 0 day s o f th e dat e o f reques t b

y th e TACB . Request s fo r additiona l tim

e t o perfor m stac k samplin

g shal l be submitte

d t o th e regiona l office . E . Th e therma l oxidize r shal l be teste d a t maximu

m plan t operatin

g condition s durin g stac k emissio

ntesting . Primar y operating parameter s that enabl e determinatio n o f VOC generationrat e shal l b e monitored an

d recorde

d durin g the stac k test . Thes e parameter s ar e t o b e determine

d a t th

e pretes t meeting . I f th e plant * i s unabl e t o operat e a t maximu m rate s durin

g testing , the

n future productionrate s ma y b e limite

d t o th

e rate s establishe

d durin

g testing . Additiona l stac k testin g ma y be required whe nhighe r productio nrate s ar e achieved . F . Samplin

g report s shal l compl y withth

e provision s o f Chapter 1 4 o f th

e TACB Samplin

g Procedure s Manual * Pou r copie s o f th e samplin g repor t shal l b

e distributed a s follows : On e cop y t o the TAC B Regio

n8 Offic e i

nFor t Worth . On e cop y t o an y appropriat e loca l ai r pollutioncontro l program . On e cop y t o the Quality

Assuranc e Division , TACB,-Austi n Office . On e cop y t o th e City

o f Blu e Mound . G . A t leas t tw

o opacit y

reading s wil l b

e takendurin

g the testing .



# 6P. 8

SPECIA L PROVISION S 1942 4 Pag e 5

16 . Th e holde r o f thi s permi t shal l demonstrat e tha t al l hooding , ductin g an d collection-system s ar e effectiv e i ncapturin

g emission s an

d routin

g the m t o the therma l oxidizer . Th e buildin g ventilatio

nsyste

m shal l b

e operate

d a t maximu

m durin g th e tests . CONTINUOU S DEMONSTRATIO N O F COMPLIANC E 17 . Th e holde r o f thi s permi t shal l continuousl y monito r an

d recor d ga s temperature i nth e retentio nchambe r o f the therma l oxidize r t o demonstrat e continuou s complianc e vit hSpecia l Provisio

nNo . 2 . 18 . Th e holde r o f thi s permi t shal l install , calibrat e an d maintai na continuou s emissio nmonitorin g syste

m (CEMS ) t o measur e an

d recor d TH C i nth e therma l oxidize r stack . Th e monitorin

g shal l b

e don e i naccordanc e vit hcurren t TAC B Qualit y Assurance s procedures . A . The TH C CEMS shal l mee t the desig nan d performanc e specifications , pas s th e field test s an d mee t the installatio

nrequirements , dat a analysi s an d reportin

g requirement s (al l appropriat e procedure s equivalen t t o 4 0 CF R60 , Appendi xB ) specifie d b y th e TAC B Qualit y Assuranc e Division . B . The syste

m shal l b

e zeroe

d an d spanne

d dail y

vhil e operatin

g an d corrective actio ntake nwhenth e 24-hour spa ndrif t exceed s tw

o time s th

e amount s specified ih4 0 CF R60 , AppendixB or a s specifie d b y th e TAC B Qualit y Assuranc e Division . C . Th e TH C monito

r shal l us e styren e a s th e referenc e gas . D . Th e TH C concentration s shal l b e recorde

d i nppmv . RECORDKEEPIN

G REQUIREMENT S 19 . A cop y o f thi s permi t shal l b e kep t a t th e plan t sit e an

d b e availabl e a t th

e reques t o f personne l fro m the TACB , an

y ai r pollutio

ncontro l agenc

y wit happropriat e jurisdictio nor the City o f Blue Mound . 20 . Record s o f emissions shal l b e maintaine

d t o demonstrat e complianc e wit hth

e limit s o f thi s permit . Thes e record s shal l be accumulate

d monthl

y t o giv e year-to-dat e total s for eac h compoun d an d proces s an

d shal l be retaine d for a minimu

m o f 2 4 month s ona rollin g two-yea r basis . The y wil l b e kep t on sit e an d mad e availabl e t o representative s o f th e TAC B or an

y othe r ai r pollutio ncontro l agency

havin g jurisdictio

nan d shal l contai na s a minimum :


# 7P. 9

SPECIA L PROVISION S 1942 4 Pag e 6

A . Materia l usag e i npound s pe r hou r fo r eac hfiberglas s productio

nan d coplane r process . B . Therma l oxidize r stack VO C emissions , inpound s pe r hour , calculate

d usin g th e output o f th e monito r require d b y S P 1 8 (above ) an

d th e estimate

d stac k volumetri c flo w a s determined b

y sampling . C . Dail y

hour s of operatio nfor th

e facility

an d fo r th e pane l lin

e an d pultrusio

nline . D . Materia l Safety Dat a Sheet s (MSDS ) for eachcompoun d store d o r used . E . Purchas e record s fo r al l compound s stored or use d at th e facility . F . Record s of initia l an d recurrin

g trainin

g for operator s o f th e therma l oxidizer . G . Recorde r stri p chart s containin g the therma l oxidize r retentio

nchambe r temperatur e an d TH C stac k concentratio n i nppmv .



# fP.1 0



### EMISSIO N SOURCE

S - MAXIMU

M ALLOWABL

E EMISSIO

N RATE S 1942 4

Thi s tabl e list s th e maximu m allowabl e emissio n rate s and al l source s o f ai r contaminant s o n th e applicant' s propert y covere d b y thi s permit . Th e emissio n rate s shown ar e thos e derive d fro m informatio n submitte d a s par to f th e applicatio n fo rpermi tan d ar e th e maximu

m rate s allowe d fo rthes e facilities . An

y propose d increas e i n emissio n rate s ma y requir e a

n

(1 ) Emissio n poin tidentificatio n - eithe rspecifi c equipmen tdesignatio n o r emissio n poin tnumbe rfro m plo tplan . • (2 ) Specifi c poin tsourc e name. Fo rfugitiv e source s us e are anam e o r fugitiv e sourc e name . (3 ) P M - particulat e matte r PMI O - particulat e matte rles s tha n 1 0 micron s VO C - volatil e organi c compound s a s define d i n Genera l Rul e 101. 1 NO x - tota l oxide s o f

nitroge n C O - carbo n monoxid e 1-1-1
- TC

E - 1-1- 1 tricloroethan e F-22/F-1 2 - freo n 2 2 and freo n 1 2 mixtur e * Emissio n rate s ar e base d o n an d th e facilitie s ar e limite d b y th e followin g maximu

m operatin g schedule : Hrs/da y 2

4 Days/weekj g Weeks/yea r5 2 o rHrs/yea r600 0

N o VO C emittin g productio n operation s vil l b e conducte d betvee n 7:0 0 a.m . Saturda y an d 7:0 0 a.m . Monday. Revised . appii c ;ati (

Emissio n poin t No . TO I

V 4
VF C l

. 3 _>

n to e



# m a mouiiicatio n o i ui e

Sourc e Nam e 12. Therma l Oxidize r

Pane l Baghous e Fabricatio nBaghous e Coplana r Ven t Coplana r Ven t isciiiue s covere d oy *cni s permi*c . AI RCONTAMINANT S DAT A Ai r Contaminan t Nam e (3 1 VO C NO X " C O PM/PM1 0 PM/PM1 0 1-1- 1 TC E F-22/F-1 2 

### Emissio nRate s *

lb/h r TP Y 9.7 9 4.0 9 6.5 1 0.3 4 0.2 0 2.0 0 3.5 3 12.0 0

12.2 8 19.5 4 1.0 3 0.6 0 1.8 0 3.1 8



# 1