PM2.5 (tpy) (tpy) Paved Paved roadways and watering, as need. No VE except 1 minute in any 60-minute period for paved roadways. 0.05 0.21 1.08 LAER/BACT Analysis: Coal and Coke Storage Piles Ohio EPA emissions unit number F002. Fugitive Dust LAER/BACT Control Technology LAER/BACT Opacity Limitation LAER Rate for PM2.5 (tpy) BACT Emission Rate for PM10 (tpy) BACT Rate for PM (tpy) Coal Piles Berm around storage piles, radical stacker, with front-end loader, and wet suppression. No VE except 1 minute in any period for coal storage piles. 1.29 3.64 7.51 Coke Piles Stacker conveyor load-in, with loader, wet material. No VE except 1 minute in any period for coke storage piles. Combined with coal storage piles. Combined with coal storage piles. Combined with coal storage piles. LAER/BACT Analysis: Coal Handling, Processing, and Transfer Ohio EPA emissions unit number F003. Fugitive Dust LAER/BACT Control Technology LAER/BACT Opacity Limitation LAER Rate for PM2.5 (tpy) BACT Emission Rate for PM10 (tpy) BACT Rate for PM (tpy) Coal Enclosure and wet suppression; enclosed (except Visible particulate emissions shall not exceed 0.52 1.67 3.47 end
and where prohibited by safety) and wet material. 10% opacity, as a 3-minute average. LAER/BACT Analysis: Coke Breeze Handling and Processing Ohio EPA emissions unit number F004. Fugitive Dust LAER/BACT Control Technology LAER/BACT Opacity Limitation LAER Rate for PM2.5 (tpy) BACT Emission Rate for PM10 (tpy) BACT Rate for PM (tpy) Coke Breeze Handling and Enclosed building (except where prohibited by safety), wet material and fabric filter (from operations) with a 0.008 grains per dry standard cubic feet (dscf) limitation of PM2.5. Visible particulate emissions shall not exceed 20% opacity, as a 6-minute average from any stack. Visible fugitive dust particulate emissions shall not exceed 10% opacity, as a 3-minute average. 15.55 16.71 18.60 LAER/BACT Analysis: Coke Quenching Ohio EPA emissions unit number P001. Process LAER/BACT Control Technology LAER/ BACT Opacity LAER/ BACT Limitations LAER Rate for (tpy) BACT Rate for PM10 (tpy) BACT Rate for PM (tpy) Coke MACT standards of no more Visible 0.027 lb of 12.32 20.08 54.75 r. 5
than 5% of the quench tower may be open to the sky; baffles must be washed each day unless prohibited by cold temperature; verify that the quench water total dissolved solids (TDS) is less than or equal to 1,100 mg/L by sampling; process water from a river, lake or steam, storm water runoff, or water used for cooling is acceptable. shall not 20% as a ton of coal for LAER; 0.044 lb of ton of coal and 0.12 lb of PM/wet ton of coal for BACT. See specific details of both the LAER and the BACT analysis in the air permit-to-install application. LAER/BACT Analysis: Heat Recovery Coke Plant Ohio EPA emissions unit number P901. Contained within the heat recovery coke plant are the following operations: charging, coking, waste gas by passing both HRSG and the lime spray dryer/baghouse, and pushing. Process LAER/BACT Control LAER/ BACT Opacity LAER/ BACT Limitations LAER Rate for PM2.5 (tpy) BACT Rate for PM10 (tpy) BACT Rate for PM (tpy) Charging Baghouse with traveling hood Visible shall 0.0081 lb of ton of coal 3.4 from the 0.18 3.4 from the 0.37 3.4 from the 1.23 charge charge on on on e. charge
not exceed 10% opacity, as a average from any stack. Visible fugitive dust shall not exceed 20% opacity, as an average of five for LAER; 0.0081 lb of PM10 and PM/dry ton of coal for BACT. Process LAER/BACT Control Technology LAER/ BACT Limitations LAER/BACT Emission Rate for SO2 (tpy) Charging Work practices 0.0003 lb of SO2/wet ton of coal charged for LAER and BACT. 0.14 Process BACT Control Technology BACT Limitation BACT Emission Rate for CO (tpy) Charging N/A 0.0028 lb of CO/wet ton of coal charged for BACT. 1.28 Process BACT Control LAER/ BACT Opacity LAER/ BACT LAER Rate for BACT Rate for BACT Rate for PM on on charge s. charge charges
PM2.5 (tpy) (tpy) Coking with heat steam and lime spray dryer – main stack Baghouse (used in with a spray dryer to control SO2 Visible shall not exceed 10% opacity, as a average from the lime spray dryer/ baghouse stack. No visible shall be from the common battery tunnel or its piping. 0.1 lb of /ton of coal coked (0.005 gr/dscf) for LAER and BACT. 46.9 46.9 46.9 Process Operations LAER/BACT Control Technology LAER/ LAER/BACT Limitations LAER/BACT Emission Rate for SO2 (tpy) Coking operations with heat recovery steam generators and lime spray dryer – main stack Fabric filter, common tunnel afterburner, and lime spray dryer. Designed to obtain 92 percent control efficiency. 700.8 Process BACT BACT Limitation BACT Emission Rate for minute
Operations Control Technology CO (tpy) Coking operations with heat recovery steam generators and lime spray dryer – main stack Combustion during coking process shall be optimized by monitoring the temperature in each oven crown and sole flue and adding air as needed through dampers in each oven. 0.21 lb of CO/wet ton of coal charged (20 ppm) for BACT. 95.54 Process Operations LAER/BACT Control Technology LAER/BACT Limitation LAER Emission Rate for NOx (tpy) BACT Emission Rate for NOx (tpy) Coking operations with heat recovery steam generators and lime spray dryer – main stack Staged combustion 1.0 lb of NOx/wet ton of coal charged for BACT. 1.0 lb of NOx/wet ton of coal charged for LAER. 465.25 include NOx emissions from the main stack after passing thru the lime spray filter and during of the lime spray 465.25 include NOx emissions from the main stack after passing thru the lime spray dryer/fabric filter and during maintenance of the lime spray dryer/filter. Process Operations BACT Control Technology BACT Limitations BACT Emission Rate for H2SO4 (tpy) Coking operations with heat Fabric filter, common tunnel afterburner, and Designed to obtain 95 percent control efficiency. 11.13
recovery steam generators and lime spray dryer – main stack lime spray dryer. Middletown Coke Company presented a redundant FGD system as a possible control option to control emissions when FDG maintenance is being performed which would require the installation of a spray dryer/baghouse with instrumentation along with steel ductwork with dampers. Middletown Coke Company deemed that this option as technically feasible, but presented documentation in the application that it was not cost effective to employ this option during FDG maintenance. Based upon that analysis, the following was deemed to satisfy BACT/LAER requirements. Process LAER/BACT Control LAER/ BACT Opacity LAER/ BACT LAER Rate for (tpy) BACT Rate for BACT Rate for PM (tpy) Coking with heat steam and lime spray dryer – main stack when the lime spray dryer is Work practices and limited number of hours operated (5 days/year) Visible shall not exceed 20% opacity, as a average. No visible shall be from the common battery tunnel or its Based upon of 0.049 gr/dscf 6.3 6.3 6.3 minute bypass
NOx (tpy) Coking operations with heat recovery steam generators and lime spray dryer – main stack when the lime spray dryer is bypassed. Staged combustion 1.0 lb per wet ton of coal charged 6.25 6.25 Process Operations BACT Control Technology BACT Limitation BACT Emission Rate for H2SO4 (tpy) Coking operations with heat recovery steam generators and lime spray dryer – main stack when the lime spray dryer is bypassed. Limiting the annual maintenance to no more than five days per year; and by following good work practices which shall reduce SO2 emissions by 28 percent. 91.5 lbs per hour. 5.49 Middletown Coke Company presented two possible control options to control emissions HRSG maintenance. These two options are employing a spray quench system at each HRSG to cool individual waste heat gases and the other option is to install additional HRSGs and increase the size of the waste heat tunnel over current design specifications. Both options were deemed not technically feasible. However, in both cases, Middletown Coke Company presented documentation in the application that it was not cost effective to use either one of these options. Based upon that analysis, the following was deemed to satisfy BACT/LAER requirements. Process BACT Control LAER/ BACT Opacity LAER/ BACT LAER Rate for PM2.5 (tpy) BACT Rate for BACT Rate for PM (tpy) Waste gas from the coking Work limit HRSG Visible Based upon of 12.6 12.6 12.6 on
process – waste gas stacks. to one HRSG at a time, and limited number of hours (10 shall not exceed 20% opacity, as a 0.049 gr/dscf. Process LAER/BACT Control Technology LAER/ BACT Limitations LAER/BACT Emission Rate for SO2 (tpy) Waste gas from the coking process – waste gas stacks. Work practices, limit HRSG maintenance to one HRSG at a time, and limited number of hours operated (10 days/year). 23.92 lb/wet ton of coal 299 Process LAER/BACT Control Technology LAER/ BACT Limitations LAER/BACT Emission Rate for NOx (tpy) Waste gas from the coking – waste gas stacks. Stage combustion 1.0 lb/ton of wet coal charged. 12.5 Process Operations BACT Control Technology BACT Limitation BACT Emission Rate for CO (tpy) Waste gas from the coking process – Combustion during coking process shall be optimized by monitoring the 20 ppm 2.62 operate minute e.
waste gas stacks. temperature in each oven crown and sole flue and adding air as needed through dampers in each oven. Process Operations BACT Control Technology BACT Limitations BACT Emission Rate for H2SO4 (tpy) Waste gas from the coking process – waste gas stacks. Work practices, limit HRSG maintenance to one HRSG at a time, and limited number of hours operated (10 days/year). 25.4 lbs per hour. 15.25 Process BACT Control LAER/ BACT Opacity LAER/ BACT LAER Emission Rate for PM2.5 (tpy) BACT Rate for BACT Rate for PM (tpy) Pushing with flat hot car vented to dust Flat push and hood with multi- cyclone Visible shall not exceed 20% opacity, as a 0.04 lb/ton 13.09 13.09 13.09 Process Operations LAER/BACT Control Technology LAER/ BACT Limitations LAER/BACT Emission Rate for SO2 (tpy) Pushing operations with flat hot car vented to multiclone Work Practices 0.098 lb/wet ton of coal charged. 44.71 average minute on