major source operating permitadem.alabama.gov/newsevents/notices/jun20/pdfs/6hunt.pdffacility name:...

MAJOR SOURCE OPERATING PERMIT

PERMITTEE: Hunt Refining Company

FACILITY NAME: Tuscaloosa Petroleum Refinery

FACILITY/PERMIT NO.: 413-0007

LOCATION: 1855 Fairlawn Dr., Tuscaloosa, Tuscaloosa County,

Alabama

In accordance with and subject to the provisions of the Alabama Air Pollution Control Act of 1971, as

amended, Ala. Code 1975, §§22-28-1 to 22-28-23 (2006 Rplc. Vol. and 2007 Cum. Supp.) (the "AAPCA")

and the Alabama Environmental Management Act, as amended, Ala. Code 1975, §§22-22A-1 to

22-22A-15, (2006 Rplc. Vol. and 2007 Cum. Supp.) and rules and regulations adopted thereunder, and

subject further to the conditions set forth in this permit, the Permittee is hereby authorized to construct,

install and use the equipment, device or other article described above.

Pursuant to the Clean Air Act of 1990, all conditions of this permit are federally enforceable by EPA, the Alabama Department of Environmental Management, and citizens in general. Those provisions which are not required under the Clean Air Act of 1990 are considered to be state permit provisions and are not federally enforceable by EPA and citizens in general. Those provisions are contained in separate sections of this permit.

Issuance Date: DRAFT June 24, 2020

Effective Date:

Expiration Date:

Alabama Department of Environmental Management

[THIS PAGE LEFT BLANK INTENTIIONALLY]

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TABLE OF CONTENTS

GENERAL PERMIT PROVISOS .............................................................................................................. 1

SUMMARY PAGE FOR PRE-BLACK WARRIOR EXPANSION UNITS: PROCESS HEATERS & BOILERS ......... 17

PROVISOS FOR PRE-BLACK WARRIOR EXPANSION UNITS: PROCESS HEATERS & BOILERS ................... 21

Applicability ........................................................................................................................................ 21

Emission Standards ............................................................................................................................ 22

Compliance and Performance Test Methods and Procedures .......................................................... 26

Emission Monitoring .......................................................................................................................... 27

Recordkeeping and Reporting Requirements .................................................................................... 30

SUMMARY PAGE FOR POST-BLACK WARRIOR EXPANSION UNITS: PROCESS HEATERS & BOILERS ....... 37

PROVISOS FOR POST-BLACK WARRIOR EXPANSION UNITS: PROCESS HEATERS & BOILERS ................. 39

Applicability ........................................................................................................................................ 39





SUMMARY PAGE FOR EMERGENCY ENGINES .................................................................................... 53

PROVISOS FOR EMERGENCY ENGINES............................................................................................... 58

Applicability ........................................................................................................................................ 58





SUMMARY PAGE FOR NSPS QQQ: OILY WASTEWATER SYSTEM ......................................................... 69

PROVISOS FOR OILY WASTEWATER SYSTEM ..................................................................................... 70

Applicability ........................................................................................................................................ 70





SUMMARY PAGE FOR MACT CC AND BWON NESHAP: WASTEWATER STREAM CONTAINING HAPS .... 75

PROVISOS FOR WASTEWATER STREAM CONTAINING HAPS .............................................................. 76

Applicability ........................................................................................................................................ 76




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SUMMARY PAGE FOR NSPS VVA & MON: DI-METHYL SULFIDE (DMS) UNIT ....................................... 81

PROVISOS FOR DMS UNIT ................................................................................................................ 82

Applicability ........................................................................................................................................ 82





SUMMARY PAGE FOR NSPS K: PETROLEUM LIQUID STORAGE VESSELS .............................................. 89

PROVISOS FOR NSPS K PETROLEUM LIQUID STORAGE VESSELS ......................................................... 90

Applicability ........................................................................................................................................ 90





SUMMARY PAGE FOR NSPS KA: PETROLEUM LIQUID STORAGE VESSELS ........................................... 95

PROVISOS FOR NSPS KA PETROLEUM LIQUID STORAGE VESSELS ....................................................... 96

Applicability ........................................................................................................................................ 96





SUMMARY PAGE FOR NSPS KB PETROLEUM LIQUID STORAGE VESSELS ........................................... 101

PROVISOS FOR NSPS KB PETROLEUM LIQUID STORAGE VESSELS ..................................................... 102

Emission Standards .......................................................................................................................... 102

Compliance and Performance Test Methods and Procedures ........................................................ 103

Emission Monitoring ........................................................................................................................ 104

Recordkeeping and Reporting Requirements .................................................................................. 105

SUMMARY PAGE FOR MACT CC: ORGANIC HAP STORAGE VESSELS .................................................. 109

PROVISOS FOR MACT CC: ORGANIC HAP STORAGE VESSELS ............................................................ 111

Applicability ...................................................................................................................................... 111





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SUMMARY PAGE FOR MACT EEEE: (NON-GASOLINE) ORGANIC LIQUIDS DISTRIBUTION (OLD) SYSTEMS

HANDLING HAPS ............................................................................................................................ 121

PROVISOS FOR NON-GASOLINE OLD SYSTEMS HANDLING HAPS ...................................................... 122

Applicability ...................................................................................................................................... 122





SUMMARY PAGE FOR NSPS GGG: FUGITIVE EQUIPMENT LEAKS ...................................................... 133

PROVISOS FOR SUMMARY PAGE FOR FUGITIVE EQUIPMENT LEAKS ................................................ 134




Recordkeeping and Reporting Requirement .................................................................................... 136

SUMMARY PAGE FOR NSPS GGGA: FUGITIVE EQUIPMENT LEAKS OF VOC & OHAP EMISSIONS ......... 139

PROVISOS FOR FUGITIVE EQUIPMENT LEAKS OF VOC & OHAP EMISSIONS ....................................... 140




Recordkeeping and Reporting Requirement .................................................................................... 142

SUMMARY PAGE FOR MACT CC: GASOLINE LOADING RACK AND VAPOR COMBUSTOR .................... 145

PROVISOS FOR SUMMARY PAGE FOR GASOLINE LOADING RACK AND VAPOR COMBUSTOR ............ 146

Applicability ...................................................................................................................................... 146





SUMMARY PAGE FOR NESHAP Y AND MACT CC: MARINE VESSEL LOADING OPERATIONS ................ 157

PROVISOS FOR SUMMARY PAGE FOR MARINE VESSEL LOADING OPERATIONS ................................ 158

Applicability ...................................................................................................................................... 158





SUMMARY PAGE FOR MACT CC: HEAT EXCHANGERS (COOLING TOWERS) ....................................... 161

PROVISOS FOR HAPS FROM COOLING TOWERS............................................................................... 162

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Applicability ...................................................................................................................................... 162





SUMMARY PAGE FOR MACT CC: FENCELINE MONITORING FOR BENZENE EMISSIONS ...................... 167

PROVISOS FOR MACT CC: FENCELINE MONITORING FOR BENZENE EMISSIONS ................................ 168

Applicability ...................................................................................................................................... 168





SUMMARY PAGE FOR NSPS JA AND MACT CC: DELAYED COKING UNITS (DCU) PROCESS VENTS ....... 171

PROVISOS FOR DCU PROCESS VENTS .............................................................................................. 172

Applicability ...................................................................................................................................... 172





SUMMARY PAGE FOR MACT CC: MISCELLANEOUS PROCESS VENTS (INCLUDING MAINTENANCE VENTS

AND BYPASS LINES) ........................................................................................................................ 177

SUMMARY PAGE FOR MISCELLANEOUS PROCESS VENTS (INCLUDING MAINTENANCE VENTS) .......... 178

Applicability ...................................................................................................................................... 178





SUMMARY PAGE FOR MACT UUU: BYPASS LINES FOR CRU AND SRU VENTS .................................... 185

PROVISOS FOR BYPASS LINES FOR CRU AND SRU VENTS ................................................................. 186

Applicability ...................................................................................................................................... 186





SUMMARY PAGE FOR MACT UUU: CATALYTIC REFORMING UNIT (CRU) VENTS ................................ 191

PROVISOS FOR CATALYTIC REFORMING UNIT (CRU) VENTS ............................................................. 192

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Applicability ...................................................................................................................................... 192





SUMMARY PAGE FOR NSPS J AND MACT UUU: SULFUR RECOVERY SYSTEMS & THERMAL

OXIDIZERS ..................................................................................................................................... 199

PROVISOS FOR SULFUR RECOVERY SYSTEMS & THERMAL OXIDIZERS .............................................. 200

Applicability ...................................................................................................................................... 200





SUMMARY PAGE FOR NSPS JA & MACT CC: PROCESS FLARES AND ASSOCIATED PROCESS UNIT

VENTS ............................................................................................................................................ 211

PROVISOS FOR PROCESS FLARES AND ASSOCIATED PROCESS UNIT VENTS ....................................... 213

Applicability ...................................................................................................................................... 213





SUMMARY PAGE FOR MACT LLLLL: ASPHALT PROCESSING FACILITY & THERMAL OXIDIZER .............. 227

PROVISOS FOR ASPHALT PROCESSING FACILITIES & THERMAL OXIDIZER ......................................... 228

Applicability ...................................................................................................................................... 228





SUMMARY PAGE FOR PETROLEUM COKE DRYING AND PULVERIZING SYSTEMS ............................... 245

PROVISOS FOR PETROLEUM COKE DRYING AND PULVERIZING SYSTEMS ......................................... 246

Applicability ...................................................................................................................................... 246





APPENDIX A: HEATERS & BOILERS MONITORING ............................................................................ 251

APPENDIX B: GASOLINE LOADING RACK AND VAPOR COMBUSTOR UNIT ......................................... 259

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APPENDIX C: SULFUR RECOVERY SYSTEMS’ THERMAL OXIDIZER ...................................................... 263

APPENDIX D: FACILITY FLARE MONITORING .................................................................................... 265

APPENDIX E: ASPHALT PROCESSING FACILITY & THERMAL OXIDIZER MONITORING ......................... 267

APPENDIX F: PETROLEUM COKE DRYING & PULVERIZING SYSTEM ................................................... 271

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General Permit Provisos

Federally Enforceable Provisos Regulations

1. Transfer

This permit is not transferable, whether by operation of law or otherwise, either

from one location to another, from one piece of equipment to another, or from

one person to another, except as provided in Rule 335-3-16-.13(1)(a)5.

Rule 335-3-16-.02(6)

2. Renewals

An application for permit renewal shall be submitted at least six (6) months, but

not more than eighteen (18) months, before the date of expiration of this

permit.

The source for which this permit is issued shall lose its right to operate upon the

expiration of this permit unless a timely and complete renewal application has

been submitted within the time constraints listed in the previous paragraph.

Rule 335-3-16-.12(2)

3. Severability Clause

The provisions of this permit are declared to be severable and if any section,

paragraph, subparagraph, subdivision, clause, or phrase of this permit shall be

adjudged to be invalid or unconstitutional by any court of competent

jurisdiction, the judgment shall not affect, impair, or invalidate the remainder

of this permit, but shall be confined in its operation to the section, paragraph,

subparagraph, subdivision, clause, or phrase of this permit that shall be directly

involved in the controversy in which such judgment shall have been rendered.

Rule 335-3-16-.05(e)

4. Compliance

(a) The permittee shall comply with all conditions of ADEM Admin. Code

335-3. Noncompliance with this permit will constitute a violation of the

Clean Air Act of 1990 and ADEM Admin. Code 335-3 and may result in

an enforcement action; including but not limited to, permit termination,

revocation and reissuance, or modification; or denial of a permit

renewal application by the permittee.

Rule 335-3-16-.05(f)

(b) The permittee shall not use as a defense in an enforcement action that

maintaining compliance with conditions of this permit would have

required halting or reducing the permitted activity.

Rule 335-3-16-.05(g)

5. Termination for Cause

This permit may be modified, revoked, reopened and reissued, or terminated

for cause. The filing of a request by the permittee for a permit modification,

revocation and reissuance, or termination, or of a notification of planned

changes or anticipated noncompliance will not stay any permit condition.

Rule 335-3-16-.05(h)

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6. Property Rights

The issuance of this permit does not convey any property rights of any sort, or

any exclusive privilege.

Rule 335-3-16-.05(i)

7. Submission of Information

The permittee must submit to the Department, within 30 days or for such other

reasonable time as the Department may set, any information that the

Department may request in writing to determine whether cause exists for

modifying, revoking and reissuing, or terminating this permit or to determine

compliance with this permit. Upon receiving a specific request, the permittee

shall also furnish to the Department copies of records required to be kept by

this permit.

Rule 335-3-16-.05(j)

8. Economic Incentives, Marketable Permits, and Emissions Trading

No permit revision shall be required, under any approved economic incentives,

marketable permits, emissions trading and other similar programs or processes

for changes that are provided for in this permit.

Rule 335-3-16-.05(k)

9. Certification of Truth, Accuracy, and Completeness:

Any application form, report, test data, monitoring data, or compliance

certification submitted pursuant to this permit shall contain certification by a

responsible official of truth, accuracy, and completeness. This certification shall

state that, based on information and belief formed after reasonable inquiry, the

statements and information in the document are true, accurate and complete.

Rule 335-3-16-.07(a)

10. Inspection and Entry

Upon presentation of credentials and other documents as may be required by

law, the permittee shall allow authorized representatives of the Alabama

Department of Environmental Management and EPA to conduct the following:

Rule 335-3-16-.07(b)

(a) Enter upon the permittee’s premises where a source is located or

emissions-related activity is conducted, or where records must be kept

pursuant to the conditions of this permit;

(b) Review and/or copy, at reasonable times, any records that must be kept

pursuant to the conditions of this permit;

(c) Inspect, at reasonable times, this facility’s equipment (including

monitoring equipment and air pollution control equipment), practices,

or operations regulated or required pursuant to this permit;

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(d) Sample or monitor, at reasonable times, substances or parameters for

the purpose of assuring compliance with this permit or other applicable

requirements.

11. Compliance Provisions

(a) The permittee shall continue to comply with the applicable

requirements with which the company has certified that it is already in

compliance.

Rule 335-3-16-.07(c)

(b) The permittee shall comply in a timely manner with applicable

requirements that become effective during the term of this permit.

12. Compliance Certification

On, or before, March 1, a compliance certification shall be submitted. Rule 335-3-16-.07(e)

(a) The compliance certification shall include the following:

(1) The identification of each term or condition of this permit that

is the basis of the certification;

(2) The compliance status;

(3) The method(s) used for determining the compliance status of

the source, currently and over the reporting period consistent

with Rule 335-3-16-.05(c) (Monitoring and Recordkeeping

Requirements);

(4) Whether compliance has been continuous or intermittent;

(5) Such other facts as the Department may require to determine

the compliance status of the source;

(b) The compliance certification shall be submitted to:

Alabama Department of Environmental Management

Air Division

P.O. Box 301463

Montgomery, AL 36130-1463

and to:

Director, Air Enforcement and Toxics Branch

EPA Region 4

61 Forsyth Street, SW

Atlanta, GA 30303

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13. Reopening for Cause

Under any of the following circumstances, this permit will be reopened prior to

the expiration of the permit:

Rule 335-3-16-.13(5)

(a) Additional applicable requirements under the Clean Air Act of 1990

become applicable to the permittee with a remaining permit term of

three (3) or more years. Such a reopening shall be completed not later

than eighteen (18) months after promulgation of the applicable

requirement. No such reopening is required if the effective date of the

requirement is later than the date on which this permit is due to expire.

(b) Additional requirements (including excess emissions requirements)

become applicable to an affected source under the acid rain program.

Upon approval by the Administrator, excess emissions offset plans shall

be deemed to be incorporated into this permit.

(c) The Department or EPA determines that this permit contains a material

mistake or that inaccurate statements were made in establishing the

emissions standards or other terms or conditions of this permit.

(d) The Administrator or the Department determines that this permit must

be revised or revoked to assure compliance with the applicable

requirements.

14. Additional Rules and Regulations

This permit is issued on the basis of Rules and Regulations existing on the date

of issuance. In the event additional Rules and Regulations are adopted, it shall

be the permit holder’s responsibility to comply with such rules.

§22-28-16(d), Code of

Alabama 1975, as

amended

15. Equipment Maintenance or Breakdown

(a) In the case of shutdown of air pollution control equipment (which

operates pursuant to any permit issued by the Director) for necessary

scheduled maintenance, the intent to shut down such equipment shall

be reported to the Director at least twenty-four (24) hours prior to the

planned shutdown, unless such shutdown is accompanied by the

shutdown of the source which such equipment is intended to control.

Such prior notice shall include, but is not limited to the following:

Rule 335-3-1-.07(1), (2)

(1) Identification of the specific facility to be taken out of service as

well as its location and permit number;

5



(2) The expected length of time that the air pollution control

equipment will be out of service;

(3) The nature and quantity of emissions of air contaminants likely

to occur during the shutdown period;

(4) Measures such as the use of off-shift labor and equipment that

will be taken to minimize the length of the shutdown period;

(5) The reasons that it would be impossible or impractical to shut

down the source operation during the maintenance period.

(b) In the event that there is a breakdown of equipment or upset of process

in such a manner as to cause, or is expected to cause, increased

emissions of air contaminants which are above an applicable standard,

the person responsible for such equipment shall notify the Director

within 24 hours or the next working day and provide a statement giving

all pertinent facts, including the estimated duration of the breakdown.

The Director shall be notified when the breakdown has been corrected.

16. Operation of Capture and Control Devices

All air pollution control devices and capture systems for which this permit is

issued shall be maintained and operated at all times in a manner so as to

minimize the emissions of air contaminants. Procedures for ensuring that the

above equipment is properly operated and maintained so as to minimize the

emission of air contaminants shall be established.

§22-28-16(d), Code of

Alabama 1975, as

amended

17. Obnoxious Odors

This permit is issued with the condition that, should obnoxious odors arising

from the plant operations be verified by Air Division inspectors, measures to

abate the odorous emissions shall be taken upon a determination by the

Alabama Department of Environmental Management that these measures are

technically and economically feasible.

Rule 335-3-1-.08

18. Fugitive Dust

(a) Precautions shall be taken to prevent fugitive dust emanating from

plant roads, grounds, stockpiles, screens, dryers, hoppers, ductwork,

etc.

Rule 335-3-4-.02

(b) Plant or haul roads and grounds will be maintained in the following

manner so that dust will not become airborne. A minimum of one, or a

combination, of the following methods shall be utilized to minimize

airborne dust from plant or haul roads and grounds:

6



(1) By the application of water any time the surface of the road is

sufficiently dry to allow the creation of dust emissions by the

act of wind or vehicular traffic;

(2) By reducing the speed of vehicular traffic to a point below that

at which dust emissions are created;

(3) By paving;

(4) By the application of binders to the road surface at any time the

road surface is found to allow the creation of dust emissions;

Should one, or a combination, of the above methods fail to adequately reduce

airborne dust from plant or haul roads and grounds, alternative methods shall

be employed, either exclusively or in combination with one or all of the above

control techniques, so that dust will not become airborne. Alternative methods

shall be approved by the Department prior to utilization.

19. Additions and Revisions

Any modifications to this source shall comply with the modification procedures

in Rules 335-3-16-.13 or 335-3-16-.14.

Rule 335-3-16-.13 and .14

20. Recordkeeping Requirements

(a) Records of required monitoring information of the source shall include

the following:

Rule 335-3-16-.05(c)(2).

(1) The date, place, and time of all sampling or measurements;

(2) The date analyses were performed;

(3) The company or entity that performed the analyses;

(4) The analytical techniques or methods used;

(5) The results of all analyses; and

(6) The operating conditions that existed at the time of sampling or

measurement.

(b) Retention of records of all required monitoring data and support

information of the source is required for a period of at least 5 years from

the date of the monitoring sample, measurement, report, or

application. Support information includes all calibration and

maintenance records and all original strip-chart recordings for

7



continuous monitoring instrumentation and copies of all reports

required by the permit

21. Reporting Requirements

(a) Reports to the Department of any required monitoring shall be

submitted at least every 6 months. All instances of deviations from

permit requirements must be clearly identified in said reports. All

required reports must be certified by a responsible official consistent

with Rule 335-3-16-.04(9).

Rule 335-3-16-.05(c)(3).

(b) Deviations from permit requirements shall be reported within 48 hours

or 2 working days of such deviations, including those attributable to

upset conditions as defined in the permit. The report will include the

probable cause of said deviations, and any corrective actions or

preventive measures that were taken.

22. Emission Testing Requirements

Each point of emission which requires testing will be provided with sampling

ports, ladders, platforms, and other safety equipment to facilitate testing

performed in accordance with procedures established by Part 60, of Title 40 of

the Code of Federal Regulations, as the same may be amended or revised.

Rule 335-3-1-.05(3) and

Rule 335-3-1-.04(1)

The Air Division must be notified in writing at least 10 days in advance of all

emission tests to be conducted and submitted as proof of compliance with the

Department’s air pollution control rules and regulations.

To avoid problems concerning testing methods and procedures, the following

shall be included with the notification letter:

(1) The date the test crew is expected to arrive, the date and time

anticipated of the start of the first run, how many and which sources are

to be tested, and the names of the persons and/or testing company that

will conduct the tests.

Rule 335-3-1-.04

(2) A complete description of each sampling train to be used, including type

of media used in determining gas stream components, type of probe

lining, type of filter media, and probe cleaning method and solvent to

be used (if test procedures require probe cleaning).

(3) A description of the process(es) to be tested including the feed rate, any

operating parameters used to control or influence the operations, and

the rated capacity.

8



(4) A sketch or sketches showing sampling point locations and their relative

positions to the nearest upstream and downstream gas flow

disturbances.

A pretest meeting may be held at the request of the source owner or the Air

Division. The necessity for such a meeting and the required attendees will be

determined on a case-by-case basis.

All test reports must be submitted to the Air Division within 30 days of the actual

completion of the test unless an extension of time is specifically approved by

the Air Division.

Rule 335-3-1-.04

23. Payment of Emission Fees

Annual emission fees shall be remitted each year according to the fee schedule

in ADEM Admin. Code r. 335-1-7-.04.

Rule 335-1-7-.04

24. Other Reporting and Testing Requirements

Submission of other reports regarding monitoring records, fuel analyses,

operating rates, and equipment malfunctions may be required as authorized in

the Department's air pollution control rules and regulations. The Department

may require emission testing at any time.

Rule 335-3-1-.04(1)

25. Title VI Requirements (Refrigerants)

Any facility having appliances or refrigeration equipment, including air

conditioning equipment, which use Class I or Class II ozone-depleting substances

as listed in 40 CFR Part 82, Subpart A, Appendices A and B, shall service, repair,

and maintain such equipment according to the work practices, personnel

certification requirements, and certified recycling and recovery equipment

specified in 40 CFR Part 82, Subpart F.

No person shall knowingly vent or otherwise release any Class I or Class II

substance into the environment during the repair, servicing, maintenance, or

disposal of any device except as provided in 40 CFR Part 82, Subpart F.

The responsible official shall comply with all reporting and recordkeeping

requirements of 40 CFR §82.166. Reports shall be submitted to the US EPA and

the Department as required.

40 CFR Part 82

26. Chemical Accidental Prevention Provisions

If a chemical listed in Table 1 of 40 CFR §68.130 is present in a process in

quantities greater than the threshold quantity listed in Table 1, then:

40 CFR Part 68

9



(a) The owner or operator shall comply with the provisions in 40 CFR Part

68.

(b) The owner or operator shall submit one of the following:

(1) A compliance schedule for meeting the requirements of 40 CFR

Part 68 by the date provided in 40 CFR §68.10(a) or,

(2) A certification statement that the source is in compliance with

all requirements of 40 CFR Part 68, including the registration

and submission of the Risk Management Plan.

27. Display of Permit

This permit shall be kept under file or on display at all times at the site where

the facility for which the permit is issued is located and will be made readily

available for inspection by any or all persons who may request to see it.

Rule 335-3-14-.01(1)(d)

28. Circumvention

No person shall cause or permit the installation or use of any device or any

means which, without resulting in reduction in the total amount of air

contaminant emitted, conceals or dilutes any emission of air contaminant which

would otherwise violate the Division 3 rules and regulations.

Rule 335-3-1-.10

29. Visible Emissions

Unless otherwise specified in the Unit Specific provisos of this permit, any

source of particulate emissions shall not discharge more than one 6-minute

average opacity greater than 20% in any 60-minute period. At no time shall any

source discharge a 6-minute average opacity of particulate emissions greater

than 40%. Opacity will be determined by 40 CFR Part 60, Appendix A, Method

9, unless otherwise specified in the Unit Specific provisos of this permit.

Rule 335-3-4-.01(1)

30. Fuel-Burning Equipment

(a) Unless otherwise specified in the Unit Specific provisos of this permit,

no fuel-burning equipment may discharge particulate emissions in

excess of the emissions specified in Part 335-3-4-.03.

(b) Unless otherwise specified in the Unit Specific provisos of this permit,

no fuel-burning equipment may discharge sulfur dioxide emissions in

excess of the emissions specified in Part 335-3-5-.01.

Rule 335-3-4-.03

Rule 335-3-5-.01

10



31. Process Industries – General

Unless otherwise specified in the Unit Specific provisos of this permit, no

process may discharge particulate emissions in excess of the emissions specified

in Part 335-3-4-.04.

Rule 335-3-4-.04

32. Averaging Time for Emission Limits

Unless otherwise specified in the permit, the averaging time for the emission

limits listed in this permit shall be the nominal time required by the specific test

method.

Rule 335-3-1-.05

33. Compliance Assurance Monitoring (CAM)

Conditions (a) through (d) that follow are general conditions applicable to

emissions units that are subject to the CAM requirements. Specific

requirements related to each emissions unit are contained in the unit specific

provisos and the attached CAM appendices.

(a) Operation of Approved Monitoring 40 CFR 64.7

(1) Commencement of operation. The owner or operator shall

conduct the monitoring required under this section and

detailed in the unit specific provisos and CAM appendix of this

permit (if required) upon issuance of the permit, or by such later

date specified in the permit pursuant to §64.6(d).

(2) Proper maintenance. At all times, the owner or operator shall

maintain the monitoring, including but not limited to,

maintaining necessary parts for routine repairs of the

monitoring equipment.

(3) Continued operation. Except for, as applicable, monitoring

malfunctions, associated repairs, and required quality

assurance or control activities (including, as applicable,

calibration checks and required zero and span adjustments), the

owner or operator shall conduct all monitoring in continuous

operation (or shall collect data at all required intervals) at all

times that the pollutant-specific emissions unit is operating.

Data recorded during monitoring malfunctions, associated

repairs, and required quality assurance or control activities shall

not be used for purposes of this part, including data averages

and calculations, or fulfilling a minimum data availability

requirement, if applicable. The owner or operator shall use all

the data collected during all other periods in assessing the

operation of the control device and associated control system.

A monitoring malfunction is any sudden, infrequent, not

11



reasonably preventable failure of the monitoring to provide

valid data. Monitoring failures that are caused in part by poor

maintenance or careless operation are not malfunctions.

(4) Response to excursions or exceedances. (a) Upon detecting an

excursion or exceedance, the owner or operator shall restore

operation of the pollutant-specific emissions unit (including the

control device and associated capture system) to its normal or

usual manner of operation as expeditiously as practicable in

accordance with good air pollution control practices for

minimizing emissions. The response shall include minimizing the

period of any startup, shutdown or malfunction and taking any

necessary corrective actions to restore normal operation and

prevent the likely recurrence of the cause of an excursion or

exceedance (other than those caused by excused startup or

shutdown conditions). Such actions may include initial

inspection and evaluation, recording that operations returned

to normal without operator action (such as through response by

a computerized distribution control system), or any necessary

follow-up actions to return operation to within the indicator

range, designated condition, or below the applicable emission

limitation or standard, as applicable. (b) Determination of

whether the owner or operator has used acceptable

procedures in response to an excursion or exceedance will be

based on information available, which may include but is not

limited to, monitoring results, review of operation and

maintenance procedures and records, and inspection of the

control device, associated capture system, and the process.

(5) Documentation of need for improved monitoring. After

approval of monitoring under this part, if the owner or operator

identifies a failure to achieve compliance with an emission

limitation or standard for which the approved monitoring did

not provide an indication of an excursion or exceedance while

providing valid data, or the results of compliance or

performance testing document a need to modify the existing

indicator ranges or designated conditions, the owner or

operator shall promptly notify the Department and, if

necessary, submit a proposed modification to the permit to

address the necessary monitoring changes. Such a modification

may include, but is not limited to, reestablishing indicator

ranges or designated conditions, modifying the frequency of

conducting monitoring and collecting data, or the monitoring of

additional parameters.

(b) Quality Improvement Plan (QIP) Requirements 40 CFR 64.8

12



(1) Based on the results of a determination made under Section

33(a)(4)(b) above, the Administrator or the permitting authority

may require the owner or operator to develop and implement

a QIP. Consistent with 40 CFR §64.6(c)(3), the permit may

specify an appropriate threshold, such as an accumulation of

exceedances or excursions exceeding 5 percent duration of a

pollutant-specific emissions unit's operating time for a

reporting period, for requiring the implementation of a QIP. The

threshold may be set at a higher or lower percent or may rely

on other criteria for purposes of indicating whether a pollutant-

specific emissions unit is being maintained and operated in a

manner consistent with good air pollution control practices.

(2) Elements of a QIP:

A. The owner or operator shall maintain a written QIP, if

required, and have it available for inspection.

B. The plan initially shall include procedures for evaluating

the control performance problems and, based on the

results of the evaluation procedures, the owner or

operator shall modify the plan to include procedures for

conducting one or more of the following actions, as

appropriate:

(i) Improved preventive maintenance practices.

(ii) Process operation changes.

(iii) Appropriate improvements to control

methods.

(iv) Other steps appropriate to correct control

performance.

(v) More frequent or improved monitoring (only in

conjunction with one or more steps under

paragraphs (2)(b)(i) through (iv) above).

(3) If a QIP is required, the owner or operator shall develop and

implement a QIP as expeditiously as practicable and shall notify

the Department if the period for completing the improvements

contained in the QIP exceeds 180 days from the date on which

the need to implement the QIP was determined.

(4) Following implementation of a QIP, upon any subsequent

determination pursuant to Section 33(a)(4)(b) above, the

13



Department may require that an owner or operator make

reasonable changes to the QIP if the QIP is found to have:

A. Failed to address the cause of the control device

performance problems; or

B. Failed to provide adequate procedures for correcting

control device performance problems as expeditiously

as practicable in accordance with good air pollution

control practices for minimizing emissions.

(5) Implementation of a QIP shall not excuse the owner or

operator of a source from compliance with any existing

emission limitation or standard, or any existing monitoring,

testing, reporting or recordkeeping requirement that may

apply under federal, state, or local law, or any other applicable

requirements under the Act.

(c) Reporting and Recordkeeping Requirements 40 CFR 64.9

(1) General reporting requirements

A. On and after the date specified in Section 33(a)(1)

above by which the owner or operator must use

monitoring that meets the requirements of this part,

the owner or operator shall submit monitoring reports

to the permitting authority in accordance with ADEM

Admin. Code r. 335-3-16-.05(c)(3.)

B. A report for monitoring under this part shall include, at

a minimum, the information required under ADEM

Admin. Code r. 335-3-16-.05(c)(3). and the following

information, as applicable:

(i) Summary information on the number, duration

and cause (including unknown cause, if

applicable) of excursions or exceedances, as

applicable, and the corrective actions taken;

(ii) Summary information on the number, duration

and cause (including unknown cause, if

applicable) for monitor downtime incidents

(other than downtime associated with zero and

span or other daily calibration checks, if

applicable); and

14



(iii) A description of the actions taken to implement

a QIP during the reporting period as specified in

Section 33(b) above. Upon completion of a QIP,

the owner or operator shall include in the next

summary report documentation that the

implementation of the plan has been

completed and reduced the likelihood of similar

levels of excursions or exceedances occurring.

(2) General recordkeeping requirements

A. The owner or operator shall comply with the

recordkeeping requirements specified in ADEM Admin.

Code r. 335-3-16-.05(c)(2). The owner or operator shall

maintain records of monitoring data, monitor

performance data, corrective actions taken, any written

quality improvement plan required pursuant to Section

33(b) above and any activities undertaken to

implement a quality improvement plan, and other

supporting information required to be maintained

under this part (such as data used to document the

adequacy of monitoring, or records of monitoring

maintenance or corrective actions).

B. Instead of paper records, the owner or operator may

maintain records on alternative media, such as

microfilm, computer files, magnetic tape disks, or

microfiche, provided that the use of such alternative

media allows for expeditious inspection and review,

and does not conflict with other applicable

recordkeeping requirements.

(d) Savings Provisions 40 CFR 64.10

(1) Nothing in this part shall:

A. Excuse the owner or operator of a source from

compliance with any existing emission limitation or

standard, or any existing monitoring, testing, reporting

or recordkeeping requirement that may apply under

federal, state, or local law, or any other applicable

requirements under the Act. The requirements of this

part shall not be used to justify the approval of

monitoring less stringent than the monitoring which is

required under separate legal authority and are not

intended to establish minimum requirements for the

purpose of determining the monitoring to be imposed

15



under separate authority under the Act, including

monitoring in permits issued pursuant to title I of the

Act. The purpose of this part is to require, as part of the

issuance of a permit under title V of the Act, improved

or new monitoring at those emissions units where

monitoring requirements do not exist or are inadequate

to meet the requirements of this part.

B. Restrict or abrogate the authority of the Department to

impose additional or more stringent monitoring,

recordkeeping, testing, or reporting requirements on

any owner or operator of a source under any provision

of the Act, including but not limited to sections

114(a)(1) and 504(b), or state law, as applicable.

C. Restrict or abrogate the authority of the Department to

take any enforcement action under the Act for any

violation of an applicable requirement or of any person

to take action under section 304 of the Act.

34. Permit Shield Rule 335-3-16-.10

A permit shield exists under this operating permit in accordance with ADEM

Admin. Code 335-3-16-.10 in that compliance with the conditions of this permit

shall be deemed in compliance with any applicable requirements as of the date

of permit issuance. The permit shield is based on the accuracy of the

information supplied in the application for this permit. Under this shield, it has

been determined that requirements listed as non-applicable in the application

are not applicable to this source.

16

[THIS PAGE LEFT BLANK INTENTIONALLY]

17

Summary Page for Pre-Black Warrior Expansion Units: Process Heaters &

Boilers

Permitted Operating Schedule†: 24 Hours/Day x 365 Days/Year = 8,760 Hours/Year †Except during leap year, Permitted Operating Schedule= 8,784 Hours/Year

Emission Limitations:

EMISSION

POINT DESCRIPTION POLLUTANT

EMISSION

LIMIT * REGULATIONS

APPLIES TO EACH PROCESS HEATER LISTED BELOW: SO2 LIMITED BY FUEL GAS CONTENT:

When burning fuel gas:

H2S <= 162 ppmv

(3-hour averaging period)

OR

When burning fuel oil:

S <= 0.05 Wt%

§60.104(a)(1)

[NSPS J]

Rule 335-3-16-.05(a)

APPLIES TO EACH PROCESS HEATER, EXCEPT UNIT NO.:

T-14, T-33, T-50, AND REFORMER HEATERS: HS-

2401A, B, AND C

HAPs

Work Practice Standard §63.7485, §63.7490(a)(1),

(d), §63.7500(a)(1), (e),

[Boiler MACT]

APPLIES TO EACH PROCESS HEATER LISTED BELOW: Opacity No more than one 6 min avg. >

20%

AND

No 6 min avg. > 40% in any sixty

(60) minute period

Rule 335-3-4-.01(1)(a)

Rule 335-3-4-.01(1)(b)

CRUDE UNIT:

H-501X 155.50 MMBTU/Hour

Atmospheric Tower Charge

Heater—with:

NOX CEMS

&

NEXT GENERATION ULTRA LOW-NOX

BURNERS (NGULNB)

PM10 23.30 Lb/Hour Rule 335-3-4-.03(1)

NOX 0.03 Lb/MMBTU (HHV) @ 0%

excess air

(365 day Rolling Average)

Rule 335-3-16-.05(a)

H-501 26.0 MMBTU/Hour Vacuum

Tower Charge Heater with a

maximum firing rate of 26.0

MMBtu/hr

PM10 8.6 Lb/Hour Rule 335-3-4-.03(1)

NOX 0.15 Lb/MMBTU (HHV) Rule 335-3-16-.05(a)

H-503 32.55 MMBTU/Hour Naphtha

Fractionator Reboiler Heater

PM10 9.70 Lb/Hour Rule 335-3-4-.03(1)

ASPHALT OXIDATION UNIT:

T-14 4.7 MMBTU/Hour Asphalt

Blowing Still Burner

PM10 2.35 Lb/Hour Rule 335-3-4-.03(1)



PM10 1.00 Lb/Hour Rule 335-3-4-.03(1)

18

EMISSION


EMISSION

LIMIT * REGULATIONS



PM10 2.35 Lb/Hour Rule 335-3-4-.03(1)

AX 15.33 MMBTU/Hour General

Asphalt Process Heater

PM10 6.36 Lb/Hour Rule 335-3-4-.03(1)

DISTILLATE/NAPHTHA HYDROTREATING UNIT:

H-H1 12.76 MMBTU/Hour Naphtha

Unifier Charge Heater

PM10 5.74 Lb/Hour Rule 335-3-4-.03(1)

H-H2 11.37 MMBTU/Hour Naphtha

Unifier Stripper Reboiler

Heater

PM10 5.38 Lb/Hour Rule 335-3-4-.03(1)

STODDARD UNIT:

HRC-039 8.73 MMBTU/Hour Stoddard

Tower Reboiler Heater

PM10 4.37 Lb/Hour Rule 335-3-4-.03(1)

KEROSENE HYDROTREATING UNIT:

P-H1 6.87 MMBTU/Hour Kerosene/

Naphtha Unifier Charge Heater

PM10 3.44 Lb/Hour Rule 335-3-4-.03(1)

P-H2 5.53 MMBTU/Hour Kerosene/

Naphtha Unifier Reboiler

Heater

PM10 2.77 Lb/Hour Rule 335-3-4-.03(1)

NO. 1 PLATFORMER:

H-502 28.1 MMBTU/Hour Platformer

Charge Heater

PM10 8.93 Lb/Hour Rule 335-3-4-.03(1)

P-H3B 8.79 MMBTU/Hour Platformer

No. 1 Interheater

PM10 4.40 Lb/Hour Rule 335-3-4-.03(1)

P-H3C 2.48 MMBTU/Hour Platformer

No. 2 Interheater

PM10 1.24 Lb/Hour Rule 335-3-4-.03(1)

UTILITY BOILERS:

B-01 37.14 MMBTU/Hour No. 1

Boiler

PM10 10.40 Lb/Hour Rule 335-3-4-.03(1)


Boiler

PM10 10.40 Lb/Hour Rule 335-3-4-.03(1)


Boiler

PM10 10.40 Lb/Hour Rule 335-3-4-.03(1)

B-04 74.0 MMBTU/Hour No. 4 Boiler PM10 15.40 Lb/Hour Rule 335-3-4-.03(1)

NOX 0.11 Lb/MMBTU (HHV) Rule 335-3-16-.05(a)

B-06 99.9 MMBTU/Hour No. 6 Boiler PM10 18.20 Lb/Hour Rule 335-3-4-.03(1)

NOX 11.4 Lb/Hour Rule 335-3-14-.04

[Anti-PSD Limit]

19

EMISSION


EMISSION

LIMIT * REGULATIONS

COKE PULVERIZING UNIT:

FRN-22970 9.50 MMBTU/Hour Pulverizer

Dryer Heater

PM10 4.87 Lb/Hour Rule 335-3-4-.03(1)

NOX 3.14 Lb/Hour Rule 335-3-14-.04

[Anti-PSD Limit]

NAPHTHA HYDROBON UNIT:

HS-601 16.5 MMBTU/Hour Naphtha

Hydrobon Charge Heater

PM10 6.63 Lb/Hour Rule 335-3-4-.03(1)


Hydrobon Stripper Reboiler

Heater

PM10 6.03 Lb/Hour Rule 335-3-4-.03(1)

FLEXIBLE HYDROTREATER UNIT [FEEDRATE LIMITED TO 8,400 BBL/DAY (RULE 335-3-14-.04) [ANTI-PSD LIMIT]]


Hydrotreater Charge Heater

PM10 9.11 Lb/Hour Rule 335-3-4-.03(1)


Hydrotreater Reboiler Heater

PM10 6.19 Lb/Hour Rule 335-3-4-.03(1)

HYDROGEN PLANT NO. 1

THREE (3) REFORMER HEATERS W/COMMON STACK

HS-2401A

HS-2401B

HS-2401C

42.06 MMBTU/Hour Hydrogen

Plant Reformer A

PM10

NOX

20.1 Lb/Hour

4.42 Lb/Hour

Rule 335-3-4-.03(1)

Rule 335-3-14-.04

[Anti-PSD Limit] 42.06 MMBTU/Hour Hydrogen

Plant Reformer B

42.06 MMBTU/Hour Hydrogen

Plant Reformer C

ISOMERIZATION UNIT:

HS-104 12.9 MMBTU/Hour Stabilizer

Reboiler Heater

PM10 5.78 Lb/Hour Rule 335-3-4-.03(1)

DIESEL HYDROTREATING UNIT [DHT] [TOTAL FIRING RATE LIMITED TO 34.9 MMBTU/HR OVER 12 MONTH PERIOD [ANTI-PSD LIMIT]

TWO (2) HEATERS W/COMMON STACK

H-700

H-701

26.17 MMBTU/Hour DHT

Charge Heater

PM10

NOX

10.1 Lb/Hour

7.8 Lb/Hour

Rule 335-3-4-.03(1)

Rule 335-3-14-.04

[Anti-PSD Limit] 38.83 MMBTU/Hour DHT

Fractionator Reboiler Heater

20

EMISSION


EMISSION

LIMIT * REGULATIONS

33,500 BBL/DAY DELAYED COKING UNIT [BA-602M FIRING RATE LIMITED TO 65.0 MMBTU/HR OVER 12 MONTH PERIOD

[PSD/BACT LIMIT]

TWO (2) COKER HEATERS W/COMMON STACK AND NGULNB

BA-601M

BA-602M

57.0 MMBTU/Hour Coker Drum

Charge Heater

PM10

NOX

SO2

18.8 Lb/Hour

0.025 Lb/MMBTU (HHV)

LIMITED BY FUEL GAS CONTENT:


H2S <= 162 ppmv based on a

three-hour rolling average

AND

H2S <= 59 ppmv based on a 365

consecutive day rolling average

Rule 335-3-4-.03(1)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

§60.104(a)(1)

[NSPS J]

Rule 335-3-14-.04

[Anti-PSD Limit]

65.0 MMBTU/Hour Coker

Drum Charge Heater

Opacity No more than one 6 min avg. >

10%

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

*Limits for each heater except as specified

21

Provisos for Pre-Black Warrior Expansion Units: Process Heaters & Boilers


Applicability

Each process heater and boiler on the summary page of this subpart shall

be subject to the applicable requirements of ADEM Admin. Code r. 335-3-

4-.01, “Visible Emissions”, and the requirements specified in this subpart

of this permit, except as specified.

Rule 335-3-4-.01


be subject to the requirements of ADEM Admin. Code r. 335-3-4-.03, “Fuel

Burning Equipment” for Control of Particulate Emissions and the

requirements specified in this subpart of this permit.

Rule 335-3-4-.03(1)(a)

The Flexible Hydrotreater Unit, process heater Nos.: HS-2041A, HS-2041B,

HS-2041C, H-700, H-701, FRN-22970, BA-601M, BA-602M and boiler No.

B-06 each have limits in place in order to avoid a review under ADEM

Admin. Code r. 335-3-14-.04, “Air Permits Authorizing Construction in

Clean Air Areas [Prevention of Significant Deterioration (PSD)]”, and are

subject to the requirements specified in this subpart of this permit.

Rule 335-3-14-.04

[Anti-PSD Limit]

Process heaters: BA-601M and BA-602M have best available control

technology (BACT) limits in place to comply with the requirements

specified in ADEM Admin. Code r. 335-3-14, “Prevention of Significant

Deterioration (PSD)”, and the requirements specified in this subpart of

this permit.

Rule 335-3-14-.04(8)(a) &

(b)

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

Each boiler and process heater on the summary page of this subpart shall

be subject to the requirements specified in ADEM Admin. Code r. 335-3-

16-.03, “Major Source Operating Permits”, and the requirements specified

in this subpart of this permit.

Rule 335-3-16-.03

Boiler No. B-06 shall be subject to the requirements specified in 40 CFR

Part 60, Subpart A, “General Provisions”, 40 CFR 60 Subpart Dc, “Standards

of Performance for Small Industrial-Commercial-Institutional Steam

Generating Units”, and the requirements specified in this subpart of this

permit.

Rule 335-10-.02(2)(c)

§60.40c(a), (h)


be subject to the requirements specified in 40 CFR Part 60, Subpart A,

“General Provisions”, 40 CFR Part 60, Subpart J, “Standards of

Performance for Petroleum Refineries” [NSPS J], and the requirements

specified in this subpart of this permit.

40 CFR 60 Subpart A

40 CFR 60 Subpart J

Rule 335-3-16-.05(a)

Each boiler and process heater listed on the summary page of this

subpart, except units: T-14, T-33 and T-50 and reformer heaters: HS-

2401A, B, and C , shall be subject to the requirements specified in 40 CFR

Part 63, Subpart A “General Provisions”, 40 CFR 63 Subpart DDDDD,

“National Emission Standards for Hazardous Air Pollutants for Major

§63.7485,

§63.7490(a)(1),(d)

§63.7491(i)

§63.7499(p)

§63.7565

Table 10, Boiler MACT

22



Sources: Industrial, Commercial, and Institutional Boilers and Process

Heaters” [Boiler MACT] for existing sources, and the requirements


Emission Standards

Visible emissions from each process heater and boiler, except those

specified in proviso 1 (c) of this subpart, shall meet the opacity standards

specified in proviso 1(a) and (b) of this section of this subpart.

Rule 335-3-4-.01

Each process heater and boiler shall not discharge into the

atmosphere particulate that results in an opacity greater than

20%, as determined by a 6-minute average.

Rule 335-3-4-.01(1)(a)

Except for one 6-minute period during any 60-minute period,

each process heater and boiler shall not discharge into the

atmosphere particulate that results in an opacity greater than

40%.

Rule 335-3-4-.01(1)(b)

Process heaters: BA-601M and BA-602M shall not discharge into

the atmosphere particulate that results in an opacity greater than

10%, as determined by a 6-minute average, except for one 6-

minute period during any 60-consecutive minute period.

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

Rule 335-3-16-.05(a)

Particulate Matter (PM) emissions limits shall be met for the following

units:

Rule 335-3-4-.03(1)(a)

Rule 335-3-16-.05(a)

For process heater H-503, PM10 emissions shall be maintained at

less than, or equal to, 9.7 Lb/hr.

For process heater HS-201, PM10 emissions shall be maintained at




For process heaters T-14 and T-50, PM10 emissions for each heater

shall each be maintained at less than, or equal to, 2.35 Lb/hr.

For process heater T-33, PM10 emissions shall be maintained at


For process heater AX, PM10 emissions shall be maintained at less

than, or equal to, 6.36 Lb/hr.



23





For process heater H-H1, PM10 emissions shall be maintained at


For process heater H-H2, PM10 emissions shall be maintained at


For process heater HRC-039, PM10 emissions shall be maintained

at less than, or equal to, 4.37 Lb/hr.

For process heater P-H1, PM10 emissions shall be maintained at


For process heater P-H2, PM10 emissions shall be maintained at


For process heater H-502, PM10 emissions shall be maintained at


For process heater P-H3B, PM10 emissions shall be maintained at


For process heater P-H3C, PM10 emissions shall be maintained at


For boilers: B-01, B-02, and B-03, PM10 emissions for each boiler

shall each be maintained at less than, or equal to, 10.4 Lb/hr.



The total feed to the Flexible Hydrotreater Unit shall not exceed 8,400

BBL/Day.

Rule 335-3-14-.04

[Anti-PSD Limit]

Process heaters BA-601M and BA-602M shall be subject to the following

requirements:

(a) Each process heater shall not combust fuel gas that contains

hydrogen sulfide (H2S) in excess of:

162 parts per million volume (ppmv) as determined

hourly on a three-hour rolling average basis,

AND

Rule 335-3-16-.05(a)

§60.104(a)(1)

24



59 ppmv as determined daily on a 365 consecutive day

rolling average basis.

Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

The following emission limitations shall apply:

PM10 emissions from the common stack shall be

maintained at less than, or equal to, 18.8 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)

Nitrogen oxide (NOX) emissions from the common stack

shall be maintained at less than, or equal to, 0.025

Lb/MMBTU high heating value (HHV).

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

The firing rate for process heater BA-602M shall be

limited to 65.0 MMBTU/hr, as averaged over a 12-month

period.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

The following emission standards shall be met for the emission units listed

below:

For process heater H-501X:

PM10 emissions shall be maintained at less than, or equal

to, 23.30 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)

NOX emissions shall be maintained at less than, or equal

to, 0.03 Lb/MMBTU (HHV) at zero percent (0%) excess air

over a 365-day rolling average period.

Rule 335-3-16-.05(a)

Shall be equipped with a NOX continuous emissions

monitoring system (CEMS) and next generation ultra-low

NOX burners (NGULNB).

Rule 335-3-16-.05(a)

For process heater H-501:


to, 8.6 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)


to, 0.15 Lb/MMBTU (HHV).

Rule 335-3-16-.05(a)

This heater shall be operated and maintained such that

the maximum firing rate is 26.0 MMBTU/hr, as averaged

over a 12-month period.

Rule 335-3-16-.05(a)

25



For process heater FRN-22970:


to, 4.87 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)


to, 3.14 Lb/hr.

Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

For boiler B-04:


to, 15.4 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)


to, 0.11 Lb/MMBTU (HHV).

Rule 335-3-16-.05(a)

For boiler B-06:


to, 18.2 Lb/hr.

Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)


to, 11.4 Lb/hr.

Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

For the common stack for process heaters HS-2401A, HS-2401B,

& HS-2401C:



Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)

NOX emissions from the common stack shall be


Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

For the common stack for process heaters H-700 & H-701:



Rule 335-3-4-.03(1)

Rule 335-3-16-.05(a)

NOX emissions from the common stack shall be


Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

The total firing rate for process heaters H-700 and H-701

shall be limited to 34.9 MMBTU/hr, as averaged over a

12-month period.

Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(a)

26



The following fuel gas requirements shall be met:

Each boiler or process heater shall not combust fuel gas that

contains H2S in excess of 162 ppmv as determined hourly on a

three-hour rolling average basis.

§60.104(a)(1)

Rule 335-3-16-.05(a)

Fuel oil with a maximum sulfur (S) content of 0.05 weight percent

(wt%) may only be burned during periods of fuel gas curtailment

for boilers: B-01, B-02, B-03, and B-04.

Rule 335-3-16-.05(a)

Except as allowed in §63.7500(b), the following work practice standards

(WPS) shall be met in order for affected units to comply with the Boiler

MACT:

§63.7495(b)

§63.7500(b)

Each boiler and process heater must be designed to burn gas 1

fuel such as natural gas, refinery gas and/or other gas 1 fuels.

§63.7499(l), §63.7500(e)

§63.7575

A performance tune-up shall be completed on each boiler and

process heater as specified in §63.7540.

§63.7500(a),(e)

§63.7515(d), §63.7540

Table 3 Boiler MACT

Each boiler and process heater must be operated and maintained,

including associated air pollution control equipment and

monitoring equipment, in a manner consistent with safety and

good air pollution control practices for minimizing emissions.

§63.7500(a)(3)

Rule 335-3-16-.05(a)

The WPS must be met at all times that a boiler or process heater

is operating.

§63.7505(a)

Compliance and Performance Test Methods and Procedures

Compliance with the opacity standards shall be determined using Method

9 or Method 22 of 40 CFR part 60, Appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

Each boiler and/or process heater that is subject to performance testing

shall be tested in accordance with the following test methods and

procedures:

Rule 335-3-16-.05(c)(1)(i)

40 CFR Part 60, Appendix A-1, Method 1 or 1A to determine the

sampling site

Rule 335-3-1-.05

40 CFR Part 60, Appendix A-1, Method 2 or 2A or 2B or 2C or 2D

or 2E to determine the volumetric flow rate of the effluent gas

Rule 335-3-1-.05

40 CFR Part 60, Appendix A-2, Method 3 or 3A or 3B or 3C to

determine the gas analysis

Rule 335-3-1-.05

27



40 CFR Part 60, Appendix A-3, Method 4 to determine the

moisture in the stack gas

Rule 335-3-1-.05

40 CFR Part 60, Appendix A-4, Method 7 OR 7A OR 7B OR 7C OR

7D OR 7E to determine NOX emissions

Rule 335-3-1-.05

40 CFR Part 60, Appendix A-7, Method 19 to determine PM, sulfur

dioxide (SO2) and NOX emissions

Rule 335-3-1-.05

The NOX continuous emission monitoring system (CEMS) on process

heater H-501X must be maintained in accordance with the following

requirements:

40 CFR §60.13 (excluding continuous opacity monitoring systems)

40 CFR Part 60, Appendices A and F

Applicable performance specifications of 40 CFR Part 60,

Appendix B

Rule 335-3-16-.05(a)

The fuel gas system shall comply with the following test requirements:

Shall be analyzed for its BTU heat content by utilizing the ASTM

Analysis Method D1826-77 or equivalent method

[Fuel Gas Heat Content (BTU/scf)]

Rule 335-3-16-.05(c)(1)(ii)

The relative accuracy evaluations for the H2S monitor shall be

conducted using the following methods and procedures:

§60.106(e)(1)

Performance Specification 7 as specified in 40 CFR Part

60, Appendix B

§60.105(a)(4)(iii)

40 CFR Part 60, Appendix A, Method 11, 15, 15A or 16 as

specified in §60.106(e)(1)(i) through (iii)

§60.105(a)(4)(iii)

§60.106(e)(1)

Compliance with the Boiler MACT shall be demonstrated by conducting

tune-ups on each applicable process heater and boiler as specified in

§63.7540(a)(10)(i) through (vi) of the Boiler MACT.

§63.7540(a)(10)

Emission Monitoring

Provided that visible emissions in excess of the opacity standards occur

on a unit, a visible emissions observation must be conducted to determine

opacity or to determine presence of fugitive emissions from the unit.

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

28



The following requirements shall be met for performance testing

conducted on process heaters: H-700, H-701, BA-601M, BA-602M, H-501,

on the common stack for HS-2041A, B, C and on boilers: B-04 and B-06:

Rule 335-3-16-.05(c)(1)(i)

Rule 335-3-14-.04

[BACT & Anti-PSD Limits]

Test for NOX emissions once every five (5) years in accordance

with the Heating Units Subject to NOX Testing section found in

Appendix A of this permit.

A test shall consist of three runs of at least 1-hour in duration

each.

The results of performance tests shall be submitted to the

Department within 30 days of the test date.

The pollutant tested for may be modified upon receiving

Departmental approval.

Emission factors (EF) for each air pollutant shall be determined in

pounds per million BTU.

[Test EF (Lb/MMBTU)]

Process heater H-501X shall be equipped with a NOX CEMS. Rule 335-3-16-.05(a)

Rule 335-3-16-.05(c)(1)(ii)

The CEMS shall be monitored in accordance with the Heating

Units with NOX CEMS section found in Appendix A of this permit.

In lieu of the requirements of 40 CFR Part 60, Appendix F, §§5.1.1,

5.1.3, and 5.1.4, either a Relative Accuracy Audit (RAA) or a

Relative Accuracy Test Audit (RATA) must be conducted on the

CEMS at least once every three (3) years.

A cylinder gas audit (CGA) must be conducted each calendar

quarter during which a RAA or a RATA in not performed.

The Flexible Hydrotreater Unit feedrate limit and the firing rate limits for

H-700 & H-701, H-501, and BA-602M shall be demonstrated through

monthly calculations.

Rule 335-3-16-.05(c)(1)(ii)

Rule 335-3-14-.04


The fuel gas system must meet the following requirements:

A H2S fuel gas monitor that continuously monitors and records the

concentration (dry basis) of H2S in the fuel gas before being

burned in any fuel gas combustion devices shall be installed,

Rule 335-3-16-.05(c)(1)(ii)

§60.105(a)(4)

§60.13

29



calibrated, maintained and operated as specified in §60.105(a)(4)

[NSPS J] and §60.13 of Subpart A.

Relative accuracy evaluations must be conducted on the fuel gas

system CEMS used to determine the H2S concentration. A CGA

must be conducted each calendar quarter during which a RAA or

a RATA in not performed.

§60.13(a)

Rule 335-3-16-.05(a)

Process heaters and boilers with a common source of fuel gas may

be monitored at only one location if that location accurately

represents the H2S concentration of the fuel being burned.

§60.105(a)(4)(ii)

BTU heat content testing shall consist of capturing a

representative sample of the fuel gas stream at a frequency of no

less than once each month.


Rule 335-3-16-.05(c)(1)(ii)

The frequency of analysis may be modified upon receiving


Rule 335-3-16-.05(c)(1)(ii)

The following monitoring requirements shall be met to comply with the

WPS for affected sources designed to burn gas 1 fuels subcategory under

the Boiler MACT:

Each process heater and boiler with a heat input capacity greater

than or equal to 10 million Btu per hour (MMBTU/hr) must

complete a tune-up annually as specified in §63.7540(a)(10).

Subsequent tune-ups must occur no more than thirteen (13)

months after the previous tune-up.

§63.7510(e)

§63.7515(d)

§63.7540(a)(10)

Each process heater and boiler with a heat input capacity greater

than 5 MMBtu/hr and less than 10 MMBTU/hr must complete a

tune-up every two (2) years or biennially as specified in

§63.7540(a)(10). Subsequent tune-ups must occur no more than

twenty-five (25) months after the previous tune-up.

§63.7500(e)

§63.7510(e)

§63.7515(d)

§63.7540(a)(11)

Each process heater and boiler with a heat input capacity less

than or equal to 5 MMBTU/hr must complete a tune-up every five

(5) years as specified in §63.7540(a)(10). Subsequent tune-ups

must occur no more than sixty-one (61) months after the previous

tune-up.

§63.7500(e)

§63.7510(e)

§63.7515(d)

§63.7540(a)(12)

30



The following requirements must be met for each tune-up:

Each tune-up must be conducted while burning the type

of fuel that provided the majority of the heat input to the

unit over the 12 months prior to the tune-up.

§63.7540(a)(10)

Annual tune-ups do not apply to units with continuous

oxygen trim systems that maintain an optimum air to fuel

ratio.

§63.7540(a)(10)

For units with oxygen trim or less than 5 MMBtu/hr,

burner inspections may be delayed until the next

scheduled or unscheduled unit shutdown; however, you

must inspect each burner at least once every seventy-two

(72) months.

§63.7540(a)(12)

If an oxygen trim system is utilized on a unit without

emission standards to reduce the tune-up frequency to

once every five (5) years, set the oxygen level no lower

than the oxygen concentration measured during the most

recent tune-up.

§63.7540(a)(12)

If the unit is not operating on the required date for a tune-

up, the tune-up must be conducted within 30 calendar

days of startup.

§63.7540(a)(13)

Recordkeeping and Reporting Requirements

A record of the information specified in provisos 1(a) through (n) of this

section of this subpart shall be maintained and made available for

inspection. These records may be in electronic format provided they are

readily accessible.

The date, starting time and duration of each deviation from the

requirements specified in this subpart along with the cause and

corrective actions taken.

Rule 335-3-16-.05(c)(2)

§63.7560

The date, time, and results of each performance test along with

any other tests conducted on the boiler and/or process heater

that provides additional stack pollutant content data.

Rule 335-3-16-.05(c)(2)

Date and type of boiler or process heater maintenance that

affects air emissions shall be maintained.

Rule 335-3-16-.05(c)(2)

Fuel gas BTU heat content

[Heat Content (BTU/scf)]

Rule 335-3-16-.05(c)(2)

31



Fuel gas H2S content

[H2S Content (Mole %)]

Rule 335-3-16-.05(c)(2)

§60.48c(f)(4)

§60.105(a)(4)

Fuel gas consumption rate per unit

[Volume (Mscf/Month)]

Rule 335-3-16-.05(c)(2)

§60.48c(g)(2)

For all units, except asphalt burners: T-14, T-33, and T-50,

this consumption rate shall be recorded by a continuous

monitor on each unit.

For asphalt burners: T-14, T-33, and T-50, this

consumption rate shall be based on design specifications,

engineering calculations, and/or a continuous monitor.

MMBTU of fuel gas consumption per unit: Rule 335-3-16-.05(c)(2)

Unit Fuel Gas Heat Input (MMBTU/Month) =

[ Volume (Mscf/Month)] X [ Heat Content (BTU/scf) ]

{1,000}

A running total of hours per calendar year when a fuel other than

natural gas or other gas-1 fuel is burned in a process heater

and/or boiler shall be maintained.

§63.7555(h)

Operating hours per unit

[Unit Hours (Hours/Month)]

Rule 335-3-16-.05(c)(2)

Monthly NOX emissions shall be determined for process heater H-

501, process heater H-503, process heater AX, the combined stack

for process heaters H-700 & H-701, the combined stack for

process heaters HS-2401A, HS-2401B, & HS-2401C, the combined

stack for process heaters BA-601M & BA-602M, boiler B-04, and

boiler B-06 as follows:

Rule 335-3-16-.05(c)(2) &

Rule 335-3-14-.04


Unit Emissions (Lb/Month) =

[Unit Heat Input (MMBTU/Month)] X [Test EF (Lb/MMBTU)]

(i) For units subject to emissions testing, [Test

emission factors (Lb/MMBTU)] shall be taken

from the most recent performance test.

32



(ii) For all other units, [Test emission factors

(Lb/MMBTU)] shall be either AP-42 emissions

factors, or manufacturer’s emission factors.

Unit Emissions (Lb/Hour) =

[ Unit Emissions (Lb/Month) ]

[ Unit Hours (Hours/Month) ]

For the common stack for process heaters H-700 & H-701, H-501

and process heater BA-602M:

Rule 335-3-16-.05(c)(2)

Rule 335-3-14-.04


Process Unit Operating hours

[ Process Hours (Hours/Month) ]

Monthly Average Firing Rate [MMBTU/hr] =

[Unit Heat Input (MMBTU/Month)]

[Process Hours (Hours/Month)]

Total Annual Firing Rate [MMBTU/hr] =

Monthly Average Firing Rate [MMBTU/hr] +

∑ previous 11-months Average Firing Rate [MMBTU/hr]

Annual Average Firing Rate [MMBTU/hr] =

Total Annual Firing Rate [MMBTU/hr]

12-Months

For the Naphtha Hydrotreating [NH] Unit: Rule 335-3-16-.05(c)(2)

Rule 335-3-14-.04

[Anti-PSD Limit]

Naphtha Processed

[BBL/Month]

NH Operating Time

[Days/Month]

Daily Average Naphtha Processed [BBL/Day] =

Naphtha Processed [BBL/Month]

NH Operating Time [Days/Month]

Total Naphtha Processed [BBL/Day] =

Daily Average Naphtha Processed [BBL/Day] + ∑ previous 11-months Daily

Average Naphtha Processed [BBL/Day]

33



Total Average Naphtha Processed [BBL/Day] =

Total Naphtha Processed [BBL/Day]

12-Months

A copy of the NOX CEMS monitoring record for process heater H-

501X shall be maintained onsite in a form suitable for inspection.

Rule 335-3-16-.05(c)(2)

A record of each visible emission observation conducted on a unit. Rule 335-3-16-.05(c)(2)

To demonstrate compliance with NSPS J, the following reporting

requirements shall be met:

Rule 335-3-16-.05(c)(2)

An excess emissions report and/or summary report shall be

submitted semi-annually on the following reporting schedule:

Reporting Period Submittal Date

January 1-June 30 August 28

July 1 - December 31 February 28

§60.7(c), (d),

§60.19(d), (e)

The excess emission report shall include each rolling 3-hr period

during which the average H2S concentration in the fuel gas

(measured using the continuous H2S monitor) exceeds its

allowable.

§60.105(e)(3)(ii)

The information specified in §60.7(c) of Subpart A and §60.107(g)

of NSPS J shall be provided in each excess emissions report.

§60.105(e)

§60.107(g)

To demonstrate compliance with the Boiler MACT, the following


The following notifications shall be submitted: §63.7545

Notifications specified in §63.7545(a) of the Boiler MACT §63.7545(a)

Notification of alternative fuel usage during periods of

natural gas curtailment or supply interruption shall be

submitted within forty-eight (48) hours of the declaration

of such period

§63.7545(f)

The following records shall be maintained: §63.7555

A copy of each notification and report to comply with this

subpart according to §63.10(b)(2)(xiv) of Subpart A

§63.7555(a)(1)

Records of compliance demonstrations as required by

§63.10(b)(2)(viii) of Subpart A

§63.7555(a)(2)

34



If an alternative fuel is used in the boilers or process

heaters during periods of gas curtailment or gas supply

emergencies, the following records shall be maintained:

§63.7555(h)

(i) Record of the total hours per calendar year that

the alternative fuel is burned

(ii) Record of the total hours per calendar year that

the unit operated during periods of gas

curtailment or gas supply emergencies.

A record of burner inspection shall be maintained for

units with delayed tune-ups

§63.7550(c)(5)(xiv)

Records must be kept and maintained as specified in §63.7560 of the

Boiler MACT for a period of five years following each occurrence.

§63.7560

The following reporting requirements shall be met: §63.7550

An annual, biennial, or 5-year compliance report shall be

submitted as specified in §63.7550(b)(1) through (3) of

the Boiler MACT, except as allowed in §63.7550(b)(4) of

the Boiler MACT.

§63.7550(b)

§63.10(a)(7)

The compliance report must contain the information

specified in §63.7550(c)(1) of the Boiler MACT.

§63.7550(c)(1)

The reports must be submitted electronically to the EPA

via CEDRI, except as allowed, and a copy of the report

must be submitted to the Department for tracking

purposes.

§63.7550(h)(3)

A periodic monitoring report (PMR) meeting the requirements specified

in proviso 4(a) and (b) of this section of this subpart shall be submitted to

the Department.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(i)

Each report shall identify each incidence of deviation from a

permit term or condition including those that occur during

startups and shutdowns.

A deviation shall mean any condition determined by

observation, by data derived from any monitoring or

testing or recordkeeping which is required by the permit

that can be used to determine or indicate compliance,

that identifies an affected source has failed to meet an

applicable emission limit or standard, or that a work

practice was not complied with or completed.

35



If no deviation event occurred during the reporting

period, a statement that indicates there were no

deviations from the permit requirements shall be

included in the report.

Except as provided for in proviso 4(c) of this section, the report

shall include the information specified in proviso 4(b)(1) of this

section of this subpart.

For each deviation event, the following information shall

be submitted.

(i) Emission source description

(ii) Permit requirement

(iii) Date

(iv) Starting time

(v) Duration

(vi) Actual quantity of pollutant or parameter

(vii) Cause

(viii) Actions taken to return to normal operating

conditions

(ix) Total operating hours of the affected source

during the reporting period

(x) Total hours of deviation events during the

reporting period

(xi) Total hours of deviation events that occurred

during startups, shutdowns, and malfunctions


Each report shall cover a calendar semi-annual period and

shall be submitted according to the following reporting

schedule:


January 1- June 30 August 28


36



The report content specified in proviso 4(b) of this section may be

modified upon receipt of Departmental approval.

Each deviation from the requirements specified in this subpart, including

those that occur during startups, shutdowns, and malfunctions, shall be

reported to the Department in a manner that complies with proviso 15(b)

and 21(b) of the general proviso subpart of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

37

Summary Page for Post-Black Warrior Expansion Units: Process Heaters &

Boilers

Permitted Operating Schedule†: 24 Hours/Day x 365 Days/Year = 8,760 Hours/Year †Except during leap year, Permitted Operating Schedule = 8,784 Hours/Year


EMISSION


EMISSION

LIMIT/STANDARD REGULATIONS

APPLIES TO EACH PROCESS HEATER LISTED BELOW: SO2 LIMITED BY FUEL GAS

CONTENT:


H2S <= 162 ppmv

AND

H2S <= 59 ppmv based on

a 365-day consecutive

rolling avg.

40 CFR §60.102a(g)(1)

[NSPS Ja]

Rule 335-3-14-.04(9)

[Anti-PSD Limit]

APPLIES TO EACH PROCESS HEATER, EXCEPT REFORMER

HEATER, HP2-H-3600:

HAPs Work Practice Standard §63.7485, §63.7490(a)(2), (b),

§63.7500(a)(1), (e)

[Boiler MACT]

APPLIES TO EACH PROCESS HEATER LISTED BELOW: Opacity No more than one 6 min

avg. > 10%

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

33,500 BBL/DAY DELAYED COKING UNIT:

BA-603 198.0 MMBTU/Hour

Coker Pre-heater —with:

NOX CEMS

NGULNB

PM10 0.0075 Lb/MMBTU Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

NOX 0.025 Lb/MMBTU

@ 0% excess air

(30 Day Rolling Average)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

§60.102a(g)(2)

[NSPS Ja]

VOC 0.0054 Lb/MMBTU Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

22,200 BBL/DAY CONTINUOUS CATALYST REGENERATION [CCR] PLATFORMING UNIT:

Three (3) CCR Heaters w/ Common Stack, NOX CEMS, & NGULNB

CR-H-3801

CR-H-3802

CR-H-3803

69.3 MMBTU/Hour CCR

Platformer Charge Heater

78.2 MMBTU/Hour CCR

Interstage Heater No. 1

60.9 MMBTU/Hour CCR

Interstage Heater No. 2

PM10 0.0075 Lb/MMBTU Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

NOX 0.025 Lb/MMBTU (HHV)

@ 0% excess air


Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

§60.102a(g)(2)

[NSPS Ja]


[BACT/PSD Limit]

38

EMISSION


EMISSION


31.9 MMSCF/DAY HYDROGEN PLANT NO. 2:

HP2-H-3600 254.0 MMBTU/hr No. 2

Hydrogen Plant

Reformer—with:

NOX CEMS

NGULNB

PM10 0.0075 Lb/MMBTU Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]


@ 0% excess air


Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

40 CFR 60.102a(g)(2)

[NSPS Ja]


[BACT/PSD Limit]

30,000 BBL/DAY HYDROCRACKING UNIT:

Two (2) Hydrocracker Heaters w/ Common Stack, NOX CEMS, & NGULNB

HD-H-3401

HD-H-3402

60.28MMBtu/hr

Hydrocracker Reactor

Charge Heater

98.3 MMBtu/hr

Fractionator Feed Heater

PM10 0.0075 Lb/MMBTU Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]


@ 0% excess air


Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

40 CFR 60.102a(g)(2)

[NSPS Ja]


[BACT/PSD Limit]

RAILCAR LOADING OPERATIONS:

B-07 59.8 MMBtr/hr Steam

Boiler with continuous

oxygen trim system

PM10 13.64 Lb/Hour Rule 335-3-4-.03(1)

Opacity No more than one 6 min

avg. > 20%

AND

No 6 min avg. > 40% in

any sixty (60) minute

period

Rule 335-3-4-.01(1)(a)

Rule 335-3-4-.01(1)(b)

SO2 LIMITED BY FUEL GAS

CONTENT:


H2S <= 162 ppmv based

on a 3-hour rolling avg.

AND

H2S ≤ 60 ppmv on a 365-

day consecutive rolling

avg.

40 CFR §60.102a(g)(1)(ii)

[NSPS Ja]

HAPs Work Practice Standard §63.7500(a)(1), (e), [Boiler

MACT]

39

Provisos for Post-Black Warrior Expansion Units: Process Heaters & Boilers


Applicability

Boiler No. B-07 shall be subject to the requirements of ADEM Admin.

Code r. 335-3-4-.03, “Fuel Burning Equipment” for Control of

Particulate Emissions and the requirements specified in this subpart of

this permit.

Rule 335-3-4-.03(1)(a)

Each process heater on the summary page of this subpart is subject to

a fuel gas limit in order to avoid a review under ADEM Admin. Code r.

335-3-14-.04, “Air Permits Authorizing Construction in Clean Air Areas

[Prevention of Significant Deterioration (PSD)]", and are subject to the


Rule 335-3-14-.04

[Anti-PSD Limit]

Each process heater on the summary page of this subpart shall have

best available control technology (BACT) limits in place to comply with

the requirements specified in ADEM Admin. Code r. 335-3-14,

“Prevention of Significant Deterioration (PSD)”, and the requirements


Rule 335-3-14-.04(8)(a) & (b)

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

Each emission sources listed on the summary page of this subpart shall

be subject to the requirements specified in ADEM Admin. Code r. 335-

3-16-.03, “Major Source Operating Permits”, and the requirements


Rule 335-3-16-.03

Boiler No. B-07 shall be subject to the requirements specified in 40 CFR

Part 60, Subpart A, “General Provisions”, 40 CFR 60 Subpart Dc,

“Standards of Performance for Small Industrial-Commercial-

Institutional Steam Generating Units”, and the requirements specified


Rule 335-10-.02(2)(c)

§60.40c(a), (h)

Each emission source listed on the summary page of this subpart shall

be subject to the requirements specified in 40 CFR Part 60, Subpart A,

“General Provisions”, 40 CFR Part 60, Subpart Ja “Standards of

Performance for Petroleum Refineries” [NSPS Ja], and the


§60.100a(a)

§60.40c(h)

Each emission source listed on the summary page of this subpart,

except process heater HP2-H-3600, shall be subject to the

requirements specified in 40 CFR Part 63, Subpart A “General

Provisions”, 40 CFR 63 Subpart DDDDD, “National Emission Standards

for Hazardous Air Pollutants for Major Sources: Industrial, Commercial,

and Institutional Boilers and Process Heaters” [Boiler MACT], for new

sources, and the requirements specified in this subpart of this permit.

§63.7485,

§63.7490(a)(2), (b)

§63.7491(i)

§63.7499(p)

§63.7565

Table 10, Boiler MACT

40



Emission Standards

The following opacity standards shall be met for the process heaters

and boilers:

(a) Each process heater shall not discharge into the atmosphere

particulate that results in an opacity greater than 10%, as

determined by a 6-minute average, except for one 6-minute

period during any 60-consecutive minute period.

Rule 335-3-16-.05(a)

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

(b) Boiler B-07 shall comply with the following opacity standards.

This unit shall not discharge into the atmosphere

particulate that results in an opacity greater than 20%,

as determined by a 6-minute average.

Rule 335-3-4-.01(1)(a)

Except for one 6-minute period during any 60-minute

period, this unit shall not discharge into the

atmosphere particulate that results in an opacity

greater than 40%.

Rule 335-3-4-.01(1)(b)

The following emission standards shall be met for the emission units

listed below:

For process heater BA-603, the common stack for heaters HD-

H-3401 & HD-H-3402, and the common stack for heaters CR-

H-3801, CR-H-3802, & CR-H-3803, the following limits shall

apply for each heater or common heater stack:

Particulate matter, PM10, emissions shall be

maintained at less than, or equal to, 0.0075

Lb/MMBTU.

Rule 335-3-4-.03(1)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

Nitrogen oxide (NOX) emissions shall be maintained at

less than, or equal to, 0.025 Lb/MMBTU high heating

value (HHV) at zero percent (0%) excess air averaged

over a 30-day period.

§60.102a(g)(2)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

Volatile organic compound (VOC) emissions shall be

maintained at less than, or equal to, 0.0054

Lb/MMBTU.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

For heater HP2-H-3600:

PM10 emissions shall be maintained at less than, or

equal to, 0.0075 Lb/MMBTU.

Rule 335-3-4-.03(1)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

41



Rule 335-3-16-.05(a)

NOX emissions shall be maintained at less than, or

equal to, 0.035 Lb/MMBTU (HHV) at zero percent (0%)

excess air averaged over a 30-day period.

§60.102a(g)(2)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

VOC emissions shall be maintained at less than, or

equal to, 0.0054 Lb/MMBTU.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Rule 335-3-16-.05(a)

For Boiler B-07,

(1) PM10 emissions shall be maintained at less than, or

equal to, 13.64 Lb/Hour.

Rule 335-3-4-.03(1)

(2) Shall not combust fuel gas that contains H2S in excess

of:

§60.102a(g)(1)(ii)

§60.40c(h)

(i) 162 ppmv as determined hourly on a three-

hour rolling average basis

AND

(ii) 60 ppmv as determined on a 365-calendar

day consecutive rolling average

Each process heater or common stack shall be equipped with a NOX

continuous emission monitoring system (CEMS), including an oxygen

(O2) monitor and next generation ultra-low NOX burners (NGULNB).

§60.107a(d)(1)

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Each process heater shall meet the following fuel gas emission

standards:

Shall not combust fuel gas that contains H2S in excess of: Rule 335-3-5-.01(1)(b)

Rule 335-3-16-.05(a)

162 ppmv as determined hourly on a three hour-

rolling average basis

AND

§60.102a(g)(1)(ii)

59 ppmv as determined daily on a 365-calendar day

consecutive rolling average

Rule 335-3-14-.04

[Anti-PSD Limit]

An alternative means of emission limitation may be

established as specified in §60.103a(j)

§60.103a(j)

A root cause analysis and corrective action analysis shall be

conducted for each exceedance of an applicable short-term

emissions limit if the sulfur dioxide (SO2) discharged to

§60.103a(c)(2)

42



atmosphere is 227 kilograms (kg) (500 Lb) greater than the

amount that would have been emitted if the emission limits

had been met during one or more consecutive period of

excess emissions or any 24 hour period, whichever is shorter

Except as allowed in §63.7500(b), the following work practice

standards (WPS) shall be met to comply with the Boiler MACT for all

affected sources listed on the summary page of this subpart.

§63.7495(b)

§63.7500(b)

Each unit must be designed to burn gas 1 fuel such as natural

gas, refinery gas and/or other gas 1 fuels.

§63.7499(l), §63.7500(e)

§63.7575

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

A performance tune-up shall be completed on each unit as

specified in §63.7540.

§63.7500(a),(e)

§63.7515(d), §63.7540

Table 3 Boiler MACT

Each unit must be operated and maintained, including

associated air pollution control equipment and monitoring

equipment, in a manner consistent with safety and good air

pollution control practices for minimizing emissions.

§63.7500(a)(3)

WPS must be met at all times that a unit is operating. §63.7505(a)


Compliance with the opacity standards shall be determined using

Method 9 or Method 22 of 40 CFR part 60, appendix A.

Rule 335-3-1-.05

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

Rule 335-3-16-.05(a)

Except as specified in §60.8(b), performance testing, when applicable,

shall be conducted on each process heater in accordance with the

following test methods and procedures:

§60.104a (a) and (c)

§60.104a(i)

Rule 335-3-16-.05(c)(1)(i)


sample and velocity tranverses

§60.104a(i)(1)

Rule 335-3-16-.05(c)(1)(i)


velocity and volumetric flow rate

§60.104a(i)(2)

Rule 335-3-16-.05(c)(1)(i)

40 CFR Part 60, Appendix A-2, Method 3 OR 3A OR 3B to

determine the gas analysis. ANSI/ASME PTC 19.10-1981, “Flue

and Exhaust Gas Analyses,” (incorporated by reference-see

§60.17) is an acceptable alternative to EPA Method 3B

§60.104a(i)(3)

Rule 335-3-16-.05(c)(1)(i)

43





Rule 335-3-16-.05(c)(1)(i)

40 CFR Part 60, Appendix A-7, Method 19 to determine PM,

sulfur dioxide (SO2) and NOX emissions

Rule 335-3-16-.05(c)(1)(i)

40 CFR Part 60, Appendix A-6, Method 18 OR 40 CFR Part 60,

Appendix A-7, Method 25A OR 25B or 25C OR 25D OR 25E to

determine VOC emissions

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

NOX CEMS on the process heaters shall comply with the following

methods and procedures:

Performance evaluations shall be conducted in accordance

with §60.13(c) and Performance Specification (PS) 2 as

specified in 40 CFR Part 60, Appendix B.

§60.107a(c)(1)-(5), (d)

Relative accuracy evaluations shall be conducted using one of

the following methods and procedures:

§60.107a(c)(2)

40 CFR Part 60, Appendix A-4, Method 7 OR 7A OR 7C

OR 7D OR 7E to determine the moisture content and

NOX concentration calculated as NO2.

ANSI/ASME PTC 19.10-1981, “Flue and Exhaust Gas

Analyses,” (incorporated by reference-see §60.17) is

an acceptable alternative to 40 CFR Part 60, Appendix

A-4, Method 7 OR 7C

The F-factor of the fuel gas stream shall be determined using

the methods and procedures specified in §60.107a(d)(1)-(4).

§60.107a(d)

The O2 monitor shall comply with the following methods and

procedures:

§60.107a(c)(3)

Performance evaluations shall be conducted in

accordance with §60.13(c) and Performance

Specification 3 of 40 CFR Part 60, Appendix B.

§60.107a(c)(4)

Relative accuracy evaluations shall be conducted

using one of the following methods and procedures:

§60.107a(c)(4)

(i) 40 CFR Part 60, Appendix A-2, Method 3 OR

3A OR 3B

44



(ii) ANSI/ASME PTC 19.10-1981, “Flue and

Exhaust Gas Analyses,” (incorporated by

reference-see §60.17) is an acceptable

alternative to 40 CFR Part 60, Appendix A-2,

Method 3B

The quality assurance requirements in Procedure 1 of 40 CFR

Part 60, Appendix F shall be met for each NOX and O2 monitor.

§60.107a(c)(5)


Shall be analyzed for its BTU heat content by utilizing the

ASTM Analysis Method D1826-77 or equivalent method.

[ Fuel Gas Heat Content (BTU/scf)]

Rule 335-3-16-.05(c)(1)(ii)

Performance evaluations shall be conducted on the H2S

monitor in accordance with §60.13(c) and Performance

Specification 7 as specified in 40 CFR Part 60, Appendix B.

§60.107a(a)(2)(ii)

Relative accuracy evaluations for the H2S monitor shall be

conducted using one of the following methods and

procedures:

§60.107a(a)(2)(ii)

40 CFR Part 60, Appendix A-5, Method 11 to

determine the H2S content of the fuel gas stream


determine H2S emissions

40 CFR Part 60, Appendix A-5, Method 15A;


Analyses,” (incorporated by reference-see §60.17) is

an acceptable alternative to EPA Method 15A


determine sulfur emissions from stationary sources

The applicable quality assurance procedures in Appendix F of

Part 60, shall be met.

§60.107a(a)(2)(iii)

Compliance with the Boiler MACT shall be demonstrated by

conducting tune-ups on each process heaters as specified in

§63.7540(a)(10)(i) through (vi).

§63.7540(a)(10)

45



Emission Monitoring

Provided that visible emissions in excess of the opacity standards

occur on a unit, a visible emissions observation must be conducted to

determine opacity or to determine presence of fugitive emissions

from the unit.

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

The following performance test requirements must be met to

determine emissions from each process heater or common stack:

Rule 335-3-16-.05(c)(1)(i)

Rule 335-3-14-.04


Each unit shall be tested for VOC emissions once every five (5)

years in accordance with the Heating Units Subject to VOC

Testing section found in Appendix A of this permit.

A test shall consist of three runs of at least 1-hour in duration

each.

The results of performance tests shall be submitted to the

Department within 30 days of the test date.

Emission factors shall be determined in pounds per million

BTU.

[Test Emission Factors (Lbs/MMBTU)]

Each root cause analysis and corrective action analysis shall meet the

following requirements to demonstrate compliance with NSPS Ja:

Shall be completed as soon as possible, but no later than forty-

five (45) days after a discharge

§60.103a(d)

Special circumstances affecting the number of root cause

analyses and/or corrective action analyses are identified in

§60.103a(d)

§60.103a(d)

Corrective actions identified in the corrective action analysis

shall comply with the applicable requirements specified in

§60.103a(e)

§60.103a(e)

The NOX CEMS on each of the process heaters shall be installed,

operated, calibrated, and maintained as follows:

Shall continuously monitor and record the concentration (dry

basis, 0-percent excess air) of NOX emissions into the

atmosphere

§60.107a(d)

46



The F-factor of the fuel gas stream shall be determined no less

frequently than once per day

§60.107a(d)

Must include an O2 monitor for correcting the data for excess

air

§60.107a(c)(2)

§60.107a(d)(1)

Shall be monitored in accordance with the Heating Units with

NOX CEMS section found in Appendix A of this permit.

Rule 335-3-16-.05(c)(1)(ii)

§60.13

A Relative Accuracy Test Audit (RATA) shall be conducted on

the NOX CEMS at least once every four calendar quarters as

specified in Part 60, Appendix F, Procedure 1, Section 5.1.2

§60.107a(c)(5)

Rule 335-3-16-.05(c)

A Cylinder Gas Audit shall be conducted on the NOX CEMS at

least once every calendar quarter as specified in Part 60,

Appendix F, Procedure 1, Section 5.1.2, except that a CGA is

not required during a quarter when a RATA is being

performed.

§60.107a(c)(5)

Rule 335-3-16-.05(c)

An Annual accuracy determination shall be made for the O2

monitors

§60.107a(c)(5)

Daily calibration drifts shall be made on both the NOX and O2

monitors

§60.107a(c)(5)


Shall be equipped with a fuel gas H2S monitor that is installed,

operated, calibrated, and maintained to continuously monitor

and record the concentration by volume (dry basis) of H2S in

the fuel gas before being burned in a process heater or boiler.

§60.107a(a)(2)

§60.13(c)

A Relative Accuracy Test Audit (RATA) shall be conducted on

the H2S monitor at least once every four calendar quarters as

specified in Part 60, Appendix F, Procedure 1 Section 5.1.2

§60.107a(a)(2)(iii)

A Cylinder Gas Audit shall be conducted on the H2S monitor at

least once every calendar quarter as specified in Part 60,

Appendix F, Procedure 1, Section 5.1.2, except that a CGA is

not required during a quarter when a RATA is being

performed.

§60.107a(a)(2)(iii)

BTU heat content testing shall consist of capturing a

representative sample of the fuel gas stream at a frequency of

no less than once each month.


Rule 335-3-16-.05(c)(1)(ii)

47



The frequency of analysis may be modified upon receiving


Rule 335-3-16-.05(c)(1)(ii)

The following monitoring requirements shall be met to comply with

the WPS for new or reconstructed units designed to burn gas 1 fuels

subcategory under the Boiler MACT:

Each process heater with a heat input capacity greater than or

equal to 10 million Btu per hour (MMBTU/hr) must complete

a tune-up annually as specified in §63.7540(a)(10).

§63.7510(g), §63.7515(d),

§63.7540(a)(10)

Subsequent tune-ups must occur no more than thirteen (13)

months after the previous tune-up.

§63.7515(d)

Each tune-up must be conducted while burning the type of

fuel that provided the majority of the heat input to the unit

over the 12 months prior to the tune-up.

§63.7540(a)(10)

Annual tune-ups do not apply to units with continuous oxygen

trim systems that maintains an optimum air to fuel ratio.

§63.7540(a)(10)

For units with an oxygen trim and less than 5 MMBtu/hr,

burner inspections may be delayed until the next scheduled or

unscheduled unit shutdown; however, you must inspect each

burner at least once every seventy-two (72) months.

§63.7540(a)(12)

If an oxygen trim system is utilized on a unit without emissions

standards to reduce the tune-up frequency to once every five

(5) years, set the oxygen level no lower than the oxygen

concentration measured during the most recent tune-up.

§63.7540(a)(12)

If the unit is not operating on the required date for a tune-up,

the tune-up must be conducted within 30 calendar days of

startup.

§63.7540(a)(13)


A record of the information specified in provisos 1(a) through (l) of this


inspection. These records may be in electronic format provided they

are readily accessible.

The date, starting time and duration of each deviation from

the requirements specified in this subpart along with the

cause and corrective actions taken.

Rule 335-3-16-.05(c)(2)

§60.107a(i)(1)(ii), (3),(4)

§63.7560

48



The date, time, and results of each performance tests along

with any other tests conducted on the boiler or process heater

that provides additional stack pollutant content data.

Rule 335-3-16-.05(c)(2)

Date and type of process heater maintenance that affects air

emissions

Rule 335-3-16-.05(c)(2)

Fuel gas BTU heat content

[Heat Content (BTU/scf)]

Rule 335-3-16-.05(c)(2)

Fuel gas H2S content


Rule 335-3-16-.05(c)(2)

§60.102a(g)(1)(ii)

Fuel gas consumption per unit

[Volume (Mscf/Month)]

Rule 335-3-16-.05(c)(2)

§60.13, §60.48c(g)(2)

§60.107a(a) & (b)

where, the fuel gas consumption rate shall be recorded by a

continuous monitor on each unit

MMBTU of fuel gas consumption per unit: Rule 335-3-16-.05(c)(2)

Unit Fuel Gas Heat Input (MMBTU/Month) =

[ Volume (Mscf/Month)] X [ Heat Content (BTU/scf) ]

{1,000}

A running total of hours per calendar year when a fuel other

than natural gas or other gas-1 fuel is burned in a process

heater and/or boiler

§63.7555(h)

Operating hours per unit

[Unit Hours (Hours/Month)]

Rule 335-3-16-.05(c)(2)

Monthly VOC emissions shall be determined for each process

heater or combined stack, as follows:

Rule 335-3-16-.05(c)(2) &

Rule 335-3-14-.04


Unit Emissions (Lbs/Month) =

[Unit Heat Input (MMBTU/Month)] X [Test EF (Lbs/MMBTU)]

where, test emission factors (EF) (Lbs/MMBTU) shall be taken

from the most recent performance test

49



Unit Emissions (Lbs/Hour) =

[ Unit Emissions (Lbs/Month) ]

[ Unit Hours ( Hours/Month) ]

A copy of the NOX CEMS monitoring record for process heaters

shall be maintained onsite in a form suitable for inspection.

Rule 335-3-16-.05(c)(2)

§60.107a(c)(1)-(5)

A record of each visible emission observation conducted on a

unit, when required.

Rule 335-3-16-.05(c)(2)

To demonstrate compliance with NSPS Ja, the following recordkeeping

and reporting requirements shall be met:

§60.108a(a)

§60.7



Rule 335-3-16-.05(c)(2)

§60.7(c), (d), §60.19(d), (e)


January 1 - June 30 August 28


The excess emission report shall include the following: §60.107a

Each rolling 3-hr period and each rolling 365-day

period during which the average H2S concentration in

the fuel gas (measured using the continuous H2S

monitor) exceeds its allowable.

§60.107a(i)(1)(ii)

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

Discharges greater than 500 Lb SO2 in excess of the

allowable limits shall be recorded as specified in

§60.108a(c)(6) no later than 45 days following the end

of the discharge exceeding the threshold

§60.108a(c)(6)

Each rolling 30-day period during which the average

concentration of NOX (measured by the NOX CEMS)

exceeds its allowable.

§60.107a(i)(3)

Rule 335-3-14-.04(9)(b)

[PSD/BACT Limit]

The information specified in §60.7(c) and the applicable

requirement in §60.108a(d) shall be provided in each excess

emissions report.

§60.7(c)

§60.108a(d)

To demonstrate compliance with the Boiler MACT, the following


The following notifications shall be submitted: §63.7545

50



Notifications specified in §63.7545(a) §63.7545(a)

Notification of alternative fuel usage during periods of

natural gas curtailment or supply interruption shall be

submitted within forty-eight (48) hours of the

declaration of such period

§63.7545(f)

The following records shall be maintained: §63.7555

A copy of each notification and report to comply with

this subpart according to §63.10(b)(2)(xiv)

§63.7555(a)(1)

Records of compliance demonstrations as required by

§63.10(b)(2)(vii)

§63.7555(a)(2)

If an alternative fuel is used in the boilers or process

heaters during periods of gas curtailment or gas

supply emergencies, the following records shall be

maintained:

§63.7555(h)

(i) Record of the total hours per calendar year

that the alternative fuel is burned

(ii) Record of the total hours per calendar year

that the unit operated during periods of gas

curtailment or gas supply emergencies.

A record of burner inspection shall be maintained for

units with delayed tune-ups

§63.7550(c)(5)(xiv)

Records must be kept and maintained as specified in §63.7560

for a period of five years following each occurrence.

§63.7560

The following reporting requirements shall be met: §63.7550

An annual compliance report shall be submitted as

specified in §63.7550(b)(1) through (3), except as

allowed in §63.7550(b)(4)

§63.7550(b), §63.10(a)(7)

The compliance report must contain the information

specified in §63.7550(c)(1.

§63.7550(c)(1)

The reports must be submitted electronically to the

EPA via CEDRI, except as allowed and a copy of the

report must be submitted to the Department for

tracking purposes

§63.7550(h)(3)

51



A periodic monitoring report (PMR) meeting the requirements

specified in proviso 4(a) and (b) of this section of this subpart shall be

submitted to the Department.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(i)






testing or recordkeeping which is required by the

permit that can be used to determine or indicate

compliance, that identifies an affected source has

failed to meet an applicable emission limit or

standard, or that a work practice was not complied

with or completed.








For each deviation event, the following information

shall be submitted.



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause


conditions

52






reporting period




Each report shall cover a calendar semi-annual period

and shall be submitted according to the following

reporting schedule:




The report content specified in proviso 4(b) of this section may

be modified upon receipt of Departmental approval.

Each deviation from the requirements specified in this subpart,

including those that occur during startups, shutdowns, and

malfunctions, shall be reported to the Department in a manner that

complies with proviso 15(b) and 21(b) of the general proviso subpart

of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

53

Summary Page for Emergency Engines

Permitted Operating Schedule/Unit:

Emergency Operating Schedule: Unlimited [§60.4211(f)(1)]

Maintenance and Testing Operating Schedule: 100 hours/yr-Non-Emergency Hours per year

[§60.4211(f)(2)]

Non-Emergency Operating Schedule: < 50 Hours per year [§60.4211(f)(3)]


EMISSION

POINT

DESCRIPTION POLLUTANT EMISSION

LIMIT *

REGULATIONS

40 CFR 60 SUBPART IIII [NSPS IIII] COMPRESSION IGNITION EMERGENCY FIRE PUMP ENGINES ≥ 500 BHP:

UE-P-100A

UE-P-100B

700 BHP, Generac, C18 ACERT

Diesel- Fired Emergency Fire

Pump Engine No. 1

700 BHP Generac, C18 ACERT

Diesel- Fired Emergency Fire

Pump Engine No. 2

PM

NOX + NMHC

CO

0.23 Lb/hr [0.15 g/HP-

hr]

4.63 Lb/hr [3.0 g/HP-hr]

4.01 Lb/hr [2.6 g/HP-hr]

§60.4205(c), Table 4

§60.4205(c), Table 4

Rule 335-3-14-.04

[Anti-PSD Limit]

§60.4205(c), Table 4

40 CFR 60 SUBPART IIII [NSPS IIII] COMPRESSION IGNITION EMERGENCY ENGINE ≥ 500 BHP:

US-ME-3249X 762 BHP, Generac, SD/MD 500,

Diesel Fired, South Complex

Flare Area Emergency Electric

Generator Engine

PM

NOX + NMHC

CO

0.15 g/HP-hr

4.78 g/HP-hr

2.61 g/HP-hr

§60.4201(a)

§60.4204(b)

§89.112(a), Table 1

§60.4202(a)(2)

§60.4205(b)

§89.112(a), Table 1

§60.4201(a)

§60.4204(b)

§89.112(a), Table 1

EACH EMERGENCY ENGINE LISTED ABOVE Opacity During these specified

periods:

20% during acceleration

mode

15% during lugging

mode

50% during peak periods

§60.4201(a)

§60.4204(b)

[NSPS IIII]

§89.113(a)(1)

§89.113(a)(2)

§89.113(a)(3)

54

EMISSION

POINT

DESCRIPTION POLLUTANT EMISSION

LIMIT *

REGULATIONS

Opacity During all other periods:

No more than one 6 min

avg> 20%

OR

No 6 min avg. > 40% in

any sixty (60) minute

period

Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

Sulfur Burn non-road diesel fuel:

Maximum sulfur content

of 15 parts per million

(ppm) per gallon

AND

Must meet a cetane index

of at least 40

OR

Maximum aromatic content

of 35 volume percent

§60.4207(b)

§80.510(b)(1)(i)

§80.510(b)(2)(i)

§80.510(b)(2)(ii)

*Limits are for each engine listed

55


Emergency Operating Schedule Unlimited [40 CFR §60.4243(d)(1)]


[40 CFR §60.4243(d)(2)]

Non-Emergency Operating Schedule: < 50 Hours per year [40 CFR §60.4243(d)(3)]


EMISSION


EMISSION

LIMIT REGULATIONS

40 CFR 60 Subpart JJJJ [NSPS JJJJ] SPARK IGNITION EMERGENCY ENGINES ≤ 500 BHP:

US-ME-3249 402 BHP BHP , Generac SG300,

Four stroke rich burn (4SRB),

Natural Gas-Fired Backup

Emergency Electrical Generator

Engine w/catalytic converter

NOX

CO

VOC

1.77 Lb/hr [2.0 g/HP-hr]

3.54 Lb/hr [4.0 g/HP-hr]

0.89 Lb/hr [1.0 g/HP-hr]

§60.4233(e), Table 1

Rule 335-3-14-.04

[Anti-PSD Limit]

SC-OPS-SG150 230.3 BHP, Generac SG150, 4SRB,

Natural Gas-Fired, OPS Shelter

emergency generator engine

NOX

CO

VOC

2.0 g/HP-hr

4.0 g/HP-hr

1.0 g/HP-hr

§60.4233(e), Table 1

EACH EMERGENCY ENGINE LISTED ABOVE Opacity No more than one 6 min

avg> 20%

OR

No 6 min avg. > 40% in any

sixty (60) minute period

Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

56


Emergency Operating Schedule Unlimited [40 CFR §63.6640(f)(1)]


[§63.6640(f)(2)]

Non-Emergency Operating Schedule: < 50 Hours per year [40 CFR §63.6640(f)(2), (f)(3)]


EMISSION


EMISSION

LIMIT* REGULATIONS

EXISTING MACT ZZZZ ENGINES, MAJOR HAPS ≤ 500 BHP:

00439

00680

10317

20214

00649

136 BHP Diesel-Fired Emergency No. 2

Fire Pump Engine

110.7 BHP Natural Gas-Fired Main

Office Emergency Electrical Generator

Engine

80 BHP Diesel Fired CU Emergency

Stormwater Pump Engine

80 BHP Diesel Fired CK Emergency

Stormwater Pump Engine

20 BHP Liquefied Petroleum Gas (LPG)-

Fired Guard House Emergency Electrical

Generator Engine

HAPs Applicable Work Practices:

Change Oil and Filter every 500

hrs or annually, whichever

comes first or according to

§63.6625(i)

Check Air Cleaner [CI] OR Spark

Plugs [SI] every 1,000 hrs or

annually, whichever comes

first

Check Belts & Hoses every 500

hrs or annually, whichever

comes first

§63.6602, Table 2(c)

§63.6625(i)

EACH ENGINE LISTED ABOVE Opacity No more than one 6 min avg>

20%

OR



Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

*Work Practice and Opacity Standards are for each engine listed

57


24 Hours/Day x 365 Days/Year = 8,760 Hours/Year

Except during leap year, Permitted Operating Schedule = 8,784 Hours/Year


EMISSION


EMISSION

LIMIT REGULATIONS

EXISTING MACT ZZZZ ENGINE, MAJOR HAPS >500 BHP:

00445 525 BHP Diesel-Fired No. 4

Emergency Fire Pump

Engine

NOX

CO

VOC

NONE Exempt from requirements

under MACT ZZZZ

[§63.6590(b)(3)(iii]

Opacity No more than one 6 min avg>

20%

OR



Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

58

Provisos for Emergency Engines


Applicability

Each emergency engine, except the UE-P-100A and B engines, is

subject to the applicable requirements of ADEM Admin. Code r.

335-3-4-.01, “Visible Emissions” for Control of Particulate

Emissions and to the requirements of this subpart of this permit.

Rule 335-3-4-.01(1)(a) and (b)

Engine Nos.: US-E-P-100A, US-E-P-100B, and US-ME-3249., are

subject to an emission limits limit in order to avoid a review

under ADEM Admin. Code r. 335-3-14-.04, “Air Permits

Authorizing Construction in Clean Areas [Prevention of Significant

Deterioration (PSD)]”, and they are subject to the requirements

specified in this subpart of this permit. Compliance with emission

limits under 40 CFR 60 Subpart IIII, demonstrate compliance with

the subpart.

Rule 335-3-14-.04

[Anti-PSD Limit]

Each emergency engine on the summary page of this subpart

shall be subject to the requirements specified in ADEM Admin.

Code r. 335-3-16-.03, “Major Source Operating Permits”, and the


Rule 335-3-16-.03

The following engines are subject to the requirements of 40 CFR

60 Subpart IIII, “Standards of Performance for Compression

Ignition (CI) Internal Combustion Engines” [NSPS IIII] and to the

requirements of this subpart of this permit: Engine Nos. US-E-P-

100A, US-E-P-100B, and US-ME-3249X.

§60.4200(a)(2)(i) [Non-Fire Pump]

§60.4200(a)(2)(ii) [Fire Pump]

§60.4200(a)(4), §60.4208

§63.6590(b)(1)(i)

The following engines are subject to the requirements of 40 CFR

60, Subpart JJJJ, “Standards of Performance for Stationary Spark

Ignition Internal Combustion Engines” [NSPS JJJJ] and to the

requirements of this subpart of this permit: Engine Nos. US-ME-

3249 and SC-OPS-SG150.

§60.4230(a)(4)(iv)

§63.6590(c)(6)

The following engines are subject to the major source

requirements of 40 CFR 63 Subpart ZZZZ, “National Emission

Standards for Hazardous Air Pollutants (HAPs) for Stationary

Reciprocating Internal Combustion Engines (RICE)” [MACT ZZZZ,

RICE MACT] and to the requirements of this subpart of this

permit: Engine Nos. 00439, 00680, 10317, 20214, and 00649.

§63.6580

§63.6585(a),(b)

§63.6590(a)(1)(ii), (b)(1)(i),(b)(3)(iii)

§63.6645(f)

The following engines are subject only to the limited

requirements under this subpart as specified in

§63.6645(f): Engine Nos. US-E-P-100A, US-E-P-100B, and

US-ME-3249X.

§63.6590(b)(1)(i)

59



The SC-OPS-SG150 engine satisfies the requirements of

MACT ZZZZ by complying with NSPS JJJJ. No further

requirements apply under this subpart.

§63.6590(c)(6)

Engine No. 00445 is exempt from the requirements of

this subpart provided that it meets the requirements

specified in §63.6590(b)(3)(iii).

§63.6590(b)(3)(iii)

Each engine is subject to the applicable requirements of 40 CFR

60, Subpart A “General Provisions”, and 40 CFR 63 Subpart A,

“General Provisions” as specified in the applicable subparts and

to the requirements of this subpart of this permit.

§60.4218, Table 8, NSPS IIII

§60.4246, Table 3, NSPS JJJJ

§63.6665, Table 8, RICE MACT

§63.6590(b)(3)

Emission Standards

The emergency engines must comply with the following opacity

standards and/or smoke emission standards

For each engine, the following opacity standards

specified below shall be met

The engine shall not discharge into the

atmosphere particulate that results in an opacity

greater than 20%, as determined by a 6-minute

average.

Rule 335-3-4-.01(1)(a)

Except for one 6-minute period during any 60-

minute period, the engine shall not discharge

into the atmosphere particulate that results in

an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

For Engine Nos.: US-P-100A and B and US-ME-3249X, the

following smoke emission standards specified in §89.113

shall be met during the specified periods found below

and during all other periods the requirements specified

in proviso 1(a) of this section of the permit shall be met:

§60.4211(a)(3)

§89.113(a)

Acceleration mode, opacity shall not exceed 20

percent (%)

§89.113(a)(1)

Lugging mode, opacity shall not exceed 15% §89.113(a)(2)

Peaks in either the acceleration or lugging

modes, opacity shall not exceed 50 %

§89.113(a)(3)

60



To comply with the requirements of NSPS IIII and Anti-PSD Limits

(where applicable), the following emissions standards shall be

adhered to over the entire life of each certified engine

§60.4205(c), §60.4206

Table 4

§60.4211(c)

For emergency fire pump engines UE-P-100A and B,

Particulate Matter (PM) emissions for each

engine shall not exceed 0.23 pounds per hour

(Lb/hr) [0.15 grams per horsepower hour (g/HP-

hr)].

§60.4205(c), Table 4

Nitrogen Oxide (NOx) + Non-Methane

Hydrocarbon (NHMC or Volatile Organic

Compounds (VOC)) emissions for each engine

shall not exceed 4.63 Lb/hr [3.0 g/HP-hr].

§60.4205(c), Table 4

Rule 335-3-14-.04

[Anti-PSD Limit]

Carbon Monoxide (CO) emissions for each

engine shall not exceed 4.01 Lb/hr [2.6 g/HP-hr].

§60.4205(c), Table 4

For emergency generator engine US-ME-3249X, §60.4202(a)(2), §60.4205(b)

PM emissions shall not exceed 0.15 g/HP-hr. §60.4201(a), §60.4204(b)

[NSPS IIII]

§89.112(a), Table 1

NOX + NMHC emissions shall not exceed 4.78

g/HP-hr.

§60.4202(a)(2), §60.4205(b)

[NSPS IIII]

§89.112(a), Table 1

CO emissions shall not exceed 2.61 g/HP-hr. §60.4201(a), §60.4204(b)

[NSPS IIII]

§89.112(a), Table 1

If an emergency engine does not meet the non-

emergency engine standards, the engine shall be

equipped with a non-resettable hour meter prior to

startup of the engine.

§60.4209(a)

If a special fuel, not certified to meet the applicable

standard is used in an engine, the requirements specified

in §60.4217 shall be met.

§60.4217

Except as allowed under §60.4207(b), fuel gas for the

emergency engines shall meet the following per-gallon

gas requirements:

§60.4207(b), §80.510(b)

Maximum sulfur content of 15 ppm §80.510(b)(1)

61



Minimum cetane index of 40 or maximum

aromatic content of 35 volume percent

§80.510(b)(2)(i) or (ii)

To comply with the requirements of NSPS JJJJ and Anti-PSD Limits

(where applicable), the following emissions standards shall be

met:

Engine No. US-ME-3249 shall adhere to the following

requirements:

NOX emissions shall not exceed 1.77 Lb/hr [2.0

g/HP-hr].

§60.4233(e), Table 1

Carbon Monoxide (CO) emissions shall not

exceed 3.54 Lb/hr [4.0 g/HP-hr].

§60.4233(e), Table 1

VOC emissions shall not exceed 0.89 Lb/hr [1.0

g/HP-hr].

§60.4233(e), Table 1

Shall be equipped with a catalytic converter Rule 335-3-14-.04

[Anti-PSD Limit]

Engine No. SC-OPS-SG150 shall adhere to the following

emission limitations the entire life of the engine:

§60.4233(e), Table 1

(1) NOX emissions shall not exceed 2.0 g/HP-hr.

(2) CO emissions shall not exceed 4.0 g/HP-hr.

(3) VOC emissions shall not exceed 1.0 g/HP-hr.

Each engine is certified, and it must adhere to the

requirements specified in §60.4243(a)(1) or (2).

§60.4243(a) and (b)(1)

Each engine may operate using propane for a maximum

of 100 hours per year as an alternative fuel solely during

emergency operations.

§60.4243(e)

To comply with the requirements of MACT ZZZZ, the following

work practice standards shall be adhered to for Engine Nos.:

00439, 00680, 10317, 20214, and 00649 as specified in Table No.

2c, Item Nos. 1 (for compression ignition diesel-fired engines)

and No. 6 (for spark ignition natural gas-fired engines):

§63.6602, Table No. 2c

§63.6605(b), Table No. 6

The oil and oil filter shall be changed according one of the

following schedules:

62



(1) Every 500 hours of operation, or annually,

whichever comes first,

(2) According to the Oil Analysis Program outlined in

§63.6625(i)

Inspect the following component every 1000 hours of

operation, or annually, whichever comes first.

(1) For a Compression Ignition Source, check the Air

Cleaner

(2) For a Spark Ignition Source, check the spark plugs

Inspect all hoses and belts every 500 hours of operation,

or annually, whichever comes first. Hoses and belts shall

be replaced as necessary.

The management practices specified in provisos 4(a)

through (c), may be delayed if the unit is operating during

an emergency situation, or if the required management

practices would result in an unacceptable risk. In this

case, the required management practice(s) shall be

conducted as soon as possible.

Each unit shall be operated and maintained in a manner

consistent with safety and good air pollution control

practices for minimizing emissions.

Except as otherwise specified, each emergency engine subject to

requirements under this subpart of this permit shall adhere to

the following operating schedules:

For emergency situations, there is no limit on the use of

the engine.

§60.4211(f)(1) [NSPS IIII]

§60.4243(d)(1)[NSPS JJJJ]

§63.6640(f)(1) [MACT ZZZZ]

Any operation other than emergency operations,

maintenance and testing, emergency demand response,

and operation in non-emergency situation for 50 hours

per year is prohibited.

§60.4211(f) [NSPS IIII]

§60.4243(d) [NSPS JJJJ]

§63.6640(f) [MACT ZZZZ]

For any combination of purposes specified in proviso

5(c)(1) through (3) of this section, each emergency

engine may be operated for a maximum of 100 hours per

calendar year. Any operation for non-emergency

situations as allowed by proviso 5 (d) of this section

§60.4211(f)(2) [NSPS IIII]

§60.4243(d)(2) [NSPS JJJJ]

§63.6640(f)(2),(3) [MACT ZZZZ]

63



counts as part of the 100 hours per calendar year

allowed.

(1) Maintenance checks and readiness testing

(2) Emergency demand response

(3) Periods where there is a deviation of voltage or

frequency of five (5) percent or greater below

standard voltage or frequency.

For non-emergency situations, each engine may operate

for up to 50 hours per calendar year. Additionally, for a

generator engine these 50 hours shall not be used for

peak shaving, non-emergency demand response, or

income generation.

§60.4211(f)(3) [NSPS IIII]

§60.4243(d)(3) [NSPS JJJJ]

§63.6640(f)(3) [MACT ZZZZ]

Where applicable, the start-up, idling, and loading period

of the engine shall not exceed 30 minutes.

§63.6625(h)

If emergency engines do not operate in accordance with

the requirement listed in the subpart, the engine will not

be considered an emergency engine and it must comply

with non-emergency engine requirements.

§60.4211(f) [NSPS IIII]

§60.4243(d) [NSPS JJJJ]

§63.6640(f) [MACT ZZZZ]

These requirements do not apply to Engine No.: 00445 §63.6590(b)(3)(iii)

Each engine shall only burn fuel that meets the appropriate

specifications for either natural gas, liquefied petroleum gas

(LPG), or diesel, except as allowed.

Rule 335-3-14-.04 [Anti-PSD]

§60.4207(b), §60.4243(e)

§80.510(b)



Method 9 or Method 22 of 40 CFR 60 Appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

The following requirements must be adhered to when

performance testing is required:

Rule 335-3-1-.05

Rule 335-3-16-.05(c)(1)(i)

§60.4212, §60.4244

A test shall consist of three runs of at least 1-hour in

duration.

Each run shall test for the applicable pollutants NOX, CO,

and VOC using the reference methods and procedures

specified in NSPS IIII and/or NSPS JJJJ if required.

64



(1) For NOX emissions, 40 CFR 60 Appendix A,

Method 7 OR 7A OR 7B OR 7C OR 7D OR 7E

(2) For CO emissions, 40 CFR 60 Appendix A, Method

10 OR Method 10A OR Method 10B

(3) For VOC emissions, 40 CFR 60 Appendix A,

Method 18 OR Method 25 OR Method 25A, OR

Method 25B OR Method 25D OR Method 25E

Particulate emissions shall be measured using 40 CFR 60

Appendix A, Method 5.

The pollutants tested for and the methods and

procedures that are utilized may be modified upon

receiving Departmental approval.

Emission Monitoring

Provided that visible emissions, in excess of the opacity

standards, are observed from an engine at any time that the unit

is operating, a visible emission observation shall be conducted

utilizing one the specified methods.

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

If an emergency engine does not meet the standards applicable

to non-emergency engines, a non-resettable hour meter shall be

installed on each engine.

§60.4209(a), §60.4214(b)

§60.4237

§63.6625(f)

The catalytic converter installed on Engine No. US-ME-3249 must

meet the following requirements:

Rule 335-3-14-.04

[Anti-PSD Limit]

§60.4243g

Must be maintained and operated in a manner so as to

minimize the emissions of regulated air pollutants

Shall not be operated without the entire gas stream

passing through the catalytic converter

Air-to-fuel ratio controllers must be maintained and

operated appropriately in order to ensure proper

operation of the engine and control device to minimize

emissions at all times

65



For engines subject to the requirements of NSPS IIII (Engine Nos.:

UE-P-100A, UE-P-100B, and US-ME-3249X) or NSPS JJJJ (Engine

No.: SG-OPS-SG150 and US-ME-3249), compliance with the

applicable emissions standards shall be determined by meeting

one of the following monitoring requirements:

Operate and maintain the unit according to

manufacturer’s specifications for the life of the unit.

For NSPS IIII Engines:

§60.4206, §60.4211(a)

For NSPS JJJJ Engines:

§60.4248, §60.4243(a)(1), (b)(1), (d)

Perform emissions testing every three years or 8,760

hours of operation, whichever comes first

For NSPS IIII Engines:

§60.4211(g)(3), §60.4212,

§60.4213

For NSPS JJJJ Engines:

§60.4243(a)(2), (b)(2),

§60.4244, §60.4245(d) and (e)

For engines subject to the requirements of MACT ZZZZ (Engine

Nos.: 00439, 00680, 10317, 20217, and 00649), one of the

following operations and maintenance plans outlined in Table

No. 6, No. 9 shall be complied with:

Rule 335-3-16-.05(c)(1)

§63.6640(a)

§63.6625(e)(3)

Operate and maintain the stationary engine according to

the manufacturer’s emission-related operation and

maintenance instructions

The facility may develop and follow its own maintenance

plan, provided this plan ensures, to the extent

practicable, the operation and maintenance of the unit

in a manner consistent with good air pollution practices.


A record of the information specified in provisos 1(a) through (i)

of this section of this subpart shall be maintained and made

available in a form suitable for inspection for a period of five (5)

years or as specified in the applicable subpart of §60.7(f) or

§63.10(b):

Rule 335-3-16-.05(c)(2)

§60.7(f), §63.10(b)

The date, starting time and duration of each deviation

from the requirements specified in this subpart along

with the cause and corrective actions taken.

§63.6655(a)(1)

§63.6660(a) & (b)

66



The date, starting time and, and duration of each

malfunction, along with steps taken to minimize

emissions, and corrective actions taken.

Rule 335-3-16-.05(c)(2)

§63.6655(a)(2) & (5)

§63.6660(a) & (b)

Date and type of engine maintenance that affects air

emissions

Rule 335-3-16-.05(c)(2)

§60.4214(a)(2)(ii) §60.4245(a)(2)

§63.6655(a)(4), (d), & (e)(2)

§63.6660(a) & (b)

A copy of the manufacturer’s certification OR other proof

that the unit is meeting the required emission limits.

For Diesel Engines:

§60.4214(a)(2)(iii) & (iv)

For Natural Gas Engines:

§60.4245(a)(3) & (4)

A copy of the fuel gas certification shall be maintained

onsite.

Rule 335-3-16-.05(c)(2)

§63.6660(a) & (b)

Operating hours for each engine’s usage type:

[ Operating Hours/Month]

Rule 335-3-14-.04

[Anti-PSD Limit]

Rule 335-3-16-.05(c)(2)

§60.4214(b), §60.4245(b)

§63.6655(f)

§63.6660(a) & (b)

If an emergency engine operates for more than 15 hours

per calendar year for the purposes specified in NSPS IIII

or NSPS JJJJ, an annual report shall be submitted:

§60.4214(d)

§60.4245 (e)

(1) The report must contain the information

specified in the applicable subpart

§60.4214(d)(1)

§60.4245 (e)(1)

(2) The report must be submitted on the schedule

specified in the applicable subpart

§60.4214(d)(2)

§60.4245 (e)(2)

(3) Except as allowed, the annual report must be

submitted electronically using the subpart

specific reporting form in the Compliance and

Emissions Data Reporting Interface (CEDRI) that

is accessed through EPA's Central Data Exchange

(CDX) (www.epa.gov/cdx). A notification of the

annual report’s submittal to EPA must be

provided to the Department.

§60.4214(d)(3)

§60.4245 (e)(3)

If an engine is subject to NSPS JJJJ, the following

recordkeeping requirement shall be met:

67



The records specified in §60.4245(a) shall be

maintained.

§60.4245(a)

For engines that do not meet the standards

applicable for non-emergency engines, the

requirements specified in §60.4245(b) shall be

maintained.

§60.4245(b)

Provided that propane is used for a maximum of

100 hours per year as an alternative fuel during

emergency operation, a record of such use shall

be maintained.

§60.4243(e)

Records of each occurrence when a visible emission

observation was conducted on an engine shall be

maintained

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

These records may be kept in electronic form, provided

that they are readily accessible. Alternatively, they may

be kept in hardcopy form.

Rule 335-3-16-.05(c)(2)

§63.6660(a), (b), & (c)

If performance testing is required a copy of the test much be

submitted to the Department within 60 days after the test has

been completed.

§60.4245(d)



malfunctions, shall be reported to the Department in a manner

that complies with proviso 15(b) and 21(b) of the General Permit

Provisos subpart of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

§63.6640(b)

§63.6650(f)

68


69

Summary Page for NSPS QQQ: Oily Wastewater System

Permitted Operating Schedule: 24 Hours/Day x 365 Days/Year = 8,760 Hours/Year †Except during leap year, Permitted Operating Schedule = 8,784 Hours/Year

Emission limitations:

EMISSION


EMISSION

LIMIT REGULATIONS

Each aggregate facility that receives,

treats or processes oily wastewater,

comprising:

Individual drain system

Downstream sewer lines

Downstream oil-water separators

VOC

OHAPs

Work Practices:

Install & Maintain Seals

NONE*

Classified as Group 2

wastewater stream under

MACT CC

§60.692-2

Rule 335-3-6-.08(5)

§63.647

AGGREGATE FACILITIES FOR:

Diesel Hydrotreater

Crude Unit Pumping Station

Gasoline Loading Rack

Hydrocracker

CCR Platformer

No. 2 Hydrogen Plant

No. 2 Amine System

No. 2 Wastewater Plant

70

Provisos for Oily Wastewater System


Applicability

Each affected facility that is identified on the Summary page of this subpart

shall be subject to the requirements of ADEM Admin. Code r. 335-3-16,

“Major Source Operating Permits”, and to this subpart of this permit.

Rule 335-3-16-.03

Each aggregated facility is subject to the requirements of 40 CFR 60 subpart

QQQ “Standards of Performance for VOC Emissions from Petroleum

Refinery Wastewater Systems” [NSPS QQQ] and the requirements


§60.690(a)(1), (4), (b)

Compliance with this subpart shall demonstrate compliance with

ADEM Admin. Code r. 335-3-6-.08(5), “Petroleum Refinery

Sources” for any wastewater (oil/water) separator at a petroleum

refinery.

Rule 335-3-6-.08(5)

335-3-10-.01(2)

The wastewater stream has been designated as a Group 2 stream

under “National Emission Standard for Hazardous Air Pollutants

(HAPs) from Petroleum Refineries” [Refinery MACT 1/MACT CC];

therefore, there are no requirements for Group 2 wastewater

streams unless the requirement in §63.640(o)(2) of MACT CC are

met.

§63.640(o)(2)

§63.641

Compliance with the applicable requirements of 40 CFR 60 subpart

A, “General Provisions” shall be met as specified in NSPS QQQ.

40 CFR 60 Subpart A

Emission Standards

Except as specified in §60.692-1(d) and §60.692-2(d), each individual drain

system shall meet the following requirements at all times, except during

periods of start-ups, shutdowns, and malfunctions:

§60.692-1(a), (d)

§60.692-2(d)

§60.692-4

Each drain shall be equipped with a water seal. §60.692-1(a), §60.692-2(a)(1)

§60.692-4

Each junction box shall be equipped with a cover that is tightly

sealed around the edges. The junction box may have a vent pipe

that is at least 90 cm [~3 ft] long, with a diameter of not more than

10.2 cm [~4 in].

§60.692-1(a)

§60.692-2(b)(1), (2)

§60.692-4

Each sewer line shall not be open to atmosphere and shall be

covered or enclosed in a manner so as to have no visual gaps or

cracks in joints, seals, or other emission interfaces.

§60.692-1(a)

§60.692-2(c)(1)

§60.693-1(e)(1)

§60.692-4

71



As an alternative to the standards found in §60.692-2 for individual

drain systems, the drain system may be constructed such that it is

completely enclosed and equipped with a closed vent system that

meets the standards in §60.692-5.

§60.692-1

§60.692-2

§60.692-4

§60.693-1

An alternative means of emission limitation to meet the requirements of

§§60.692-2 through 60.692-4 may be granted as provided in §60.694.

§60.692-1(c)

§60.692-2-§60.692-4

§60.692-4


The test methods and procedures specified in section §60.696 of 40 CFR

Part 60, Subpart QQQ shall be followed.

§60.696

Emission Monitoring

Each individual drain system shall be visually or physically inspected

according to the following frequencies:

Each drain in active service shall be visually inspected initially, and

monthly thereafter for indications of low water levels, or other

conditions that would reduce the effectiveness of the water seal

controls.

§60.692-2(a)(2)

Each drain not in active service shall be visually inspected:

(1) Initially, and weekly thereafter for indications of low water

levels, or other problems that could result in VOC

emissions.

§60.692-2(a)(3)

OR

(2) Initially, and semi-annually thereafter to ensure that a

tightly sealed caps and/or plugs is in place and properly

installed.

§60.692-2(a)(4)

Each junction box shall be visually inspected initially, and semi-

annually thereafter to ensure that the cover is in place and tightly

sealed around the edges.

§60.692-2(b)(3)

Each unburied sewer system shall be visually inspected initially,

and semi-annually thereafter to check for cracks, gaps, or other

problems that could result in VOC emissions.

§60.692-2(c)(2)

§60.693-1(e)(2)

The following requirements shall apply to problems discovered during

visual and/or physical inspections of the individual drain system:

72



In the event that a drain seal or plug is missing, and/or the drain

water level is low, water shall be added or first efforts at repair

shall be made as soon as practicable, but not later than 24 hours

after detection, except as provided in §60.692-6.

§60.692-2(a)(5)

§60.692-6.

In the event that a junction box cover is missing or seal is cracked,

or a gap or crack is discovered in an unburied sewer line, a first

attempt at repairs/replacements shall be attempted as soon as

practicable, but not later than 15 days after discovery.

§60.692-2(b)(4)

§60.692-2(c)(3)

§60.693-1(e)(3)

In the event that emissions are detected from a closed vent

system, a first attempt at repairs/replacements shall be attempted

as soon as possible, but no later than 30 days after discovery.

§60.693-1(b)

§60.692-5(e)

As an alternative to provisos 2(a) through (c) of this section, repairs

may be delayed if it is technically impossible to complete the

repairs without shutting down all or part of the facility or process

unit. Repairs shall be completed by the end of the next facility or

process unit shutdown.

§60.692-6

If the alternative standards of individual drain systems found in §60.693-1

are elected, the monitoring requirements specified in §60.695 for a closed

vent system shall be met as applicable.

§60-692-5,

§60.693-1(b)

§60.695


The recordkeeping requirements specified in proviso 1(a) through (f) of this

section shall be complied with.

The location, date, and corrective action taken for each problem

uncovered during inspections of drains, junction boxes, sewer

lines, and closed vent systems.

§60.692-1(b),

§§60.697(a), (b), (d)

For a closed vent system complying with the standards found in

60.692-5 and closed drain systems complying with the alternative

standards specified in §60.693-1, the records specified in

§60.697(d) shall be maintained.

§60.692-5

§60.693-1

§60.697(d)

For systems placed on the Delay of Repair (DOR) list, as allowed by

§60.692-6, a written document signed by the owner or operator

(or designee) explaining the reason(s) for the delay, the expected

date of repair, and the actual date of repair shall be retained

onsite.

§60.692-1(b)

§§60.697(a), (e)

73



A copy of the design specification as described in §60.697(f) for all

equipment used to comply with the proviso of this subpart shall be

maintained for the life of the source in a readily accessible location.

§60.697(f)

A copy of the information specified in §§60.697(g) through (k) shall

be maintained.

§§60.697(g)-(k)

The records specified in §60.7 of 40 CFR Part 60, Subpart A shall be

maintained.

§60.7

Periodic monitoring reports (PMR) meeting the requirements specified in

proviso 2(a) and 2(b) of this section of this subpart shall be submitted to

the Department.

Rule 335-3-16-.05(c)(3)(i)

§60.7

§60.19

§60.698

Each report shall identify each incidence of deviation from a permit

term or condition including those that occur during startups,

shutdowns, and malfunctions.

(1) A deviation shall mean any condition determined by

observation, by data collected by any continuous

monitoring system or periodic monitoring required by the

permit that can be used to determine compliance, that

identifies an affected source has failed to meet an



(2) If no deviation event occurred during reporting period, a

statement that indicates there were no deviations from

the permit requirement requirements shall be included in

the report.




(1) For each deviation event, the following information shall

be submitted.



(iii) Date

(iv) Starting time

74



(v) Duration


(vii) Cause


conditions




reporting period






schedule:










Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

75

Summary Page for MACT CC and BWON NESHAP: Wastewater Stream

Containing HAPs



Emission

Point Description Pollutant

Emission

Limit/Standard Regulations

Wastewater streams and treatment

operation contacting or containing

hazardous air pollutants

OHAP

Operate in a manner

consistent with the minimum

or maximum (as appropriate)

permitted concentration or

operating parameter value.

§63.640(c)(3), §63.647

40 CFR 63, Subpart CC

For TAB < 10 Mg/yr

For TAB >10 Mg/yr

Benzene

Benzene

Work Practices-Calculate and

Record TAB

Work Practices—Install

controls to reduce benzene

emissions

§61.342(a)

[NESHAP FF]

§61.342(c)-(d)

[NESHAP FF]

76

Provisos for Wastewater Stream Containing HAPs


Applicability

Each wastewater stream and treatment operation shall be subject to the

requirements specified in ADEM Admin. Code r. 335-3-16, “Major Source

Operating Permits”, and to this subpart of this permit.

Rule 335-3-16-.03

Except as provided for in §63.640(d) and (g) of 40 CFR Part 63 Subpart CC

“National Emission Standard for Hazardous Air Pollutants (HAPs) from

Petroleum Refineries” [Refinery MACT 1/MACT CC], each wastewater

stream and treatment operation that meets the following criteria shall be

subject to MACT CC and to this subpart of this permit.

§63.640(c)(3)

§63640(d) & (g)

§63.647(a)

Is located at a petroleum refinery site that is a major HAP emission

source.

§63.640(a)(1)

§63.641

§61.340(a)

Emits or has equipment containing or contacting one or more of

the hazardous air pollutants as defined in Table No. 1 of MACT CC.

§63.640(a)(2)

Table No. 1

Is a Group 1 wastewater steam as defined in §63.641 and as

follows:

§63.641

§63.647(a)

Has a total annual benzene (TAB) loading of 10 megagrams

(Mg) per year (~22,046 pounds per year) or greater.

Has a flow rate of 0.02 liters (0.00258 gallons) per minute

or greater

Has a benzene concentration equal to or greater than 10

parts per million by weight (ppmw)

Is not exempt from the control requirements under the

provisions of 40 CFR Part 61, Subpart FF

A Group 1 or Group 2 wastewater stream that is conveyed, stored,

or treated in a wastewater steam management unit that also

receives stream subject to §63.133 through §63.147 of 40 CFR 63

Subpart G, “National Emission Standards for Organic Hazardous

Air Pollutants from the Synthetic Organic Chemical Manufacturing

Industry for Process Vents, Storage Vessels, Transfer Operations,

and Wastewater” for wastewater provisos shall comply with

requirements specified in §63.640(o)(2) to comply with MACT CC.

§63.640(o)(2)

Compliance with MACT CC shall be met by complying with the

applicable requirements by reference found in 40 CFR Part 61,

Subpart FF “National Emission Standards for Benzene Waste

Operations” [BWON] for hazardous waste treatment, storage, and

§61.340(a), (b)

§63.647(a)

77



disposal facilities that treat, store, or dispose of hazardous waste

generated by petroleum refineries.

Each wastewater stream and treatment operation shall be subject to the

applicable requirements specified in Table 6 of MACT CC, 40 CFR 63

Subpart A, “General Provisions”, and this subpart of this permit.

§63.642(c)

Table 6, 40 CFR 63, Subpart CC

Emission Standards

If the total annual benzene (TAB) quantity from facility waste is less than

10 Mg/yr (11 tons/year), it is exempt from the requirements of §61.342(b)

and (c) of the BWON. The TAB waste quantity shall be determined as

specified in §61.342(a) of the BWON on an annual basis.

§61.342 (a)

If the total annual benzene (TAB) quantity from facility waste is greater

than or equal to 10 Mg/yr (11 tons/year) as determined by §61.342(a) of

the BWON, the facility waste shall comply with the requirement of

§61.342(c) through (h) of the BWON.

§61.342 (b)

§61.342(c)-(h)

A Group 1 wastewater stream shall comply with the requirements of

§61.340 through §61.355 of the BWON for a process wastewater stream

that meets the definition in §63.641.

§61.340

§61.355

§63.641

§63.647(a)

All terms not defined in §63.641 of MACT CC shall have the

meaning provided in §63.641 of the BWON.

§63.647(b)

If a flare is used as a control device, the flare shall meet the

requirements of §63.670 of MACT CC.

§63.647(c)

Operate in a manner consistent with the minimum or maximum

(as appropriate) permitted concentration or operating parameter

values, if required under the BWON to perform periodic

measurement of benzene concentration in wastewater, or to

monitor process or control device operating parameters.

§63.647(d)

Operation of the process, treatment unit, or control device

resulting in a measured concentration or operating parameter

value outside the permitted limits shall constitute a violation of the

emission standards

§63.647(d)

Failure to perform required leak monitoring for closed vent

systems and control devices or failure to repair leaks within the

time period specified in the BWON shall constitute a violation of

the standard.

§63.647(d)

78



A Group 2 wastewater stream does not meet the definition of a Group 1

wastewater stream as defined in §63.641.

§63.641

The following exemptions shall apply for Group 1 wastewater streams:

Waste streams identified in §61.340(c) of the BWON and

§63.640(d)(1) of MACT CC are exempt from the requirements of

those subpart.

§61.340(c)

§63.640(d)(1)

Any gaseous stream from a waste management unit, treatment

process, or wastewater treatment system routed to a fuel gas

system, as defined in §61.341, is exempt from the BWON.

§61.340(d)

No testing, monitoring, recordkeeping, or reporting is required

under this subpart for any gaseous stream from a waste

management unit, treatment process, or wastewater treatment

unit routed to a fuel gas system

§61.340(d)


Compliance with the BWON shall be determined by review of facility

records and results from tests and inspection using the methods and

procedures specified in §61.355 of the BWON.

§61.342(g)

§61.355

Emission Monitoring

Monitoring of operations that are subject to proviso 2 and 3 of the emission

standards section of this subpart, shall be conducted as specified in

§61.354 to ensure that the unit is properly operated and maintained by the

appropriate monitoring procedures.

§61.354


The following recordkeeping and reporting requirements shall be met to

demonstrate compliance with the wastewater provisions specified in

§63.647:

§63.647

§63.655(a)

Unless the requirements of §63.640(o)(2)(ii) of MACT CC are being

met, the recordkeeping requirements specified in §61.356 of the

BWON and the reporting requirements specified in §61.357 of the

BWON shall be complied with.

§61.356

§61.357

§63.640(o)(2)(ii)

§63.655(a)

There are no additional reporting and recordkeeping requirements

for wastewater under MACT CC unless a wastewater stream is

included in an emissions average.

§63.655(a)

79



Recordkeeping and reporting for emissions averages are specified

in §63.653 and in §63.655(f)(5) and (g)(8) of MACT CC.

§63.653

§63.655(a)

§63.655(f)(5)

§63.655(g)(8)

Each record shall be maintained in a readily accessible location at

the facility site for a period not less than two years from the date

the information is recorded unless otherwise specified.

§61.356

A periodic monitoring report (PMR) meeting the requirements specified in

proviso 2(a) and (b) of this section of this subpart shall be submitted to the

Department.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(i)


term or condition including those that occur during startups and

shutdowns.




that can be used to determine or indicate compliance, that




If no deviation event occurred during the reporting period,

a statement that indicates there were no deviations from

the permit requirements shall be included in the report.


shall include the information specified in proviso 2(b)(1) and (2) of

this section of this subpart.

(1) For each deviation event, the following information shall

be submitted:



(iii) Date

(iv) Starting time

(v) Duration


80



(vii) Cause


conditions




reporting period




A copy of emissions test performed per MACT CC, or a

statement referencing those tests, shall be included with

each monitoring report.



schedule:






A copy of the Total Annual Benzene [TAB] calculation covering a calendar

12-month period shall be submitted to the Department annually within 60

days of the end of the calendar annual reporting period.

Rule 335-3-16-.05(c)(3)





Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

81

SUMMARY PAGE FOR NSPS VVa & MON: DI-METHYL SULFIDE (DMS) UNIT



EMISSION


EMISSION

LIMIT REGULATIONS

INDIVIDUAL SOURCES PART OF THE DMS UNIT:

STORAGE TANKS:

T-300 Methanol Storage Tank

w/Internal Floating Roof

Methanol Complying with

NSPS Kb

§63.2535(c)

[MON/MACT FFFF]

PROCESS VENTS:

None No vent meets the

definitions in §63.2550 of

the MON

TRANSFER RACKS:

Transfer Racks are classified

as Group 2

OHAP None*

*Classified as a Group 2 Rack

§63.2475

[MON/MACT FFFF]

WASTEWATER STREAMS:

DMS Produced water

stream & Maintenance

water stream

Methanol Work practices

Recordkeeping & Reporting

per 40 CFR 63 Subpart G

§63.2485

[MON/MACT FFFF]

FUGITIVE VOC & OHAP EMITTING EQUIPMENT

Valves, flanges, pumps,

piping, etc.

OHAP

VOC

LDAR Program

LDAR Program

§63.2480

[NESHAP UU]

§60.482-1a

[NSPS VVa]

82

Provisos for DMS Unit


Applicability

Each affected facility that is identified on the Summary Page of this subpart

shall be subject to the requirements of ADEM Admin. Code r. 335-3-16,

“Major Source Operating Permits”, and to this subpart of this permit.

Rule 335-3-16-.03

Each piece of equipment in organic hazardous air pollutant (OHAP) service

(including wastewater, piping, and ancillary equipment) that is listed on the

summary page is subject to the requirements of 40 CFR 63 Subpart FFFF ,

“National Emission Standards for Hazardous Air Pollutants: Miscellaneous

Organic Chemical Manufacturing“ [MON/NESHAP FFFF], and the

requirements in this subpart of this permit

§63.2430, MON

§63.2435, MON

§63.2440(a), (b), (c)(1) , MON

§63.2445, MON

§63.2450, MON

§63.2550, MON

Compliance with the applicable requirements of 40 CFR 63 subpart

A, “General Provisions” [Subpart A], shall be met as specified in

Table No. 12 of the MON.

§63.2540, MON

Table 12, MON

Nothing in this section shall preclude the Permittee from selecting

another compliance option allowed by this subpart, provided

written notice is first supplied to the Department.

§63.2480, MON

§63.2485, MON

Each piece of equipment in VOC service listed on the summary page is

subject to the requirements of 40 CFR 60 Subpart VVa, “Standards of

Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals

Manufacturing Industry” [NSPS VVa], and the requirements in this subpart

of this permit

§60.480a, NSPS VVa

§60.481a, NSPS VVa

Emission Standards

Except as specified in §63.2485(b) through (o) of the MON and during

periods of start-ups, shutdowns, or malfunctions, the wastewater stream

off of the DMS unit shall meet the following requirements:

§63.2450(a) , MON

§63.2455(a, MON)

§63.2485(a) , MON

Table 7, No. 2, MON

(a) A maintenance wastewater stream containing methanol, which is

listed as an organic HAP in Table 9 of the MON, shall meet the

maintenance wastewater requirements specified in §63.105 of 40

CFR 63, Subpart F, “National Emission Standards for Organic

Hazardous Air Pollutants From the Synthetic Organic Chemical

Manufacturing Industry" [NESHAP F], and the requirements in this

subpart of this permit, except as specified in §63.2485 of the MON.

§63.2450(a), MON

Table 7, No. 2, MON

§63.2485(a) & (b)

§63.105, NESHAP F

83



(1) As specified in §63.105(b) of the MON, a description of

maintenance procedures for management of wastewaters

generated from the emptying and purging of equipment in

the process during temporary shutdowns for maintenance-

turnaround and during routine maintenance shall be

prepared

§63.105(b), MON

(i) This document shall be kept current and modified

as needed to reflect operational procedures.

§63.105(c), MON

(ii) Procedures from this document shall be

incorporated into the start-up, shutdown, and

malfunction plan.

§63.105(d), MON

A record of the information required in the maintenance

procedure description shall be retained onsite as part of the

start-up, shutdown, and malfunction plan.

§63.105(e), MON

A process wastewater stream containing methanol, which is listed

as an organic HAP in Table 9 of the MON, shall comply with the

applicable requirements specified in 40 CFR 63, Subpart G,

“National Emission Standards for Organic HAP from the Synthetic

Organic Chemical Manufacturing Industry for Process Vents,

Storage Vessels, Transfer Operations, and Wastewater” [NESHAP

G], and the requirements in this subpart of this permit, except as

specified in §63.2485 of the MON.

§63.2450(a), MON

Table 7, No. 2, MON

§63.2485(a) & (b), MON

(1) The wastewater stream classification [Group 1 or Group 2]

will be determined using the following criteria initially and

whenever a process change is made that could affect the

status:

63.2450(a) , MON

Table No. 7, No. 1, MON

§63.2485(a), (b), & (c), MON

§63.132(a)(1)(i), (b)(1)(i),

(b)(2)(i), & (c), NESHAP G

(i) A wastewater stream will be designated as Group 1

if one (or more) of the following is met:

(A) The total annual average concentration of

compounds listed in Table No. 8 of the MON

is ≥ 10,000 ppmv AND the total annual load

of compounds listed in Table No. 8 of the

MON is ≥ 200 Lb/yr

OR

(B) The total annual average concentration of

compounds listed in Table No. 8 of the MON

is ≥ 1,000 ppmv AND the annual average

flowrate is ≥ 1 L/min

84



OR

(C) The combined total annual average

concentration of compounds listed in Table

Nos. 8 & 9 of the MON is ≥ 30,000 ppmv

AND the combined total annual load of

compounds listed in Table Nos. 8 & 9 of the

MON is ≥ 1 Ton/yr

(ii) Any stream not designated as Group 1 will be

designated as Group 2.

A Group 1 Stream shall meet the emission standards in

§63.133, §63.134, §63.135, §63.136, §63.137, and §63.138

of NESHAP G, except as modified by §63.2485(d), (e), (f), (g),

(m), and (n) of the MON.

§63.2450(a), MON

Table No. 7, No. 1, MON

§63.2485(a), (b), & (c), MON

§63.132(a)(2) & (b)(3),

NESHAP G

A Group 2 Stream shall only be subject to the applicable

recordkeeping and reporting requirements specified in

§63.146(b)(1) and §63.147(b)(8) of NESHAP G.

§63.2450(a), MON

Table No. 7 , No. 1, MON

§63.2485(a), (b), & (c), MON

§63.132(a)(3) & (b)(4) NESHAP G

Each piece of equipment shall comply with the applicable equipment leak

requirements specified in §63.1021 through §63.1037 of 40 CFR Part 63

Subpart UU, “National Emission Standards For Equipment Leaks—Control

Level 2 Standards”, [NESHAP UU], except as modified by §63.2480(b) of the

MON. Additionally, all equipment shall be subject to §§60.482-1a through

§60.484a of NSPS VVa.

§63.2480(a), MON

Table No. 6, No. 1(a) and 2(a)(i),

MON

§63.2450(a), MON

§60.480a, NSPS VVa

Opening of a safety device shall be allowed at any time that it is required to

avoid unsafe operating conditions.

§63.2450(p), MON

If the emissions from different emission sources subject to this subpart of

this permit are combined and are sent to a single control device, the

requirements specified in §63.2450(c) of the MON shall be met.

§63.2450(c), MON

Each affected source, including air pollution control and monitoring

equipment, shall always be operated and maintained in accordance with the

requirements specified in proviso §63.6(e)(1)(i) of Subpart A.

§63.2450(a), MON

The following requirement shall be met for control devices subject to the

MON:

(a) Provided a non-flare control device is being utilized, a monitoring

plan shall be submitted that meets the control device requirements

specified in proviso §63.2450(e) of the MON.

§63.2450(e), MON

85



(b) A flare used as a control device shall meet the flare compliance

requirements in §63.2450(f) of the MON.

§63.2450(f), MON

A written startup, shutdown, and malfunction plan shall be developed and

implemented in accordance with the requirements specified in proviso

§63.6(e)(3) of Subpart A.

§63.2450(a), MON

Table 12, MON

Each affected source shall be operated in accordance with §63.6(e)(1) and

(3) of Subpart A during each startup, shutdown, or malfunction.

§63.2450(a), MON

Table 12, MON


Each wastewater stream shall be sampled according to the methods

specified in §63.143, §63.144, and §63.145 of NESHAP G, except as modified

by §63.2485(h), (j), and (k) of the MON.

§63.2485(a), MON

Evaluations on flares shall be conducted when necessary according to

§63.2450(f) of the MON.

§63.2450(f), MON

Performance tests on non-flare control devices shall be conducted when

necessary according to §63.2450(g), (h), and (i) of the MON.

§63.2450(g), MON

Leaks shall be determined according to the methods and procedures

specified in §63.1023 of NESHAP UU AND §60.485a (d)-(f) of NSPS VVa.

Rule 335-3-16-.05(c)(1)(i),

§60.480a(e)(2)(i), NSPS VVa

§63.1023, NESHAP UU

Emission Monitoring

The following monitoring systems requirements shall be met to

demonstrate compliance with the MON:

(a) A Continuous Emissions Monitoring System (CEMS) OR Continuous

Parameter Monitoring System [CPMS] shall be installed, operated,

and maintained on each control device.

§63.2450(j) & (k), MON

A CEMS shall meet the requirements of §63.2450(j) of the

MON

CPMS shall meet the requirements of §63.2450(k) of the

MON

The requirements for performance tests as specified in 63.2450(g)

of the MON shall be complied with where applicable for control

devices.

§63.2450(g), MON

86



For equipment leaks, the following monitoring requirements shall be met:

Inspections and monitoring shall meet the applicable requirements

and frequency specified in §§63.1021 through §63.1037 of NESHAP

UU, except as modified by §63.2480(b) of the MON.

§63.2480(a), MON

Table No. 6, No. 1(a) OR No.

2(a)(i), MON

§63.2450(a), MON

All equipment leaks shall comply with the monitoring requirements

in §60.482-1a through §60.484a of NSPS VVa.

§60.480a, NSPS VVa

The annual average concentration and annual average flowrate shall be

determined for each wastewater stream associated with the DMS Unit. The

procedures for flexible operating units specified in §63.144 (b) and (c) of

NESHAP G do not apply for the purposes of the MON.

§63.2485(j), MON


A copy of the following records shall be maintained onsite for a period of

five (5) years:

§63.10(b), Subpart A

A description of all operating scenarios as specified in §63.2525(b)

of the MON shall be kept.

§63.2525(b), MON

For the wastewater streams:

For all Group 1 streams, as applicable, records of all of the

items required by §63.147 of NESHAP G shall be

maintained.

§63.2525(a), MON

§63.147, NESHAP G

For all Group 2 streams, records of only the items in

§63.147(b)(8)(i) through (iv) of NESHAP G shall be

maintained.

§63.2525(a), MON

§63.147(b)(8), NESHAP G

Records required by §63.1038 of NESHAP UU and §60.486a of NSPS

VVa shall be maintained.

§63.2525(a), MON

§60.486a

Records of all control devices and closed vent systems, in use §63.2525(a), MON

A record of each time a safety device is opened to avoid an unsafe

condition in accordance with §63.2450(s) of the MON.

§63.2525(f), MON

A record of each CEMS OR CPMS check, maintenance, and date,

time, and duration of each downtime.

§63.2485(o), MON

§63.2525(g) & (h), MON

The date, time, and duration of each start-up, shutdown, and

malfunction, along with the corrective actions taken.

§63.2525(h), MON

87



The following reporting requirements shall be met:

(a) A Compliance Report shall include the applicable information

specified in §63.2520(e)(1) through (10) of the MON.

§63.2450(m), MON

§63.2520(e)(1)-(10), MON

Table 11, No. 3, MON


observation, by data derived from any monitoring or testing

or recordkeeping which is required by the permit that can

be used to determine or indicate compliance, that identifies

an affected source has failed to meet an applicable

emission limit or standard, or that a work practice was not

complied with or completed.

If there are no deviations events that occurred during the

reporting period, a statement that indicates there were no

deviations from the permit requirements shall be included

in the report.

Each report shall be submitted semi-annually on the following

reporting schedule:




§§63.2520(a), (b)(5)





Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

88


89

Summary Page for NSPS K: Petroleum Liquid Storage Vessels



EMISSION


EMISSION


All petroleum liquid storage vessels with a capacity > 40,000 gallons and constructed, reconstructed, or modified after June 11, 1973, but before May 19, 1978

Maximum True Vapor Pressure (TVP)

1.5 psia < TVP < 11.1 psia

TVP > 11.1 psia

VOC Work Practice Standards

Install floating roof or vapor recovery system or equivalent system

Install vapor recovery system or equivalent system

§60.112(a)(1) [NSPS K] §60.112(a)(2) [NSPS K]

STORAGE VESSELS:

WITH EXTERNAL FLOATING ROOF:

T-088

T-089

1,614,350 gallons [Subject to NSPS K & Group 2 MACT CC| Comply NSPS K]

1,614,350 gallons [Subject to NSPS K & Group 2 MACT CC| Comply NSPS K]

90

Provisos for NSPS K Petroleum Liquid Storage Vessels


Applicability

Each storage vessel that is identified in the Summary Page of this

subpart shall be subject to the requirements specified in ADEM Admin.

Code r. 335-3-16, “Major Source Operating Permits”, and in this

subpart of this permit.

Rule 335-3-16-.03

Except as provided for in §60.110(b) of 40 CFR Part 60, Subpart K

“Standards of Performance for Storage Vessels from Petroleum

Liquids” [NSPS K], each storage vessel that is identified in the Summary

Page of this subpart shall comply with the requirements of NSPS K and

the requirements specified in this subpart of this permit.

Rule 335-3-10-.02(9)

§60.110(a) and (b)

If overlap of 40 CFR Part 63 Subpart CC “National Emission

Standard for Hazardous Air Pollutants from Petroleum

Refineries” [Refinery MACT 1/MACT CC], with NSPS K occurs

after the compliance dates specified in §63.640(h) of MACT CC

the following requirements shall be met:

§63.640(h)

Each Group 2 storage vessel subject to NSPS K and

MACT CC, but not subject to the control requirements

under NSPS K, must comply only with the

requirements specified under MACT CC.

§63.640(n)(7)

§63.641

Each Group 2 storage vessel that is subject to the

control requirements under NSPS K, must comply only

with the requirements specified under NSPS K.

§63.640(n)(6)

§63.641

The applicable requirements specified under 40 CFR Part 60,

Subpart A, “General Provisions”, shall be complied with.

40 CFR 60 Subpart A

Emission Standards

Provided that the true vapor pressure of the petroleum liquid, as

stored, is greater than or equal to 1.5 psia but less than or equal to 11.1

psia, the storage vessel shall be equipped with one of the following:

§60.112(a)(1)

A floating roof

A vapor recovery system

An equivalent system

Provided that the true vapor pressure of the petroleum liquid, as

stored, is greater than 11.1 psia, the storage vessel shall be equipped

with one of the following:

§60.112(a)(2)

91



A vapor recovery system

An equivalent system


There are no testing requirements for NSPS K tanks.

Emission Monitoring

Periodic monitoring shall be in the form of maintaining records as

specified in the recordkeeping and reporting requirements section of

this subpart.

Rule 335-3-16-.05(c)(1)(ii)


Except as provided for in §60.113(d) of NSPS K, the following

recordkeeping and reporting requirements specified in §60.113 of

NSPS K shall be maintained on a monthly basis, made available for

inspection and submitted to the Department when requested:

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

§60.113(a), (b), (c), and (d)

§60.7(a) and (b)

§60.19

Record of the petroleum liquid stored

Record of the period of storage

Record of the maximum true vapor pressure of the liquid

during the respective storage period as specified in §60.113(b)

and (c) of NSPS K

A monthly record of the information specified in provisos 2(a) through

(c) of this section of this subpart shall be maintained for each storage

vessel.

Rule 335-3-16-.05(c)(2)

Contents of each tank

ThrougHPut of each tank

Average storage temperature of each tank

A periodic monitoring report (PMR) meeting the requirements

specified in proviso 3(a) and (b) of this section of this subpart shall be


Rule 335-3-16-.05(c)(3)(i)




92








failed to meet an applicable emission limit or standard,

or that a work practice was not complied with or

completed.









shall be submitted.



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause


conditions




reporting period




93





reporting schedule:










of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

94


95

Summary Page for NSPS Ka: Petroleum Liquid Storage Vessels



EMISSION


EMISSION


All petroleum liquid storage vessels with a capacity > 40,000

gallons and constructed, reconstructed, or modified after

May 18, 1978, but before July 23, 1984

Maximum True Vapor Pressure (TV)

1.5 psia < TVP < 11.1 psia

TVP > 11.1 psia

VOC

Work Practice Standards:

Install floating roof or vapor

recovery system and vapor

return or disposal system to

reduce emissions to atmosphere

by at least 95% by weight or

equivalent system

Install vapor recovery system

and a vapor return or disposal

system to reduce emissions to

atmosphere by at least 95% by

weight

§60.112a(a)

[NSPS Ka]

§60.112a(b)

[NSPS Ka]

STORAGE VESSELS WITH INTERNAL FLOATING ROOF

T–094 630,000 gallon [Subject to NSPS Ka & Group 2 MACT CC| Comply w/NSPS Ka]

T-095 630,000 gallon [Subject to NSPS Ka & Group 2 MACT CC| Comply w/NSPS Ka]

96

Provisos for NSPS Ka Petroleum Liquid Storage Vessels


Applicability

Each storage vessel that is identified in the Summary Page of this subpart

shall be subject to the requirements specified in ADEM Admin. Code r.

335-3-16, “Major Source Operating Permits”, and in this subpart of this

permit.

Rule 335-3-16-.03

Except as provided for in §60.110a(b) of 40 CFR Part 60, Subpart Ka

“Standards of Performance for Storage Vessels from Petroleum Liquids”

[NSPS Ka], each storage vessel that is identified in the Summary Page of

this subpart shall comply with the requirements of NSPS Ka and the


Rule 335-3-10-.02(9)(a)

§60.110a(a) and (b)

If overlap of 40 CFR Part 63 Subpart CC “National Emission

Standard for Hazardous Air Pollutants from Petroleum Refineries”

[Refinery MACT 1/MACT CC] with NSPS Ka occurs, each Group 2

storage vessel under MACT CC that is subject to the control

requirements under NSPS Ka, must comply only with the

requirements specified under NSPS Ka, except as specified in

§63.640(n)(9) of MACT CC.

§63.640(h)

§63.640(n)(6) and (n)(9)

§63.641

The applicable requirements specified under 40 CFR Part 60,

Subpart A, “General Provisions” shall be met only as specified in

§60.110a(c)(2) of NSPS Ka.

§60.110a(c)(2)

Emission Standards

Provided the true vapor pressure of the petroleum liquid, as stored, is

greater than or equal to 1.5 psia but not greater than 11.1 psia, the

storage vessel shall be equipped with one of the following controls:

§60.112a(a)

A fixed roof and an internal floating roof that meets the

requirements specified §60.112a(a)(2) of NSPS Ka and as follows:

§60.112a(a)(2)

Roof shall be equipped with a continuous closure device

between the tank wall and cover edge.

Cover shall be floating (off the leg supports) at all-times

except during initial fill and when the tank is completely

emptied and subsequently refilled.

Emptying and refilling when the cover is resting on the leg

supports shall be continuous and shall be accomplished

as rapidly as possible

97



Each opening in the cover, except for automatic bleeder

vents and the rim space vents, is to provide a projection

below the liquid surface.

Each opening in the cover except for automatic bleeder

vents, rim space vents, stub drains and leg sleeves is to be

equipped with a cover, seal, or liquid which is to be

maintained in a closed position at all times except when

the device is in actual use.

Automatic bleeder vents are to be closed at all time when

the cover is floating except when the cover is being

floated off or is being landed on the leg supports.

Rim vents are to be set to open only when the cover is

being floated off the leg supports or at the

manufacturer’s recommended settings.

OR

Other controls specified in §60.112a (a)(1), (3), or (4). Nothing in

this permit shall preclude a source from selecting a different

control allowed under this subpart.

§60.112a(a)(1) , (3), (4)

Provided the true vapor pressure of the petroleum liquid, as stored, is

greater than 11.1 psia, the storage vessel shall be equipped with a vapor

recovery system and a vapor return or disposal system that meets the

requirements specified in §60.112a(b) of NSPS Ka.

§60.112a(b)

As an alternative means of compliance, compliance with 40 CFR part 65,

Subpart C may be elected to satisfy the requirements of §60.112a through

§60.114a of NSPS Ka for storage vessels that store petroleum liquids with

a maximum true vapor pressure (TVP) greater than or equal to 10.3 kPa

(1.5 psia).

§60.110a(c)

§60.112a-§60.114a

40 CFR part 65, Subpart C


There are no testing requirements for NSPS Ka tanks that are equipped

with a fixed roof and internal floating roof.

NSPS Ka tanks that are equipped with an external floating roof or for

which a vapor recovery and return or disposal system is equipped shall

comply with testing and procedures specified in §60.113a.

§60.113a

98



Emission Monitoring

Except as specified in §60.115a(d) of NSPS Ka, monitoring as specified in

§60.115a(a) of NSPS Kaa shall be in the form of recordkeeping as specified

in the recordkeeping and reporting section of this subpart of this permit.

§60.115a(a), (d)


Except as provided in §60.115a(d) of NSPS Ka, the following records shall

be maintained on a monthly basis for each storage vessel during the

respective storage period:

§60.7(a), (b)

§60.19

§60.115a(d)

Record of the petroleum liquid stored §60.115a(a)

Period of storage §60.115a(a)

Maximum true vapor pressure of the liquid §60.115a(a)

Typical Reid vapor pressure and the maximum expected storage

temperature if used to determine the maximum true vapor

pressure

§60.115a(b)

True vapor pressure of each type of crude oil §60.115a(c)

A periodic monitoring report (PMR) meeting the requirements specified

in proviso 2(a) and (b) of this section of this subpart shall be submitted to

the Department.

Rule 335-3-16-.05(c)(3)(i)

(a) Each report shall identify each incidence of deviation from a






that can be used to determine or indicate compliance,








99







be submitted.



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause


conditions




reporting period






schedule:






100







Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

101

Summary Page for NSPS Kb Petroleum Liquid Storage Vessels



EMISSION


EMISSION


All volatile organic liquid petroleum liquid storage vessels

with a capacity > 19,812.9 gallons and constructed,

reconstructed, or modified after July 23, 1984

VOC Work Practice Standards:

DESIGN CAPACITY MAX TVP

19,812 gallons < DC < 39,890 gallons (75m 3 < DC < 151m3)

4.0 psia < Max TVP < 11.1 psia (27.6 kPa < Max TVP < 76.6 kPa)

DC > 39,890 gallons (DC > 151m3)

0.754 psia < Max TVP < 11.1 psia (5.2 kPa < Max TVP < 76.6 kPa)

DC > 19,812 gallons

(DC > 75m3)

Max TVP > 11.1 psia

(Max TVP > 76.6 kPa)

Install floating roof or

Closed Vent System (CVS)

and control device or

equivalent system

Install CVS and control

device or equivalent

system

§60.112b(a)

[NSPS Kb]

§60.112b(b)

[NSPS Kb]

STORAGE VESSELS:

WITH FIXED ROOF AND CVS [§60.112b(a)(3)]:

T-301

T-302

T-303

20,305 gallons

20,305 gallons

232,190 gallons

[Subject to NSPS Kb & Group 2 MACT CC| Comply w/NSPS Kb]



WITH INTERNAL FLOATING ROOF [§60.112b(a)(1)]: :

T-097

T-199

T-201

T-202

T-300

T-354

840,000 gallons

3,360,000 gallons

3,360,000 gallons

3,360,000 gallons

271,072 gallons

42,000 gallons

[Subject to NSPS Kb & NSPS QQQ| Comply w/NSPS Kb]




[Subject to NSPS Kb & 40 CFR 63 Subpart FFFF [MON] | Comply w/NSPS Kb]

[Subject to NSPS Kb & Group 1 MACT CC | Comply w/NSPS Kb]

102

Provisos for NSPS Kb Petroleum Liquid Storage Vessels


Applicability

Each storage vessel that is identified in the Summary Page of this

subpart shall be subject to the requirements specified in ADEM Admin.

Code r. 335-3-16, “Major Source Operating Permits”, and in this


Rule 335-3-16-.03

Except as provided in §60.110b(b) and (d) of 40 CFR Part 60, Subpart

Kb, “Standards of Performance for Volatile Organic Liquid (VOL)

Storage Vessels” [NSPS Kb], each storage vessel that is identified in the

Summary Page of this subpart is subject to the requirements of NSPS

Kb and this subpart of this permit

Rule 335-3-10-.02(9)(b)

§60.110b(a)

§60.110b(b)

§60.110b(d)

Since there is overlap of 40 CFR Part 63 Subpart CC, “National

Emission Standard for Hazardous Air Pollutants from

Petroleum Refineries” [Refinery MACT 1/MACT CC] with NSPS

Kb after the compliance dates found in §63.640(h) of MACT CC

for storage vessels, each MACT CC Group 1 and Group 2

storage vessels also subject to NSPS Kb, shall comply only with

NSPS Kb, except as specified in §63.640(n)(8) of MACT CC.

§63.640(h)

§63.640(n)(1), (2), (8)

Since there is overlap of 40 CFR Part 63 Subpart FFFF, “National

Emission Standard for Hazardous Air Pollutants: Miscellaneous

Organic Chemical Manufacturing” [NESHAP FFFF] with NSPS

Kb for storage vessels, the requirements specified under NSPS

Kb only shall be met for the T-300 storage vessel.

§63.2535(c)

Compliance with 40 CFR 60 Subpart A, “General Provisions”

shall be met as specified in NSPS Kb.

§60.110b(e)(2)

Emission Standards

Table No. 1:

Storage Tank

Design Capacity (DC)

(Gallons)

Volatile Organic Liquid


(psia)

19,812 Gallons < DC < 39,890 Gallons & 4 psia < Max TVP <11.1 psia

DC > 39,890 Gallons & 0.75 psia < Max TVP <11.1 psia

§60.112b(a)

Each storage vessel meeting the applicable requirements specified in

Table No. 1 of this section shall comply with NSPS Kb by equipping each

storage vessels with one of the following:

§60.112b(a)

Install, operate, and maintain a fixed roof in combination with

an internal floating roof that meets the requirements specified

section §60.112b(a)(1) of NSPS Kb.

§60.112b(a)(1)

103



Install, operate, and maintain any other control device, closed

vent system and control device, or an equivalent system as

allowed under §60.112b(a)(2), (3), or (4) of NSPS Kb. Nothing

in this subpart shall preclude a source from complying with

another control allowed under this subpart.

§60.112b(a)(2), (3), (4)

Install, operate, and maintain a system equivalent to those

described in either proviso 1(a) or 1(b) of this section that

meets alternative means of emission limitation specified in

§60.114b of NSPS Kb.

§60.112b(a)(4)

§60.114b

Table No. 2:

Storage Tank


(Gallons)



(psia)

DC > 19,812 Gallons & Max TVP > 11.1 psia

§60.112b(b)

Each storage vessel meeting the requirements specified in Table No. 2

of this section shall comply with NSPS Kb by meeting the requirements

specified in §60.112b(b).

§60.112b(b)

Each storage vessel storing a waste mixture of indeterminate or

variable composition shall comply with the requirements specified in

§60.116b(f) of NSPS Kb.

§60.116b(f)

As an alternative means of compliance, compliance with 40 CFR part

65, Subpart C may be elected to satisfy the requirements of §60.112b

through §60.117b of NSPS Kb for storage vessels that store petroleum

liquids meeting the requirements in §60.110b(e).

§60.110b(e)

§60.112b-§60.117b

Table No. 3:

Storage Tank


(Gallons)



(psia)

19,812 Gallons < DC < 39,890 Gallons & Max TVP <2.176 psia

DC > 39,890 Gallons & Max TVP <0.508 psia

§60.110b(b)

Storage vessels meeting the requirements specified in Table No. 3 of

this section and those specified in §60.110b(d) of NSPS Kb are exempt

from the requirements of this subpart.

§§60.110b(b), (d)


The test methods and procedures specified in §60.113b(a) of NSPS Kb

shall be utilized after a permanently affixed roof and internal floating

roof has been installed a storage vessel.

§60.113b(a)

104



Emission Monitoring

Storage vessels equipped with a permanently affixed roof and internal

floating roof shall be monitored as follows:

§60.113b(a)

The internal floating roof, the primary seal, and the secondary

seal (if in service) shall be visually inspected prior to being filled

with a VOL.

§60.113b(a)(1)

The internal floating roof and the primary seal or the

secondary seal (if in service) shall be visually inspected through

manholes and roof hatches on the fixed roof at least once

every 12 months, but at intervals no greater than 10 years if a

liquid-mounted or mechanical shoe primary seal is installed on

the storage vessel.

§60.113b(a)(2)

§60.113b(a)(4)

Repairs shall be made to the storage vessel or the

vessel shall be emptied and removed from service

within 45 day if defects or failures as specified in

§60.113b(a)(2) of NSPS Kb occur.

If a failure detected during inspections cannot be

repaired or emptied within 45 days, a 30-day

extension may be requested as specified in

§60.113b(a)(2) of NSPS Kb.

Storage vessels equipped with a double-seal system shall be

visually inspected as specified in proviso 1(c)(1) or 1(c)(2) of

this section of this subpart:

§60.113b(a)(3)

§60.113b(a)(4)

At least once every five years, but at intervals no

greater than five years, the vessel shall be visually

inspected as specified in §60.113b(a)(4) of NSPS Kb.

OR

As specified in proviso 1(b) of this section of this

subpart.

Each time the storage vessel is emptied and degassed, a visual

inspection must be conducted on the internal floating roof, the

primary seal, the secondary seal, gaskets, slotted membranes,

and sleeve seals (if any).

§60.113b(a)(4)

Inspections shall occur at intervals no greater than 10

years

105



Prior to the vessel being refilled, all defects and

failures must be repaired


Except as specified in §60.115b(c)(1), storage vessels meeting the

design capacity and maximum TVP requirements in Table 1 of the

emission standards section of this subpart, records and submitted

reports (depending on the control equipment) shall be maintained for

two years.

§60.115b

§60.115b(c)(1)

The following records shall be maintained for storage vessels equipped

with a fixed roof and internal floating roof:

§60.115b(a)

A report describing the control equipment and certifying that

the control equipment meets the requirements of

§60.112b(a)(1) and §60.113b(a)(1) of NSPS Kb shall be

submitted, with the notification required by §60.7(a)(3) of

subpart A, to the Department.

§60.115b(a)(1)

§60.112b(a)(1)

§60.113b(a)(1)

§60.7(a)(3)

A record of each inspection performed as required under

§60.113b(a)(1) through (a)(4) of NSPS Kb shall be maintained

and shall include the following information:

§60.115b(a)(2)

Identify the storage vessel the inspection was

performed on

Contain the date the vessel was inspected

Contain the observed condition of each component of

the control equipment (seals, internal floating roof,

and fittings).

If any failures or defects are detected during a visual inspection

a report shall be submitted to the Department within 30 days

of the inspection and shall include the following information:

§60.115b(a)(3)

Identify the storage vessel

Identify the nature of the defects

Identify the date the storage vessel was emptied or

the nature of and date the repair was made

The dimensions and an analysis showing the capacity of each storage

vessel subject to NSPS Kb shall be maintained and kept readily

accessible for the life of each vessel.

§60.116b(a) and (b)

106



Table No. 4:

Storage Tank


(Gallons)



(psia)

19,812 Gallons < DC < 39,890 Gallons & Max TVP > 2.176 psia

DC > 39,890 Gallons & Max TVP > 0.508 psia

§60.116b(c)

Unless a storage vessel meeting the requirements specified in Table

No. 4 stores a waste mixture of indeterminate or variable composition

or it is equipped with a CVS and a control device, the following records

shall be maintained for each vessel for at least two years:

§60.116b(c), (e), (f), (g)

Record of the VOL stored

Period of storage

Maximum true vapor pressure of the liquid

Table No. 5:

Storage Tank


(Gallons)



(psia)

19,812 Gallons < DC < 39,890 Gallons Max TVP normally < 4.0 psia

DC > 39,890 Gallons Max TVP normally < 0.754 psia

§60.116b(d)

Unless a storage vessel meeting the requirements in Table No. 5 is

equipped with a CVS and a control device, the Department shall be

notified within 30 days when the maximum TVP of the liquid exceeds

the respective maximum true vapor pressure values for each volume

range. This record shall be maintained for at least 2 years.

§60.116b(d)

§60.116b(g)

The Department shall be notified prior to the filling or refilling of each

storage vessel that has to be visually inspected as specified in

§60.113b(a)(5) of NSPS Kb.

§60.113b(a)(5)

Periodic Monitoring Reports (PMR) meeting the requirements

specified in proviso 7(a) and 7(b) of this section of this subpart shall be


Rule 335-3-16-.05(c)(3)(i)



startups, shutdowns, and malfunctions.

107





monitoring system or periodic monitoring required by

the permit that can be used to determine compliance,












shall be submitted.



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause


conditions




reporting period




108





reporting schedule:










of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

109

Summary Page for MACT CC: Organic HAP Storage Vessels



EMISSION


EMISSION


VOLATILE ORGANIC LIQUID STORAGE VESSELS OHAP Closed vent system w/95%

OHAP reduction or Install

floating roof w/seals and

maintain seals

§63.660(a)

[MACT CC]

GROUP 1 STORAGE VESSELS, AS DEFINED IN §63.641:

Equipped w/ Internal Floating Roof (IFR):

T-003

T-004

T-049

T-203

572,381 gallons

572,381 gallons

804,328 gallons

39,145 gallons

Equipped w/ External Floating Roof (EFR):

T-010

T-011

T-017A

T-060

T-061

T-062

T-063

T-064

T-065

T-066

T-067

T-083

514,805 gallons

514,805 gallons

324,575 gallons

783,214 gallons

783,214 gallons

783,214 gallons

783,214 gallons

840,000 gallons

840,000 gallons

1,599,356 gallons

1,599,356 gallons

2,463,420 gallons

110

EMISSION


EMISSION


VOLATILE ORGANIC LIQUID STORAGE VESSELS OHAP NONE

*Installed pre-1972

not reconstructed or

modified

§63.660(a)

[MACT CC]

GROUP 2 STORAGE VESSELS, AS DEFINED IN §63.641:

Equipped w/ Vertical Fixed Roof (VFR):

T-008

T-023

T-027

T-028

T-029

T-031

T-032

T-034

T-035

T-036

T-037

T-038

T-039

T-040

T-042

T-044

T-046

T-048

T-052

T-053

T-055

T-056

T-057

T-058

T-059

T-068

T-080

T-081

T-082

T-087

T-093M

T-096

T-102

T-200

T-353

T-374

E-1

E-2

E-3

E-5

E-6

E-7

E-8

E-9

E-11

E-12

E-13

E-14

E-16

E-17

Equipped w/ External Floating Roof (EFR):

T-085

T-086

111

Provisos for MACT CC: Organic HAP Storage Vessels Federally Enforceable Provisos Regulations

Applicability

Each organic hazardous air pollutant (OHAP) storage vessel shall be subject

to the requirements specified in ADEM Admin. Code r. 335-3-16, “Major

Source Operating Permits”, and the requirements specified in this subpart of

this permit.

Rule 335-3-16-.03

§63.642(a)

The requirements of 40 CFR 63 Subpart A, “General Provisions”, apply only

as specified in 40 CFR 63, Subpart WW, “National Emission Standards for

Storage Vessels (Tanks)-Control Level 2”, and as specified in this subpart of

this permit.

§63.1060

Each OHAP storage vessel shall be subject to the requirements specified in

40 CFR 63 Subpart CC, “National Emission Standards for Hazardous Air

Pollutants (HAPs) from Petroleum Refineries” [Refinery MACT 1/MACT CC],

and the requirements specified in this subpart of this permit.

§63.640 (a), (c)(2), (c)(7),

(e), (h),(n)

A Group 1 Storage Vessel part of an existing source on or after

February 1, 2016 is defined as a storage vessel that meets the

requirements in proviso 3(a) (1) or (2) of this section of the permit:

§63.641

§63.660

Design Capacity

(DC)

Stored-Liquid

Maximum True

Vapor Pressure

(TVP)

Annual Average

HAP Liquid

Concentration

(1) ≥ 151 cubic meter (m3)

(≥ 40,000 gallons)

≥ 5.2kPa

(0.75 psi)

>4% by weight

total organic HAPs

(2) 76 m3 ≥ DC < 151 m3

(20,000 gallons ≥ DC < 40,000 gallons)

≥ 13.1kPa

(1.9 psi)

>4% by weight

total organic HAPs

(b) A Group 1 Storage Vessel part of a new source on or after February

1, 2016 is defined as a storage vessel that meets the requirements in

proviso 3(b) (1) or (2) of this section of the permit:

§63.641

§63.660

Design Capacity

(DC)

Stored-Liquid

Maximum True

Vapor Pressure

(TVP)

Annual Average

HAP Liquid

Concentration

(1) ≥ 151 m3

(≥ 40,000 gallons)

≥ 3.4 kPa

(0.5 psi)

>2% by weight total

organic HAPs

(2) 76 m3 ≥ DC < 151 m3

(20,000 gallons ≥ DC < 40,000 gallons)

≥ 13.1kPa

(1.9 psi)

>2% by weight total

organic HAPs

(c) A Group 2 Storage Vessel part of a new source or an existing source

is any storage vessel that does not meet the definition of a Group 1

Storage Vessel as specified in Proviso 3(a) or (b) of this section.

§63.641

112


(d) Compliance with MACT CC will satisfy the requirements of the

following storage vessels subject to other regulations:

§63.641

§63.640(a), (c)(2), (c)(7),

(e)(1), (e)(2),§63.640(n),

(q), 63.642(c), (i), (j), (k),

(l), §§63.660 (a), (b), (c)

A Group 1 storage vessel that is part of a new source and

subject to 40 CFR 60 Subpart Kb.

§63.640 (n)(2)

A Group 2 storage vessel that is part of a new source and

subject to 40 CFR 60 Subpart Kb, but not required to install

controls.

§63.640 (n)(4)

A Group 1 storage vessel that is subject to 40 CFR 60 Subpart

K and/or Subpart Ka.

§63.640 (n)(5)

A Group 2 storage vessel that is subject to 40 CFR 60 Subpart

K and/or Subpart Ka, but not required to install controls.

§63.640 (n)(7)

Any storage tank also subject to the requirements of ADEM

Admin. Code Rule 335-3-6-.02, 335-3-6-.03, 335-3-6-.04, and

335-3-6-.23.

§63.640(q)

Rule 335-3-11-.01(2)

(e) Group 1 Storage vessels shall comply with the requirements of 40

CFR 63 Subpart WW OR 40 CFR 63 Subpart SS, “National Emission

Standards for Closed Vent Systems, Control Devices, Recovery

Devices and Routing to a Fuel Gas System or a Process”, as

referenced in MACT CC.

§63.660

All terms not defined in §63.641 shall have the meaning

given to them in subpart A, WW, or SS of 40 CFR Subpart 63.

§63.660(a)

The definitions of “Group 1 storage vessel” (paragraph (2))

and “Storage vessel” in §63.641 shall apply in lieu of the

definition of “Storage vessel” in §63.1061.

§63.660(a)

All references specified in §63.660(c)(1) through (6) shall

apply for the purposes of MACT CC.

§63.660(c)

Nothing in this permit will preclude the Permittee from

selecting an alternate method of compliance allowed under

MACT CC according to §63.980 of Subpart SS.

§63.660

§63.980

113


Emission Standards

A Group 1 storage vessel that is part of a new or existing source storing liquid

with a maximum true vapor pressure less than 76.6 kilopascals (11.1 pounds

per square inch) shall comply with the requirements in 40 CFR 63 Subpart

WW according to the requirements specified in §63.660(a) through (i) of

MACT CC and as specified below:

§63.660

The storage vessel must meet one of following control requirements:

Operate and maintain an internal floating roof (IFR) §63.1062(a)(1)

Operate and maintain an external floating roof (EFR) §63.1062(a)(2)

Comply with an equivalent to the requirements of Proviso

1(a)(1) or (2) by complying with an alternative means of

emission limitation as specified in §63.1064.

§63.1062(a)(3)

§63.1064

Provided that a Group 1 storage vessel is equipped with a floating

roof to comply with §63.1062 of WW, the following requirements

shall be met:

§63.1063

For IFR storage vessels, the design requirements for rim seals

shall be met by equipping the storage vessel with one of the

seal configurations specified in §63.1063(a)(1)(i)(A) through

(C), except as specified in §63.1063(a)(1)(i)(D).

§63.1063(a)(1)(i)(A)-(D)

For EFR storage vessels, the design requirements for rim

seals shall be met by equipping the storage vessel with one

of the seal configurations specified in §63.1063(a)(1)(ii)(A) or

(B), except as specified in §63.1063(a)(1)(ii)(C).

§63.1063(a)(1)(ii)(A)-(C)

For IFR and EFR storage vessels, the design requirements for

deck fittings shall be met as follows:

(i) Equip the opening through the deck of the floating

roof with a fitting as specified in §63.1063(a)(2)(i)

through (viii), except as specified in

§63.1063(a)(2)(ix).

§63.1063(a)(2)(i) through

(ix)

(ii) Provided that the requirements specified in Proviso

1(b)(3)(i) are not met as of June 30, 2014, those

requirements do not apply until the next time the

vessel is completely emptied and degassed, or

January 30, 2026, whichever comes first.

§63.660(b)

114


(iii) In addition to the options specified in

§63.1063(a)(2)(viii)(A) and (B) and §63.1064, a

flexible enclosure device and either a gasketed or

welded cap at the top of the guidepole may be used

to comply with §63.1063(a)(2)(viii).

§63.660(b)(1)

(iv) Each opening through a floating roof for a ladder

having at least one slotted leg shall be equipped with

one of the configurations specified in §63.660(b)(2).

§63.660(b)(2)

For IFR and EFR storage vessels, the storage vessel must

meet the operational requirements specified in §63.1063(b).

§63.1063(b)

For IFR and EFR storage vessels, conditions causing

inspection failures under §63.1063(d) shall comply with the

repair requirements under §63.1063(e).

§63.1063(e)

For a Group 1 storage vessel that is part of a new or existing source storing

liquid with a maximum true vapor pressure greater than or equal to 76.6

kilopascals (11.1 pounds per square inch) shall comply with the requirements

specified in 40 CFR 63 Subpart SS and as follows:

§63.660

(a) If a flare is used as a control device, the flare shall meet the

requirements of §63.670

§63.660(i)(1)

§63.670

(b) If a closed vent system contains a bypass line that could divert a vent

stream either directly to the atmosphere or to a control device that

does not comply with the requirement of Subpart SS, the bypass line

must comply with the following requirements:

§63.660(i)(2)

Meet the requirements specified in §63.983(a)(3)(i) or (ii) or

§63.660(i)(2)(iii)

Except as specified in §63.660(i)(2)(i) or (ii) for routine

maintenance, use of the bypass at any time to divert a Group

1 storage vessel is an emission standard violation as

specified in §63.660(i)(2)

For an uncontrolled fixed roof storage vessel that commenced construction

on or before June 30, 2014, and that meets the definition of “Group 1 storage

vessel”, paragraph (2), in §63.641 but not the definition of “Group 1 storage

vessel”, paragraph (1), in §63.641, the requirements of §63.982 of Subpart

SS and/or §63.1062 of Subpart WW do not apply until the next time the

storage vessel is completely emptied and degassed, or January 30, 2026,

whichever occurs first.

§63.660(d)

115


At all times, the storage vessels must be operated and maintained, including

associated air pollution control equipment and monitoring equipment, in a

manner consistent with safety and good air pollution control practices for

minimizing emissions as specified in §63.642(n).

§63.642(n)

Emission Monitoring

Inspections shall be conducted on Group 1 Storage vessels that are

complying with Subpart WW to comply with MACT CC as follows:

For IFR storage vessels the following requirements shall be met:

Before the initial filling of an IFR storage vessel inspection

shall be conducted as follows:

§63.1063(c)(1)

(i) Visually inspect the floating roof deck, deck fittings,

and rim seals from within the storage vessel.

§63.1063(d)(1)

(ii) The inspection may be performed entirely from the

top side of the floating roof, as long as there is visual

access to all deck components specified in

§63.1063(a).

§63.1063(d)(1)

(iii) Any of the conditions described in §63.1063 (d)(1)(i)

through (d)(1)(v) constitutes inspection failure.

§63.1063(d)(1)(i)-(v)

Subsequent inspections shall be performed by meeting the

requirements specified in Proviso 1(a)(2)(i) and (ii) of this

section of this subpart:

§63.1063(c)(1)

(i) At least once per year conduct tank-top inspections

of the IFR by visually inspecting the floating roof

deck, deck fitting, and rim seal through opening in

the fixed roof,

§63.1063(c)(1)(i)(A), (d)(2)

(A) Any of the conditions described in §63.1063

(d)(1)(i) through (d)(1)(iv) of this section

constitutes inspection failure.

(B) Identification of holes or tears in the rim seal

is required only for the seal that is visible

from the top of the storage vessel.

(ii) Each time the storage vessel is completely emptied

and degassed, or every 10 years, whichever occurs

first, the IFR shall be inspected as specified in Proviso

1(a)(1)(i)-(iii) of this section of this subpart.

§63.1063(c)(1)(i)(B)

116


Instead of the inspection frequency specified in Proviso

1(a)(2) above, subsequent inspections for storage vessels

equipped with two rim seals may be performed each time

the storage vessel is completely emptied and degassed, or

every 5 years, whichever occurs first and according to the

requirements specified in Proviso 1(a)(1)(i)-(iii) of this


§63.1063(c)(1)(ii)

For EFR storage vessels the following requirements shall be met:

To determine the presence and size of gaps between the rim

seals and the wall of the storage vessel the requirements

specified in proviso 1(b)(1)(i) and (ii) of this section of this

subpart shall be met by conducting seal gap inspections as

specified in §60.1063(d)(3)(i) :

§60.1063(d)(3)(i)

(i) Inspections of the storage vessels primary and

secondary rim seals shall be inspected within 90

days after the initial filling of the storage vessel

§60.1063(c)(2)(i),(d)(3)

(ii) For subsequent testing, the secondary seal of the

EFR shall be inspected at least once every year and

the primary seal of the EFR shall be inspected at least

every 5 years

§60.1063(c)(2)(ii), (d)(3)

(iii) An exceedance of the following gap requirements

shall constitute inspection failure

§60.1063(d)(3)

(A) The ratio of seal gap area to vessel diameter

for the primary seal shall not exceed 212

square centimeters per meter of vessel

diameter (10 square inches per foot of

vessel diameter) and the maximum gap

width shall not exceed 3.81 centimeter (1.5

inches)

§60.1063(d)(3)(ii)

(B) Except when the secondary seal must be

pulled back or removed to inspect the

primary seal, the ratio of seal gap area to

vessel diameter for the secondary seal shall

not exceed 21.2 square centimeters per

meter of vessel diameter (1 square inch per

foot of vessel diameter) and the maximum

gap width shall not exceed 1.27 centimeter

(0.5 inches)

§60.1063(d)(3)(iii)

117


Each time the storage vessel is completed emptied and

degassed, or every 10 years, whichever comes first the

requirements specified in Proviso 1(a)(1)(i)-(iii) of this

section of this subpart shall be met.

§60.1063(c)(2)(iii)

Provided that it has been determined that it is unsafe to

perform the floating roof inspections in Proviso 1(b)(1)(i) or

(ii) of this section of this subpart, the requirements specified

in §60.1063(c)(2)(iv) shall be met.

§60.1063(c)(2)(iv)

For storage vessels previously subject to requirements in §63.646, initial

inspection requirements in §63.1063(c)(1) and (c)(2)(i) or in

§63.983(b)(1)(i)(A), as applicable are not required.

§63.660(e)

Failure to perform other inspections and monitoring required shall constitute

a violation of the applicable standard of this subpart.

§63.660(e)


Seal gap inspections conducted to measure rim seals on EFR storage vessels

for gaps must be performed using the procedures specified in §60.1063

(d)(3)(i).

§60.1063(d)(3)(i)

Good engineering judgment or test results may be used to determine the

stored liquid weight percent total organic HAP for purposes of group

determination.

§63.660(a)(1)

If the Department and the facility do not agree on whether the annual

average weight percent organic HAP in the stored liquid is above or below 4

percent for a storage vessel at an existing source or above or below 2 percent

for a storage vessel at a new source, an appropriate method (based on the

type of liquid stored) as published by EPA or a consensus-based standards

organization shall be used.

§63.660(a)(2)


The recordkeeping requirements shall be met for storage vessels as follows: §63.642(e), §63.655(i)

§63.655(i)(1)(v) and (vi)

Applicable records specified in §63.1065 of Subpart WW found

below or §63.998 of Subpart SS shall be maintained for Group 1

storage vessels.

§63.655(i)(1)(v)

§63.998

§63.1065

Records of the vessel dimension and capacity as specified in

§63.1065(a)

§63.1065(a)

Records of inspection results as specified in §63.1065(b) §63.1065(b)

118


Records of floating roof landing as specified in §63.1065(c) §63.1065(c)

Documentation of extensions used in accordance with

§63.1065(e)(2) or §63.1065(c)(2)(iv)(B)

§63.1065(d)

Records specified in §63.1065(a) of Subpart WW shall be maintained

for Group 2 storage vessels. If a storage vessel is determined to be

Group 2 because the weight percent total organic HAP of the stored

liquid is less than or equal to 4 percent for existing sources or 2

percent for new sources, a record of any data, assumptions, and

procedures used to make this determination shall be retained.

§63.655(i)(1)(vi)

§63.660(a)(1)

Copies of all applicable reports and records shall be kept for at least

5 years except as otherwise specified in §63.655(i).

§63.655(i)

§63.1065

All applicable records shall be maintained in such a manner that they

can be readily accessed within 24 hours.

§63.655(i)

§63.1065

Records may be maintained in hard copy or computer-readable form

including, but not limited to, on paper, microfilm, computer, flash

drive, floppy disk, magnetic tape, or microfiche.

§63.655(i)

§63.1065

References in §63.1066(a) to initial startup notification requirements do not

apply.

§63.660(f)

A Notification of Compliance Status (NOCS) Report shall be submitted and

shall include the information specified in §63.655(f)(1)(i) and

§63.655(h)(6)(ii) for storage vessels.

§63.655(e)(1),

§63.655(f)(1)(i)

§63.655(g)(14)

§63.655(h)(6)

§§63.660(g)

A Periodic Report meeting the following requirements shall be met for

storage vessels:

§63.642(f)

§63.655 (e)(2) and (g)

§§63.660(g)

The applicable requirements specified in §63.655(g)(1), (2)(ii), (3)(ii),

or (5) and §63.1066(b) shall be included in the report.

§63.655(g)

Reports shall be submitted to the Department on a semi-annual

calendar basis according to the following reporting schedule:



July 1- December 31 February 28

§63.642(f)

§63.655(g)

119


(c) A Periodic Report is not required if no events specified in the

applicable requirements of §63.655(g)(2) through (5) occurred

during the reporting period.

§63.655(g)

§63.655(g)(2)-(5)

Notifications of inspections shall be submitted as specified in §63.655(h)(2)

and as follows:

§63.655(h)(2)

The Department shall be notified of refilling of each Group 1 Storage

vessel that has been emptied and degassed as specified in

§63.655(h)(2)(i) in order to allow for an opportunity to inspect the

storage vessel prior to refilling. Except as specified in

§63.655(h)(2)(i)(B) and (C), notifications shall be provided in writing

at least 30 calendar days prior to filling or refiling each storage vessel

with organic HAPs.

§63.655(h)(2)(i)

In order to allow the Department, the opportunity to observe seal

gap measurements of Group 1 storage vessels equipped with an EFR,

a notification must be submitted in writing at least 30 calendar days

in advance of the measurement. The Department can waive the

notification requirement for all or some storage vessels subject to

this rule or allow less than 30 calendar day notices.

§63.655(h)(2)(ii)




and 21(b) of the General Provisos subpart of this permit.

Rule 335-3-16-.05(c)3(ii)

120


121

Summary Page for MACT EEEE: (Non-Gasoline) Organic Liquids Distribution

(OLD) Systems Handling HAPs



EMISSION


EMISSION


ORGANIC LIQUID (OLD)(NON-GASOLINE) DISTRIBUTION SOURCES:

STORAGE TANKS

Volatile organic liquid storage

vessels

OHAP Install floating roof

w/seals & maintain seals

§63.2346(a)

[OLD MACT]

WITH INTERNAL FLOATING ROOF:

T-001

T-002

T-092

1,010,096 gallons

1,010,096 gallons

7,116,665 gallons

VOC

VOC

VOC

None

None

83 Tons/Yr

Rule 335-3-14-.04 [Anti-PSD Limit]

WITH EXTERNAL FLOATING ROOF:

T–015

T-091

T-90M

6,908,028 gallons

7,116,665 gallons

2,514,112 gallons

VOC

VOC

VOC

83 Tons/Yr

10 Tons/Yr

None



FUGITIVE OHAP EMITTING EQUIPMENT, INCLUDING RAILCAR CRUDE OIL LOADING RACK

Valves, pumps, sampling

connections in organic liquid

service prior to process

equipment

OHAP LDAR Program §63.2346(c)

122

Provisos for Non-Gasoline OLD Systems Handling HAPs


Applicability

Tank Nos.: T-015, T-091, and T-092 each have enforceable limits in place

in order to avoid a review under ADEM Admin. Code r. 335-3-14-.04, “Air

Permits Authorizing Construction in Clean Air Areas [Prevention of

Significant Deterioration (PSD)] and the requirements specified in this


Rule 335-3-14-.04

[Anti-PSD Limit]

Each affected source listed on the summary page of this subpart shall be

subject to the requirements specified in ADEM Admin. Code r. 335-3-16,

“Major Source Operating Permits”, and the requirements specified in this


Rule 335-3-16-.03

Except as specified in §63.2334(c) of 40 CFR 63 Subpart EEEE, “ National

Emission Standards for HAPs: Organic Liquid Distribution (Non-Gasoline)”

[OLD MACT], each piece of equipment listed on the summary page is

subject to the requirements of the OLD MACT and the requirements

specified in this subpart of this permit:

§63.2330

§§63.2334(a) (c)

§§63.2338(a),(d)-(f)

§63.2342

§63.2406

Except as specified in §63.2338(c) of the OLD MACT, affected

sources includes piping, loading/transfer racks, ancillary

equipment, and storage vessels that handle crude oil and are

located upstream of the process and other sources specified in

§63.2338(a) of the OLD MACT.

§§63.2338(a),(b),(c)

§63.2343(a)

The applicable requirements specified in 40 CFR 63, Subpart A,

“General Provisions” [Subpart A] and this subpart of this permit

shall be met as specified in Table 12 of the OLD MACT.

§63.2398

Table 12, OLD MACT

Nothing in this section shall preclude the Permittee from

selecting another compliance option allowed by this subpart,

provided written notice is first supplied to the Department.

Compliance with control options for storage vessels specified in

40 CFR 63, Subpart WW, “National Emission Standard for

Storage Vessels (Tanks)-Control Level 2” [NESHAP WW] shall only

be met as referenced in this subpart.

§63.2346(a)(3)

§63.1060

Compliance with control options for equipment leak

components specified in 40 CFR 63, Subpart TT “National

Emission Standard for Equipment Leaks-Control Level 1”

[NESHAP TT] shall only be met as referenced in this subpart.

§63.1000(a)

§63.2346(c)

123



Emission Standards

Storage vessel Nos. T-015 and T-092 shall not emit into the atmosphere

volatile organic compound (VOC) emissions in excess of 83 Tons per

twelve (12) consecutive months/storage vessel.

Rule 335-3-14-.04

[Anti-PSD Limit]

Storage vessel No. T-091 shall not emit into the atmosphere volatile

organic compound (VOC) emissions in excess of 10 Tons per twelve (12)

consecutive months.

Rule 335-3-14-.04

[Anti-PSD Limit]

The requirements under the OLD MACT for storage vessels shall be met

by complying with the following emission limitations, operating limits,

and work practice standards at all times when in OLD operation:

§63.2346(a)(3)

§63.2350(a)

(a) For existing Tank Nos.: T-001, T-002, and T-092 storing crude oil

and/or non-crude oil (with a maximum True Vapor Pressure

(TVP) less than 76.6 kilopascals (kPa) (11.1 pounds per square

inch (psia)), compliance with the OLD MACT shall be met by

installing, operating, and maintaining an internal-floating roof

(IFR) in accordance with the requirements specified in §63.1063

of NESHAP WW.

§63.2346(a)(3), OLD MACT

§63.1062(a)(1), NESHAP WW

§60.1063(a)(1)(i), NESHAP WW

Table 2, No. 2, OLD MACT Table

2,No. 1(a)(ii), OLD MACT

Table 4, No. 1(a), OLD MACT

§63.2350(b)

§63.2370

(b) For existing Tank Nos.: T-015 and T-091 and modified tank No.

90M storing crude oil and/or non-crude oil (with a maximum TVP

less than 76.6 kilopascals kPa (11.1 psia)), compliance with the

OLD MACT shall be met by installing, operating, and maintaining

an external floating roof (EFR) in accordance with the

requirements specified in §63.1063 of NESHAP WW.

§63.2346(a)(3), OLD MACT

§63.1062(a)(2), NESHAP WW)

Table 2, No. 2 and 5, OLD MACT

Table 2, No. 1(a)(ii), OLD MACT

Table 4, No. 1(a), OLD MACT

§63.2350(b), §63.2370

(c) An equivalent to the requirements specified in proviso 3(a) or (b)

of this section may be met as specified in §63.1064 of NESHAP

WW.

§63.2346(a)(3), OLD MACT

§63.1062(a)(3), NESHAP WW

Storage vessels equipped with a floating roof to comply with §63.1062 of

NESHAP WW, shall meet the following requirements:

§63.1063

§63.2346(a)(3)

For IFR storage vessels, the design requirements for rim seals

shall be met by equipping the storage vessel with one of the seal

configurations specified in §63.1063(a)(1)(i)(A) through (C),

except as specified in §63.1063(a)(1)(i)(D).

§63.1063(a)(1)(i)(A)-(D)

For EFR storage vessels, the design requirements for rim seals

shall be met by equipping the storage vessel with one of the seal

configurations specified in §63.1063(a)(1)(ii)(A) or (B), except as

specified in §63.1063(a)(1)(ii)(C).

§63.1063(a)(1)(ii)(A)-(C)

124



For IFR and EFR storage vessels, the design requirements for

deck fittings shall be met as follows:

Equip the opening through the deck of the floating roof

with a fitting as specified in §63.1063(a)(2)(i) through

(viii), except as specified in §63.1063(a)(2)(ix).

§63.1063(a)(2)(i) through (ix)

For IFR and EFR storage vessels, the storage vessel must

meet the operational requirements specified in

§63.1063(b).

§63.1063(b)

For IFR and EFR storage vessels, conditions causing

inspection failures under §63.1063(d) shall comply with

the repair requirements under §63.1063(e).

§63.1063(e)

§63.2378(a)

Table 10, No. 3

Equipment leak component associated with storage vessels that operate

in OLD service for at least 300 hours per year, shall comply with MACT

EEEE by meeting the applicable requirements specified in NESHAP TT at

all times when in OLD operation for each pump, valve (excluding relief

and check valves), and sampling connection.

§63.2346(c)

§63.2350(a)

§63.2406

Table 4, No. 4, MACT EEEE

The standards specified in §63.1006 of NESHAP TT shall be met

for valves in gas and vapor service and in light liquid service.

§63.1006


for pumps in light liquid service.

§63.1007


for pumps in heavy liquid service.

§63.1010


for sampling connection systems.

§63.1013


for closed vent systems and control devices; or emissions routed

to a fuel gas system or process.

§63.1015

Compliance with the emission standards found in provisos 5 (a)-

(d) of this section can be met by using an enclosed-vented

process unit that meets the requirements of §63.1016 of

NESHAP TT.

§63.1016

Equipment components that are insulated to provide protection

against persistent sub-freezing temperatures are subject to the

“difficult to monitor” provisions in NESHAP TT.

§63.2346(c)

125



No controls are required for each transfer rack that only unloads organic

liquids (no organic liquids are loaded at the transfer rack); however,

documentation must be maintained as specified in S63.2343 (a) of MACT

EEEE.

§63.2343(a)

An alternative to the emission limitations, operating limits, and work

practice standards under MACT EEEE may be requested as specified in

§63.6(g) of Subpart A.

§63.2346(g)

§63.6(g)

§63.1002(b), §63.1016

Opening of a safety device shall be allowed at any time that it is required

to avoid unsafe operating conditions.

§63.2346(i)

Each affected source must always be operated and maintained, including

air pollution control and monitoring equipment, according to the

provisions in §63.6(e)(1)(i) of subpart A.

§63.2350(b)

§63.6(e)(1)(i)

Each affected source shall be operated in accordance with §63.6(e)(1)

and (3) of Subpart A and §63.2378(b) of MACT EEEE during each startup,

shutdown, or malfunction.

§S63.6(e)(1), (3)

§63.2350(a)

§63.2378(b)

A written startup, shutdown, and malfunction plan shall be developed

and implemented in accordance with the requirements specified in

proviso §63.6(e)(3) of Subpart A.

§63.2350(c)

§63.2378(b)

§63.6(e)(3)

Emission Monitoring

Inspections shall be conducted on storage vessels equipped with floating

roofs that are complying with Subpart WW to comply with MACT EEEE as

follows:

§63.2358(d)

(a) For IFR storage vessels the following requirements shall be met: §63.2378(a)

Table 10, No. 1

Before the initial filling of an IFR storage vessels

inspection shall be conducted as follows:

§63.1063(c)(1)

(i) Visually inspect the floating roof deck, deck

fittings, and rim seals from within the storage

vessel.

§63.1063(d)(1)

(ii) The inspection may be performed entirely from

the top side of the floating roof, as long as there

is visual access to all deck components specified

in §63.1063(a).

§63.1063(d)(1)

126



(iii) Any of the conditions described in §63.1063

(d)(1)(i) through (d)(1)(v) constitutes inspection

failure.

§63.1063(d)(1)(i)-(v)

Subsequent inspections shall be performed by meeting

the requirements specified in Proviso 1(a)(2)(i) and (ii) of

this section of this subpart:

§63.1063(c)(1)

(i) At least once per year, conduct tank-top

inspections of the IFR by visually inspecting the

floating roof deck, deck fitting, and rim seal

through opening in the fixed roof.

§63.1063(c)(1)(i)(A), (d)(2)

(A) Any of the conditions described in

§63.1063(d)(1)(i) through (d)(1)(iv) of

this section constitutes inspection

failure.

(B) Identification of holes or tears in the rim

seal is required only for the seal that is

visible from the top of the storage

vessel.

(ii) Each time the storage vessel is completely

emptied and degassed, or every 10 years,

whichever occurs first, the IFR shall be inspected

as specified in Proviso 1(a)(1)(i)-(iii) of this


§63.1063(c)(1)(i)(B)

Instead of the inspection frequency specified in Proviso

1(a)(2) above, subsequent inspections for storage

vessels equipped with two rim seals may be performed

each time the storage vessel is completely emptied and

degassed, or every 5 years, whichever occurs first, and

according to the requirements specified in Proviso

1(a)(1)(i)-(iii) of this section of this subpart.

§63.1063(c)(1)(ii)

For EFR storage vessels the following requirements shall be met: §63.2378(a)

Table 10, No. 2

To determine the presence and size of gaps between the

rim seals and the wall of the storage vessel the

requirements specified in proviso 1(b)(1)(i) and (ii) of

this section of this subpart shall be met by conducting

seal gap inspections as specified in §60.1063(d)(3)(i) :

§60.1063(d)(3)(i)

127



(i) Inspections of the storage vessels primary and

secondary rim seals shall be inspected within 90

days after the initial filling of the storage vessel

§60.1063(c)(2)(i),(d)(3)

(ii) For subsequent testing, the secondary seal of

the EFR shall be inspected at least once every

year and the primary seal of the EFR shall be

inspected at least every 5 years

§60.1063(c)(2)(ii), (d)(3)

(iii) An exceedance of the following gap

requirements shall constitute inspection failure

§60.1063(d)(3)

(A) The ratio of seal gap area to vessel

diameter for the primary seal shall not

exceed 212 square centimeters per

meter of vessel diameter (10 square

inches per foot of vessel diameter) and

the maximum gap width shall not

exceed 3.81 centimeter (1.5 inches)

§60.1063(d)(3)(ii)

(B) Except when the secondary seal must be

pulled back or removed to inspect the

primary seal, the ratio of seal gap area

to vessel diameter for the secondary

seal shall not exceed 21.2 square

centimeters per meter of vessel

diameter (1 square inches per foot of

vessel diameter) and the maximum gap

width shall not exceed 1.27 centimeter

(0.5 inches)

§60.1063(d)(3)(iii)

Each time the storage vessel is emptied and degassed, or

every 10 years, whichever comes first the requirements

specified in Proviso 1(a)(1)(i)-(iii) of this section of this

subpart.

§60.1063(c)(2)(iii)

Provided that it has been determined that it is unsafe to

perform the floating roof inspections in Proviso 1(b)(1)(i)

or (ii) of this section of this subpart, the requirements

specified in §60.1063(c)(2)(iv) shall be met.

§60.1063(c)(2)(iv)

A leak detection and repair (LDAR) program, as specified in NESHAP TT,

shall be implemented for equipment leak components in OLD service.

Table 7, No. 4(a)(i) & Table 10, No.

5 of MACT EEEE

§63.2370(a), §63.2378(a)

§63.1002(a), §63.1003

128



Leak monitoring shall be conducted as specified in §63.1004 of

NESHAP TT

§63.1004

Leak repair shall be conducted as specified in §63.1005 of

NESHAP TT

§63.1005


To determine the HAP content of the organic liquid, Method 311 of 40

CFR part 63, Appendix A, or other methods approved by the Department

may be used.

§63.2354(c)

Seal gap inspections conducted to measure rim seals on EFR storage

vessels for gaps must be performed using the procedures specified in

§60.1063 (d)(3)(i) of NESHAP WW.

§60.1063(d)(3)(i)

§63.2358(b)

Table 7, No. 1 & 2, MACT EEEE

§63.2370(a), (c)

Equipment component leaks shall be determined according to Method

21 of 40 CFR 60 Appendix A, and the procedures specified in §63.1004 of

NESHAP TT.

§63.1004


A monthly record of the VOC emissions from storage vessels No. T-015,

T-091, and T-092 shall be determined using the following information:

Rule 335-3-14-.04

[Anti-PSD]

The througHPut of each storage vessel

Petroleum liquid (Gallons/Month)

The emission rate for each storage vessel while utilizing the

methods and procedures specified by EPA computer simulator

Tanks 3.0 or 4.1 or the most recent version thereof, or any similar

program for estimating tank emissions.

Individual Vessel Emissions (Lbs/Month)

A twelve (12) consecutive month record of the VOC emissions from each

tank shall be estimated while utilizing the results of the current month

estimates as determined in proviso 1(b) of this section of this subpart

summated with the previous eleven (11) months emission estimates.

Rule 335-3-14-.04

Individual Vessel Emissions (Lbs/12 Months) =

Current month [Individual Vessel Emissions (Lb/Month)] +

∑Previous eleven (11) months [Individual Vessel Emissions (Lb/Month)]

129



Individual Vessel Emissions (Tons/12 Months) =

[ Individual Vessel Emissions (Lbs/12 Months)]

[ 2000 Lbs/Ton ]

Periodic Monitoring Reports (PMR) meeting the requirements specified

in proviso 3(a) and (b) of this section of this subpart shall be submitted

to the Department.

Rule 335-3-16-.05(c)(3)(i)






monitoring system or periodic monitoring required by

the permit that can be used to determine compliance,




If no deviation event occurred during reporting period, a

statement that indicates there were no deviations from

the permit requirement requirements shall be included

in the report.





be submitted.



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause

130




conditions




reporting period






reporting schedule:






The following recordkeeping and reporting requirements shall be met for

to demonstrate compliance with MACT EEEE:

Applicable notifications specified in §63.2342(d), §63.2382,

§63.2386, §63.2390, and §63.2394 of MACT EEEE,

§63.1066(b)(1) of NESHAP WW, and §63.1018(b) of NESHAP TT.

§63.2342(d)

§63.2382, §63.2386

§63.2390, §63.2394

§63.1018(b)

§63.1066(b)(1)

Applicable records specified in §63.1065 of Subpart WW found

below shall be maintained for storage vessels equipped with a

floating roof:

§63.1065

§63.2390(b)(2)

Table 10 No. 1-3

Records of the vessel dimension and capacity as

specified in §63.1065(a)

§63.1065(a)

Records of inspection results as specified in §63.1065(b) §63.1065(b)

§63.1066(b)(2)

Records of floating roof landing as specified in

§63.1065(c)

§63.1065(c)

131



Documentation of extensions used in accordance with

§63.1065(e)(2) or §63.1065(c)(2)(iv)(B)

§63.1065(d)

The applicable recordkeeping requirements specified in

§63.1016(b) of NESHAP TT, if an alternate means of emission

limitation is elected, or §63.1017 of NESHAP TT must be

maintained for equipment components.

§63.1016(b)

§63.1017

Documentation demonstrating that no controls are required on

transfer racks that only unload at a facility must be maintained

as follows to demonstrate compliance with MACT EEEE:

§63.2343(a)

Must be kept up-to-date and in a form suitable and

readily available for expeditious inspection and review

according to §63.10(b)(1) of Subpart A, including records

stored in electronic form in a separate location.

The documentation may consist of identification of the

transfer racks on a plant site plan or process and

instrumentation diagram (P&ID).

Copies of all applicable files (including all reports and

notifications) shall be maintained for at least 5 years following

the date of each occurrence, measurement, maintenance,

corrective action, report, or record.

§63.2394(b), (c)

§63.1065

You must keep each record on site for at least 2 years

after the date of each occurrence, measurement,

maintenance, corrective action, report, or record.

You may keep the records offsite for the remaining 3

years.

All applicable records shall be maintained in a form suitable and

readily available for expeditious inspection and review according

to §63.10(b)(1), including records stored in electronic form at a

separate location

§63.10(b)(1)

§63.2394(a)

§63.1065

Records may be maintained in hard copy or computer-readable

form including, but not limited to, on paper, microfilm,

computer, flash drive, floppy disk, magnetic tape, or microfiche.

§63.1065

The following reports shall be submitted to demonstrate compliance

with the MACT EEEE:

132



A Compliance Report shall include the applicable information

specified in §63.8693(c)(1)-(9) and the applicable information

specified in §63.8693(d).

§63.2386(c), (d)

A Periodic Report shall include the information specified in

§63.1066(b) of NESHAP WW to demonstrate compliance with

MACT EEEE for storage vessels

§63.1066(b)

A Periodic Report shall include the information specified in

§63.1018(a) of NESHAP TT to demonstrate compliance with

MACT EEEE for equipment components

§63.1018(a)

Each report shall cover a semi-annual reporting period and shall

be submitted according to the following reporting schedule:




§63.2386(b)



reported to the Department in a manner that complies with proviso

15(b) and 21(b) of the General Provisos subpart of this permit.

Rule 335-3-16-.05(c)3(ii)

133

Summary Page for NSPS GGG: Fugitive Equipment Leaks

Permitted Operating Schedule†: 24 Hours/Day x 365 Days/Year = 8,760 Hours/Year



EMISSION


EMISSION


AFFECTED COMPONENTS:

Group of Equipment (valves, pumps,

pressure relief devices, sampling

connection systems, open-ended valve

or line, and flanges or other

connectors) within a process unit

Compressors (except those in hydrogen

service)

VOC

BZ

VHAPs

OHAP

LDAR Program §60.592 [NSPS GGG]

§60.482 [NSPS VV]

Rule 335-3-16-.05(a)

INDIVIDUAL PROCESS UNITS [OHAP & VOC SERVICE]:

Diesel Hydrotreater


No. 1 Platformer

No. 1, No. 2, & No. 3 Merox Units

Kerosene Hydrotreater

Naphtha Unifiner

Stoddard Tower

Sour Water Stripper

ISOM Unit

Naphtha Hydrobon

Crude Unit Closed Vent System & Flare

Hydrobon Unit Closed Vent System & Flare

Gasoline Loading Rack Closed Vent System & Vapor Combustor

MISCELLANEOUS LOADING RACKS [OHAP & VOC SERVICE], PRE-1973:

Diesel

Old 8A Tank

7A Tank

Double bay

Specialty

Cutback (T36-T39)

North Emulsion

South Emulsion

Tank 14 spout

Tank 50 spout

Marine dock

134

Provisos for Summary Page for Fugitive Equipment Leaks


Applicability

Each component of each process unit specified on the summary page

of this subpart shall be subject to the requirements specified in ADEM

Admin. Code r. 335-3-16, “Major Source Operating Permits”, and the


Rule 335-3-16-.03

The group of all equipment within a process unit and each compressor

will be subject to the requirements of 40 CFR Part 60, Subpart GGG,

“Standards of Performance for Equipment Leaks of VOC in Petroleum

Refineries” and the requirements of this subpart of this permit.

§60.590, NSPS GGG

Compliance with NSPS GGG will demonstrate compliance with

the requirements specified in 40 CFR Part 63 Subpart CC,

“National Emission Standards for Hazardous Air Pollutants

(HAPs) Emissions from Petroleum Refineries”, [Refinery MACT

1/MACT CC].

§63.640(p)(2)

NSPS GGG

Existing facilities shall comply with the equipment leak

requirements of 40 CFR 60 Subpart GGG, "Standards of

Performance for Equipment Leaks of VOC in Petroleum

Refineries", [NSPS GGG] instead of the requirements in 40 CFR

Part 61, Subparts J and V, Part 63, Subparts F, H, and CC, and

ADEM Admin. Code r. Rule 335-3-6-.21 leak detection and

repair (LDAR) requirements that are federally enforceable.

Rule 335-3-16-.05(a)

Except as specified in §60.593 of NSPS GGG, the applicable

requirements of 40 CFR 60 Subpart VV, “Standards of

Performance for Equipment Leaks of VOC in the Synthetic

Organic Chemicals Manufacturing Industry” [NSPS VV] by

reference, shall demonstrate compliance with NSPS GGG.

§60.592(a), (b)(1) & (2)

§60.593, NSPS GGG

The applicable requirements under 40 CFR 60, Subpart A,

"General Provisions" [Subpart A] shall be met as specified in

NSPS VV and as specified in this subpart of this permit, except

that §60.7(b) and (d) of Subpart A do not apply to affected

facilities under NSPS VV.

40 CFR 60 Subpart A

§60.486(k)

Covered components under NSPS GGG shall include the

following:

§60.590(a)

Each compressor

Each valve

Each pump

135



Each pressure relief device

Each sampling connection system

Each instrumentation system

Each open-ended valve or line

Each flange or other connector in VOC service

Process units shall mean components assembled to produce

intermediate or final products from petroleum, unfinished petroleum

derivatives, or other intermediates; a process unit can operate

independently if supplied with sufficient feed or raw materials and

sufficient storage facilities for the product.

§60.590(e)

Emission Standards

Except as provided for in §60.484 of NSPS VV for equivalent means of

emission limitations, each affected process unit component shall

comply with the following requirements:

§60.592(a)-(e)

§60.593

(a) Each compressor shall comply with the requirements specified

in §60.482-3 of NSPS VV, except that:

§60.592(a)

§60.482-1

§60.482-3

Compressors proven to be in hydrogen service, as

determined using the requirements specified in

§60.593(b) of NSPS GGG, are exempt from the

requirements of §60.592 of NSPS GGG.

§60.593(b)

Any existing compressor that has been modified or

reconstructed is exempt from the applicable

requirements of §60.482-3 of NSPS VV as specified in

§60.593(c) of NSPS GGG, provided that it can be

demonstrated that recasting the distance piece or

replacing the compressor are the only options to bring

the compressor in compliance.

§60.593(c)

Each valve shall comply with the requirements specified in

§60.482-7 of NSPS VV for valves in gas/vapor and light liquid

service and §60.482-8 of NSPS VV for valves in heavy liquid

service, except that the methods specified in §60.592(b) of

NSPS GGG may be elected as an alternative.

§60.592(a), §60.482-1

§60.482-7, §60.482-8

§60.592(b)

136



Each pump shall comply with the requirements specified in

§60.482-2 of NSPS VV for pumps in light liquid service and

§60.482-8 of NSPS VV for pumps in heavy liquid service.

§60.592(a), §60.482-1

§60.482-2, §60.482-8

Each pressure relief device (PRD) shall comply with the

requirements specified in §60.482-4 of NSPS VV for a PRD in

gas/vapor service and §60.482-8 of NSPS VV for a PRD in light

or heavy liquid service.

§60.592(a), §60.482-1

§60.482-4, §60.482-8

Each sampling connection system shall comply with the

requirements specified in §60.482-5.

§60.592(a), §60.482-1

§60.482-5

Each open-ended valves or lines shall comply with §60.482-6

of NSPS VV, except that those containing asphalt are exempt

from the requirements of §60.482-6(a) through (c) of NSPS VV

§60.592(a), §60.482-1

§60.482-6, §60.592(f)

Each connector shall comply with the requirements specified

in §60.482-8 of NSPS VV.

§60.592(a), §60.482-1,

§60.482-8

Delay of repair shall be allowed if applicable conditions

stipulated in §60.482-9 are met.

§60.592(a), §60.482-1

§60.482-9

A closed vent system (CVS) and control device used to comply

with any of the above requirements, shall comply with the

requirements specified in §60.482-10 of NSPS VV.

§60.592(a), §60.482-1

§60.482-10


Except as specified in 60.593(d) of NSPS GGG, the test methods and

procedure specified in §60.485 of NSPS VV may be utilized.

§60.8

§60.482-1(b), §60.485,

§60.485(e)

§60.592(a), (e), §60.593(d)

Emission Monitoring

The inspection and monitoring requirements specified in §60.482-1

through §60.482-10 of NSPS VV and either §60.483-1 or §60.483-2 of

NSPS VV shall be complied to demonstrate compliance with NSPS GGG.

§60.482-1(b)

§60.592(a), (b)

Recordkeeping and Reporting Requirement

The recordkeeping requirements specified in §60.7 and §60.19 of

Subpart A and §60.486 of NSPS VV shall be maintained for a period of

five (5) years, made available for inspection, and submitted to the

Department when required. Records shall include the following:

§60.482-1(b)

§60.486

§60.592(e)

Rule 335-3-16-.05(a)

137



(a) Records of each leak detected as specified in §60.486(b)(1)

through (3) of NSPS VV.

§60.486(b)(1)

(b) Record of the information specified in §60.486(c)(1) through

(9) of NSPS VV shall be recorded in a log and shall be kept for

two years in a readily accessible location.

§60.486(c)(1)-(9)

(c) Records pertaining to the design requirements for CVS and

control devices shall be maintained as specified in

§60.486(d)(1) through (5) of NSPS VV.

§60.486(d)(1)-(5)

(d) The applicable information specified in §60.486(e),

§60.486(f), §60.486(h), §60.486(j), and the exemptions

specified in 60.486(i) of NSPS VV shall be recorded in a log that

is kept in a readily accessible location.

§60.486(e), (f),(h), (i), (j)

(e) The information specified in §60.486(g) of NSPS VV shall be

maintained for valves complying with §60.483-2 of NSPS VV.

§60.486(g)

A semi-annual report meeting the following requirement shall be

submitted to demonstrate compliance with NSPS GGG:

§60.482-1(b)

§60.487

§60.592(e)

Reports shall include the information specified in §60.487(c)(1)

through (4) of NSPS VV.

§60.487(c)

Records of each deviation event shall be included in the report. Rule 335-3-16-.05(c)2

Rule 335-3-16-.05(c)3(i)






failed to meet an applicable emission limit or standard,

or that a work practice was not complied with or

completed.

If there are no deviations events that occurred during

the reporting period, a statement that indicates there

were no deviations from the permit requirements

shall be included in the report.

138



Each report shall be submitted to the Department on the

following reporting schedule:




§60.487(a), (b), (c)

Rule 335-3-16-.05(c)




complies with proviso 15(b) and 21(b) of the General Provisos subpart

of this permit.

Rule 335-3-16-.05(c)3(ii)

139

Summary Page for NSPS GGGa: Fugitive Equipment Leaks of VOC & OHAP

Emissions




EMISSION


EMISSION


AFFECTED COMPONENTS:

Group of Equipment (valves, pumps,

pressure relief devices, sampling

connection systems, open-ended valve

or line, and connectors) within a

process unit

Compressors (except those in hydrogen

service)

VOC

VOC & OHAP

OHAP

LDAR Programs §60.482a [NSPS VVa]

Rule 335-3-6-.21

§60.592a [NSPS GGGa]

INDIVIDUAL PROCESS UNITS [VOC & OHAP SERVICE]:

Hydrocracker Unit

Hydrocracker Unit Closed Vent System & Flare

CCR Platformer


No. 1 Amine Unit

No. 2 Amine Unit

Delayed Coking Unit

Wastewater Treatment Plant

Coker Unit Closed Vent System & Flare

Bio-Fuel Blending System

No. 1 Sulfur Recovery System & Thermal Oxidizer

No. 2 Sulfur Recovery System & Thermal Oxidizer

Railcar Loading Rack

Crude Unit (Modified)

Flexible Hydrotreater

140

Provisos for Fugitive Equipment Leaks of VOC & OHAP Emissions


Applicability

Each component of each process unit specified on the summary page of

this subpart shall be subject to the requirements specified in ADEM Admin.

Code r. 335-3-16, “Major Source Operating Permits”, and the requirements


Rule 335-3-16-.03

Except as specified in §60.593a, each component of each process unit

specified on the summary page of this subpart shall comply with the

equipment leak requirements of 40 CFR 60 Subpart GGGa, "Standards of

Performance for Equipment Leaks of VOC in Petroleum Refineries" [NSPS

GGGa] and this subpart of this permit.

§60.590a(a), (b)

§60.593a

Overlap of NSPS GGGa with equipment leak standards specified in

§63.648 of 40 CFR Part 63, Subpart CC, “National Emission

Standards for Hazardous Air Pollutants (HAPs) Emissions from

Petroleum Refineries” [Refinery MACT 1/MACT CC], requires

compliance only with NSPS GGGa, except that pressure relief

devices in organic HAP service must only comply with the

requirements in §63.648(j) of MACT CC.

§63.640(p)(2)

§63.648(j)

Overlap with NSPS GGGa with equipment leak standards specified

in ADEM Admin. r. 335-3-6-.21, "Leak from Petroleum Refinery

Equipment" requires compliance with the NSPS GGGa provided

that the requirements of ADEM Admin. r. 335-3-10-.01(2)(a) and

(b) are met.

Rule. 335-3-10-.01(2)

§63.640(q)

Compliance with 40 CFR 60 Subpart VVa, “Standards of

Performance for Equipment Leaks of VOC in the Synthetic Organic

Chemicals Manufacturing Industry” [NSPS VVa] by reference, shall

demonstrate compliance with NSPS GGGa for existing sources.

§60.592a

The applicable requirements under 40 CFR 60, Subpart A, "General

Provisions" [Subpart A] ,shall be met as specified in NSPS VVa and

as specified in this subpart of this permit ,except that §60.7(b) and

(d) of Subpart A do not apply to affected facilities under this

subpart.

40 CFR 60 Subpart A

§60.486a(k)

Covered components under NSPS GGGa shall include the

following:

§60.590a(a)

§60.591a

Each compressor

Each valve

Each pump

141



Each pressure relief device

Each sampling connection system

Each open-ended valve or line

Each connector

Process units shall mean components assembled to produce intermediate

or final product from petroleum, unfinished petroleum derivates, or other

intermediates; a process unit can operate independently if supplied with

sufficient feed or raw materials and sufficient storage facilities for the

product.

§60.590a(e)

Emission Standards

Except as provided for in §60.484a of NSPS VVa for equivalent means of

emission limitations, each affected process unit component shall comply

with the following requirements:

§60.592a(a)-(e)

§60.593a

(a) Each compressor shall comply with the requirements specified in

§60.482-3a of NSPS VVa, except that:

§60.592a(a)

§60.482-1a

§60.482-3a

Compressors proven to be in hydrogen service, as

determined using the requirements specified in

§60.593a(b) of NSPS GGGa, are exempt from the

requirements of 60.529a of NSPS GGGa.

§60.593a(b)

Any existing compressor that has been modified or

reconstructed is exempt from the applicable requirements

of §60.482-3a of NSPS VVa as specified in §60.593a(c) of

NSPS GGGa, provided that it can be demonstrated that

recasting the distance piece or replacing the compressor

are the only options to bring the compressor in

compliance.

§60.593a(c)

§60.488a

Each valve shall comply with the requirements specified in

§60.482-7a of NSPS VVa for valves in gas/vapor and light liquid

service and §60.482-8a of NSPS VVa for valves in heavy liquid

service, except that the methods specified in §60.592a(b) of NSPS

GGGa may be elected as an alternative.

§60.592a(a), §60.482-1a

§60.482-7a, §60.482-8a

§60.592a(b)

Each pump shall comply with the requirements specified in

§60.482-2a of NSPS VVa for pumps in light liquid service and

§60.482-8a of NSPS VVa for pumps in heavy liquid service.

§60.592a(a), §60.482-1a

§60.482-2a, §60.482-8a

§60.592a(b)

142



Except as specified in §63.648(j)(4) of MACT CC, each pressure

relief device (PRD) (such as relief valves or rupture disks) in organic

HAP gas or vapor service shall comply with the requirements

specified in §63.648(j) of MACT CC instead of those specified in

§60.482-4a of NSPS VVa.

§63.640(p)(2), MACT CC

§63.648(j), MACT CC

Each sampling connection system shall comply with the

requirements specified in §60.482-5a.

§60.592a(a)

§60.482-1a

§60.482-5a

Each open-ended valves or lines shall comply with §60.482-6a of

NSPS VVa, except that those containing asphalt are exempt from

the requirements of §60.482-6a(a) through (c) of NSPS VVa.

§60.592a(a), §60.482-1a

§60.482-6a, §60.591a

§60.593a(f)

Except as specified in §60.593a(g) of NSPS GGGa and as specified

in §63.649 of MACT CC, each connector shall comply with §60.482-

8a of NSPS VVa.

§60.482-1a, §60.482-8a

§63.649, §60.592a(a)

§60.593a(g)

Delay of repair shall be allowed if applicable conditions stipulated

in 60.482-9a are met.

§60.592a(a)

§60.482-1a

§60.482-9a

A closed vent system (CVS) and control device used to comply with

any of the above requirements, shall comply with the

requirements specified in §60.482-10a of NSPS VVa.

§60.592a(a)

§60.482-1a

§60.482-10a


Except for equipment in light liquid service as specified in §60.593a(d) of

NSPS GGGa, the test methods and procedure specified in §60.485a of NSPS

VVa may be utilized.

§60.8

§60.485a, §60.485a(e)

§60.482-1a(b)

§60.592a(a), (e, §60.593a(d)

Emission Monitoring

The inspection and monitoring requirements specified in §60.482-1a

through §60.482-10a of NSPS VVa and either §60.483-1a or §60.483-2a of

NSPS VVa shall be complied with to demonstrate compliance with NSPS

GGGa, except as specified in §60.593a of GGGa.

§60.482-1a(b)

§60.592a(a), (b)

§60.593a

Recordkeeping and Reporting Requirement

The recordkeeping requirements specified in §60.7 and §60.19 of Subpart

A and §60.486a of NSPS VVa shall be maintained for a period of 5 years,

made available for inspection, and submitted to the Department when

required. Records shall include the following information:

§60.482-1a(b)

§60.486a

§60.592a(e)

143



Records specified in §60.486a(3)(i)-(v) of NSPS VVa for each

required monitoring event

§60.486a(a)(3)

Records of each leak detected as specified in §60.486a(b)(1)

through (4) of NSPS VVa

§60.486a(b)(1)

Records of the information specified in §60.486a(c)(1) through (9)

of NSPS VVa shall be recorded in a log and shall be kept for two

years in a readily accessible location

§60.486a(c)(1)-(9)

Records pertaining to the design requirements for CVS and control

devices shall be maintained as specified in §60.486a(d)(1) through

(5) of NSPS VVa

§60.486a(d)(1)-(5)

The applicable information specified in §60.486a(e), §60.486a(f),

§60.486a(h), §60.486a(j), and the exemptions specified in

§60.486a(i) of NSPS VVa shall be recorded in a log that is kept in a

readily accessible location

§60.486a(e), (f),(h), (i), (j)

The information specified in §60.486a(g) of NSPS VVa shall be

maintained for valves complying with §60.483-2a of NSPS VVa

§60.486a(g)


(a) A semi-annual report meeting the following requirement shall be

submitted to demonstrate compliance with NSPS VVa and GGGa:

§60.482-1a(b)

§60.487a, §60.59a2(e)

Initial reports shall include the information specified in

§60.487a(b)(1) through (4) of NSPS VVa.

§60.487a(b)

Subsequent reports shall include the information specified

in §60.487a(c)(1) through (4) of NSPS VVa.

§60.487a(c)

Records of each deviation event shall be included in the

report.

Rule 335-3-16-.05(c)2

Rule 335-3-16-.05(c)3(i)

(i) A deviation shall mean any condition determined

by observation, by data derived from any

monitoring or testing or recordkeeping which is

required by the permit that can be used to

determine or indicate compliance, that identifies

an affected source has failed to meet an applicable

emission limit or standard, or that a work practice

was not complied with or completed.

144



(ii) If there are no deviations events that occurred

during the reporting period, a statement that

indicates that there were no deviations from the

permit requirements shall be included in the

report.

Each report shall be submitted to the Department on the following

reporting schedule:




§60.487a(a), (b),(c), (f)





Rule 335-3-16-.05(c)3(ii)

145

Summary Page for MACT CC: Gasoline Loading Rack and Vapor Combustor




EMISSION


EMISSION


TRUCK GASOLINE LOADING RACK TOC

(as VOC)

10 mg of TOC per L of gasoline

loaded §63.650(a)

VOC Work Practice-- Air Sticker Rule 335-3-6-.06(3)

Rule 335-3-6-.20(4)

CLOSED VENT SYSTEM ASSOCIATED WITH THE

GASOLINE LOADING RACKS

(INCLUDING PIPING, FLANGES, ETC)

VOC LDAR Program-- Complying with

requirements under the MACT

CC: Fugitive Equipment Leaks of

OHAP and VOC subpart of this

permit

§60.592(a)

[NSPS GGG]

ZCT2-8-35X-3/8 GASOLINE VAPOR

COMBUSTOR UNIT (VCU)

Opacity No more than one 6 min avg>

20%

OR


(60) minute period

Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

SO2 When burning fuel gas:

H2S <= 162 ppmv over a 3-hour

averaging period

§60.104(a)(1)

[NSPS J]

Rule 335-3-16-.05(a)

146

Provisos for Summary Page for Gasoline Loading Rack and Vapor Combustor


Applicability

The gasoline vapor combustor unit (VCU) shall be subject to the

applicable requirements of ADEM Admin. Code r. 335-3-4-.01, “Visible

Emissions”, and the requirements specified in this subpart of this

permit.

Rule 335-3-4-.01

The gasoline loading rack vapor collection system shall be subject to

the requirements of ADEM Admin. Code r. 335-3-6-.20(4)(a), “Air

Permits for Gasoline Tank Trucks”, and the requirements specified in

this subpart of this permit.

Rule 335-3-6-.06(3)(e)

Rule 335-3-6-.20(4)

The gasoline loading rack and gasoline VCU located at the refinery shall

be subject to the requirements specified in ADEM Admin. Code r. 335-

3-16, “Major Source Operating Permits”, and the requirements


Rule 335-3-16-.03

§63.642(a)

The gasoline VCU shall be subject to the applicable requirements

specified in 40 CFR Part 60, Subpart A, “General Provisions”, 40 CFR

Part 60, Subpart J, “Standards of Performance for Petroleum

Refineries” [NSPS J], for fuel gas combustion devices and the

requirements specified in this subpart of this permit. Compliance with

NSPS J shall satisfy the requirements of ADEM Admin. Code r. 335-3-4-

.03.

§60.100(a) and (b)

§60.101(g)

Rule 335-3-16-.05(a)

Equipment leaks from fugitive components associated the gasoline

truck loading rack shall comply with the requirements specified in 40

CFR Part 63, Subpart CC, “National Emission Standards for Hazardous

Air Pollutants (HAPs) Emissions from Petroleum Refineries” [MACT CC],

and the requirements specified in the NSPS GGG: Fugitive Equipment

Leaks of OHAP and VOC subpart of this permit. No further

requirements will be included under this subpart of this permit.

§63.640(p)(1), (r)

§63.648

Except as provided for in §63.640(d) and (g) of MACT CC, each gasoline

loading rack subject to the requirements of MACT CC shall meet the

following requirements:

§63.640(a), (c)(5), (d), (g)

§63.641

§63.642(i), (j), (l)

§63.652, §64.2(b)(1)(i)

The requirements specified in §63.640(a) of MACT CC §63.640(a)(1), (2)

Demonstrate compliance with the requirements of ADEM

Admin. Code r. 335-3-6-.06 for bulk gasoline terminals and the

ancillary equipment, except as specified in ADEM Admin. Code

r. 335-3-6-.06(3)(e) by complying with MACT CC.

Rule 335-3-6-.06

§63.640(q)

Each Group 1 gasoline loading rack located within a contiguous

area and under common control with a petroleum refinery

§63.650(a)

§63.422

147



shall comply with the applicable regulations under 40 CFR 63,

Subpart R, “NESHAP emissions for Gasoline Distribution

Facilities (Bulk Gasoline Terminals and Pipeline Breakout

Stations)” [NESHAP R], by reference as specified in §63.650(a)

of MACT CC and this subpart of this permit.

§60.502(a), (d), (e)-(g)

The applicable portions of NESHAP R are §63.421,

§63.422(a)-(c) and (e), §63.425(a)–(c), §63.425(e)-(h),

§63.427(a) and (b), §63.428(b), (c), (g)(1), (h)(1)-(3),

and (k).

§63.650(a)

All terms not defined in §63.641 of MACT CC shall have

the meaning given them in 40 CFR part 63, Subpart A

or in NESHAP R. The §63.641 definition of “affected

source” applies under MACT CC.

§63.650(b)

Gasoline loading racks are subject to the provisions of

40 CFR Part 60, Subpart XX, “Standards of Performance

for Gasoline Terminal” [NSPS XX], by reference as

specified in §63.650(a) of MACT CC and §63.422(a) of

NESHAP R and in this subpart of this permit.

§63.422(a)

§63.650(a)

The requirements specified in §60.502 of NSPS XX shall

be met except as specified in §60.502(b), (c), and (j) of

NSPS XX.

Each gasoline loading rack shall be subject to the applicable

requirements specified in Table 6 of MACT CC, in 40 CFR 63

Subpart A, “General Provisions”, and this subpart of this

permit.

§63.642(c)

Table 6, 40 CFR 63, Subpart CC

Per §64.2(b)(1)(i), the VCU would be exempt from the requirements of

40 CFR 64, “Compliance Assurance Monitoring” [CAM]. Compliance

with MACT CC shall meet the requirements of CAM.

§64.2(b)(1)(i)

Emission Standards

Visible emissions from the gasoline vapor combustor unit (VCU) shall

meet the opacity standards specified in proviso 1(a) and (b) of this


Rule 335-3-4-.01(a), (b)

The unit shall not discharge into the atmosphere particulate

that results in an opacity greater than 20%, as determined by

a 6-minute average.

Rule 335-3-4-.01(1)(a)

148




the unit shall not discharge into the atmosphere particulate

that results in an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

Only gasoline cargo tanks which have a valid Air Sticker may be loaded

at the gasoline loading rack.

Rule 335-3-6-.06(3)(e)

Rule 335-3-6-.20(4)

§63.422(c), §60.502(a)

The gasoline loading rack VCU shall not combust any fuel gas, as

defined in §60.101(d) of NSPS J, that contains H2S in excess of 162 parts

per million (ppmv) as determined hourly on a three hour rolling

average basis.

§60.104(a)(1)

Rule 335-3-16-.05(a)

The gasoline loading rack shall be equipped with a vapor collection

system designed to collect the total organic compounds (TOC)

displaced from gasoline cargo tanks during product loading. The

collection system shall comply with the following standards:

§60.502(a)

§63.422(a)

Rule 335-3-6-.20(3)(a)

The vapor collection system shall prevent the collected vapors

from passing from one loading rack to another loading rack.

§60.502(a), (d)

Rule 335-3-6-.20(3) and (7)

Loading of liquid product into the gasoline cargo tank shall be

limited to vapor-tight gasoline cargo tanks meeting the

requirements specified in §60.502(e) of NSPS XX.

Rule 335-3-6-.20(3)(a), (4)(a), (7)

§60.502(a), (e)

§63.422(a)

The loading of gasoline cargo tanks shall only be made into

tanks equipped with vapor collection equipment that is

compatible with the terminal’s vapor collection system.

Rule 335-3-6-.20(3)(a), (4)(a)

§60.502(a), (f)

§63.422(a)

The terminal and the cargo tank’s vapor collection system shall

be connected during each loading of a gasoline cargo tank.

Rule 335-3-6-.20(5)

§60.502(a), (g)

§63.422(a)

The vapor collection and liquid loading equipment shall be

designed and operated to prevent gauge pressure in the

delivery tank from exceeding 4,500 pascals (450 mm of water)

during product loading. This level is not to be exceeded when

measured by the procedures specified in §60.503(d) of NSPS

XX.

Rule 335-3-6-.20(5)(a)(1)

§60.502(a), (h)

§63.422(a)

No pressure-vacuum vent in the bulk gasoline terminal's vapor

collection system shall begin to open at a system pressure less

than 4,500 pascals (450 mm of water).

Rule 335-3-6-.20(5)

§60.502(a), (i)

§63.422(a)

149



As an alternative to complying with requirements specified in

proviso 4 (e) and (f) of this section of this permit, the

requirements specified in §63.422(e) of NESHAP R may be met.

§63.422(e)

Emissions to the atmosphere from the vapor collection and processing

systems due to the loading of gasoline cargo tanks shall not exceed 10

milligrams of total organic compounds per liter (mg/L) of gasoline

loaded

§63.422(b)

§63.427(b)

The gasoline VCU firebox temperature shall be maintained

above the minimum temperature established during the latest

performance test conducted on the unit.

Operation of the vapor processing system in a manner falling

below the established gasoline VCU firebox temperature shall

constitute a violation of this emission standard.

The applicable requirements specified in §63.648 of MACT CC shall

apply at all times.

§63.642(b)

§63.648

At all times, the gasoline loading rack must be operated and

maintained, including associated air pollution control equipment and

monitoring equipment, in a manner consistent with safety and good

air pollution control practices for minimizing emissions as specified in

§63.642(n) of MACT CC.

§63.642(n)

Rule 335-3-16-.05(a)



Method 9 or Method 22 of 40 CFR 60 Appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

Provided that the assist gas combusted in the vapor combustor is the

same as the fuel gas used in the heaters and boilers, the Permittee may

elect to use heater and boiler records to satisfy the test requirements

for the assist gas. Otherwise, performance evaluations of the H2S

monitor shall follow the procedures specified under §60.106(e)(1).

Rule 335-3-16-.05(c)(1)(i) and (ii)

§60.105(a)(4)(ii)

§60.106(e)(1)

The gasoline VCU (thermal oxidation system other than a flare) shall be

equipped with a continuous parameter monitoring system (CPMS)

meeting the following requirements:

§63.427(a)(3)

Must be installed, calibrated, certified, operated, and

maintained, according to manufacturer's specifications,

§63.427(a)

Must be capable of measuring temperature §63.427(a)(3)

150



Must be installed in the firebox or in the ductwork immediately

downstream from the firebox in a position before any

substantial heat exchange occurs.

§63.427(a)(3)

The vapor processing system shall be operated in a manner not

to go below the firebox temperature established during the

latest performance test that showed compliance with the

limit.

§63.427(b)

To demonstrate compliance with MACT CC, the test methods and

procedures specified below shall be met:

§63.425(a)-(c), (e)-(i)

A performance test must be conducted on the vapor

processing and collection systems using the methods and

procedures specified in §63.425(a)(1) of NESHAP R to

demonstrate that emissions to the atmosphere from gasoline

loading does not exceed 10 mg of TOC/Liter of gasoline loaded.

§63.425(a)(1)

Volume of air-vapor mixture exhausted (Vesi) shall be

determined using Method 2B of 40 CFR 60 Appendix A for

combustion vapor processing systems, OR Method 2A of 40

CFR 60 Appendix A for any other type system.

§60.503(c)(4), (5)

§63.425(a)(1)

Average Concentration of Total Organic Compounds (Cei) shall

be determined using Method 18, Method 25A, Method 25B of

40 CFR 60 Appendix A or another EPA-approved method.

Methane and Ethane may be excluded when appropriate.

§63.425(a)(1)

§60.503(c)(4), (6)

For a leak detection test, Method 21 of 40 CFR 60 Appendix A-

7 (section 4.3.2 of Method 21 shall be omitted) and the

procedures specified in specified in §63.425(f)(2) of NESHAP R

shall be used.

§63.425(f)(2)

§63.650(a)

§60.503(b)

Emission Monitoring

Provided that visible emissions in excess of the opacity standards occur

from the gasoline VCU, a visible emissions observation must be

conducted to determine opacity or to determine presence of fugitive

emissions from the unit as specified in Appendix B: Gasoline Loading

Rack and Combustor Monitoring section of this permit.

Rule 335-3-16-.05(c)(2)

A vapor collection system shall not load or cause loading to a gasoline

tank truck without a valid Air Sticker for the gasoline tank truck as

specified in ADEM Admin Code r. 335-3-6-.20(4).

Rule 335-3-6-.20(4)(a), (b)

Rule 335-3-16-.05(c)(2)

§63.502(e)(5)

151



An Air Sticker may be obtained once the requirements for a

vapor tightness test as specified in ADEM Admin Code r. 335-

3-6-.20(4) are satisfied.

Rule 335-3-6-.20(4)(a)

An Air Permit and Air Sticker shall be issued by the Department

OR by the Jefferson County Department of Health.

Rule 335-3-6-.20(4)(a),(b)

The Air Sticker shall be renewed annually Rule 335-3-6-.20(4)(c)

A valid Air Sticker must be attached and visibly be displayed

near the Department of Transportation Certification plate

required by 49 CFR 178.340-10b.

Rule 335-3-6-.20(3)(b), (4)(d)

A monitoring system that meets the requirements specified in the

§60.15(a)(4) of NSPS J and §60.13 of Subpart A shall be installed,

calibrated, maintained, and operated.

Rule 335-3-16-.05(c)(1)(ii)

§60.13

§60.105(a)(4)

§60.105(a)(4)(ii)

Periodic monitoring as specified in Appendix B: Gasoline Loading Rack

and Combustor Monitoring section of this permit shall be met for the

gasoline VCU.

Rule 335-3-16-.05(c)(1)(i)

Subsequent performance testing of the vapor processing system shall

be conducted within twenty-four (24) months of the latest

performance test and once every two (2) years, thereafter to

demonstrate that emissions to the atmosphere from gasoline loading

does not exceed 10 mg of TOC/Liter of gasoline loaded.

Rule 335-3-1-.05

Tests shall be conducted using methods and procedures found

in §60.8 of 40 CFR Subpart A and §60.503(a) of NSPS XX, except

that the 3-run requirement in §60.8 (f) does not apply.

§63.425(a)(1)

§60.503(a)

Immediately before the performance test, the facility, or its

agent, shall check the loading rack for vapor leaks. A leak shall

be defined as a reading of 500 ppm, or greater. All leaks shall

be repaired prior to conducting the test.

§63.425(a)(1)(i)

§60.503(b)

The test shall be conducted during 6-hour period in which the

highest througHPut normally occurs and shall be conducted

according to the requirements specified in §60.503(c)(1) of

NSPS XX.

§63.425(a)(1)

§60.503(c)(1)

The test shall include at least two start-ups and shutdowns of

the vapor processor, which shall be manually controlled, if

necessary, and the vapor holder level shall begin and end at

the same setpoint.

§63.425(a)(1)

§60.503(c)(2)

152



During each performance test, the combustor firebox

temperature shall be continuously recorded, and the

minimum firebox temperature setpoint established.

§63.425(a)(1), (b)

Reasons for any changes to firebox temperature since the

previous performance test shall be documented.

§63.425(c)

The emissions rate (E) of total organic compounds during testing shall

be determined using the following equation.

§60.503(3)

=

=n

1i

6

eiesi

10*L

CVK E

where,

E = Emission Rate of Total Organic Compounds in (mg/L

gasoline loaded)

§63.425(a)(1)

§60.503(c)(3)

K = Density of the calibration gas: §63.425(a)(1)

§60.503(c)(3)

For Propane: 1.83 x 106 mg/scm

For Butane: 2.41 x 106 mg/scm

i = emission testing interval of 5-minutes. During each interval,

the following parameters used in the equation are to be

measured:

Vesi = Volume of air-vapor mixture exhausted §63.425(a)(1)

§60.503(c)(4), (5)

Cei = Average Concentration of Total Organic

Compounds

§63.425(a)(1)

§60.503(c)(4), (6)

n = number of testing intervals. This is to be determined by

dividing total time of the test (in minutes), by 5-minutes (the

duration of each interval)

§63.425(a)(1)

§60.503(c)(4)

L = Total volume of gasoline loaded in liters. This is to be

determined using facility records.

§63.425(a)(1)

§60.503(c)(7)

To ensure that cargo tanks meet the vapor-tight requirements, the

facility must follow the procedures specified in §60.502(e)(1)-(5) of

NSPS XX or follow an alternative approved procedures specified in

§60.502(e)(6) of NSPS XX.

Rule 335-3-6-.20(3)(a)

§60.502(e)

153



The vapor collection system pressure shall demonstrate compliance

with the gauge pressure requirements under §60.502(h) of NSPS XX as

follows:

§60.502(h)

§60.503(d)

A pressure measurement device (liquid manometer,

magnehelic gauge, or equivalent instrument) used to monitor

the pressure shall be calibrated and installed and shall meet

the requirements specified in §60.503(d)(1) of NSPS XX

§60.503(d)(1)

During performance testing, the following data shall be

recorded:

§60.503(d)(2)

The pressure shall be recorded every five minutes

while a gasoline truck is being loaded

The highest instantaneous pressure that occurs during

each loading shall be recorded

Every loading position must be tested at least once

during the performance test.


A record of each visible emission observation conducted on the

gasoline VCU shall be maintained as specified in the chosen method of

monitoring.

Rule 335-3-16-.05(c)(2)

Documents demonstrating that a valid Air Sticker has been obtained

from the Department or from Jefferson County Health Department

shall be maintained.

Rule 335-3-16-.05(c)(2)

Records of H2S content of fuel gas burned in the gasoline VCU shall be

maintained.


Rule 335-3-16-.05(c)(2)

§60.48c(f)(4)

§60.105(a)(4)

To demonstrate compliance with NSPS J the following reporting


Rule 335-3-16-.05(a)



Rule 335-3-16-.05(c)(2)

§60.7(c), (d), §60.19(d), (e)

154






The excess emission report shall include each rolling 3-hr

period during which the average H2S concentration in the fuel

gas (measured using the continuous H2S monitor) exceeds its

allowable.

§60.105(e)(3)(ii)

The information specified in §60.7(c) of Subpart A and

§60.107(g) of NSPS J shall be provided in each excess emissions

report.

§60.105(e)

§60.107(g)

The following requirements shall be met to demonstrate compliance

with the recordkeeping and reporting requirements under MACT CC

for gasoline loading racks:

§63.650

The applicable recordkeeping and reporting provisions

specified in §63.428(b),(c), (g)(1), (h)(1) through (h)(3), and (k)

of NESHAP R and as summarized in Table 4 of MACT CC shall

be met.

§63.655(b)

§63.428(b),(c), (g)(1), (h)(1)-

(h)(3), (k)

Table 4, MACT CC

(1) A copy of the test results for each gasoline cargo tank

loading at a bulk gasoline terminal shall be maintained

as specified in §63.428(b) of NESHAP R at the terminal,

alternative recordkeeping requirements specified in

§63.428(k) of NESHAP R may be complied with.

§63.428(b)

§63.428(k)

(2) Records of the continuous monitoring data specified in

§63.428(c)(1) of NESHAP R shall be maintained

§63.428(c)(1)

A semi-annual report meeting the following requirement shall

be submitted to demonstrate compliance with MACT CC:

The report shall be submitted on a calendar basis on

the following reporting schedule:




§63.428(g)

The report shall include each loading of a gasoline

cargo tank for which vapor tightness documentation

had not been previously obtained by the facility.

§63.428(g)(1)

155








§63.10(e)(3)

§63.428(h)

An excess emissions report shall be submitted to the

Department regardless of whether or not a CMS is

installed

§63.428(h)

The excess emission report shall include each of the

occurrences specified in §63.428(h)(1) through (3) of

NESHAP R.

§63.428(h)(1)-(3)

There are no additional reporting and recordkeeping

requirements for gasoline loading racks under MACT CC unless

a gasoline loading rack is included in an emissions average.

§63.655(b)

Recordkeeping and reporting for emissions averages are

specified in §63.653 and in §63.655(f)(5) and (g)(8) of MACT

CC.

§63.653, §63.655(a)

§63.655(f)(5)

§63.655(g)(8)

Each record shall be maintained in a manner such that they can

be readily accessed within 24 hours and shall be maintained

for a period not less than five years from the date the

information is recorded unless otherwise specified.

§63.10(b)

§63.420(h)

Table 1 of NESHAP R

Each performance test report conducted on the gasoline vapor

recovery unit shall be submitted to the Department within 30 days of

the test date.

Rule 335-3-16-.05(c)(2)





of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

156


157

Summary Page for NESHAP Y and MACT CC: Marine Vessel Loading

Operations




EMISSION


EMISSION


MARINE VESSEL LOADING OPERATIONS

EAST DOCK

WEST DOCK

OHAP Maintain tons per year (TPY) of HAPs

and loading througHPut below levels

that would trigger applicability during

marine loading operations

*Existing Source with:

<10 TPY of one HAP

<25 TPY all HAPs

<10 M Barrels of Gasoline per year

<200 M Barrels of Crude Oil per year

§63.651, [MACT CC]

§63.567(j)(4)[NESHAP Y]

§63.560(a)(2), (b)(2)*

[NESHAP Y]

158

Provisos for Summary Page for Marine Vessel Loading Operations


Applicability

Each marine vessel loading operation shall be subject to the


Operating Permits”, and the requirements specified in this subpart of this

permit.

Rule 335-3-16-.03

§63.642(a)

Each marine vessel loading operation shall be subject to the applicable

requirements of 40 CFR 63 Subpart A, “General Provisions” as specified

in the applicable subpart under 40 CFR Part 63 and the requirements


§63.642(c)

Table 6, MACT CC

§63.560(c)

Table 1, NESHAP Y

Each marine vessel loading operation shall be subject to the

requirements specified in 40 CFR 63 Subpart CC, “National Emission

Standards for Hazardous Air Pollutants (HAPs) from Petroleum

Refineries” [Refinery MACT 1/MACT CC], and the requirements specified

in this subpart of this permit, except as specified in §63.640(d) and (g).

§63.640 (a), (c)(6), (d), (g), (i),

(j), (l)

§63.651

Compliance with MACT CC shall be met by complying with the

applicable requirements specified in §63.560 through §63.568 of

40 CFR 63, Subpart Y, “National Emission Standards For Marine

Tank Vessel Loading Operations” [NESHAP Y] and the


§63.651

§63.567(b)(1)

63.560(d)(3)

All terms not defined in §63.641 shall have the meaning shall

have the meaning given to them in subpart 40 CFR 63 Subpart A

or in NESHAP Y. The §63.641 definition of “affected source”

applies under MACT CC.

§63.651(b)

The notification reports under §63.567(b) of NESHAP Y are not

required.

§63.651(c)

§63.567(b)

The compliance time of 4 years after promulgation of NESHAP Y

does not apply. The compliance time is specified in

§63.640(h)(1).

§63.640(h)(1)

§63.651(d)

If a flare is used as a control device, the flare shall meet the

requirements of §63.670 of MACT CC.

§63.651(d)

Emission Standards

Existing sources at a major source having aggregate actual HAPs

emissions less than 10 and 25 tons calculated annually from marine tank

vessel loading operations at all loading berths are exempt from the

emissions standards specified in §63.562(b) and (d) of NESHAP Y.

§63.641

§63.560(a)(2),(3)

§63.561

§63.565(l)

159



A source with less than 10 and 25 tons that increase emissions

such that it becomes a source with emissions of 10 or 25 tons

shall comply with the maximum achievable control technology

(MACT) standards in §63.562(b) of NESHAP Y within 3 years

following the exceedance of the threshold level.

§63.561

§63.560(e)(1)(iii)

§63.562(b)

Existing sources with emissions less than 10 and 25 tons shall

comply with the submerged fill requirements specified in

§63.560(a)(4) of NESHAP Y.

§63.641

§63.560(e)(1)(iv)

Existing sources at a major source with a througHPut of less than 10

million (M) barrels of gasoline annually and of less than 200 M barrels of

crude oil annually are exempt from the emissions standards specified in

§63.562(c) and (d) of NESHAP Y.

§63.560(b)(2)

§63.561

A source with a througHPut less than 10 M barrels and 200 M

barrels that increases its througHPut such that it becomes a

source with a througHPut of 10 M barrels or 200 M barrels shall

comply with the reasonably available control technology (RACT)

standards in §63.562(c) of NESHAP Y within 3 years following the

exceedance of the threshold levels. An extension of the

compliance date can be granted as specified in proviso 2(b) of


§63.561

§63.560(e)(2)(iv)

§63.562(c)

Source with througHPut of 10 M barrels or 200 M barrels may

apply for approval from the Department for an extension of the

compliance date of up to 1 year if it is demonstrated that that

the additional time is necessary for installation of the control

device.

§63.561

§63.560(e)(2)(v)

The applicable requirements specified in §63.651 of MACT CC

shall apply at all times.

§63.642(b)

§63.651

At all times, marine vessel loading must be operated and

maintained, including associated air pollution control equipment

and monitoring equipment, in a manner consistent with safety

and good air pollution control practices for minimizing emissions

as specified in §63.642(n).

§63.642(n)


The emission estimation procedures specified in §63.565(l) shall be used

to determine an annual estimate of HAPs emissions:

§65.565(l)

160



The commodities exempted by §63.560(d) of NESHAP Y from

marine tank vessel loading operations shall not be included in

the annual estimate.

Emission estimates and emission factors shall be based on test

data, or if test data is not available, shall be based on

measurement or estimating techniques generally accepted in

industry practice for operating conditions at the source.

Emission Monitoring

Monitoring would consist of maintaining the records specified in the

recordkeeping and reporting section of this subpart.

Rule 335-3-16-.05(c)(1)(ii)

§63.560(a)(3)



with the recordkeeping and reporting requirements under MACT CC:

The applicable recordkeeping and reporting provisions specified

in §63.567(a) and §63.567(j)(4) of NESHAP Y and as summarized

in Table 5 of MACT CC shall be met.

§63.655(c)

§63.560(a)(3),

§63.567(a), (j)(4)

Table 5, MACT CC

(1) A copy of the emission estimates determined in

§63.565(l) of NESHAP Y shall be maintained.

(2) Records of marine tank vessel loading operation’s actual

througHPuts by commodity shall be maintained onsite.

There are no additional reporting and recordkeeping

requirements for marine vessel loading operations under MACT

CC unless a wastewater stream is included in an emissions

average.

§63.655(c)

Recordkeeping and reporting for emissions averages are

specified in §63.653 and in §63.655(f)(5) and (g)(8) of MACT CC.

§63.653

§63.655(a), §63.655(f)(5)

§63.655(g)(8)

Each record shall be maintained in a readily accessible location

at the facility site for a period not less than five years from the

date the information is recorded unless otherwise specified.

§63.567(j)(4)



reported to the Department in a manner that complies with proviso

15(b) and 21(b) of the general proviso subpart of this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

161

Summary Page for MACT CC: Heat Exchangers (Cooling Towers)



EMISSION


EMISSION

LIMIT/STANDARD * REGULATIONS

CLOSED-LOOP RECIRCULATION HEAT EXCHANGE SYSTEMS

Individual Sources:

Pre- Black Warrior Expansion Cooling Towers:

Old Coker Cooling Tower

Crude Unit Cooling Tower

Hydrobon Cooling Tower

VOC/OHAP Inlet VOC Concentration

AND

Outlet VOC Concentration

§63.654

Post-Black Warrior Expansion Cooling Towers:

New Coker Cooling Tower

Hydrocracker Cooling Tower

VOC/OHAP Inlet VOC Concentration

AND

Outlet VOC Concentration

§63.654

Particulate Work practice-- Install Drift

Eliminators

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Each Cooling Tower Opacity No more than one 6 min avg>

20%

OR



Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

162

Provisos for HAPs from Cooling Towers


Applicability

The cooling towers shall be subject to the applicable requirements of

ADEM Admin. Code r. 335-3-4-.01, “Visible Emissions”, and the


Rule 335-3-4-.01

The New Coker Cooling Tower and the Hydrocracker Cooling Towers

shall each have limits in place in order to avoid a review under ADEM

Admin. Code r. 335-3-14-.04, “Air Permits Authorizing Construction in

Clean Air Areas [Prevention of Significant Deterioration (PSD)]", and

are subject to the requirements specified in this subpart of this permit.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Each cooling tower shall be subject to the requirements specified in

ADEM Admin. Code r. 335-3-16, “Major Source Operating Permits”,


Rule 335-3-16-.03

§63.642(a)

Except as specified in §63.640(d) and (g) and §63.654(b) of 40 CFR 63

Subpart CC “National Emission Standards for Hazardous Air Pollutants

(HAPs) from Petroleum Refineries” [Refinery MACT 1/MACT CC], each

heat exchange system (cooling tower) associated with petroleum

refining process units shall be subject to the requirements of MACT CC

and as specified in this subpart of this permit.

§63.640(a)(1), (2)

§63.640(c)(8), (d), (g), (i), (j), (l)

§63.654(a),(b)

Each cooling tower is subject to the applicable requirements of 40 CFR

63 Subpart A, “General Provisions” [Subpart A], as specified in the

applicable subpart under 40 CFR Part 63 and the requirements


§63.1, §63.642(c)

Table 6, 40 CFR 63 Subpart CC

Emission Standards

Visible emissions from each cooling tower shall meet the opacity

standards specified in proviso 1(a) and (b) of this section of this

subpart.

Rule 335-3-4-.01(a), (b)


that results in an opacity greater than 20%, as determined by

a 6-minute average.

Rule 335-3-4-.01(1)(a)


the unit shall not discharge into the atmosphere particulate

that results in an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

The New Coker Cooling Tower and the Hydrocracker Cooling Tower

shall each be equipped with drift eliminators in order to minimize

particulate emissions.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

163



To demonstrate compliance with MACT CC, monitoring to identify

leaks of total strippable volatile organic compounds (VOC) for a closed-

loop recirculation heat exchange system as specified in §63.654(c)(1)

shall be met.

§63.654(c)(1)



Method 9 or Method 22 of 40 CFR part 60, appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

Drift eliminators shall be maintained according to the test methods

and procedures specified under the manufacturer’s specification.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Determine the total strippable hydrocarbon concentration (in parts per

million by volume (ppmv) as methane) at each monitoring location

using the “Air Stripping Method (Modified El Paso Method) for

Determination of Volatile Organic Compound Emissions from Water

Sources” Revision Number One, dated January 2003, Sampling

Procedures Manual, Appendix P: Cooling Tower Monitoring, prepared

by Texas Commission on Environmental Quality, January 31, 2003

(incorporated by reference—see §63.14) using a flame ionization

detector (FID) analyzer for on-site determination as described in

Section 6.1 of the Modified El Paso Method.

§63.654(c)(3)

Emission Monitoring

Provided that visible emissions, in excess of the opacity standards, are

observed from a cooling tower at any time that the unit is operating, a

visible emission observation shall be conducted utilizing one of the

specified methods.

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

The drift eliminators shall be installed, maintained, and operated in

accordance with the manufacturer’s specifications.

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

To demonstrate compliance with MACT CC, each cooling tower must


Samples shall be taken and analyzed as specified in

§63.654(c)(1)(i) or (ii) for a closed-loop recirculation heat

exchange system.

§63.654(c)(1)(i) or (ii)

For existing sources, comply with the monitoring frequency

and leak action level specified in provisos 3(b)(1) or (2) of this

section of this permit and the requirement specified in

§63.654(c)(4).

§63.654(c)(4)

164



Monitor monthly using a leak action level defined as a

total strippable hydrocarbon concentration (as

methane) in the stripping gas of 6.2 ppmv.

§63.654(c)(4)(i)

Monitor quarterly using a leak action level defined as

a total strippable hydrocarbon concentration (as

methane) in the stripping gas of 3.1 ppmv unless repair

is delayed as specified in §63.654(f). If a repair is

delayed as provided in paragraph (f) of this section,

monitor monthly.

§63.654(c)(4)(ii)

For new sources, comply with the monitoring frequency and

leak action level must be met by conducting monthly

monitoring using a leak action level defined as a total strippable

hydrocarbon concentration (as methane) in the stripping gas of

3.1 ppmv.

§63.654(c)(5)

A leak for a closed-loop recirculation heat exchange system is

detected if a measurement value of the sample taken from a

location specified in Proviso 3(a) of this section equals or exceeds

the leak action levels specified above.

§63.654(c)(6)(ii)

Except as specified in §63.654(e) and (f), if a leak is detected, the

leak must be repaired to reduce the measured concentration to

below the applicable action level as soon as practicable, but no

later than 45 days after identifying the leak, unless the leak is from

a non-HAP source.

§63.654(d), (e), (f)

If the conditions specified in §63.654(f) are met, repair to a

leaking heat exchange may be delayed.

§63.654(f)


A record of each visible emission observation conducted on a cooling

tower shall be maintained as specified in the chosen method of

monitoring.

Rule 335-3-16-.05(c)(2)

The following records shall be kept for cooling towers equipped with

drift eliminators:

Rule 335-3-14-.04(9)(b)

[BACT/PSD Limit]

Records of any periods when the drift eliminators were not

maintained and operated in accordance with manufacturer’s

specifications.

The date, time, and description of all maintenance performed

on the drift eliminators.

165



To demonstrate compliance with the recordkeeping and reporting

requirements under MACT CC, the following requirements shall be

met:

The recordkeeping requirements shall be met for cooling

towers as follows:

A Notification of Compliance Status records shall be

maintained as specified in §63.655(f)(1)(vi)

§63.655(f)(1)(vi)

The records specified in §63.654(g) must be

maintained to delay the repair of a leaking heat

exchange system

§63.654(g)

Comply with the recordkeeping requirements

specified in §63.655(i)(5).

§63.655(i)(5)

Copies of all applicable reports and records shall be

kept for at least 5 years except as otherwise specified

in §63.655(i).

§63.655(i)

All applicable records shall be maintained in such a

manner that they can be readily accessed within 24

hours.

§63.655(i)

Records may be maintained in hard copy or computer-

readable form including, but not limited to, on paper,

microfilm, computer, flash drive, floppy disk, magnetic

tape, or microfiche.

§63.655(i)

A heat exchange system at an existing source must notify the

Department at least 30 calendar days prior to changing from

one of the monitoring options specified in §63.654(c)(4) to the

other.

§63.655(h)(7)

A Periodic Report meeting the following requirements shall be

met for each cooling tower:

§63.642(f)

§63.655 (e) and (g)

The requirements specified in §63.655(g)(9)(i) through

(v) shall be included in the report.

§63.655(g)(9)

Reports shall be submitted to the Department on a

semi-annual calendar basis according to the following

reporting schedule:

§63.13(f)

§63.642(f)

§63.655(g)

166






A Periodic Report is not required if no events specified in

§63.655(g)(9) occurred during the reporting period.

§63.655(g)

§63.655(g)(9)





of this permit.

Rule 335-3-16-.05(c)3(ii)

167

Summary Page for MACT CC: Fenceline Monitoring for Benzene Emissions



EMISSION


EMISSION


Fenceline monitoring along the facility

property boundary

Benzene (BZ)

Annual average benzene

concentration (Δc) below the

determined action level

§63.658

[MACT CC]

168

Provisos for MACT CC: Fenceline Monitoring for Benzene Emissions Federally Enforceable Provisos Regulations

Applicability

The fenceline monitoring system shall be subject to the requirements

specified in ADEM Admin. Code r. 335-3-16, “Major Source Operating

Permits”, and the requirements specified in this subpart of this permit.

Rule 335-3-16-.03

§63.642(a)

The fenceline monitoring system is subject to the applicable requirements of

40 CFR 63 Subpart A, “General Provisions”, as specified in the applicable

subpart under 40 CFR Part 63 and the requirements specified in this subpart

of this permit.

§63.1

§63.642(c)

Table 6, MACT CC

The fenceline monitoring system shall be subject to the requirements

specified in 40 CFR 63 Subpart, CC “National Emission Standards for

Hazardous Air Pollutants (HAPs) from Petroleum Refineries’, and the


§63.640(a), §63.658

Emission Standards

The action level for benzene (BZ) is 9 micrograms per cubic meter (µg/m3) on

an annual average basis

§63.658(a)

§63.658(f)(3)

If the annual average benzene concentration (Δc) is less than or equal

to 9 µg/m3, the concentration is below the action level.

If the annual average benzene concentration (Δc) is greater than 9

µg/m3, the concentration is above the action level and a root cause

analysis and corrective action shall be conducted as specified in

§63.658(g). A corrective action plan shall be developed provided

that the conditions specified in §63.654(h) are met.

§63.658(g), (h)

Approval for a site-specific monitoring plan to account for offsite upwind

sources or onsite sources excluded under §63.640(g) may be requested from

the Department according to the requirements specified in §63.658(i)(1)

through (4).

§63.658(i)


Samples shall be analyzed in accordance with Methods 325A and 325B of 40

CFR 63, Appendix A or an alternative test method may be requested as

specified in §63.658(k).

§63.658(a)

§63.658(k); §63.7(f)

Except as specified in §63.658(c)(1)(i) through (iv), passive monitor

locations shall be determined in accordance with Section 8.2 of Method

325A of 40 CFR 63, Appendix A.

A root cause analysis and corrective action may include, but is not limited to,

the methods and procedures specified in §63.658(g)(1) through (4).

§63.658(g)(1)-(4)

169


Emission Monitoring

The following monitoring requirements shall be met for sampling to

demonstrate compliance with MACT CC for fenceline monitoring:

Sampling shall be conducted along the facility property boundary. §63.658(a)

The target analyte is benzene. §63.658(b)

Meteorological data shall be collected and recorded as specified in

§63.658(d).

§63.658(d)

For a root cause analysis, the following requirements shall be met: §63.658(g)

A root cause analysis shall be conducted to determine the cause of

the exceedance and to determine appropriate corrective action

within 5 days of determining that the action level has been exceeded

for any annual average Δc and no longer than 50 days after

completion of the sampling period.

A root cause analysis and initial corrective action analysis shall be

completed, and initial corrective actions taken no later than 45 days

after determining there is an exceedance.

For a corrective action plan, the following requirements shall be met: §63.658(h)

(a) The corrective action plan shall describe the corrective action(s)

completed to date, additional measures proposed to reduce

fenceline concentrations below the action level, and a schedule for

completion of these measures.

(b) The plan shall be submitted to the Department within 60 days after

receiving the analytical results indicating that the Δc value for the 14-

day sampling period following the completion of the initial corrective

action is greater than 9 µg/m3.

if no initial corrective actions were identified, the plan shall be

submitted to the Department no later than 60 days following the

completion of the corrective action analysis required in §63.658(g).


The following recordkeeping requirements shall be met for fenceline

monitoring under MACT CC:

§63.655(i)

§63.655(i)(8)

Records, specified in §63.655(i)(8)(i) through (x), shall be kept on an

ongoing basis.

170




All applicable records shall be maintained in such a manner that they

can be readily accessed within 24 hours.

Records may be maintained in a hard copy or computer-readable

form including, but not limited to, on paper, microfilm, computer,

flash drive, floppy disk, magnetic tape, or microfiche.

The following reporting requirements shall be met for fenceline monitoring

under MACT CC:

§63.642(f), §63.655 (e)(3),

§63.655(h)(8), (10)

§63.658(j)

Table 11, No.4(vi),

Except as specified in §63.655(h)(10), the information specified in

§63.655(h)(8)(i) through (viii) shall be electronically submitted

quarterly to EPA’s Compliance and Emission Data Reporting Interface

(CEDRI) by accessing it through EPA’s Central Data Exchange (CDX)

(htps://cdx.epa.gov/).

Reports shall be submitted electronically on a calendar quarterly

basis according to the following reporting schedule:


Q1| January 1-March 31 May 15

Q2| April 1- June 30 August 15

Q3| July 1- September 30 November 15

Q4| October 1- December 31 February 15

A notification demonstrating submission of the quarterly report to

EPA along with a summary of the two week sampling Δc and annual

average Δc determined during the reporting period shall be

submitted to the Department on the schedule specified in proviso 2

(b) of this section of this permit.





Rule 335-3-16-.05(c)3(ii)

171

Summary Page for NSPS Ja and MACT CC: Delayed Coking Units (DCU)

Process Vents



EMISSION


EMISSION


ALL RELEASES ASSOCIATED WITH DECOKING OPERATIONS

OF A DELAYED COKING UNIT

COKE DRUM A

COKE DRUM B

COKE DRUM C

COKE DRUM D

VOC

HAPs

Average vessel pressure

of 2 psig or less

determined on a rolling

60-event average;

Depressure to blowdown

system

§60.103a(i) [NSPS Ja]

§63.640(c)(9)

§63.657(a)(1)(i)

[MACT CC]

172

Provisos for DCU Process Vents


Applicability

Each delayed coking unit shall be subject to the requirements specified

in ADEM Admin. Code r. 335-3-16, “Major Source Operating Permits”,


Rule 335-3-16-.03

§63.642(a)

Each delayed coking unit is subject to the applicable requirements of

40 CFR 60 Subpart A, “General Provisions”, as specified in the

applicable subpart under 40 CFR Part 60, and the requirements


§60.1

Each coke drum vent shall demonstrate compliance with the

requirements of 40 CFR Part 60, Subpart Ja ”Standards of Performance

for Petroleum Refineries” [NSPS Ja] ,and the requirements specified in

this subpart of this permit.

§60.100a(a), (b) and (c)(1)

§63.103a(i)

§63.640(q)

Compliance with this subpart shall be met by complying with

the requirements to send uncondensed vapor to the flare as

specified under the Process Flares and Associated Process Vent

Units subpart of this permit.

§63.670

Compliance with this subpart shall be met by complying with

the pressure requirements specified under 40 CFR 63 Subpart

CC “National Emission Standards for Hazardous Air Pollutants

(HAPs) from Petroleum Refineries” [Refinery MACT 1/MACT

CC], for each delay coking unit and the requirements specified


§63.640 (a), (i), (j), (l). (q)

§63.657(a)

Each delayed coking unit is subject to the applicable requirements of

40 CFR 63 Subpart A, “General Provisions”, as specified in the

applicable subpart under 40 CFR Part 63 and the requirements


§63.1, §63.642(c)


All releases associated with the decoking operations of a delayed

coking unit, as defined in §63.641, shall be subject to the requirements

specified in MACT CC and the requirements specified in this subpart of

this permit.

§63.640(a), (c)(9), (h), (l)

§63.641

§63.657(a)(1)(i)

Table 11 of MACT CC

Emission Standards

To demonstrate compliance with MACT CC for delayed coking units,

the following standards must be met:

§63.640(c)(9)

Prior to venting to atmosphere, draining, or deheading the

coke drum at the end of the cooling cycle, each coke drum shall

§63.642(h)

§63.657(a)(1)(i)

173



meet an average vessel pressure of 2 psig or less determined

on a rolling 60-event average.

Each coke drum shall be depressurized to a closed blowdown

system until the coke drum vessel pressure meets an average

vessel pressure of 2 psig or less.

§63.642(h)

§63.657(a)(1)(i)

§63.657(d)

The coke drum vessel pressure shall be determined on

a 5-minute rolling average basis while the coke drum

is vented to the closed blowdown system and the last

complete 5-minute rolling average pressure just prior

to initiating steps to isolate the coke drum prior to

venting, draining or deheadings shall be used

determine the average coke drum vessel pressure.

Pressure readings after initiating steps to isolate the

coke drum from the closed blowdown system, just

prior to atmospheric venting, draining, or deheading

the coke drum, shall not be used in determining the

average coke drum vessel pressure.

The applicable requirements specified in §63.657 of MACT CC

shall apply at all times.

§63.642(b)

§63.657

At all times, the delayed coking unit must be operated and

maintained, including associated air pollution control

equipment and monitoring equipment, in a manner consistent

with safety and good air pollution control practices for

minimizing emissions as specified in §63.642(n).

§63.642(n)


No performance testing requirements apply to delayed coking units. §63.642(d)

Emission Monitoring

To comply with the pressure limits under MACT CC for delayed coking

units, the following requirements shall be met:

§63.657(b)

A monitoring system capable of determine the coke drum

vessel pressure, shall be installed, operated, calibrated, and

maintained

The pressure monitoring system shall be located at the top of

the coke drum or in the overhead line of the coke drum as near

as practical to the coke drum in a representative location that

§63.657(a)(1)(i)

§63.657(b)(1)

174



minimizes or eliminates pulsating pressure, vibration, and to

the extent practical, internal and external corrosion.

The pressure monitoring system must be capable of measuring

a pressure of 2.0 psig within ± 0.5 psig.

§63.657(b)(2)

To ensure that the pressure monitoring system is functioning as

required under MACT CC, the following requirements shall be met:

The system must be verified annually or at the frequency

recommended by the instrument manufacturer.

§63.657(b)(3)

The system must be verified following any period of more than

24 hours throughout which the pressure exceeded the

maximum rated pressure of the sensor, or the data recorder

was off scale.

§63.657(b)(3)

All components of the system must be visually inspected for

integrity, oxidation and galvanic corrosion every 3 months,

unless the system has a redundant pressure sensor.

§63.657(b)(4)

The output of the system must be reviewed each day the unit

is operated to ensure that the pressure readings fluctuate as

expected between operating and cooling/decoking cycles to

verify the pressure taps are not plugged.

§63.657(b)(5)

Plugged pressure taps must be unplugged or otherwise

repaired prior to the next operating cycle.

§63.657(b)(5)




(a) The recordkeeping requirements shall be met for delayed

coking units as follows:

§63.642(e), §63.655(i)

§63.655(i)(7)

Records of the average pressure for the 5-minute

period prior to venting to the atmosphere, draining or

deheading the coke drum for each cooling cycle for

each coke drum shall be maintained.

Records of each 60-cycle rolling average pressure,

considering all coke drum venting events shall be

maintained.

175





in §63.655(i).



hours.






met for delayed coking units:

§63.642(f)

§63.655 (e) and (g)

The requirements specified in §63.655(g)(12)(i)

through (iii) shall be included in the report.

§63.655(g)(12)



reporting schedule:




§§63.13(f)

§63.642(f)

§63.655(g)

A Periodic Report is not required if no events specified

in §63.655(g)(12) occurred during the reporting

period.

§63.655(g)

§63.655(g)(11)





of this permit.

Rule 335-3-16-.05(c)3(ii)

176


177

Summary Page for MACT CC: Miscellaneous Process Vents (Including

Maintenance Vents and Bypass Lines)

Permitted Operating Schedule for

Maintenance Vents:

During startup, shutdown, maintenance, or inspection of

equipment [§63.643(c)]

Permitted Operating Schedule for all other

Miscellaneous Process Vents†:

24 Hours/Day x 365 Days/Year = 8,760 Hours/Year

†Except during leap year, Permitted Operating Schedule = 8,784 Hours/Year


Emission

Point

Description Pollutant Emission

Limit/Standard

Regulations

Group 1 Miscellaneous Process Vents

(MPV)

HAPs Reduce emissions of organic HAPs using a

flare

§63.643(a)(1)

[MACT CC]

Maintenance Vents HAPs/VOC

Vapor in the equipment served by the vent

has a lower explosive limit (LEL) of less than

10 percent

OR

The pressure in the equipment served by

the vent is reduced to five (5) pounds per

square inch gauge (psig) or less

OR

The equipment served by the vent contains

less than 72 pounds of total VOC

OR

Vents associated with equipment

containing pyrophoric catalyst and no pure

hydrogen supply, the LEL of the vapor must

be less than 20 percent, except for one

event per year not to exceed 35 percent

OR

The pressure in the equipment served by

the vent is reduced to 2 psig or less. Active

purging of the equipment may be used

provided that the equipment pressure at

the location where the purge gas is

introduced remains at 2 psig

§63.643(c)

[MACT CC]

Bypass Lines on Group 1

Miscellaneous Process Vents

HAPs Route vent stream to the flare that meets

the requirement

§63.644(c)

[MACT CC]

178

Summary Page for Miscellaneous Process Vents (Including Maintenance Vents)


Applicability

Miscellaneous process vents (including maintenance vents) shall be subject

to the requirements specified in ADEM Admin. Code r. 335-3-16-.03, “Major

Source Operating Permits”, and the requirements specified in this subpart

of this permit.

Rule 335-3-16-.03

§63.645(a)

Miscellaneous process vents (including maintenance vents) are subject to

the applicable requirements of 40 CFR 63 Subpart A, “General Provisions”,

as specified in the applicable subpart under 40 CFR Part 63 and the


§63.1

§63.642(c)


Miscellaneous process vents (including maintenance vents) shall be subject

to the requirements specified in 40 CFR 63 Subpart, CC “National Emission

Standards for Hazardous Air Pollutants (HAPs) from Petroleum Refineries"

[Refinery MACT 1/MACT CC], and the requirements specified in this subpart

of this permit.

§63.640(a), (c)(1),(h)

§63.643(a) and (c)

Group 1 miscellaneous process vents, as defined in §63.641 of MACT CC,

shall be subject to the applicable requirements of 40 CFR 63 subpart G,

“Process vent provisions—performance test methods and procedures to

determine compliance”, by reference in MACT CC.

§63.641

§63.645(a)-(d)

Emission Standards

Group 1 miscellaneous process vents shall reduce emissions of organic

hazardous air pollutants (HAPs) using a flare subject to the requirements of

§63.670 and §63.671 of MACT CC as specified in the Process Flares and

Associated Process Unit Vents subpart of this permit.

§63.641

§63.643(a)(1)

§63.644(c)

§63.670 and §63.671

Provided that the vent system contains bypass lines that could

divert a vent stream away from the control device either directly to

the atmosphere or to a control device that does not comply with

the requirements in §63.643(a) the requirements specified in

§63.644(c)(1),(2), or (3) shall be met.

§63.643(a)

§63.644(c)

A violation is deemed to occur provided a bypass line is used to

divert a Group 1 miscellaneous process vent stream to atmosphere

or to a control device that does not meet the requirements on

§63.643(a).

§63.643(a)

§63.644(c)

A process vent may be designated as a maintenance vent if the vent is only

used as a result of startup, shutdown, maintenance, or inspection of

equipment where equipment is emptied, depressurized, degassed or placed

into service. Process vents designated as maintenance vents must only


§63.643(c)

179



Prior to venting to the atmosphere, the following conditions shall

be met as specified in §63.643(c) of MACT CC:

§63.643(c)

Process liquids shall be removed from the equipment as

much as is practical.

§63.643(c)(1)

Equipment shall be depressured to a control device

meeting the requirements specified in §63.643 (a)(1) for a

flare or §63.643 (a)(2) for a control device other than a

flare, a fuel gas system, or back to the process.

§63.643(a), (c)(1)

Except as specified in proviso 2(b) of this section of this

permit, depressuring shall occur until one of the following

conditions, as applicable, is met:

(i) The vapor in the equipment served by the

maintenance vent has a lower explosive limit (LEL)

of less than 10 percent.

§63.643(c)(1)(i)

(ii) If there is no ability to measure the LEL of the vapor

in the equipment based on the design of the

equipment, the following requirements shall be

met:

§63.643(c)(1)(ii)

(A) The pressure in the equipment served by

the maintenance vent shall be reduced to 5

pounds per square inch gauge (psig) or less.

(B) Upon opening the maintenance vent,

active purging of the equipment cannot be

used until the LEL of the vapors in the

maintenance vent (or inside the equipment

if the maintenance is a hatch or similar type

of opening) is less than 10 percent.

(iii) The equipment served by the maintenance vent

contains less than 72 pounds of total volatile

organic compounds (VOC).

§63.643(c)(1)(iii)

180



(iv) If the maintenance vent is associated with

equipment containing pyrophoric catalyst

(e.g. hydrotreaters and hydrocrackers) and a pure

hydrogen supply is not available at the equipment

at the time of the startup, shutdown, maintenance,

or inspection activity, the LEL of the vapor in the

equipment must be less than 20 percent, except for

one event per year not to exceed 35 percent.

§63.643(c)(1)(iv)

If, after applying best practices to isolate and purge equipment

served by a maintenance vent, none of the applicable criterion in

provisos 2(a)(3)(i) through (iv) of this section of the permit can be

met prior to installing or removing a blind flange or similar

equipment blind, the pressure in the equipment served by the

maintenance vent is reduced to 2 psig or less. Active purging of the

equipment may be used provided the equipment pressure at the

location where purge gas is introduced remains at 2 psig or less.

§63.643(c)(1)(v)

At all times any affected source, including associated air pollution control

equipment and monitoring equipment, must be operated and maintained

as follows:

In a manner consistent with safety and good air pollution control

practices for minimizing emissions as specified in §63.642(n) for

each maintenance venting event.

§63.642(n)

§63.643(d)

In a manner consistent with the minimum and/or maximum

operating parameter value or procedure required to be monitored

under §63.644(a) and (b) for Group 1 miscellaneous process vents.

§63.644(a), (b), (e)

Operation of the control device in a manner that constitutes a

period of excess emissions, as defined in §63.655(g)(6), or failure to

perform procedures required shall constitute a violation of the

applicable emission standard of this subpart.

§63.644(e)

§63.655(g)(6)


Except for maintenance vents complying with the alternative specified in

proviso 2(a)(3)(iii) of the emission standards section of this permit, the

lower explosive limit (LEL) or, if applicable, equipment pressure must be

determined by following the procedures for calibration and maintenance

according to manufacturer’s specification.

§63.643(c)(2)

181



For maintenance vents complying with the alternative in proviso 2(a)(3)(iii)

of the emission standards section of this permit, equipment size may be

determined from equipment design specifications and equipment contents

may be determined using process knowledge.

§63.643(c)(3)

Except as specified in §63.116(a)(1), (d), and (e) of Subpart G and §63.645(b)

through (d) and (i), Group 1 miscellaneous process vents shall demonstrate

compliance with MACT CC by conducting the applicable performance test

methods and procedures specified in §63.116.

§63.116

§63.645

Provided that it is necessary to determine the total organic compound (TOC)

for Group 1 miscellaneous process vents, the applicable methods and

procedures specified in §63.645(e), (f), or (g) shall be met.

§63.645(e), (f), (g)

Whenever process changes, as specified in §63.645(h), are made to

determine whether a vent is Group 1 or Group 2, the TOC emission rate shall

be re-calculated for each Group 2 process vent.

§63.645(h)

Method 22 of 40 CFR 60 Appendix A shall be used to determine visible

emissions.

§63.645(i)

Emission Monitoring

When applicable, the LEL or equipment pressure shall be determined using

process instrumentation or portable measurement devices.

§63.643(c)(2)

When applicable, the mass of VOC in the equipment served by the

maintenance vent shall be determined based on the equipment size and

contents after considering any contents drained or purged from the

equipment.

§63.643(c)(3)

Except that an approval is made as allowed under §63.644(b) to monitor an

alternative parameter other than those specified in §63.644(a), each Group

1 miscellaneous process vent shall vent to a flare that meets the following

requirements:

§63.644(a),(b)

§63.670

The requirements of §63.670 as specified in the emission

monitoring section of the Process Flares and Associated Process

Unit Vents subpart of this permit.

All monitoring equipment shall be installed, calibrated, maintained,

and operated according to manufacturer's specifications or other

written procedures that provide adequate assurance that the

equipment will monitor accurately.

182



A range shall be established that ensures compliance with the emission

standard for each parameter monitored.

§63.644(d)

Provided that a Group 1 miscellaneous process vent using a vent system

contains a bypass line that could divert a vent stream away from a control

device, the requirements specified in §63.644(c) shall be met.

§63.644(c)

To determine whether a miscellaneous process vent from a distillation unit

is subject to the requirements of MACT CC, the procedures specified in

§63.640(f) shall be met.

§63.640(f)


The following recordkeeping requirements shall be met to demonstrate

compliance with MACT CC:

§63.643(a), §63.655(i),

§63.655(i)(3), (4), (12)

Records specified in §63.655(i)(3)(i) through (v) shall be maintained

for Group 1 miscellaneous process vents required to continuously

monitor operating parameters.

For each closed vent system that contains bypass lines that could

divert a vent stream shall maintain a record of the information

specified in §63.655(i)(4).

Records specified in §63.655(i)(12)(i) through (vi) shall be kept for

each opening of maintenance vents.



All applicable records shall be maintained in such a manner that

they can be readily accessed within 24 hours.

Records may be maintained in a hard copy or computer-readable

form including, but not limited to, on paper, microfilm, computer,

flash drive, floppy disk, magnetic tape, or microfiche.

Records necessary to demonstrate compliance with the

requirements of §63.642(n), including, if appropriate, records of

existing standard site procedures used to deinventory equipment

for safety purposes shall be kept.

§63.643(d)

§63.642(n)

A Periodic Report meeting the following requirements shall be met for

maintenance vents:

§63.643(a)

§63.655(e)(2), (g)(13)

183



The information specified in §63.655(g)(13)(i) through (iv) shall be

included for any release exceeding the applicable limits specified in

§63.643(c)(1) for maintenance vents.

§63.643(c)(1)

§63.655(g)(13)

If complying with the standard specified in proviso

2(a)(3)(iv) of the emission standards section of this permit,

each venting event for which the lower explosive limit is 20

percent or greater must be reported.

If complying with the standard specified in in proviso 2(b)

of the emission standards section of this permit, each

venting event conducted under these provisions must be

reported and must include an explanation for each event

and why utilization of this alternative was required.

Subsequent reports shall be submitted on a semi-annual calendar

basis according to the following reporting schedule:

§63.6(i), §63.643(a)

§63.655(f), (g)




A Periodic Report is not required if no events specified in §63.655(g)(13)

occurred during the reporting period.

§63.655(g)

The information required in §63.655(f)(3) is required to be maintained in

the Notification of Compliance Status report in order to establish the range

to ensure compliance with the emission standards for each parameter

monitored.

§63.644(d)

§63.655(f)(3)

Provided that a different parameter is monitored other than those specified

in §63.644 the information specified in §63.655(h)(4) shall be submitted.

§63.644

§63.655(h)(4)





Rule 335-3-16-.05(c)3(ii)

184


185

Summary Page for MACT UUU: Bypass Lines for CRU and SRU Vents


EMISSION


EMISSION


BYPASS LINES ASSOCIATED WITH THE FOLLOWING UNITS

Sulfur Recovery System No. 1

Sulfur Recovery System No. 2

Platformer No. 1

ISOM Unit

HAPS

WORK PRACTICE

STANDARDS

Vent to a Flare meeting the


and §63.671

OR

Comply with other options

allowed under this subpart

§63.1569(a)(1)(iv)

[MACT UUU]

§63.1569(a)(1) or (2)

Table 36., MACT UUU

CCR Platformer HAPS Install and operate an

electronic valve position

monitor to determine

whether flow is present in

the bypass line.

OR

Comply with other options

allowed under this subpart

§63.1569(a)(1)(i)

[MACT UUU]

§63.1569(a)(1) or (2)

Table 36., MACT UUU

186

Provisos for Bypass Lines for CRU and SRU Vents


Applicability

Each bypass line shall be subject to the applicable requirements of ADEM

Admin. Code r. 335-3-16, “Major Source Operating Permits”, and in this


Rule 335-3-16-.03

Each Group 1 miscellaneous process vents (MPV) using a vent system that

contains bypass lines that could divert a vent stream away from a control

devices used to comply with 40 CFR Part 63 Subpart CC, “National Emission

Standards for Hazardous Air Pollutants from Petroleum Refineries”

[Refinery MACT 1/MACT CC] shall met the requirements under §63.644(c)

of MACT CC . No further requirements shall be applicable to those bypass

lines under this subpart of this permit.

§63.643

§63.644(c)

Except as specified §63.1562 (f)(4), each bypass line serving a new, existing,

or reconstructed catalytic reforming unit (CRU) or sulfur recovery unit

(SRU) shall be subject to the requirements specified in 40 CFR Part 63 MACT

UUU, “National Emission Standards for Hazardous Air Pollutants (HAPs) for

Petroleum Refineries” [MACT UUU], and this subpart of this permit.

§63.1560

§63.1561

§63.1562(a), (b)(4), (c)-(e)

§63.1562(f)(4), §63.1563

§63.1569(a)

Each bypass line is subject to the applicable requirements of 40

CFR 63 Subpart A “General Provisions”, as specified in Table 44 of

MACT UUU and in this subpart of this permit.

§63.1577

Table 44, MACT UUU

Nothing in this subpart shall preclude the Permittee from selecting

an alternative method allowed under this subpart, provided that

written notification is first submitted to the Department.

§63.1569(a)(1)(i)-(iv)

§63.1569(a)(2)

Emission Standards

Bypass lines serving the CRU and SRU vents shall be vented to a flare

meeting the requirements specified §63.670 of MACT CC and as specified

in the emissions standards section under the Provisos for Process Flares

and Associate Process Unit Vent subpart of this permit.

§63.670

§63.1569(a)(1)(iv)

Table 36, No. 4, Option 4,

Table 38, No. 1d, Option 4,

MACT UUU

The CCR wash tower vent shall install and operate an electronic valve

position monitor meeting the following work practice standards:

§63.1569(a)(1)(i)

Table 36, No. 1, Option 1,

MACT UUU

The monitor shall either continuously or at least every hour,

determine whether flow is present in the bypass line.

The monitor shall be installed as near as practical to the entrance

to any bypass line that could divert the vent stream away for the

control device to the atmosphere.

187



A written operation, maintenance, and monitoring plan shall be developed

and implemented in accordance with §63.1574(f). Each flare and

electronic valve position monitor used to control bypass lines shall be

operated at all times in accordance with the procedures in the plan.

§§63.1569(a)(3), (b)(3), (c)(2)

§63.1574(f)

§63.1576(e)

Each CRU and SRU vent, including air pollution control and monitoring

equipment, shall always be operated and maintained at all times in a

manner consistent with safety and good air pollution control practices for

minimizing emissions as specified in §63.1570(c).

§63.1570(c)


The methods and procedures specified in §63.670 of MACT CC for flares

and as specified in Proviso 4 of the compliance and performance test

methods and procedures section under the Provisos for Process Flares and

Associate Process Unit Vent subpart of this permit shall be met to

demonstrate compliance with MACT UUU for bypass lines.

§63.670

Continuous compliance with the work practice standards shall be

demonstrated by complying with the procedures in your operations,

maintenance, and monitoring plan.

§63.1569(c)(1)

Emission Monitoring

The flare monitoring requirements specified in §63.671 of MACT CC and as

specified in Proviso 6 and 7 of the emission monitoring section under the

Provisos for Process Flares and Associate Process Unit Vent subpart of this

permit shall be met to demonstrate compliance with MACT UUU for bypass

lines.

§63.671

§63.1569(c)(1)

Table 39, No. 4 Option 4, MACT

UUU

An electronic valve position monitor shall demonstrate compliance as

follows:

§63.1569(c)(1)


UUU

Monitor and record on a continuous basis or at least every hour

whether flow is present in the bypass line

Visually inspecting the device at least once every hour if the device

is not equipped with a recording system that provides a continuous

record

Record whether the device is operating properly and whether flow

is present in the bypass line.

188




The following recordkeeping and reporting requirements shall be met to

demonstrate compliance with MACT UUU for bypass lines:

§63.1576

A copy of all notifications and reports submitted per MACT UUU,

including for start-ups, shutdowns, and malfunctions.

§63.1576(a)(1)

§63.1569(b)(2)-(4)

§63.1574(a)(3),(d), (f)

Table 38, No. 1d., MACT UUU

The records specified in §63.1576(a)(2)(i) through (iv) shall be

maintained.

§63.1576(a)(2)

Records specified in §63.1576(b) shall be met, where applicable,

for each CEMS or COMS.

§63.1576(b)

Records of each visible emission observations shall be maintained

as specified in §63.6(h) of Subpart A.

§63.1576(c)

A record of the time and duration of any bypass shall be recorded

and reported.

§63.1569(c)(1)

§63.1576(d)


UUU

Records of performance tests, performance evaluations, and

opacity and visible emissions observations as specified in

§63.10(b)(2)(viii) of subpart A, where applicable shall be

maintained.

§63.1576(a)(3) & (c)

§63.1576(d)

A current copy of the operations, maintenance, and monitoring

plan shall be maintained onsite and available for inspection.

§63.1576(e)

The recordkeeping and reporting requirements shall be met as

specified in Proviso 4 of the recordkeeping and reporting section

under the Provisos for Process Flares and Associate Process Unit

Vent subpart of this permit to demonstrate compliance with MACT

UUU for bypass lines.

§63.670(p)

Records shall be maintained as follows: §63.10(b)(1)

§63.1576(g)-(i)

In a form suitable and readily available for expeditious review

according to §63.10(b)(1) of Subpart A.

Records must be kept for a period of 5 years following the date of

each occurrence, measurement, maintenance, corrective action,

report, or record.

189



Records must be maintained onsite for at least 2 years following


corrective action, report, or record. Records may be maintained

offsite for the remaining 3 years.



specified in §63.1575(c)(1)-(4), the applicable information

specified in §63.1575(d) or (e) for each deviation from an emission

limitation, and the applicable information in §63.1575(f).

§63.1575(a), (c)-(f)

§63.1570(f)

Table 43, No. 1 MACT UUU




§63.1570(f)

§63.1575(c)(4) or (d)








If there are no deviations events that occurred during the

reporting period, a statement that indicates there were no

deviations from the permit requirements shall be included

in the report.


reporting schedule:




§63.1575(b)





Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

190


191

Summary Page for MACT UUU: Catalytic Reforming Unit (CRU) Vents



EMISSION


EMISSION


CATALTYIC REFORMING UNITS (CRU) VENTS

Platformer No. 1 & ISOM Unit

[Semi-Regenerative CRU]:

During blow down TOC Burn in flare meeting the


§63.1566(a)(1)(i)

Table 15, Option 1

During coke burn-off and rejuvenation HCl Reduce by 92% by weight OR

reduce to a concentration of

30 ppmv (dry) @ 3% O2

§63.1567(a)(1)(i)

Table 22, No. 1

Continuous Catalytic Reformer (CCR) Platformer

[Continuous CRU]

During blow down TOC Burn in fuel gas system or Burn

in flare meeting the


§63.1562(f)(5)

Table 15, Option 1

During coke burn-off and rejuvenation HCl Reduce by 97% by weight OR

reduce to a concentration of

10 ppmv (dry) @ 3% O2

§63.1567(a)(1)(i)

Table 22, No. 3

192

Provisos for Catalytic Reforming Unit (CRU) Vents


Applicability

Each catalytic reforming unit (CRU) vent shall be subject to the



permit.

Rule 335-3-16-.03

Each CRU vent shall be subject to the requirements of 40 CFR 63, Subpart

UUU, “ National Emission Standards for Hazardous Air Pollutants (HAP) for

Petroleum Refineries” [Refinery MACT 2/MACT UUU] for catalytic

reforming units and the requirements specified in this subpart of this

permit.

§63.1560, §63.1561

§63.1562(a), (b)(2), (c)-(e)

§63.1579

The applicable requirements specified in 40 CFR 63, Subpart A,

“General Provisions” [Subpart A], and this subpart of this permit

shall be met as specified in Table 44 of MACT UUU.

§63.1577

Table 44, MACT UUU

A flare used to demonstrate compliance with the requirement of

MACT UUU shall comply with the requirements for a flare as

specified in §63.670 of 40 CFR 63 Subpart CC, “National Emission

Standards for Hazardous Air Pollutants (HAPs) from Petroleum

Refineries” [Refinery MACT 1/MACT CC], instead of the

requirements in §63.11(b) of Subpart A.

§63.1562(f)(5)

§63.1566(a)(1)(i)

Nothing in this subpart shall preclude the Permittee from selecting

an alternative method of compliance under MACT UUU, provided

that written notification is first submitted to the Department.

§63.1566

§63.1567

Emission Standards

Except as specified in §63.1566(a)(4), during initial catalyst depressurizing

and purging operations of organic hazardous air pollutants (OHAP) and

while the reactor pressure is greater than five (5) pounds per square inch

gauge (psig), the following emission limits shall be met:

§§63.1566(a)(3),(4)

The ISOM Unit vent and the No. 1 Platformer vent shall be routed

to a flare that meets the requirements specified in §63.670 of

MACT CC.

§63.1566(a)(1)(i)

Table No. 15 and No.16, Option

1

The CCR Platformer vent shall be routed to the fuel gas system.

Provided that a flare receives gas from the fuel gas system, the

flare must meet the requirements of §63.670 of MACT CC.

§63.1562(f)(5)

§63.670 of MACT CC

193



During coke burn-off and catalyst rejuvenation operations, each CRU vent

shall meet the following requirements:

(a) The ISOM Unit and Platformer No. 1 shall vent emissions to a

control device that meets the requirement specified in either

proviso 2(a)(1) or (2) of this section of this subpart.

§63.1567(a)(1)

Table No. 22, No. 1

Reduces hydrogen chloride (HCl) emissions by 92% by

weight

§63.1567(a)(1)(i)

Reduces the HCl concentration to 30 part per million

volume (ppmv) (dry basis) or less corrected to 3% oxygen

(O2)

§63.1567(a)(1)(ii)

The CCR Platformer shall vent emissions to a control device that

meets the requirement specified in either proviso 2(b)(1) or (2) of


§63.1567(a)(1)

Table No. 22, No. 2

Reduces HCl emissions by 97% by weight. §63.1567(a)(1)(i)

Reduces the HCl concentration to 10 ppmv (dry basis) or

less corrected to 3% O2

§63.1567(a)(1)(ii)

Each CRU vent shall be equipped with an internal scrubbing system

that meets one of the following requirements:

§63.1567(a)(2)

The outlet concentration by maintaining the daily average

HCl concentration in the catalyst regenerator exhaust gas

below the limit established during performance testing.

Table No. 23, No. 2

The HCl percent reduction standard by ensuring that the

daily average pH or alkalinity of the water (or scrubbing

liquid) exiting the internal scrubbing system does not fall

below the limit established during the performance test;

and the daily average liquid-to-gas ratio does not fall

below the limit established during the performance test.

Table No. 23, No. 3

A written operation, maintenance, and monitoring plan shall be developed

and implemented in accordance with §63.1574(f). Each CRU vent shall be

operated at all times in accordance with the procedures in the plan.

§§63.1566(a)(5), (c)(2),(b)(7)

§§63.1567(a)(3), (c)(2)

§63.1574(f), §63.1576(e)

Each CRU vent, including air pollution control and monitoring equipment,

shall always be operated and maintained at all times in a manner

consistent with safety and good air pollution control practices for

minimizing emissions as specified in §63.1570(c).

§63.1570(c)

194




A visible emission observation shall be conducted on a flare used to control

emissions from organic HAPS during initial catalyst depressuring and

catalyst purging operations in accordance with Method 22 of 40 CFR Part

60, Appendix A and §63.760 and §63.671 of MACT CC.

§63.1566(b)(2) and (3)

§63.1571

Table 18, Option 1(a)

§63.670 and §63.671, MACT CC

The following methods and procedures shall be followed to conduct

performance testing on each CRU vent during coke burn-off and catalyst

rejuvenation to determine inorganic HAPs emissions from an internal

scrubbing system meeting the HCl outlet concentration limit:

§§63.1567(b)(2), (3)

Table No. 25, No. 1 & 2

§63.1571(a) and b)(1)

Method 1 OR 1A of 40 CFR 60 Appendix A shall be used to

determine the sampling point

Table No. 25, No. 1(a)(2)

Method 2, 2A, 2C, 2D, 2F, OR 2G of 40 CFR 60 Appendix A shall be

used to determine the exhaust gas velocity and volumetric

flowrate

Table No. 25, No. 1(b)

Method 3, 3A OR Method 3B of 40 CFR 60 Appendix A shall be used

to determine the exhaust gas molecular weight

Table No. 25, No. 1(c)

Method 4 of 40 CFR 60 Appendix A shall be used to determine the

exhaust gas moisture content

Table No. 25, No. 1(d)

Method 26A of 40 CFR 60 Appendix A shall be used to determine

the HCl concentration in the exhaust gas

§63.1567(b)(5)

Table No. 25, No. 1(e)

Table No. 26, No. 1 & 2

Emission Monitoring

To control organic HAP emissions from a CRU vent during initial catalyst

depressuring and catalyst purging operations, the following requirements

shall be met to demonstrate initial and continuous compliance with MACT

UUU:

§63.1566(b)

§63.1566(c)(1)

For a flare used as the control device the following monitoring shall

be met:

Emissions shall be vented from the process unit to a flare

meeting the requirements of §63.670 and §63.671 of

MACT CC.

Table 20, Option 1

§63.670 and §63.671, MACT CC

The requirements specified in §63.1566(b) and §63.1571

of MACT UUU shall be met to demonstrate compliance.

Table 18, Option 1(a) and (b)

§63.1566(b)(1)

195



A monitoring system that meets the requirements

specified in §63.1572(c) shall be installed, operated,

calibrated, and maintained as specified in §63.670 and

§63.671 of MACT CC.

§63.1566(b)(1)

§63.1572(c), (d)

§63.670 and §63.671, MACT CC

Table 15, 16, 17, 20 Option 1,

MACT UUU

The flare pilot light must be present at all times and the

flare must be operated at all times that emissions may be

vented to it.

§63.1566(c)(1)

Table 21 Option 1, MACT UUU

Performance testing for a flare used to control the CRU vent

emissions shall be conducted on Platformer No. 1, the ISOM Unit,

and the CCR Platformer (when emissions are vented to the flare)

by meeting the following requirements:

§63.1566(b)(2), (3),(5)(i), (6)

§63.1566(c)(2)

§63.1571

Table 18 and 19, Option 1,

MACT CC

(1) For initial compliance using a flare demonstrating

compliance with §63.670 and §63.671 of MACT CC.

Table 18, Option 1

§63.670 and §63.671, MACT CC

(i) Conduct a visible emission observation covering

two consecutive hours

§63.1566(b)(2) & (3)

Table 18, Option 1(a)

(ii) Determine that the flare meets the requirements

for the net heating value of the gas being

combusted and exit velocity

§63.1566(b)(2) & (3)

Table 18, Option 1(b)

(iii) Maintain visible emissions at less than 5-minutes

during any consecutive 2-hour period

Table 19, Option 1

§63.1566(b)(6)

Continuous compliance shall be met by complying with the

procedures in the operation, maintenance, and

monitoring plan.

§63.1566(c)(2)

To control inorganic HAP emission during coke burn-off and catalyst

rejuvenation, the following requirements shall be met to demonstrate

initial and continuous compliance with MACT UUU:

§63.1567(b)

For an internal scrubber used as the control device to meet the HCl

outlet concentration from a CRU, the following monitoring shall be

met:

§63.1567(a)(2)

Table 23, No. 2

Periodic checks shall be conducted using a colormetric

tube sampling system to measure the HCl concentration in

the catalyst regenerator exhaust gas.

§63.1567(b)(1)

§63.1572(c), (d)

Table 24, Option 2

196



The colormetric tube sampling system must use a printed

numerical scale in ppmv, a standard measurement range

of 1 to 10 ppmv (or 1 to 30 ppmv if applicable), and a

standard deviation for measured values of no more than

±15 percent. System must include a gas detection pump

and hot air probe if needed for the measurement range.

§63.1567(c)(1)

Table No. 25, No. 3

Table 41, No. 3

The daily average HCl concentration in the catalyst

regenerator exhaust gas must not exceed the limit

established during the performance test.

§63.1567(a)(2), (b)(3)

Table 23, Option 2

Continuous compliance shall be met by maintaining the HCl

concentration below the designated emissions limit.

Table 27, No. 1 & 2

Performance testing for an internal scrubber used to control the

CRU vent emissions from each CRU shall be conducted by meeting

the following requirements:

§63.1567(b)(2)

§63.1571(b)(1)

Table 25, No. 1 & 3

Each test shall consist of three separate test runs of at least

1 hour in duration each as specified in §63.7(3) of Subpart

A.

§63.1571(b)(2)

A performance evaluation must be conducted according

§63.8(e) of subpart A.

§63.1571(b)(3)

Equation 1 and Equation 4 in §63.1567(b)(4) shall be used

to demonstrate initial compliance with the emission limit.

§63.1567(b)(4)(i), (iii)

Data from the colorimetric tubes shall be used to establish

the HCl concentration operating limit as specified in Table

25, No. 3 of MACT UUU. Requirements for colormetric

tubes are detailed in Table No. 41, No. 3 of MACT UUU.

§63.1567(b)(3)

§63.1572(c)

Table No. 25, No. 1 & 3

Table No. 41, No.3

Performance testing must be conducted once every five

years.

Rule 335-3-16-.05(c)(1)(ii)

§63.1567(c)(1)

Table 27, No. 1 & 3

Performance test results shall be submitted to the

Department within 60 days after completing the

performance test.

§63.1575(k)(1)(ii) & (2)

§63.1576(f)(1)


A record of the information specified in provisos 1(a) through (f) of this


inspection.

§§63.1576(a),(b), (d),(g)-(I)

197



Date, starting time, and duration of each deviation from the


corrective actions taken

§63.1570(f)

§63.1572(d)

Date, starting time, and duration of each catalyst regeneration

event

§63.1567(c)(2)

Date, time, and results of each visual emission observation §63.1576(a)(3) & (c)

Record of the 4-hour HCl concentrations from each CRU vent §63.1567(c)(1)

The continuous parameter monitoring system (CPMS) records

and/or monthly visible inspection records for each vent

§63.1566(a)(1)

§63.1576(b) & (d)

A copy of all notifications and reports submitted per MACT UUU,

including for start-ups, shutdowns, and malfunctions

§63.1576(a)(1) & (a)(2)

Records shall be maintained as follows: §63.10(b)(1), §63.1576(g)-(i)


according to §63.10(b)(1) of Subpart A

Must be kept for a period of 5 years following the date of each

occurrence, measurement, maintenance, corrective action, report,

or record

Must be maintained onsite for at least 2 years following the date

of each occurrence, measurement, maintenance, corrective

action, report, or record. Records may be maintained offsite for

the remaining 3 years

The following reports shall be submitted to demonstrate compliance with

MACT UUU

§63.1575(a), (g)

Table 43, No. 1, MACT UUU


specified in §63.1575(c)(1)-(4), the applicable information

specified in §63.1575(d) or (e) for each deviation from an emission

limitation, and the applicable information in §63.1575(f)

§63.1575(c)-(f)





§63.1570(f)

§63.1575(c)(4) or (d)

198



If there are no deviations from any emission limitation or

work practice standard that applies to you, a statement

that there were no deviations from the standards during

the reporting period and that no continuous opacity

monitoring system or continuous emission monitoring

system was inoperative, inactive, out-of-control, repaired,

or adjusted.

If you have a deviation from any emission limitation or

work practice standard during the reporting period, the

report must contain the information in §63.1575(c)

through (e).

Each report shall cover a semi-annual reporting period and shall be

submitted according to the following reporting schedule:




§63.1575(b)





Rule 335-3-16-.05(c)3(ii)

199

Summary Page for NSPS J and MACT UUU: Sulfur Recovery Systems &

Thermal Oxidizers



EMISSION


EMISSION


SULFUR RECOVERY SYSTEMS

Each with:

Claus Sulfur Recovery Unit

Tailgas Treating Unit

Thermal Oxidizer

Oxygen Enrichment

Each Assist Gas Content /Fuel gas H2S ≤ 0.10 gr/dscf (~162 ppmv) §60.104(a)(1)

[NSPS J]

Each Process Gas Streams H2S Gas stream must be burned

to maintain offsite

concentration to 20 ppbv of

H2S in ambient air

Rule 335-3-5-.03(1) and

(2)

Each Thermal Oxidizer Opacity No more than one 6 min

avg> 20%

OR



Rule 335-3-4.-01(1)(a)

Rule 335-3-4-.01(1)(b)

100 LTon/Day Sulfur Recovery System No. 1:

D10.0801 12.2 MMBTU/Hr Thermal Oxidizer SO2 250 ppmv @ 0% excess air

averaged over a 12-hour

period

§60.104(a)(2)

§63.1568(a)(1)(i)

[MACT UUU]

80 LTon/Day Sulfur Recovery System No. 2

M.1801 6.5 MMBTU/Hr Thermal Oxidizer

w/ Oxygen enrichment

NOX 0.8 Lbs/Hour Rule 335-3-14-.04

[Anti-PSD Limit]

Particulate 2.0 Lbs/Hour Rule 335-3-14-.04

[Anti-PSD Limit]

SO2 250 ppmv @ 0% excess air

averaged over a 12-hour

period

AND

150 ppm averaged over a

365-Consecutive Day period

§60.104(a)(2)

§60.105(e)(4)

§63.1568(a)(1)(i)

[MACT UUU]

Rule 335-3-14-.04

[Anti-PSD Limit]

200

Provisos for Sulfur Recovery Systems & Thermal Oxidizers


Applicability

Each thermal oxidizer shall be subject to the requirements of ADEM

Admin. Code r. 335-3-4-.01, “Visible Emissions”, and this subpart of this

permit.

Rule 335-3-4-.01(1)

The refinery handles gas or refinery gas that contains more than 0.10

grains of hydrogen sulfide (H2S) per standard cubic foot (scf); therefore,

the thermal oxidizers will be subject to the requirements of ADEM

Admin. Code r. 335-3-5-.03, “Petroleum Production”, and this subpart of

this permit.

Rule 335-3-5-.03(2)

Each sulfur recovery plant (SRP) with a thermal oxidizer shall be subject

to the requirements specified in ADEM Admin. Code r. 335-3-16, “Major

Source Operating Permits”, and in this subpart of this permit.

Rule 335-3-16-.03

Thermal oxidizer No. M.1801 has enforceable particulate, sulfur dioxide

(SO2), and nitrogen oxide (NOX) limits in place in order to prevent it from

being subject to the provisions of ADEM Admin. Code Rule 335-3-14-.04,

“Air Permits Authorizing Construction in Clean Air Areas” [Prevention of

Significant Deterioration (PSD)] as specified in this subpart of this

permit.

Rule 335-14-.04

[Anti-PSD Limit]

Each SRP system (as defined in §60.101) and each thermal oxidizer is

subject to the requirements found in 40 CFR Part 60, Subpart J,

”Standards of Performance for Petroleum Refineries” [NSPS J] and in this


§60.100(a) & (b)

§60.101

Rule 335-3-16-.05(a)

Each thermal oxidizer shall be subject to the fuel gas

combustion device requirements specified in NSPS J.

§60.100(a) & (b)

§60.101

The applicable requirements of 40 CFR 60, Subpart A “General

Provisions” shall be met as specified in NSPS J.

40 CFR 60, Subpart A

Rule 335-3-16-.05(a)

Except as specified in §63.1562(f)(2) and (3), process vents or group of

process vents on sulfur recovery units (SRU) or tail gas treatment units

(TGU) serving a sulfur recovery plant (SRP), shall be subject to the

requirements of 40 CFR 63 Subpart UUU, “National Emission Standards

for Hazardous Air Pollutants (HAPs) for Petroleum Refineries” [MACT

UUU] and to this subpart of this permit.

§63.1560, §63.1561(a)

§§63.1562(a), (b)(3), (c), (d),

(f)(2)-(3)

§63.1568, §63.1579

§64.2(b)(1)(i)

The emissions limits specified in §60.104(a)(2)(i) of NSPS J may

be used to demonstrate compliance with MACT UUU.

§60.104(a)(2)(i)

§63.1568(a)(1)(i)

Table 29, No. 1 of MACT UUU

201



The applicable requirements of 40 CFR 63, Subpart A “General

Provisions” shall be met as specified in Table 44 of MACT UUU.

§63.1577

Per §63.2(b)(1)(i), the sulfur recovery units would be exempt

from the requirements of 40 CFR 64, “Compliance Assurance

Monitoring” [CAM}. Compliance with MACT UUU shall meet the

requirements CAM.

§63.2(b)(1)(i)

Nothing in this subpart shall preclude the Permittee from

selecting an alternative method of compliance under MACT

UUU, provided that written notification is first submitted to the

Department.

§63.1568

The thermal oxidizer is subject to the monitoring requirements under

CAM as indicated in Proviso 33 of the General Permit Provisos subpart

and in this subpart of this permit.

40 CFR 64

The following definitions shall apply for this subpart: Rule 335-3-16-.05(a)

“Acid Gas” shall mean any gas that contains hydrogen sulfide

and is generated at a refinery by the regeneration of an amine

scrubber solution.

“Sour Water Stripper Gas [SWS Gas]” shall mean the gas

produced by the process of stripping refinery sour water.

“Tail Gas Incident” shall mean the combustion of tail gas in a

thermal that result in excess emissions of 500 pounds, or more,

of sulfur dioxide in any 24-hour period. Only those time periods

having sulfur dioxide concentrations in excess of 250 ppm (1-

hour block average) shall be used to determine the amount of

excess sulfur dioxide emissions from the incinerator. The

Permitee shall use engineering judgment and monitoring data

during periods in which the sulfur dioxide emission analyzer

exceeds the range of the instrument or is out of service.

Emission Standards

Visible emissions from each thermal oxidizer shall meet the opacity

standards specified in proviso 1(a) and (b) of this section of this subpart.


that results in an opacity greater than 20%, as determined by a

6-minute average.

Rule 335-3-4-.01(1)(a)

202




the unit shall not discharge into the atmosphere particulate that

results in an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

All process gas streams containing 0.10 of a grain of hydrogen sulfide

(H2S) per scf shall be burned to the extent that the ground level

concentrations of H2S shall be less than twenty (20) parts per billion

beyond plant property limit, averaged over a thirty (30) minute period.

Rule 335-3-5-.03(2)

The following emission and operational limits shall apply to the Sulfur

Recovery Systems:

Sulfur Recovery System No. 1 and Thermal Oxidizer No.

D10.0801 shall not emit greater than 250 ppmv SO2 at 0% excess

air based on a rolling 12-hour average.

§60.104(a)(2)(i)

§63.1568(a)(1)(i)

Table No. 29, Item 1a, MACT

UUU

§63.1570(a)

Sulfur Recovery System No. 2 and Thermal Oxidizer No. M.1801

shall not emit greater than:

NOX emissions of 0.8 pounds per hour (Lb/hr) Rule 335-3-14-.04

[Anti-PSD Limit]

Particulate emissions of 2.0 Lb/hr Rule 335-3-14-.04

[Anti-PSD Limit]

SO2 emissions of:

(i) 250 ppmv SO2 at 0% excess air based on a

rolling 12-hour average

AND

§60.104(a)(2)(i)

§63.1568(a)(1)(i)

Table No. 29, Item 1a, MACT

UUUU

§63.1570(a)

(ii) 150 ppmv based on a rolling 365-day average Rule 335-3-14-.04

[Anti-PSD Limit]

Sulfur pit emissions shall be routed so that they are eliminated,

controlled, or included and monitored as part of the Sulfur

Recovery Plant’s 250 ppmv/rolling 12-hour average

Rule 335-3-16-.05(a)

To demonstrate compliance with NSPS J, any assist fuel gas that contains

H2S in excess of 0.10 grains per standard cubic feet (gr/scf) (~162 ppmv)

shall not be burned in the thermal oxidizers.

§60.104(a)(1)

203



To demonstrate compliance with MACT UUU during periods of startup

and shutdown, the thermal oxidizer shall be operated such that the

following requirements are met when purge gas is routed to it:

§63.1568(a)(4)(iii)

At a minimum the hourly average temperature of 1200 degrees

Fahrenheit (oF) in the firebox is maintained,

AND

A minimum hourly average outlet oxygen (O2) concentration of

2 volume percent (dry basis)

A written operation, maintenance, and monitoring plan shall be

developed and implemented in accordance with §63.1574(f). Each

sulfur recovery plant and thermal oxidizer shall be operated at all times

in accordance with the procedures in the plan.

§§63.1568(a)(3), (b)(6), (c)(2)

§63.1574(f)

§63.1576(e)

Enhanced maintenance and operation of the sulfur recovery plant (SRP)

and the appropriate upstream process units shall be included in a

Preventive Maintenance and Operation Plan (PMO Plan).

Rule 335-3-16-.05(a)

§63.1570(c)

The PMO Plan shall be a compilation of approaches for

exercising good air pollution control practices and for

minimizing SO2 emissions from sulfur processing and other

production processes at the refinery.

The PMO Plan shall have as its goal the elimination of acid gas

flaring and operation of the SRP between scheduled

maintenance turnarounds with minimization of emissions.

The PMO shall be implemented at all times, including periods of

startup, shutdown, and malfunction of the SRP.

A root cause analysis and corrective action analysis shall be conducted

for each Tail Gas Incident if the sulfur dioxide (SO2) emissions discharged

to atmosphere is 500 pounds or greater in a 24-hour period.

Rule 335-3-16-.05(a)


Compliance with the opacity standards for the thermal oxidizer shall be

determined using Method 9, Method 22 of 40 CFR Part 60, Appendix A,

or other methods approved by the Department.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

The following methods and procedures shall be met to conduct

performance testing to determine NOX emissions from the M.1801

thermal oxidizer:

Rule 335-14-.04

[Anti-PSD Limit]

204



Method 1 OR 1A of 40 CFR Part 60, Appendix A to determine the

sample and velocity tranverses

Method 2, 2A, 2B, 2C, 2D, OR 2E of 40 CFR Part 60, Appendix A

to determine the velocity and volumetric flow rate


gas analysis

Method 4 of 40 CFR Part 60, Appendix A to determine the


Method 7E of 40 CFR Part 60, Appendix A to determine NOX

emissions

The following methods and procedures shall be met to demonstrate

compliance with performance test requirements in NSPS J for the

thermal oxidizers.

The H2S emission limit shall be determined using the following

method and procedures specified in Method 11, 15, OR 15A of

Appendix A-5 to part 60, OR Method 16 of Appendix A-16- to

part 60, as required in §60.106(e)(1).

§60.105(a)(4)(iii)

§§60.106(a), (e)(1)

Performance evaluations for each H2S monitor shall be

conducted according to the requirements of §60.13(c) of

Subpart A and Performance Specification (PS) 7 of Appendix B,

Part 60.

§60.105(a)(4)(iii)

Relative accuracy evaluations shall be conducted using the

methods and procedures specified in Proviso 3(a) of this section

of the permit.

§60.105(a)(4)(iii)

The following methods and procedures shall be met to demonstrate

compliance with performance test requirements in NSPS J for the sulfur

recovery plants:

Compliance with the SO2 emission limit and O2 concentration

shall be determined using the following methods and

procedures:

§60.106(f)


Method 6 OR 6C of 40 CFR Part 60, Appendix A to determine the

SO2 concentration

§60.106(f)(1)

Method 4 of 40 CFR Part 60, Appendix A to determine the

moisture content of the gas

§60.106(f)(1)

205



Method 15 of 40 CFR Part 60, Appendix A to determine the H2S

concentration

§60.106(f)(2)


oxygen concentration used to correct the emission rate for

excess air

§60.106(f)(3)

Performance evaluations for each SO2 monitor shall be

conducted according to the requirements of §60.13(c) and PS 2

of Appendix B, Part 60,

§60.105(a)(5)(ii)

Emission Monitoring

Provided that visible emissions, in excess of the opacity standards, are

observed from the thermal oxidizer at any time that the unit is

operating, a visible emission observation shall be conducted.

Rule 335-3-4-.01(2)

Rule 335-3-16-.05(c)(1)(i)

The fuel gas assist shall be monitored as specified in the Process Heaters

and Boiler subpart of this permit.

Rule 335-3-16-.05(c)(1)(i)

CAM requirements for each thermal oxidizer shall be met as specified in

Appendix C: Sulfur Recovery Systems’ Thermal Oxidizer of this permit

shall be met to demonstrate that the H2S offsite concentration

requirement is being met.

Rule 335-3-5-.03(2)

§64.3

§64.6(b)

A compliance test for NOX emissions from Sulfur Recovery System No. 2

shall meet the following requirements:

Rule 335-3-16-.05(c)(1)(i)

Shall be conducted once every five (5) years

Shall consist of three runs of at least 1-hour in duration each

This test may be conducted at the same time as the annual SO2

compliance test.

An instrument to continuously monitor and record the concentration by

volume (dry basis) of H2S in the fuel gas before being burned in the

thermal oxidizer shall be installed, operated, calibrated, and

maintained.

§60.105(a)(4)

The span value for the instrument is 425 mg/dscf H2S. §60.105(a)(4)(i)

An exemption from H2S monitoring may be requested for low-

sulfur fuel gas streams by meeting the requirements specified

in §60.105(a)(4)(iv).

§60.105(a)(4)(iv)

§60.105(b)

206



A common source of fuel gas may be monitored at only one

location if monitoring at this location accurately represents the

concentration of H2S in the fuel gas being burned in the

respective thermal oxidizer.

§60.105(a)(4)(ii)

To determine the H2S concentration, the monitoring

requirements in §60.106(e)(1)(i)-(iii) shall be met.

§60.106(e)(1)

H2S samples shall be corrected to 0% excess air using the

equation found in §60.106(h)(6).

§60.106(h)(6)

Emission monitoring for the sulfur recovery plants shall be met as

follows:

§60.105(a)(5)

An instrument for continuously monitoring and recording the

concentration (dry basis, zero percent (0%) excess air) of any

SO2 emissions into the atmosphere shall be installed, operated,

calibrated, and maintained. The monitor shall include an

oxygen monitor for correcting the data for excess air.

§60.105(a)(5)

§63.1568(b)(1)

§63.1572(a), (d)

Table 31, No. 1a, MACT UUU


A SO2 CEMS and an O2 monitor shall be installed, operated, and

maintained.

§63.1568(b)(5)

§63.1572(a)(1)


The span value is 500 ppm for the SO2 monitor and 25 percent

for the O2 monitor.

§60.105(a)(5)(i)

Table 40, Item Nos.5 & 9, MACT

UUU

The applicable monitoring requirements specified in

§60.106(f)(1)-(3) shall be met.

§60.106(f)

SO2 samples shall be corrected to 0% excess air using the

equation found in §60.106(h)(6).

§60.106(h)(6)

The following data shall be collected to determine continuous

compliance with the emission limit:

§63.1568(c)(1)


Table 35, No. 5a & b, MACT

UUU The hourly average SO2 monitoring data (dry basis,

percent excess air)

Each 12-hr rolling average concentration of SO2 shall be

determined and recorded

Each 12-hour rolling average concentration of SO2 at or

below 250 ppmv at 0% excess air (dry basis) shall be

maintained

207



Continuous (at least once every 15 minutes) and hourly

average temperature monitoring data shall be collected

according to §63.1572 and the daily average firebox

temperature at or above 1200 oF shall be maintained

during periods of startup and shutdown

Continuous (at least once every 15 minutes) and hourly

O2 monitoring data shall be collected according to

§63.1572 and the O2 concentration at or above 2

volume percent (dry basis) shall be maintained during

periods of startup and shutdown

Performance testing on the sulfur recovery plants shall comply

with requirements specified in §63.1568(b)(5), S63.1571(b) and

§63.1572(a) of MACT UUU.

§63.1568(b)(5)

§63.1571(b)

§63.1572(a)(2)


Annual compliance testing shall be conducted on each sulfur

recovery system for SO2 emissions.

Rule 335-3-16-.05(c)(1)(ii)

Performance test or CEMS performance evaluations reports shall be

submitted to the Department within 60 days of the test date and

according to the requirements specified in §63.1575(k).

§63.1575(k)

A root cause analysis and a corrective action analysis shall meet the

following requirements for Tail Gas Incidents:

Rule 335-3-16-.05(c)(2)

The requirements shall apply to tail gas unit (TGU) shutdowns,

bypasses of a TGU, or other events which result in a Tail Gas

Incident, including scheduled and unscheduled shutdowns of

the Claus Sulfur Recovery Plant.

Shall be completed as soon as possible, but no later than forty-

five (45) days after a discharge.

Corrective actions identified in the corrective action analysis

shall be consistent with good engineering practice to minimize

the likelihood of a recurrent of the Root Cause and all significant

contributing causes of that Tail Gas Incident.


A record of the information specified in provisos 1(a) through (n) of this


inspection.

§§63.1576(a),(b), (d),(g)-(I)

Rule 335-3-16-.05(c)(2)

§60.107

208



For the Assist gas, the Permittee must record:

Assist gas BTU content

[ Assist Gas (BTU/scf/)]

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Assist gas hydrogen sulfide content

[Assist Gas (H2S Mole %)]

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Provided the Assist Gas is the same as the fuel gas used

in the heaters and boilers, the Permittee may elect to

use those records to satisfy provisos 1(a)(1) and 1(a)(2).

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

The date, starting time, and duration of each deviation from the



§63.1570(f)

§63.1572(d)

For each Tail Gas Incident, the following record shall be

maintained onsite:

Rule 335-3-16-.05(a)

The date, time, and duration of each Tail Gas Incident,

along, if applicable, with the date, time, and duration of

each sub-Incident

An estimate of the quantity of the SO2 emissions

released for Tail Gas Incidents if the SO2 concentration

is greater than 250 ppmv

Steps taken to minimize emissions and/or the duration

of the event

A detailed analysis describing the Root Cause and any

contributing cause(s) to the Incident

A description of the plan(s) to minimize the recurrence

of the Incident, including possible operational changes,

cost effectiveness, and completion schedule.

A list of all corrective actions taken

A copy of the Preventative Maintenance and Operation [PMO]

Plan, along with any revisions.

Rule 335-3-16-.05(a)

The date, time, and results of each performance test along with

any other test conducted on the thermal oxidizer that provides

additional stack pollutant content data.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

§63.1576(a)(3)

209



The date and time of each shut down and startup of the gas

sweetening unit, the sulfur recovery unit, the tail gas unit, or the

thermal oxidizer.

§63.1576(a)(2)

Date and type of maintenance that affects air emissions Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Records of performance tests, performance evaluations, and

opacity and visible emissions observations as specified in

§63.10(b)(2)(viii) of Subpart A, where applicable

§63.1576(a)(3) & (c)

The hourly and twelve hour rolling average sulfur dioxide

concentration for both thermal oxidizers

§63.1568(c)(1)

The 365-day rolling average for Thermal Oxidizer No. M.1801 Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Rule 335-3-14-.04 [Anti-PSD

Limit]

For each CEMS, the records specified in §63.1576(b)(1)-(5) shall

be maintained for sulfur recovery systems.

§63.1576 (b) & (d)

Current copy of the operations, maintenance, and monitoring

plan maintained onsite and available for inspection.

§63.1576(e)

A copy of all notifications and reports submitted per MACT

UUU, including for start-ups, shutdowns, and malfunctions.

§63.1576(a)(1) & (a)(2)

Where applicable, exemption records demonstrating that the

fuel gas burned in the thermal oxidizer is inherently low in

sulfur.

§60.107(e)

Records shall be maintained as follows: §63.10(b)(1), §63.1576(g)-(i)

§64.9


according to §63.10(b)(1) of Subpart A

Records must be kept for a period of 5 years following the date

of each occurrence, measurement, maintenance, corrective

action, report, or record.

Records must be maintained onsite for at least 2 years following


corrective action, report, or record. Records may be maintained

offsite for the remaining 3 years.

210




An Excess Emissions report and/or summary shall be submitted

to the Department and shall contain the applicable information

specified in §60.105(e) and §60.107(d) and (g) of NSPS J.

§60.7(c)

§60.105(e)(3), (4)

§60.107(d) & (g)

A Compliance Report shall include any 12-hour rolling average

concentration of SO2 greater than the emission limit and the

information specified in §63.1575(c)-(f) of MACT UUU.

§63.1568(c)(1). §63.1570(f)

§63.1575(a), (c)(4)


A Periodic Monitoring Report (PMR) shall identify each

incidence of deviation from a permit term or condition including

those that occur during startups and shutdowns which are not

covered under NSPS J or MACT UUU.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(i)




§63.1570(f)

§63.1575(c)(4) or (d)





compliance, that identifies an affected source has failed

to meet an applicable emission limit or standard, or that

a work practice was not complied with or completed.

If there are no deviations events that occurred during

the reporting period, a statement that indicates there

were no deviations from the permit requirements shall

be included in the report.


reporting schedule:




Rule 335-3-16-.05(c)(2)

§60.7(c), (d), §60.19(d), (e)

§60.107(f)

§63.1575(b)




complies with proviso 15(b) and 21(b) of the general proviso subpart of

this permit.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

211

Summary Page for NSPS Ja & MACT CC: Process Flares and Associated

Process Unit Vents



EMISSION


EMISSION

LIMIT/STANDARD * REGULATIONS

FLARES WITH INTERCONNECTED FLARE GAS RECOVERY UNIT (FGRU)

BTZ-US-54C

D10.3301

M-2201

HYDROCRACKER AREA, STEAM ASSISTED

PROCESS FLARE

HYDROBON AREA, STEAM ASSISTED,

PROCESS FLARE

COKER AREA (WEST), STEAM ASSISTED,

PROCESS FLARE

H2S Burn Gas with 0.10 grains of H2S per

scf (gr/dscf)

<20 ppbv H2S offsite

Fuel gas <162 ppmv determined on

a 3-hour rolling average basis

Rule 335-3-5-.03(1)

Rule 335-3-5-.03(2)

§60.103a(h)

[NSPS Ja]

HAPs

Pilot flame present at all times

when regulated material routed to

the flare

§63.670 b)

[MACT CC]

Flare tip velocity must meet

allowable specified in §63.670(d)(1)

or (2)

§63.670(d)

[MACT CC]

NHVcz operated and maintained at

or above 270 Btu/scf based on a 15-

minute block period

§63.670 (e)

[MACT CC]

STF-2-24C CRUDE AREA (EAST), STEAM ASSISTED,

PROCESS FLARE W/FGRU

H2S Burn Gas with 0.10 grains of

H2S per scf (gr/dscf)

Rule 335-3-5-.03(1)

<20 ppbv H2S offsite Rule 335-3-5-.03(2)

Fuel gas <162 ppmv determined on

a 3-hour rolling average basis

§60.103a(h)

[NSPS Ja]

HAPs

Pilot flame present at all times

when regulated material routed to

the flare

§63.670(b)

[MACT CC]

Flare tip velocity must meet

allowable specified in §63.670(d)(1)

or (2)

§63.670 (d)

[MACT CC]

NHVcz operated and maintained at

or above 270 Btu/scf based on a 15-

minute block period

§63.670 (e)

[MACT CC]

EACH FLARE

Opacity Smokeless design capacity,

Except for five (5) minutes in a 2

consecutive hour period as allowed

§63.670 (c)

[MACT CC]

*Limits for each Flare

212

EMISSION


EMISSION


EACH ASSOCIATED MISCELLANEOUS PROCESS VENT

(INCLUDING MAINTENANCE VENTS) UNIT IN VOC AND/OR

HAPS SERVICE THAT VENTS TO FLARES OR FGRU

HAPS Route to FGRU, Closed Vent

System, & Flare OR to a Fuel

Gas System

§63.642(k), §63.643(a),

§63.643 (c)(1)(ii);

§63.660(i)(1), §63.670

[MACT CC]

DELAYED COKING UNITS

COKE DRUM A

COKE DRUM B

COKE DRUM C

COKE DRUM D

VOC Uncondensed vapors must be

recovered or vented to the

fuel gas system, a fuel gas

combustion device or flare

§60.103a(i)

[NSPS Ja]

PROCESS UNIT TURNAROUNDS VOC Depressure process unit or

vessel to a Vapor Recovery

System, Flare, or Firebox;

VOCs shall not be emitted

from a process unit or vessel

until its internal pressure is

19.6 psia [5 psig], or less

Rule 335-3-6-.08

213

Provisos for Process Flares and Associated Process Unit Vents


Applicability

Each flare shall be subject to the requirements specified in ADEM

Admin. Code r. 335-3-16, “Major Source Operating Permits”, and the


Rule 335-3-16-.03

§60.1(c)

§63.642(a)

The refinery handles gas or refinery gas that contains hydrogen sulfide

(H2S) concentrations of 0.10 grains or more per standard cubic foot (scf);

therefore, it is subject to the requirements of ADEM Admin. Code r. 335-

3-5-.03, “Petroleum Production”, and the requirements specified in this


Rule 335-3-5-.03(2)

The refinery is subject to the requirements of ADEM Admin. Code r. 335-

3-6-.08, “Petroleum Refinery Sources” for vacuum producing systems

and process unit turnarounds and the requirements specified in this


Rule 335-3-6-.08

Each flare is subject to the applicable requirements of 40 CFR 60 Subpart

A, “General Provisions” as specified in the applicable subpart under 40

CFR Part 60, and the requirements specified in this subpart of this

permit.

§60.1

Each flare and each coke drum vent shall demonstrate compliance with

the requirements of 40 CFR Part 60, Subpart Ja ”Standards of

Performance for Petroleum Refineries” [NSPS Ja] and the requirements


§60.100a(a), (b) and (c)(1)

Rule 335-3-16-.05(a)

Each flare used as a control device for an emission point subject to this

subpart shall be subject to the requirements specified in 40 CFR 63

Subpart, CC “National Emission Standards for Hazardous Air Pollutants

(HAPs) from Petroleum Refineries” [Refinery MACT 1/MACT CC] and the


§63.640 (a), (n)(8)(vii),

(n)(10)(viii), (o)(2)(i)(D),

(o)(2)(ii)(C), (s)

§64.2(b)(1)(i)

Per §64.2(b)(1)(i), the flares would be exempt from the

requirements of 40 CFR 64, “Compliance Assurance Monitoring”

[CAM}. Compliance with MACT CC shall meet the requirements

CAM.

§61.2(b)(1)(i)

Each flare is subject to the applicable requirements of 40 CFR

63 Subpart A, “General Provisions” as specified in the applicable

subpart under 40 CFR Part 63 and the requirements specified in

this subpart of this permit

§63.1, §63.642(c)


214



Emission Standards

Each flare shall comply with the following requirements, except for

periods of start-up, shutdown, relief valve leakage, and/or process

malfunction when process gases or fuel gases are released to the flare:

All process gas streams containing more than 0.10 grain of H2S

per scf (~160 parts per million (ppmv)) shall be burned to the

extent that the ground level concentrations of H2S shall be less

than twenty (20) parts per billion (ppbv) beyond plant property

limits, averaged over a thirty (30) minute period.

Rule 335-3-5-.03(2)

Provided vessels or equipment are being de-pressured and/or

emptied and the reduced pressure will not allow flow of the

process gas stream to the combustion device, venting to

atmosphere of any gas stream shall be allowed, but the

duration of the venting shall not exceed 15 continuous minutes.

Rule 335-3-5-.03(2)

During a process unit turnaround, depressurization venting of the

process unit, or vessel shall occur to a vapor recovery system, flare, or

firebox, and VOCs shall not be emitted from a process unit or vessel until

its internal pressure is 19.6 psia [5 psig], or less.

Rule 335-3-6-.08(4)

The following requirements shall be met for flares to demonstrate

compliance with NSPS Ja:

§60.103a(f)

§60.103a(b)(1)

A written flare management plan (FMP) shall be developed and

implemented as specified in §60.103a(a) and §60.103a(b) of

NSPS Ja.

§60.103a(a)(1)-(7),(b)

Except for the combustion in the flare of process upset gases or

fuel gas that is released to the flare as a result of relief valve

leakage or other emergency malfunction, any fuel gas that

contains H2S in excess of 162 ppmv determined hourly on a 3-

hour rolling average basis shall not be burned in any flare.

§60.103a(h)

An alternative means of emission limitation may be requested

to comply with this subpart as specified in §60.103a(j).

§60.103a(j)

For sulfur monitoring, a root cause analysis (RCA) and a

corrective action analysis (CAA) shall be conducted on each

flare when one of the conditions below occurs. Special

circumstances affecting the number of RCA and/or CAA are

specified in §60.103a(d).

§60.103a(c)(1), §60.103a(d)

§60.103a(f), §60.107a(g)

Rule 335-3-16-.05(a)

215



Any time the sulfur dioxide (SO2) emissions exceeds 227

kilograms (kg) (500 Lb) in any 24-hour period

Any discharge to the flare in excess of 14,160 standard

cubic meters (m3) (500,000 standard cubic feet) above

the baseline flow in any 24-hour period determined as

specified in §60.103a(a)(4) (see FMP)

Any period when the flare gas line pressure exceeds the

water seal liquid depth (if the monitoring alternative

specified in §60.107a(g) is elected).

For delayed coking units to demonstrate compliance with NSPS Ja, until

the coke drum internal pressure reaches 5 pounds per square inch

gauge (psig), the coke drum steam exhaust must be managed in an

enclosed blowdown system and the uncondensed vapor must either be

recovered or vented to the fuel gas system, a fuel gas combustion

device, or a flare.

§60.103a(i)

The applicable requirements specified in §63.670 (a) through (q) of

MACT CC shall be met at all times except that an alternative means of

emission limitation (as specified in §63.670 (r)) may be requested to be

used in lieu of the requirements specified in §63.670 (d) through (f).

§63.642(b)

§63.670 (a) through (q)

§63.670 (r)

Regulated material means any stream associated with emission

sources listed in §63.640(c) required to meet control

requirements under this subpart as well as any stream for which

this subpart or a cross-referencing subpart specifies that the

requirements for flare control devices in §63.670 must be met.

§63.641

Each flare shall operate with a pilot flame present at all times

when regulated material can be routed to the flare.

§63.670(b)

The smokeless design capacity of each flare shall be specified

and each flare shall be operated with no visible emissions

except for periods not to exceed a total of five (5) minutes

during any 2 consecutive hours when regulated material is

routed to the flare and the flare vent gas flowrate is less than

the smokeless design capacity of the flare.

§63.670(c)

Provided the appropriate monitoring systems are in place

whenever regulated material is routed to the flare for at least

15-minutes and the flare vent gas flow rate is less than the

smokeless design capacity of the flare; one the following flare

tip velocity (Vtip) requirements shall be complied with.

§63.670(d)

216



The actual flare Vtip must be less than 60 feet per

second.

§63.670(d)(1)

The Vtip must be less than 400 feet per second and also

less than the maximum allowed flare tip velocity (Vmax)

as determined in §63.670(d)(2).

§63.670(d)(2)

Each flare shall be operated to maintain the net heating value

of the flare combustion zone gas (NHVcz) at or above 270 British

thermal units per standard cubic feet (Btu/scf) determined on a

15-minute block period basis when regulated material is routed

to the flare for at least 15-minutes.

§63.670(e)

At all times any affected source, including associated air

pollution control equipment and monitoring equipment, must

be operated and maintained, in a manner consistent with safety

and good air pollution control practices for minimizing

emissions as specified in §63.642(n).

§63.642(n)

At all times and to the extent practicable, including during periods of

startup, shutdown, and/or malfunction (SSM), good air pollution control

practices for minimizing emissions consistent with 40 CFR §60.11(d) of

subpart A shall be implemented.

§60.11(d)

§60.103a(a)(5)

§63.642(g)

Each flare shall be equipped with a flare gas recovery system that meets


Rule 335-3-16-.05(a)

Except during maintenance activities, the flare gas recovery

system shall be in operation at all times in which process gases

may be sent to the flare.

The gas streams captured by the flare gas recovery system shall

be routed to the fuel gas sweetening system.


To determine compliance with the H2S concentration requirement in

§60.103a(h) the following requirements shall be met:

§60.104a(a)

Performance tests shall be completed utilizing one of the

following methods:

§60.104a(a), §60.104a(c)

§60.104a(j)(4), §60.107a(a)(2)

EPA Method 11 of appendix A-5 to part 60, and as

specified in §60.104a(j)(4)(i)

217



EPA Method 15 of appendix A-5 to part 60, and as

specified in §60.104a(j)(4)(ii)

EPA Method 15A of appendix A-5 to part 60, and as

specified in §60.104a(j)(4)(iii). Method ANSI/ASME PTC

19.10-1981, “Flue and Exhaust Gas Analysis,”

(incorporated by reference-see §60.17) is an

acceptable alternative to EPA Method 15A of Appendix

A-5.

EPA Method 16 of appendix A-6 to part 60

An H2S monitoring system shall comply with the following

requirements:

§60.107a(a)(2)

Each H2S monitor shall be installed, operated, and

maintained according to Performance Specification 7 of

40 CFR 60 Appendix B.

§60.107a(a)(2)(i)

Performance Evaluations for each H2S monitor shall be

conducted according to the requirements of §60.13(c)

of subpart A and to performance specification 7 of 40

CFR 60 Appendix B

§60.107a(a)(2)(ii)

Relative Accuracy Evaluations shall be conducted using

Methods 11, 15, or 15A* of 40 CFR 60 Appendix A-5 OR

Method 16 of 40 CFR 60 Appendix A-6

§60.107a(a)(2)(ii)

*Method ANSI/ASME PTC 19.10-1981, “Flue and

Exhaust Gas Analysis,” (incorporated by reference-see

§60.17) is an acceptable alternative to EPA Method 15A

of Appendix A-5.

The quality assurance procedures specified in 40 CFR 60

Appendix F shall be complied with for each H2S monitor.

§60.107a(a)(2)(iii)

If the composition of an exempt fuel gas stream changes, the

procedures specified in §60.107a(b)(3) shall be met.

§60.107a(a)(4)

§60.107a(b)(3)

Sulfur monitoring for assessing root cause analysis thresholds shall be

met by equipping the flares with a total reduced sulfur (TRS) monitor

and complying with the following methods and procedures specified in

NSPS Ja:

§60.107a(e)

218



Each monitor shall be installed, operated, and maintained

according to Performance Specification 5 of 40 CFR 60 Appendix

B.

§60.107a(e)(1)(i)

Performance Evaluations for each TRS monitor shall be

conducted according to the requirements of §60.13(c) of

subpart A and to Performance Specification 5 of 40 CFR 60

Appendix B.

§60.107a(e)(1)(ii)

Relative Accuracy Evaluations shall be conducted using one of

the following methods:

§60.107a(e)(1)(ii)

Methods 15A of 40 CFR 60 Appendix A-5 OR Method


Analysis,” (incorporated by reference-see §60.17)

§60.107a(a)(1)(ii)

The alternative relative accuracy procedures specified

in section 16.0 of Performance Specification 2 of 40 CFR

60 Appendix B (cylinder gas audits) may be utilized

except that it is not necessary to include as much of the

sampling probe or sampling line as practical

§60.107a(a)(1)(ii)

The quality assurance procedures specified in 40 CFR 60

Appendix F shall be complied with for each TRS monitor.

§60.107a(e)(1)(iii)

Each flow monitor shall be installed, calibrated, operated, and

maintained according to manufacturer’s procedures and specifications.

§60.107a(f)(1)

When applicable, the following test methods and procedures shall be

used to demonstrate compliance with the requirements of MACT CC:

Visible emission observations shall be conducted in accordance

with Method 22 of 40 CFR part 60, appendix A-7.

§63.670(c), §63.670(h)

The procedures specified in §63.670(i) and (k) shall be used to

monitor the actual flare tip velocity (Vtip).

§63.670(d)(1)

63.670(i), (k)

The procedures specified §63.670(j) and (l) shall be used to

monitor the gas composition and determine the net heating

value of the vent gas (NHVvg), except that an alternative to 40

CFR 60 Appendix B, PS 9 may be approved by EPA to determine

the net heating value.

§63.670(d)(2)

63.670(j), (l)

§63.7(f)

The procedures specified in §63.670(m) shall be used to

calculate the combustion zone net heating value (NHVcz).

§63.670(e), §63.670(m)

219



Emission Monitoring

Periodic Monitoring meeting the requirements specified in Appendix D:

Facility Flares Monitoring of this permit shall be met to demonstrate

that the H2S offsite concentration requirement is being met.

Rule 335-3-5-.03(2)

Rule 335-3-16-.05(c)1(ii)

When performance testing is required under NSPS Ja to determine the

H2S concentration of the fuel gas for the flares, the following

requirements shall be met in accordance with the requirements of

§60.8:

§60.8

§60.104a(a)

§60.104a (j)(4)

§60.104a (j)(4)(iv)

If monitoring is conducted at a single point in a common source

of fuel gas as allowed under §60.107a(a)(2)(iv), only one

performance test is required.

Performance tests are not required when a new affected flare

is added to a common source of fuel gas that has previously

demonstrated compliance.

Compliance may be based on the mixture used in the flare or

for each individual fuel gas stream used in the flare.

Except when the exemptions found in §60.107a(b) for low-sulfur fuel

gas streams apply, an instrument for continuously monitoring and

recording the concentration by volume (dry basis) of H2S in the fuel

gases before being burned in any flare shall be installed, operated,

calibrated, and maintained to demonstrate compliance with the H2S

concentration requirement in §60.103a(h) of NSPS Ja.

§60.107a(a)(2)

§60.107a(a)(3)

§60.107a(b)

The span value for the instrument is 300 ppmv H2S.

Flares having a common source of fuel gas may be monitored

at only one location if monitoring at this location accurately

represents the concentration of H2S in the fuel gas being

burned in the respective flares.

Except for flares exempt from monitoring as specified §60.107a(e)(4),

an instrument for continuously monitoring and recording the

concentration of TRS in gas discharged to the flare shall be installed,

operated, calibrated, and maintained to demonstrate compliance with

the root cause analysis (RCA) threshold under NSPS Ja.

§60.107a(e)

§60.107a(e)(1)

§60.107a(e)(4)

The span value for the instrument shall be determined based on

the maximum sulfur content of gas that can be discharged to

flare but no less than 5,000 ppmv.

§60.107a(e)(1)(i)

220



A dual range monitor may be used to comply with the

requirement provided that the applicable span specifications

are met.

§60.107a(e)(1)(i)

Each RCA and CAA shall be completed as soon as possible, but

no later than 45 days after a discharge.

§60.103a(b)(1), §60.103a(d)

§60.108a(c)(6)

Corrective action(s) as specified in §60.103a(e) shall be

implemented as identified in the CAA.

§60.103a(e)

Except as specified in §60.107a(f)(2), a continuous parameter

monitoring system (CPMS) shall be installed, operated, calibrated, and

maintained to measure and record the flow rate of gas discharged to

the flares.

§60.107a(f)

§60.107a(f)(2)

The following monitoring requirements shall be met to demonstrate

compliance with MACT CC:

For pilot flame monitoring, the presence of the pilot flame(s)

must be continuously monitored using the continuous

parameter monitoring system (CPMS) installed to detect the

presence of a pilot flame

§63.670(b)

§63.670(g)

For visible emission monitoring §63.670(c), §63.670(h)

The first-time regulated materials are routed to the

flare, an initial visible emissions demonstration shall be

conducted for an observation period of 2 hours.

§63.642(d)

§63.670(h)

Subsequent visible emission observations may be

conducted at least once per day, using an observation

period of five (5) minutes, for each day regulated

material is routed to the flare

§63.670(h)(1)

(i) If at any time the owner or operator sees visible

emissions while regulated material is routed to

the flare, even if the minimum required daily

visible emission monitoring has already been

performed, the owner or operator shall

immediately begin an observation period of 5

minutes

221



(ii) If visible emissions are observed for more than

one continuous minute during any 5-minute

observation period, the observation period

must be extended to 2 hours or until 5-minutes

of visible emissions are observed.

(iii) Daily 5-minute observations are not required to

be conducted for days the flare does not

receive any regulated material.

For flare vent gas, steam assist, and air assist flow rate

monitoring:

§63.670(d)(1) and (2)

§63.670(i)

A monitoring system capable of continuously

measuring, calculating, and recording the volumetric

flow rate in the flare header or headers that feed the

flare as well as any flare supplemental gas used shall be

installed, operated, calibrated, and maintained.

Different flow monitoring methods may be used to

measure different gaseous streams that make up the

flare vent gas provided that the flow rates of all gas

streams that contribute to the flare vent gas are

determined

If assist air or assist steam is used, a monitoring system

capable of continuously measuring, calculating, and

recording the volumetric flow rate of assist air and/or

assist steam used with the flare shall be installed,

operated, calibrated, and maintained.

If pre-mix assist air and perimeter assist are both used,

a monitoring system capable of separately measuring,

calculating, and recording the volumetric flow rate of

premix assist air and perimeter assist air used with the

flare shall be installed, operated, calibrated, and

maintained.

Flow monitoring system requirements and acceptable

alternatives are specified in §63.670(i)(1) through (6).

For flare vent gas composition monitoring, the requirements

specified in §63.670(j) shall be met, except that a process mass

spectrometer analyzer may be used as an alternative to

measure the NHVvg as approved by EPA.

§63.670(d)(2)

§63.670(j)

§63.7(f)

222



Cumulative flow rates and compliance with Vtip operating limits

shall be determined on a 15-minute block average

basis according to the requirements specified in §63.670(k).

§63.670(d)(1) and (2)

§63.670(k)

The net heating value of the flare vent gas (NHVvg) shall be

determined based on the composition monitoring data on a 15-

minute block average basis according to the requirements

specified in §63.670(l).

§63.670(d)(2)

§63.670(l)

Except as specified in §63.670(m)(2), the net heating value of

the combustion zone gas (NHVcz) shall be determined in 15-

minute block average NHVcz based on the 15-minute block

average vent gas and assist gas flow rate.

§63.670(e)

§63.670(m)

A flare that has the potential to operate above its smokeless

capacity under any circumstances shall comply with

the Emergency Flaring provisions specified in §63.670(o).

§63.670(o)

The flare monitoring system installed on each flare to comply with

MACT CC shall meet the following requirements:

§63.671

Each continuous parameter monitoring system (CPMS) installed

to comply with applicable provisions in §63.670 shall be

installed, operated, calibrated, and maintained as specified in

§63.671(a).

§63.671(a)

A CPMS quality control program documented in a CPMS

monitoring plan that covers each flare subject to the provisions

in §63.670 and each CPMS installed to comply with applicable

provisions in §63.670 shall be developed and implemented.

§63.671(b)

The CPMS monitoring plan must be readily available on-

site at all times and a copy of the CPMS monitoring plan

shall be submitted to the Department upon its request.

The CPMS monitoring plan must contain the

information listed in paragraphs §63.671 (b)(1) through

(5) of this section.

Except for CPMS installed for pilot flame monitoring, each

CPMS installed to comply with applicable provisions in §63.670

shall comply with the out-of-control procedures described in

paragraphs §63.671 (c)(1) and (2).

§63.671 (c)

223



Data from the CPMS installed to comply with applicable

provisions in §63.670 shall be reduced as specified in

§63.671 (d)(1) through (3).

§63.671 (d)


A record of the information specified in provisos 1(a) through (d) of this


inspection.




Rule 335-3-16-.05(c)(2)

Results of each visual emission observation Rule 335-3-16-.05(c)(2)

Monitoring reports meeting the requirements specified in proviso 2(a)

through (d) of this section of this subpart shall be submitted to the

Department.

Rule 335-3-16-.05(c)(3)(i)

§60.7(c),§60.10, §60.107a(f),

§60.108a(d), §60.107a(i)(2)(i)-

(ii), §60.107a(i)(2)(i)



startups, shutdowns, and malfunctions



testing or recordkeeping protocol which is required by

the permit that can be used to determine or indicate

compliance, that identifies an affected source has failed

to meet an applicable emission limit or standard, or

that a work practice was not complied with or

completed





Each Excess Emissions Report shall meet the requirements

specified in §60.7(c) of 40 CFR Part 60, Subpart A.

Except as provided for in proviso 2(e) of this section, the report

shall include the following information for each deviation event:

Emission source description

224



Permit requirement

Date

Starting time

Duration

Actual quantity of pollutant or parameter

Cause

Actions taken to return to normal operating conditions

Total operating hours of the affected source during the

reporting period

Total hours of deviation events during the reporting

period

Total hours of deviation events that occurred during

startups, shutdowns, and malfunctions during the

reporting period

Each report shall cover a semi-annual reporting period and shall

be submitted according to the following reporting schedule:




The report content specified in provisos 2(c) of this section may


To demonstrate compliance with NSPS Ja, the following requirements

shall be met:

The notification, recordkeeping, and reporting requirements

specified in §60.7 of subpart A shall be maintained.

§60.108a(a)

The following records shall be maintained for the flares: §60.108a(c)

Copy of the flare management plan (FMP) §60.108a(c)(1)

225



For each fuel gas stream meeting the exemptions found

under §60.107a(a)(3), a record of the specific

exemption determined to apply for each fuel stream

shall be maintained.

§60.108a(c)(5)

Records of discharges greater than 500 Lbs of SO2 in any

24-hour period from each flare.

§60.108a(c)(6)

Records of discharges to each flare in excess of 500,000

scf above baseline in any 24-hr period as required by

§60.103a(c).

§60.108a(c)(6)

The applicable information specified in

§60.108a(c)(6)(i) through (xi) shall be recorded no later

than 45 days following the end of a discharge exceeding

the thresholds specified in provisos 3(c)(3) and (4) of

this section.

§60.108a(c)(6)(i)-(xi)

An Excess Emission Report shall be submitted for all periods of

excess emissions for which a continuous monitoring device is

installed.

§60.108a(d)

§60.7(c)

The report shall be submitted according to the

requirements of §60.7(c) except that the information

specified in §60.108a(d)(1) through (7) shall be included

in the report.

Each report shall cover a semi-annual reporting period


reporting schedule:






The recordkeeping requirements shall be met for the flares as

follows:

§63.642(e), §63.655(i)

§63.655(i)(9), §63.670(p)

Records specified in §63.655(i)(9)(i) through (xii) shall

be up-to-date and maintained.

226





in §63.655(i).



hours.





A Notification of Compliance Status (NOCS) Report shall be

submitted as specified in §63.655(f).

§63.655(e)(1)

§63.655(f)

§63.655(g)(14)


met for the flares:

§63.642(f)

§63.655 (e)(2) and (g)

§63.670(q)

The requirements specified in §63.655(g)(11)(i) through

(iv) shall be included in the report.

§63.655(g)(11)



reporting schedule:




§63.642(f)

§63.655(g)

A Periodic Report is not required if no events specified

in §63.655(g)(11) occurred during the reporting period.

§63.655(g)





of this permit.

Rule 335-3-16-.05(c)3(ii)

227

Summary Page for MACT LLLLL: Asphalt Processing Facility & Thermal Oxidizer




EMISSION


EMISSION


ALL SOURCES

For charge rate [P] < 30 Ton/hr Particulate [3.59] X [P]^ 0.62 Rule 335-3-4-.04(1)

For charge rate [P] ≥ 30 Ton/hr Particulate [17.31] X [P]^ 0.16 Rule 335-3-4-.04(1)

INDIVIDUAL SOURCES

Cyclone, Knockout Drum & Thermal Oxidizer

THOX 25.6 MMBTU/Hr Thermal Oxidizer NOX ≤ 8.00 Lbs/Hr Rule 335-3-14-.04

[Anti-PSD Limit]

OHAP Capture and route vapors from

each blowing still to the Thermal

Oxidizer to achieve a combustion

efficiency of 99.5 %

§63.8684(a)

[Asphalt MACT]

SO2 Burn assist gas that contains

H2S <162 ppmv

§60.104(a)(1)

[NSPS J]


20%

Rule 335-3-4-.01(1)(a)

OR


(60) minute period Rule 335-3-4-.01(1)(b)

Blowing Stills (Controlled by the THOX) and Loading Spouts

T-14 800 Barrels per day (Bbls/Day) Blowing Still & Loading Spout

T-30X 1100 Bbls/Day, Blowing Still & Loading Spout

T-33 1100 Bbls/Day Blowing Still

T-50 800 Bbls/Day Blowing Still & Loading Spout

T-75 1100 Bbls/Day Blowing Still

GROUP 2 STORAGE VESSELS

Closed Vent System No. 1

T-006 1,850,453 gallon asphalt storage vessel Opacity 0% opacity §63.8684(a)


T-041 187,144 gallon asphalt storage vessel Opacity 0% opacity §63.8684(a)









T-16 4,200,000 gallon storage vessel Opacity 0% opacity §63.8684(a)

228

Provisos for Asphalt Processing Facilities & Thermal Oxidizer


Applicability

The Asphalt Processing Facility and Thermal Oxidizer shall comply

with the requirements specified in ADEM Admin. Code r. 335-3-4-

.01(1)(a) and (b), “Visible Emissions”, and specified in ADEM Admin.

Code r. 335-3-4-.04(1), “Process Industries-General” for Control of

Particulate Emissions and the requirements specified in this subpart

of this permit. Provided that the requirements in ADEM Admin.

Code r. 335-3-4 are less stringent than the requirements specified

in ADEM Admin. Code r. 335-3-11, compliance shall be met by

complying with the more stringent regulation found in Chapter 335-

3-11.

Rule 335-3-4-.01(1)(a) and (b)

Rule 335-3-4-.04(1)

Rule 335-3-11-.01(2)

The Asphalt Processing Facility and thermal oxidizer (THOX) have

enforceable limits in place in order to avoid a review under ADEM

Admin. Code r. 335-3-14-.04, “Air Permits Authorizing Construction

in Clean Air Areas [Prevention of Significant Deterioration (PSD)],


Rule 335-3-14-.04

[Anti-PSD Limit]

The Asphalt Processing Facility and Thermal Oxidizer shall be subject

to the requirements specified in ADEM Admin. Code r. 335-3-16,

“Major Source Operating Permits”, and the requirements specified


Rule 335-3-16-.03

The assist gas to the THOX shall be subject to the requirements

specified in 40 CFR 60 Subpart J, “Standards of Performance for

Petroleum Refineries” [NSPS J], the applicable requirements of 40

CFR 63 Subpart A, “General Provisions”, and the requirements


§60.100(a)

40 CFR 30, Subpart A

Except as specified in §63.8681(b) through (e), blowing stills, Group

2 asphalt storage tanks, and a thermal oxidizer located at an asphalt

processing facility shall be subject to the requirements of 40 CFR 63

LLLLL, “National Emission Standards for Hazardous Air Pollutants:

Asphalt Processing and Asphalt Roofing Manufacturing” [Asphalt

MACT], and the requirements specified in this subpart of this

permit.

§63.8680, §63.8681

§63.8682(a), (b)(1), (c)

§63.8698

§64.2(b)(1)(i)

Blowing stills and asphalt storage tanks subject to the

requirements of 40 CFR 60 UU, “Standards of Performance

for Asphalt Processing and Asphalt Roofing Manufacture”

[NSPS UU] are only required to comply with the Asphalt

MACT.

§63.8681(b)

229



Compliance with the applicable requirements of 40 CFR 63

Subpart A, “General Provisions” shall be met as specified in

Table 7 of the Asphalt MACT.

§63.8689

The Asphalt MACT does not apply to equipment subject to

40 CFR 63 Subpart CC or 40 CFR 60 Subpart K, Ka, or Kb.

§63.8681(c)

40 CFR 60 Subpart J, “Standards of Performance for

Petroleum Refineries” [NSPS J] does not apply to emissions

from asphalt processing facilities (including petroleum

refineries) subject to the Asphalt MACT, with the exception

of the exception of the assist gas for the asphalt THOX.

§63.8681(e)

Per §64.2(b)(1)(i), the thermal oxidizer would be exempt

from the requirements of 40 CFR 64, “Compliance

Assurance Monitoring” [CAM]. Compliance with MACT

LLLLL shall meet the requirements CAM.

§64.2(b)(1)(i)

Emission Standards

Visible emissions from the thermal oxidizer (THOX) shall meet the

opacity standards specified in proviso 1(a) and (b) of this section of

this subpart.

Rule 335-3-4-.01(a), (b)


that results in an opacity greater than 20%, as determined

by a 6-minute average.

Rule 335-3-4-.01(1)(a)

Except for one 6-minute period during any 60-minute

period, the unit shall not discharge into the atmosphere

particulate that results in an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

Particulate matter (PM10) from each asphalt blowing still and/or the

asphalt thermal oxidizer shall not exceed the allowable specified in

either proviso 2(a) or (b) of this section of this subpart.

Rule 335-3-16-.05(a)

Rule 335-3-4-.04(1)

Provided the charge rate is less than 30 Tons/Hour, the

allowed emissions shall be calculated as follows:

PM10 <= [3.59] X [Charge Rate (Tons/Hour)]0.62

Provide the charge rate is equal to or greater than 30

Tons/Hour, the allowed emissions shall be calculated as

follows:


230



The thermal oxidizer (THOX) shall comply with the following

requirements:

Nitrogen oxide (NOX) emissions shall not exceed 8.0 pounds

per hour (Lb/hr).

Rule 335-3-14-.04

[Anti-PSD Limit]

Only assist gas with a H2S content of less than or equal to

0.10 grains per dry standard cubic feet (gr/dScf) (162 ppmv)

over a 3-hour averaging period shall be burned.

§60.104(a)(1)

Vapors from each blowing still shall be captured and routed

to the thermal oxidizer and burned, such that the thermal

oxidizer maintains a 99.5% combustion efficiency.

§63.8684(a)

Table 1 No. 1(b), Asphalt MACT

Operational limits for the blowing stills shall be met by

maintaining the thermal oxidizer’s 3-hour average

combustion zone temperature at or above the operating

limit established during the most recent performance test.

A 15-minute averaging period can be used as an alternative

to the 3-hour averaging period for this parameter.

§63.8684(b)

Table 2, No. 1, subscript b

The operating limits are applicable if you are

monitoring control device operating parameters to

demonstrate continuous compliance.

Table 2, No. 1, subscript a, Asphalt

MACT

If you are using a continuous emission monitoring

system (CEMS) or continuous opacity monitoring

system (COMS), you must maintain emissions

below the value established during the initial

performance test.

Table 2, No. 1, subscript a, Asphalt

MACT

Each asphalt storage vessel at an asphalt processing facility shall

comply with the emission limitations found in Table 1 of the Asphalt

MACT and as specified in this section of this subpart:

§63.8684(a), Table 1, Asphalt

MACT

(a) Exhaust gases from each Group 2 asphalt storage tanks’

closed vent system and vent filter system shall be limited to

zero percent (0%) opacity.

§63.8684(a), Table 1, No. 4,

Asphalt MACT

The opacity limit can be exceeded for one

consecutive 15-minute period in any 24-hour

period when the storage tank transfer lines are

being cleared.

Table 1 subscript b, Asphalt MACT

During this 15-minute period, the control device

must not be bypassed.

Table 1 subscript b, Asphalt MACT

231



As an alternative to meeting the opacity standards in

proviso 4(a) of this section of this permit, asphalt storage

tanks may comply with the total hydrocarbon (THC) percent

reduction as specified in Table 1, No. 1 or the combustion

efficiency standards specified in Table 1, No. 1(b) of the

Asphalt MACT.

Table 1, subscript a,

Asphalt MACT

The asphalt processing facility shall comply with the following

general standards specified in §63.8685 of the Asphalt MACT:

§63.8685

(a) Before September 9, 2020,

The emission limits and operational limits must be

met at all times, except during periods of startup,

shutdown, and malfunction.

§63.8685(a)

(The blowing still must be operated and

maintained, including the thermal oxidizer and

monitoring equipment, according to the provisions

in §63.6(e)(1)(i) of Subpart A.

§63.8685(b)

§63.6(e)(1)(i)

A written startup, shutdown, and malfunction plan

(SSMP) must be developed and implemented in

accordance with the provision in §63.6(e)(3) of

Subpart A.

§63.8685(c)

§63.6(e)(3)

On or after September 9, 2020,

The emission limits and operational limits must be

met at all times, except during nonoperation of the

affected source (or specific portion thereof)

resulting in cessation of the emissions.

§63.8685(a)

The blowing still must be operated and maintained,

including the thermal oxidizer and monitoring

equipment, in a manner consistent with safety and

good air pollution control practices for minimizing

emissions.

§63.8685(b)

A written site-specific monitoring plan shall be developed

and implemented in accordance with §63.8688(g) and (h) of

the Asphalt MACT.

§63.8685(d)

§63.8688(g), (h)

232




Compliance with the opacity standards for the thermal oxidizer shall

be determined using Method 9 or Method 22 of 40 CFR Part 60,

Appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

Provided that testing is required to determine particulate matter

emissions, Method 5A of 40 CFR Part 60, Appendix A shall be used.

Rule 335-3-16-.05(c)(1)(i)

Provided that the assist gas combusted in the THOX is the same as

the fuel gas used in the heaters and boilers, the Permittee may elect

to use heater and boiler records to satisfy the test requirements for

the assist gas. Otherwise, performance evaluations of the H2S

monitor shall follow the procedures specified under §60.106(e)(1).

Rule 335-3-16-.05(c)(1)(i)

§60.105(a)(4)(ii)

§60.106(e)(1)

Performance testing shall be conducted in accordance with the

requirements specified in proviso 4(a) through (f) of this section of

this subpart.

NOX emissions shall be measured using Method 7E of 40 CFR

60 Appendix A.

Rule 335-3-16-.05(c)(1)(i)

The carbon monoxide (CO) concentration at the thermal

oxidizer outlet shall be measured using Method 10 of 40

CFR 60 Appendix A.

§63.8687(a), (b), (e)(3)

Table No. 3, No. 9(b)

The carbon dioxide (CO2) concentration at the thermal

oxidizer outlet shall be measured using Method 3A of 40

CFR 60 Appendix A.

§63.8687(a), (b), (e)(3)

Table No. 3, No. 9(a)

The total hydrocarbon concentration (THC) at the thermal

oxidizer outlet shall be measured using Method 25A of 40

CFR 60 Appendix A.

§63.8687(a), (b), (e)(3)

Table No. 3, No. 9(c)

The applicable methods specified Table 3, No. 1 through 4

of the Asphalt MACT shall be used as needed.

§63.8687(a), (b), (e)(3)

Table No. 3, Item Nos.1- 4

The methods and procedures may be modified upon

receiving Departmental approval.

Rule 335-3-16-.05(c)(1)(i)

For asphalt storage tanks’ vent filter systems, opacity observations,

shall be conducted utilizing Method 9 of 40 CFR part 60, Appendix

A.

Table No. 3, No. 7

Table No. 4, No. 5

The site-specific monitoring plan shall address the procedures

specified in §63.8688(h) of the Asphalt MACT.

§63.8688(h)

233



A CPMS, CEMS, or COMS must be operated and maintained in

continuous operation according to the site-specific monitoring plan.

§63.8688(f), (j)

Determination of whether a source is operating in compliance with

operation and maintenance requirements will be based on, but is

not limited to, monitoring results, review of operation and

maintenance procedures, review of operation and maintenance

records, and inspections of affected sources.

§63.8685(b)

Emission Monitoring

A monitoring system that meets the requirements specified in the

§60.105(a)(4) of NSPS J and §60.13 of Subpart A shall be installed,

calibrated, maintained, and operated.

Rule 335-3-16-.05(c)(1)(ii)

§60.13

§60.105(a)(4)

§60.105(a)(4)(ii)

Periodic monitoring shall be conducted on the thermal oxidizer as

specified in Appendix E: Asphalt Processing System & Thermal

Oxidizer of this permit.

Rule 335-3-16-.05(c)(1)(ii)

§63.8688(a), (b), (f)

§63.8690, §63.8691(a)

Table No. 5, No. 1

Before September 9, 2020,

Except for monitor malfunctions, associated

repairs, and required quality assurance or control

activities (including as applicable calibration checks

and required zero and span adjustments), each

source must be monitored continuously (or collect

data at all required intervals) at all times including

startup, shutdown, and malfunction (SSM) when

the affected source is operating.

§63.8690(b), (c)

Each instance (including SSM), in which a source did

not meet each applicable operating limit in Table 5,

must be reported as a deviation according to

§63.8693.

§63.8691(b)

§63.8693

Consistent with §§63.6(e) and 63.7(e)(1),

deviations that occur during periods of SSM are not

violations if it is determined, by the Department,

that the unit was operating in accordance with

§63.6(e)(1). On or after September 9, 2020, this

requirement no longer applies.

§63.8691(d)

§63.6(e)

On and after September 9, 2020 and except during periods

of nonoperation of the affected source (or specific portion

thereof) resulting in cessation of the emissions to which this

subpart applies, the following requirements must be met:

234



Data must be monitored and collected at all times

in accordance with §63.8685(b).

§63.8685(b)

§63.8690(b), (c)

Each instance in which a source did not meet its

applicable operating limit in Table 5 must be

reported.

§63.8691(b)

Performance testing shall be conducted on the thermal oxidizer as

follows:

The requirements of §63.8687(a) and (b) of the Asphalt

MACT shall be met.

§63.8687(a), (b)

Each test shall consist of three runs of at least 1 hour in

duration each.

Rule 335-3-16-.05(c)(1)(i)

§63.7(e)(3)

§63.8687(d)

The following equation shall be used to indicate compliance

with the combustion efficiency standard for the thermal

oxidizer:

§63.8687(e)(3), (Eq. 5)

Combustion Efficiency [CE] =

[1 – (CO/CO2) – (THC/CO2)]

where,

CO = the CO concentration at the thermal oxidizer outlet

CO2 = the CO2 concentration at the thermal oxidizer outlet

THC = the Total Hydrocarbon concentration at the thermal

oxidizer outlet

During performance testing, the thermal oxidizer

combustion zone temperature shall be recorded every 15-

minutes and then averaged to yield the minimum operating

combustion zone temperature.

§63.8689(b)

§63.8691(a)

Table No. 3, No. 11

During the performance testing, the NOX emission factor

shall be determined in Lbs/MMBTU.

Rule 335-3-16-.05(c)(1)(i)

Except as specified in §63.8691(e)(3), subsequent

performance testing shall be conducted no later than 60

months following the previous performance test.

Rule 335-3-16-.05(c)(1)(ii)

§63.8687(a) and (b)

§63.8691(a)

§63.8691(e)(1), (3)

235



The results of all emissions tests shall be submitted sixty

(60) days after the completion of the test.

Rule 335-3-16-.05(c)(1)(i)

An opacity test of each Group 2 asphalt storage tanks’ vent filter

systems shall be conducted as follows:

Table No. 3, No. 7

The requirements of §63.8687(a) and (b) of the Asphalt

MACT shall be met.

§63.8687(a) and (b)

Opacity observations shall be conducted for at least three

hours in order to obtain thirty (30) six-minute averages.

Table No. 4, No. 5

Except as specified in §63.8691(e)(3), subsequent periodic

testing shall be conducted no later than 60 months

following the previous performance test.

§63.8691(e)(1),(3)

The results of all emissions tests shall be submitted sixty

(60) days after the completion of the test.

§63.8692(e)

4. A performance evaluation must be conducted on each CPMS, CEMS,

or COMS in accordance to the site-specific monitoring plan.

§63.8688(i)


Monthly records of the following data shall be maintained in a form

suitable for inspection for a period of five years. Only the last two

years are required to be kept onsite.

For the Assist gas, the Permittee must record: Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Assist gas heat content

[ Assist Gas Heat Content (BTU/scf) ]

Assist gas hydrogen sulfide (H2S) content §60.105(a)(4)

[ Assist Gas (H2S Mole %)]

Provided that the assist gas is the same as the fuel

gas used in the heaters and boilers, the Permittee

may elect to use those records to satisfy provisos

1(a)(1) and 1(a)(2) of this section of this permit.

§60.105(a)(4)(ii)

Assist gas volume to the Thermal Oxidizer

[ Assist Gas (Mscf/Month)]

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

236



Operating hours of the Thermal Oxidizer Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

[ THOX Hours/Month]

MMBTU of fuel gas consumption of the Thermal Oxidizer Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Assist Gas (MMBTU/Month) =

[ Assist Gas (Mscf/Month)] X [ Assist Gas (BTU/scf) ]

[1,000]

NOX emissions shall be determined for the Thermal Oxidizer

as follows:

THOX Emissions (Lbs/Month) =

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)

Rule 335-3-14-.04 [Anti-PSD]

[Assist Gas (MMBTU/Month)] X [Test (Lbs/MMBTU)]

where,

the Test (Lbs/MMBTU) shall be taken from the most recent

performance test

THOX Emissions (Lbs/Hour) =

[ THOX Emissions (Lbs/Month) ]

[ THOX Emissions (Hours/Month) ]

A Periodic Monitoring Report and/or Excess Emissions Report shall

be submitted to the Department for each permit requirement not

covered under the Asphalt MACT:

Rule 335-3-16-.05(c)(2), (c)(3)(i)

§60.7(c)

§60.105(e)(3)(ii)

Each report shall identify each incidence of deviation from

a permit term or condition including those that occur during

startups, shutdowns, and malfunctions

A deviation shall mean any condition determined

by observation, by data derived from any

monitoring or testing or recordkeeping protocol

which is required by the permit that can be used to

determine or indicate compliance, that identifies an

affected source has failed to meet an applicable

emission limit or standard, or that a work practice

was not complied with or completed





237



Except as provided for in proviso 2(d) of this section, the

report shall include the following information for each

deviation event:

Emission source description

Permit requirement

Date

Starting time

Duration

Actual quantity of pollutant or parameter

Cause

Actions taken to return to normal operating

conditions

Total operating hours of the affected source during

the reporting period

Total hours of deviation events during the reporting

period

Total hours of deviation events that occurred



Each report shall cover a semi-annual reporting period and

shall be submitted to the Department according to the

following reporting schedule:




The report content specified in provisos 2(b) of this section

may be modified upon receipt of Departmental approval.

The following recordkeeping and reporting requirements shall be

met to demonstrate compliance with the Asphalt MACT:

The following records shall be maintained: §63.8694, §63.8695

238



A copy of all notifications submitted to the

Department and EPA, as specified in

§63.10(b)(2)(xiv) of Subpart A.

§63.8694(a)(1)

Before September 9, 2020, all records related to

start-ups, shutdowns, and malfunctions, as

described in §63.6(e)(3)(iii) through (v) of Subpart A

shall be maintained. On or after this date, this

requirement is no longer required.

§63.8694(a)(2)

A copy of all performance tests, performance

evaluations, and visible emissions observations, as

described in §63.10(b)(2)(viii) of Subpart A shall be

maintained as follows:

§63.8694(a)(3)

(i) A notification of intent to conduct

performance tests shall be submitted to

the Department at least sixty (60) calendar

days prior to the test as required by

§63.7(b)(1) of Subpart A.

§63.7(b)(1)

§63.8692(d)

(ii) A Notification of Compliance Status (NOCS)

shall be submitted before close of business

the 60th calendar day following completion

of a performance test, design evaluation,

opacity observation, visible emission

observation, or other compliance

demonstration as follows:

§63.8692(e)

(A) Prior to September 9, 2020, the

NOCS shall be submitted according

to §63.9(h)(2)(ii).

(B) On or after September 9, 2020, the

NOCS must be submitted to EPA via

the Compliance and Emissions Data

Reporting Interface (CEDRI) which

can be accessed through EPA’s

Central Data Exchange (CDX)

(https://cdx.epa.gov/)

239



(iii) If data from a previously-conducted

emission test is used to serve as

documentation of conformance with the

emission standards and operating limits,

test data must be submitted with the NOCS

in lieu of the initial performance test

results.

§63.8692(f)

(iv) A notification of the intent to conduct

opacity and visible emission observations

shall be submitted according to §63.9(f) of

subpart A

§63.9(f)

§63.8693(a)

Table 6, No. 3

(v) The results of all emissions tests shall be

submitted sixty (60) days after the

completion of the test

§63.8692(e)

Records specified in §63.6(h)(6) shall be maintained

for visible emission observations.

§63.8694(b)

Per No. 1 of Table No. 5 of the Asphalt MACT,

maintain a copy of the following records:

§63.8694(c)

Table 5, No. 1

(i) The hourly Thermal Oxidizer combustion

zone temperature

(ii) The hourly Thermal Oxidizer combustion

zone temperature reduced to 3-hour rolling

averages

Records of any shared equipment determinations

as specified in §63.8682(b) shall be maintained.

§63.8694(d)

Records shall be maintained in accordance with the

following requirements:

In a form suitable and readily available for

expeditious review, according to §63.10(b)(1) of

Subpart A

§63.8695(a)

Any records required to be maintained by this

subpart that are submitted electronically via EPA’s

CEDRI may be maintained in electronic format.

§63.8694(e)

240



Keep for a period of five (5) years following the date

of each occurrence, measurement, maintenance,

corrective action, report, or records as specified in

§63.10(b)(1) of Subpart A.

§63.8695(b)

You must keep each record on site for at least 2

years after the date of each occurrence,

measurement, maintenance, corrective action,

report, or record, according to §63.10(b)(1) of

Subpart A. You can keep the records offsite for the

remaining 3 years.

§63.8695(c)

The following reports shall be submitted to demonstrate

compliance with the Asphalt MACT:

A Compliance Report shall be submitted according

to the following requirements:

§63.8693(a), (e)

Table 6, No. 5

(i) The report shall include the information

specified in §63.8693(c) of the Asphalt

MACT.

§63.8693(c)

(ii) For each Deviation Event

(A) If you have a deviation from any

emission limitation (emission limit,

operating limit, opacity limit), the

report must contain the

information specified in

§63.8693(c) and (d) of the Asphalt

MACT for each deviation from an

emissions limitations.

Table 6, No. 5(c)

§63.8693(c)(5) and (d)

(B) The report shall include a

statement that there were no

deviations from the emission

limitations during the reporting

period, if there are no deviations

from any emission limitations

(emission limit, operating limit,

opacity limit)

§63.8693(c)(5)

Table 6, No. 5(a)

(iii) For each Excess Emission event

241



(A) If there were periods during which

the continuous parameter

monitoring system (CPMS) was out-

of-control, as specified in

§63.8(c)(7) of Subpart A, the report

must contain the information

specified in §63.8693(d) of the

Asphalt MACT

§63.8693(b), (d)

Table 6, No. 5(c)

(B) The report shall include a

statement if there were no periods

during which the CPMS was out-of-

control as specified in §63.8(c)(7) of

Subpart A, that there were no

periods during which the CPMS was

out-of-control during the reporting

period

§63.8693(b), (c)(6)

Table 6, No. 5(b)

(iv) Before September 9, 2020, the compliance

report shall include the information below

for each startup, shutdown, or malfunction

event. After this date, these requirements

no longer apply.

(A) If you had a startup, shutdown, or

malfunction during the reporting

period and actions consistent with

the startup, shutdown, and

malfunction plan (SSMP) were

taken, the compliance report must

include the information in

§63.10(d)(5)(i) of Subpart A.

§63.8685(c)

§63.8693(c)(4)

Table 6, No. 5(d)

(B) If you had a startup, shutdown, or

malfunction during the reporting

period and actions not consistent

with the SSMP were taken, the

compliance report must include the

information specified in

§63.10(d)(5)(ii) of Subpart A.

Table 6, No. 6

(v) Each Compliance Report shall cover a semi-

annual reporting period and shall be

submitted according to the following

reporting schedule:

§63.8693(b)(1)-(3), (5), (e)

242






(vi) On or after September 9, 2020, all

Compliance Reports shall be submitted to

EPA via the CEDRI.

§63.8693(b)(6)

An immediate SSM Report shall be submitted

according to the following requirements:

Table 6, No. 6

(i) During the reporting period before

September 9, 2020, each startup,

shutdown or malfunction event occurring

in which actions taken were not consistent

with the SSMP shall be submitted by fax or

telephone within 2 working days after

starting actions inconsistent with the plan

followed by a letter within 7 working days

after the end of the event unless you have

made alternative arrangements with the

Department.

(ii) On or after September 9, 2020, this

requirement no longer applies.

(3) On or after September 9, 2020, a performance test

report, including information in §63.7, shall be

submitted, within 60 days after the date of

completion of each performance test except as

allowed under §63.8693(h) or (i), in accordance to

the following procedures:

§63.8693(f), (h), (i)

(i) For test data collected using test methods

supported by EPA’s Electronic Reporting

Tool (ERT) at the time of the test, the

results of testing must be submitted to the

EPA via CEDRI as specified.

§63.8693(f)(1)

243



(ii) For test data collected using test methods

NOT supported by EPA’s ERT at the time of

the test, the results of the performance test

must be included as an attachment in the

ERT or alternate electronic file consistent

with the XML schema listed on EPA’s ERT

website. The ERT generated package or

alternative file must be submitted to EPA

via CEDRI as specified.

§63.8693(f)(2)

(iii) For data claimed to be Confidential

Business Information (CBI), the

requirement specified in §63.8692(e) and

§63.8693(f)(3) shall be met.

§63.8692(e)

§63.8693(f)(3)

(iv) Notification of report submittals via CEDRI

must also be provided to the Department.

(4) On or after September 9, 2020, the results of each

performance evaluation (as defined in §63.2)

conducted on a continuous monitoring system

(CMS), must be submitted within 60 days after the

date of completion of each evaluations in

accordance to the procedures specified in

§63.8693(g).

§63.2

§63.8693(g)

(i) For performance evaluations of CMS

measuring RATA pollutants that are

supported by EPA’s ERT at the time of the

evaluation, the results of the performance

evaluation must be submitted to the EPA

via CEDRI as specified.

§63.8693(g)(1)

(ii) For performance evaluations of CMS

measuring RATA pollutants that are NOT

supported by EPA’s ERT at the time of the

evaluation, the results of the performance

evaluation must be included as an

attachment in the ERT or alternate

electronic file consistent with the XML

schema listed on EPA’s ERT website. The

ERT generated package or alternative file

must be submitted to EPA via CEDRI as

specified.

§63.8693(g)(2)

244



(iii) For data claimed to be CBI, the requirement

specified in §63.8692(e) and §63.8693(g)(3)

shall be met.

§63.8692(e)

§63.8693(g)(3)

(iv) Notification of report submittals via CEDRI

must also be provided to the Department.




complies with proviso 15(b) and 21(b) of the General Provisos


Rule 335-3-16-.05(c)3(ii)

§60.105(e)(3)(ii)

§63.8693(e)

245

Summary Page for Petroleum Coke Drying and Pulverizing Systems



Emission

Point

Description Pollutant Emission

Limit/Standard

Regulations

PETROLEUM COKE PULVERIZING SYSTEM

For charge rate [P] < 30 Ton/hr

OR

Particulate [3.59] X [P]^ 0.62 Rule 335-3-4-.04(1)

For charge rate [P] ≥ 30 Ton/hr

OR

Particulate [17.31] X [P]^ 0.16 Rule 335-3-4-.04(1)

Otherwise Particulate Emissions from the baghouse

vent shall not exceed

3.0 Lb/hr

Rule 335-3-14-.04

[Anti-PSD Limit]


20%

Rule 335-3-4-.01(1)(a)

OR


(60) minute period Rule 335-3-4-.01(1)(b)

INDIVIDUAL SOURCES:

FEED SILO

DRYING/PULVERIZING MILL WITH BAGHOUSE

PRODUCT SILO WITH BIN VENT FILTER

TRUCK LOADING BAY

246

Provisos for Petroleum Coke Drying and Pulverizing Systems


Applicability

The petroleum coke drying and pulverizing system shall comply with the

requirements specified in ADEM Admin. Code r. 335-3-4-.01(1)(a) and (b),

“Visible Emissions”, and specified in ADEM Admin. Code r. 335-3-4-.04(1),

“Process Industries-General” for Control of Particulate Emissions and the


Rule 335-3-4-.01(1)(a) and (b)

Rule 335-3-4-.04(1)

The petroleum coke drying and pulverizing system shall be subject to the



permit.

Rule 335-3-16-.03

The petroleum coke drying and pulverizing system has enforceable limits in

place in order to avoid a review under ADEM Admin. Code r. 335-3-14-.04,

“Air Permits Authorizing Construction in Clean Air Areas [Prevention of

Significant Deterioration (PSD)] and the requirements specified in this


Rule 335-3-14-.04

[Anti-PSD Limit]

The baghouse shall be subject to the requirements specified in 40 CFR Part

64, “Compliance Assurance Monitoring” [CAM], proviso 33 of the “General

Permit Provisos” subpart of this permit and this subpart of this permit.

40 CFR Part §64

Emission Standards

Visible emissions from the baghouse shall meet the opacity standards

specified in proviso 1(a) and (b) of this section of this subpart.

Rule 335-3-4-.01(a), (b)

The unit shall not discharge into the atmosphere particulate that

results in an opacity greater than 20%, as determined by a 6-minute

average.

Rule 335-3-4-.01(1)(a)

Except for one 6-minute period during any 60-minute period, the

unit shall not discharge into the atmosphere particulate that results

in an opacity greater than 40%.

Rule 335-3-4-.01(1)(b)

Particulate matter (PM10) emissions from the petroleum coke drying and

pulverizing system shall not exceed the allowable specified in either proviso

2(a) or (b) or (c) of this section of this subpart.

Rule 335-3-16-.05(a)

Provided the charge rate is less than 30 Tons/Hour, the allowed

emissions shall be calculated as follows:

Rule 335-3-4-.04(1)


247



Provided the charge rate is equal to or greater than 30 Tons/Hour,

the allowed emissions shall be calculated as follows:

Rule 335-3-4-.04(1)


PM10 emissions from the baghouse vent shall not exceed 3.0

pounds per hour (Lb/hr)

Rule 335-3-14-.04

[Anti-PSD Limit]

The petroleum coke drying and pulverizing system shall meet the

requirements specified in proviso (a) through (d) of this section of this

subpart.

Rule 335-3-14-.04

[Anti-PSD Limit]

Each conveying system within the dryer/pulverizing system shall be

a closed conveying system.

The drying/pulverizing mill shall be enclosed on all sides with

outlets provided for each conveying system.

Emissions from the dryer/pulverizing mill shall be captured and sent

to the baghouse for the removal of particulate matter.

A weekly inspection of the petroleum coke drying/pulverizing

system shall be undertaken to assure proper operations. All pieces

of equipment found to be operating improperly shall be repaired or

replaced at the earliest possible time.


Compliance with the opacity standards for the petroleum coke

drying/pulverizing system shall be determined using Method 9 or Method

22 of 40 CFR Part 60, Appendix A.

Rule 335-3-1-.05

Rule 335-3-4-.01(2)

A performance test shall be conducted on the baghouse in accordance with

the following methods and procedures:

Rule 335-3-16-.05(c)(1)(i)

Rule 335-3-14-.04

[Anti-PSD Limit]

(a) Method 1 or 1A, of 40 CFR Part 60, Appendix A to determine sample

and velocity traverses

(b) Method 2 or 2A or 2B or 2C or 2D of 40 CFR Part 60, Appendix A to

determine volumetric flow rates

(c) Method 3 or 3A or 3B or 3C of 40 CFR Part 60, Appendix A to

determine oxygen emissions

248



(d) Method 4 of 40 CFR Part 60, Appendix A to determine the moisture

content in stack gases

(e) Method 5 of 40 CFR Part 60, Appendix A to determine PM emissions

(f) The methods and procedures that are utilized may be modified

upon receiving Departmental approval.

Emission Monitoring

CAM and opacity monitoring shall be conducted as specified in Appendix F:

Petroleum Coke Drying & Pulverizing System of this.

§64.3

§64.6(b)

A performance test shall be conducted on the baghouse in accordance with


Rule 335-3-16-.05(c)(1)(i) & (ii)

Rule 335-3-14-.04

[Anti-PSD Limit]

The test shall consist of three runs of at least 1-hour in duration

Each run shall test for PM10 emissions

The pollutants tested for may be modified upon receiving


Subsequent performance tests shall be conducted on the baghouse

at least once every five (5) years


A record of the information specified in provisos 1(a) through (f) of this


inspection.

Rule 335-3-16-.05(c)(2)

§64.9



corrective actions taken

The date, time, and results of each performance tests along with

any other tests conducted on the baghouse that provides additional

stack pollutant content data

The date and time of each shut down and startup of the petroleum

coke drying/pulverizing system

Date and type of maintenance that affects air emissions

Results of each visual emission observation

249



Continuous monitoring and daily visible inspection records

A periodic monitoring report (PMR) meeting the requirements specified in

proviso 2(a) and (b) of this section of this subpart shall be submitted to the

Department.

Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(i)


term or condition including those that occur during startups and

shutdowns.








If no deviation event occurred during the reporting period,

a statement that indicates there were no deviations from

the permit requirements shall be included in the report.

Except as provided for in proviso 2(c) of this section, the report shall

include the information specified in proviso 2(b)(1) of this section

of this subpart.

For each deviation event, the following information shall be

submitted:



(iii) Date

(iv) Starting time

(v) Duration


(vii) Cause


conditions

250



(ix) Total operating hours of the affected source during

the reporting period


reporting period




Each report shall cover a calendar semi-annual period and shall be submitted

according to the following reporting schedule:




The report content specified in proviso 2(b) of this section

may be modified upon receipt of Departmental approval.





Rule 335-3-16-.05(c)(2)

Rule 335-3-16-.05(c)(3)(ii)

251

APPENDIX A: HEATERS & BOILERS MONITORING

252

HEATING UNITS SUBJECT TO NOX TESTING

Monitoring approach: Periodic Monitoring

I. Indicator Calculate NOX Emissions for Pre-Black Warrior Heaters: H-501 and common stacks for H-700/H-701, BA-601M/BA-

602M, HS-2041A/B/C Calculate NOX Emissions for Pre-Black Warrior Boilers: B-04 & B-06

A. Measurement approach Fuel gas volume to each unit shall be monitored with a system capable of measuring and recording the flow rate

and/or the parameters utilized for flow rate calculation

BTU content of fuel gas stream shall be determined monthly, or at a frequency determined by the Department

Pollutant emission factors shall be determined during performance tests

II. Indicator range NOX emissions shall be maintained at less than, or equal to, the limit specified in the Emission Standards subpart

of the Pre- Black Warrior Expansion Units: Process Heaters & Boilers section of this permit

A deviation is defined as anytime the calculated emission rate exceeds the respective allowed emission rates

A deviation triggers an immediate inspection, corrective action, and reporting within 48 hours or two workdays.

A. QIP threshold Not applicable

III. Performance criteria

A. Data representiveness Fuel gas volume monitor shall be located immediately upstream of each unit.

Fuel gas BTU content shall be determined from samples that are representative of the fuel gas being consumed.

Performance tests shall be undertaken while each unit is being operated at normal loads.

B. Verification of operational status Not applicable

C. QA/QC practices & criteria The fuel gas volume monitor shall be calibrated at a frequency in accordance with the manufacturer’s

specifications, other written procedures that provide adequate assurance that the device is calibrated accurately, or

at least annually whichever is more frequent.

253

HEATING UNITS SUBJECT TO NOX TESTING


If the fuel gas monitor fails its calibration tests, the fuel gas monitor shall be taken out of service until repairs

and/or replacements are made and a new calibration test is undertaken and passed.

D. Monitoring frequency Fuel gas volume measured continuously.

Fuel gas BTU content shall be determined monthly, or at a frequency set by the Department.

Performance tests shall be undertaken every 5 years.

Data collection procedure Calculate: Monthly, or as set by the Department,

Pollutant emissions while utilizing the fuel volume, BTU content, emission factor and operating hours

Fuel gas volume consumed

Record: Monthly, or as set by the Department


Hours of operation

Pollutant emissions

Record: Each occurrence

Each fuel gas BTU content determination

Time, date, and results of each inspection and corrective actions taken

Averaging period Monthly, or as set by the Department

254

HEATING UNITS SUBJECT TO VOC TESTING


I. Indicator Calculate VOC Emissions for Black Warrior Heaters: HP2-H-3600, BA-603 and common stacks for HD-H-3401/HD-H-

3402 and for CR-H-3801/ CR-H-3802/ CR-H-3803

A. Measurement approach Fuel gas volume to each unit shall be monitored with a system capable of measuring and recording the flow rate

and/or the parameters utilized for flow rate calculation

BTU content of fuel gas stream shall be determined monthly, or at a frequency determined by the Department

Pollutant emission factors shall be determined during performance tests

II. Indicator range VOC emissions shall be maintained at less than, or equal to, the limit specified in the Emission Standards subpart

of the Black Warrior Expansion Units: Process Heaters section of the permit

A deviation is defined as anytime the calculated emission rate exceeds the respective allowed emission rates

A deviation triggers an immediate inspection, corrective action, and reporting within 48 hours or two workdays.

A. QIP threshold Not applicable


A. Data representiveness Fuel gas volume monitor shall be located immediately upstream of each unit.

Fuel gas BTU content shall be determined from samples that are representative of the fuel gas being consumed.

Performance tests shall be undertaken while each unit is being operated at normal loads.


C. QA/QC practices & criteria The fuel gas volume monitor shall be calibrated at a frequency in accordance with the manufacturer’s

specifications, other written procedures that provide adequate assurance that the device is calibrated accurately, or

at least annually whichever is more frequent.

255

HEATING UNITS SUBJECT TO VOC TESTING


If the fuel gas monitor fails its calibration tests, the fuel gas monitor shall be taken out of service until repairs

and/or replacements are made and a new calibration test is undertaken and passed.

D. Monitoring frequency Fuel gas volume measured continuously.

Fuel gas BTU content shall be determined monthly, or at a frequency set by the Department.

Performance tests shall be undertaken every 5 years.

Data collection procedure Calculate: Monthly, or as set by the Department,

Pollutant emissions while utilizing the fuel volume, BTU content, emission factor and operating hours


Record: Monthly, or as set by the Department


Hours of operation

Pollutant emissions


Each fuel gas BTU content determination

Time, date, and results of each inspection and corrective actions taken

Averaging period Monthly, or as set by the Department

256

HEATING UNITS WITH NOX CEMS


I. Indicator A NOx CEMS shall be installed on Pre-Black Warrior Heater H-501X and Post Black Warrior Heaters: HP2-H-3600,

BA-603, HD-H-3401/HD-H-3402and CR-H-3801/ CR-H-3802/ CR-H-3803

A. Measurement approach The effluent stream shall be monitored with a system capable of continuously analyzing it for its oxygen and nitrogen

oxide (NOX) content and making appropriate calculations for each monitoring cycle and each hour and each rolling

24-hour period while recording relevant information and calculation results.

II. Indicator range NOX content shall be maintained at less than, or equal to, the amount specified in the Emission Standards subpart

of the applicable Heaters & Boilers section of the permit @ 0% excess air

For all heating units, except H-501X, an exceedance is defined as anytime the 30-day rolling average NOX

concentration is > the permitted limit.

For H-501X, an exceedance is defined as anytime the 365-day rolling average NOX concentration is > the permitted

limit

An exceedance triggers an immediate inspection and corrective actions and reporting within 48 hours or two

workdays.

A. QIP threshold Not Applicable


A. Data representiveness Each effluent sensor shall be located at a point within the heater stack, or at a representative point for heaters sharing

a common stack that would result in the monitoring of all of the gases exiting the heater stack.

Each content sensor shall meet specifications required in:

40 CFR 60.13 (applicable to CEMS) for Heater H-501X, §60.107a(c)(1)-(5) for Heaters: BA-603, CR-H-3801/CR-H-

3802/CR-H-3803, HP2-H-3600, & HD-H-3401/HD-H-3402

B. Verification of operational status Not Applicable

C. QA/QC practices & criteria A program for the effluent continuous emission monitoring system shall be developed and implemented that meets

the requirements specified in the following regulations:

40 CFR 60.13 (applicable to CEMS) and Part 60 Appendices A and F and the applicable performance specification (PS)

of 40 CFR Part 60 for Heater H-501X; §60.107a(c)(1)-(5) for Heaters: BA-603, CR-H-3801/CR-H-3802/CR-H-3803, HP2-

H-3600, & HD-H-3401/HD-H-3402

257

HEATING UNITS WITH NOX CEMS


D. Monitoring frequency Effluent content shall be measured continuously

Data collection procedure For all heating units other than H-501X, calculate and record daily and rolling 30-days averages of the NOX

concentration.

For H-501X, calculate and record daily and rolling 365-day averages of the NOX concentration

Record time, date and results of each calibration

Record time, date and results of each inspection and corrective action

Averaging period For all heating units other than H-501X: Daily and rolling 30-days

For H-501X: One day and rolling 365-days

258


259

APPENDIX B: GASOLINE LOADING RACK AND VAPOR COMBUSTOR UNIT

GASOLINE LOADING RACK & VAPOR COMBUSTOR UNIT MONITORING

Periodic Monitoring Periodic Monitoring

Opacity Vapor combustor unit firebox temperature

Provided the vapor combustor is being operated and facility operating

personnel notice visible emissions being emitted from the vapor

combustor, a daily visual emission observation on the vapor combustor

shall be undertaken.

Firebox shall be monitored with system capable of

continuously measuring the fire box temperature and

making appropriate calculations for each monitoring cycle

and each hour and three-hour period while recording

relevant information and calculation results.

Duration of each observation shall be:

>= 15 minutes AND <= 120 minutes

Each observation shall be conducted with either”

Test Method 9 of 40 CFR Part 60,

OR


No more than one 6-min. average opacity reading shall exceed 20% Firebox temperature shall be maintained at => that which

was established during latest performance test which

showed compliance with the limits.

-OR-

No 6-min. average opacity reading shall exceed 40%

-OR-

The accumulated time of observed visible emissions shall not exceed

12 minutes.

A deviation is defined as anytime the observed 6-minute average

opacity exceeds 20% for the2nd time when utilizing Method 9.

An excursion is defined as anytime the three-hour average

firebox temperature is < that which was established during

the latest performance test, conducted every two years, for

which the standard was met


opacity exceeds 40% for the 1st time when utilizing Method 9.

An excursion triggers an immediate inspection and

corrective actions and reporting within 48 hours.

261


Monitoring approach: Periodic Monitoring Periodic Monitoring I. Indicator Opacity Vapor combustor unit firebox temperature

A deviation is defined as anytime the accumulated time in which

visible emissions were observed exceeds 12 minutes per observation

when utilizing Method 22.

The minimum firebox temperature may be modified upon

receipt of Departmental approval.

A deviation triggers continued visible emissions observations at a

frequency suitable to defining the duration of the visible emission

deviation event. One observation shall be undertaken to establish the

end of the visible emission deviation event.

A QIP threshold Not applicable If the accumulated hours of excursion events occurring

exceeds 5% of the vapor combustor operating time during

any quarterly reporting period, a Quality Improvement Plan

shall be developed and implemented.


A. Data representiveness Each temperature sensor shall be located within the vapor

combustor unit combustion chamber or immediately

downstream of the combustion chamber.

B. Verification of operational Not applicable

status

C. QA/QC practices & criteria A program for the firebox continuous emissions

monitoring system shall be developed and implemented

that meets the requirements specified in §63.427

If the sensor fails its calibration test, the sensor shall be

taken out of service until repairs and/or replacements are

made and a new calibration test is undertaken and passed.

262


Monitoring approach: Periodic Monitoring Periodic Monitoring I. Indicator Opacity Vapor combustor unit firebox temperature

D. Monitoring frequency Daily Temperature shall be measured continuously.

Data collection procedure Record: Daily Record hourly firebox temperature.

Each 15 second observation reading

Record calibration results


Time, date and results of corrective actions taken Record inspection results and corrective actions taken.

Averaging period Six minutes Hour

263

APPENDIX C: SULFUR RECOVERY SYSTEMS’ THERMAL OXIDIZER

264

EACH SULFUR RECOVERY SYSTEMS’ THERMAL OXIDIZER

Monitoring approach: Compliance Assurance Monitoring [CAM]

I. Indicator Operate thermal oxidizer with a flame or spark present at all times when a process gas stream

may be sent to it.

A. Measurement approach The thermal oxidizer shall be equipped either with a continuous sparking flame igniter

that is monitored by an amp meter or an equivalent device or visual observation

OR

with a continuously burning pilot light that is monitored with either a thermocouple or an

equivalent device or by visual observation.

II. Indicator range Presence of a flame or spark at burner tip

A deviation is defined as when there was no spark or flame present at the burner tip when a

process gas stream could be vented to it.

A deviation triggers an immediate inspection and corrective actions that meet the requirements

of 40 CFR Part §64.7(d) and reporting within 48 hours or two workdays.

A QIP threshold If the accumulated hours of deviation events occurring exceeds 5% of the thermal oxidizer’s

operating time during any quarterly reporting period, a Quality Improvement Plan shall be

developed and implemented.


A. Data representiveness Each flame igniter or flame monitor shall be located at the burner tip and focused on the area

where gas exits the burner.

Visual observations shall be made from the location that provides the best view of the burner

pilot lights or burner igniter.


C. QA/QC practices & criteria Each flame igniter or flame monitor shall be maintained and calibrated in accordance with the

manufacturer’s specifications, other written procedures that provide adequate assurance that

the device is properly maintained and calibrated accurately, or at least annually whichever is

more frequent.

Repairs and/or replacements shall be made immediately when non-functioning or damaged

parts are found.

Flame igniter arc length shall not exceed 10% of arc interval and shall have an arcing frequency

of no greater than once every 3 seconds.

D. Monitoring frequency Pilot flame shall be monitored either continuously with a thermocouple or daily with visual

inspections if operating staff is on site.

Flame igniter – arcing frequency shall be monitored either continuous with an amp meter or

daily with visual inspections if operating staff is on site.

Data collection procedure Record time, date and duration of each incident of when no spark or flame was present at the

flare tip when a process gas stream could have been sent to it

Record time, date and results of each visual observation

Record time, date and results of each calibration

Record time, date and results of each inspection and corrective action

Averaging period Instantaneous

265

APPENDIX D: FACILITY FLARE MONITORING

266

FACILITY FLARE MONITORING


I. Indicator Assist gas to acid gas volume ratio

A. Measurement approach Inlet assist gas and acid gas feed volume shall be monitored with a system capable of

measuring and recording the flow rate and/or the parameters utilized for flow rate

calculation or estimated utilizing material balances, computer simulations, special testing,

or other approved methods.

II. Indicator range Assist gas to acid gas volume ratio shall be equal or greater than 0.5 to 1.0.

A deviation is defined as anytime the actual ratio is less than 0.5 to 1.0.

If the total duration of deviation hours during a quarterly reporting period exceeds 5% of an

emergency flare’s operating time, an air quality modeling study that utilizes the maximum

inlet mass and flow rates shall be performed.

The minimum ratio may be modified upon receipt of Departmental approval.

A QIP threshold Not applicable


A. Data representiveness Each volume monitor shall be located upstream of the flare and shall consist of a single

device that monitors all streams or multiple devices that monitor individual or multiple

streams.

B. Verification of Not applicable

operational status

267

APPENDIX E: ASPHALT PROCESSING FACILITY & THERMAL OXIDIZER

MONITORING

268

ASPHALT PROCESSING FACILITY & THERMAL OXIDIZER

Monitoring approach: Periodic Monitoring Periodic Monitoring

I. Indicator Thermal oxidizer combustion zone temperature Opacity

A. Measurement approach Exhaust from each blowing still must be routed to the

thermal oxidizer and the thermal oxidizer’s combustion

zone shall be monitored with system capable of

continuously measuring the combustion zone

temperature and making appropriate calculations for

each monitoring cycle and each hour and three hour

period while recording relevant information and

calculation results.

[Table 5, No. 1(a)(i), §63.8688(a), (b), §63.8690(b),(c) of

Asphalt MACT]

Provided the thermal oxidizer is being operated and facility operating

personnel notice visible emissions being emitted from the thermal

oxidizer, a daily visual emission observation on the thermal oxidizer

shall be undertaken.

Duration of each observation shall be

>= 15 minutes

AND

<= 120 minutes

Each observation shall be conducted in accordance with either:

Test Method 9 of 40 CFR Part 60, Appendix A

-OR-

Test Method 22 of 40 CFR Part 60, Appendix A

A deviation is defined as anytime the three hour

average combustion zone temperature is < that which

was established during latest performance test.

[§63.8684(b), §63.8691(b), (d)]


opacity exceeds 20% for the 2nd time when utilizing Method 9.

II. Indicator range Combustion zone temperature shall be maintained at No more than one 6-min. average opacity reading shall exceed 20%

-OR-

No 6-min. average opacity reading shall exceed 40%.

-OR-

The accumulated time of observed visible emissions shall not exceed

12 minutes.

=> that which was established during latest

performance test which showed compliance with the

limits [§63.8691(a), (e)]].

A deviation is defined as anytime the observed 6- minute average

opacity exceeds 40% for the 1st time when utilizing Method 9.

269




An excursion triggers an immediate inspection and

corrective actions and reporting within 48 hours

A deviation is defined as anytime the accumulated time in which visible

emissions were observed exceeds 12 minutes per observation when

utilizing Method 22.

A deviation triggers continued visible emissions observations at a

frequency suitable to defining the duration of the visible emission

deviation event. One observation shall be undertaken to establish the

end of the visible emission deviation event.

The minimum combustion zone temperature shall be

established during each performance test required by

§63.8687(a) [Table 5, No. 1(a)(iv), Asphalt MACT]..

A QIP threshold Not applicable Not applicable


A. Data representiveness Each temperature sensor shall be located within the

thermal oxidizer combustion chamber or immediately

downstream of the combustion chamber.

[§63.8688(b)(1)]

Each temperature sensor shall meet specifications

required in §63.8688(a), (b), & Table No. 5 of the

Asphalt MACT

B. Verification of operational status The requirements specified in §63.8688(b)(4), (5), (6)

and (i) of the Asphalt MACT shall be met.

270




C. QA/QC practices & criteria A program for the combustion zone temperature

continuous emissions monitoring system shall be

developed and implemented that meets the

requirements specified in the following regulations:

§63.8688(g) & (h)

Table No. 5, Asphalt MACT

If the sensor fails its calibration test, the sensor shall be

taken out of service until repairs and/or replacements

are made and a new calibration test is undertaken and

passed.

D. Monitoring frequency Temperature shall be measured continuously. Daily

Data collection procedure Record hourly and three-hour average combustion

zone temperature [§63.8688(a)]

Record calibration results. Record: Daily


Record inspection results and corrective Record: Each occurrence

actions taken.

Time, date and results of corrective actions taken

Averaging period Three hours [Table 5, Item 1(a)(iii), Asphalt MACT] Six minutes

271

APPENDIX F: PETROLEUM COKE DRYING & PULVERIZING SYSTEM

272

PETROLEUM COKE DRYING & PULVERIZING SYSTEM

Monitoring approach: Compliance Assurance Monitoring [CAM] Compliance Assurance Monitoring [CAM]

I. Indicator Pressure drop Visible emissions

A. Measurement approach Pressure drop across baghouse shall be monitored with

system capable of continuously measuring the inlet and

outlet baghouse pressure, calculating the pressure drop

for each monitoring cycle and each hour while recording

all relevant information and calculation results.

Provided the dryer/pulverizing mill is being operated, a

daily visual emissions observation on the baghouse shall be

undertaken.

Duration of each observation shall be:

>= 15 minutes AND <= 120 minutes

Each observation shall be conducted in accordance

with either:


Or


II. Indicator range Actual pressure shall be maintained within ± 50% of The accumulated time of observed visible emissions

the pressure drop established during latest performance

test.

An excursion is defined as anytime the pressure drop does

not fall into the established range.

An excursion triggers continued pressure drop readings at

a frequency suitable to defining the duration of the

pressure drop deviation event.

Two readings three hours apart shall be undertaken to

establish the end of the deviation event.

An excursion triggers an immediate inspection, corrective

action and reporting within 48 hours or two workdays.

shall not exceed 5 minutes during any two hour period.

An excursion is defined as anytime the accumulated time

of opacity observed exceeds 5 minutes during any

observation while utilizing either Method 9 or 22.

An excursion triggers continued visible emissions

observations at a frequency suitable to defining the

duration of the visible emission deviation event.

One observation shall be undertaken to establish the end

of the visible emission deviation event. An excursion

triggers an immediate inspection, corrective action and

reporting within 48 hours or two workdays.

273

PETROLEUM COKE DRYING & PULVERIZING SYSTEM

Monitoring approach: Compliance Assurance Monitoring [CAM] Compliance Assurance Monitoring [CAM]

I. Indicator Pressure drop Visible emissions

The pressure drop range may be modified upon receipt of

Department approval.

A QIP threshold If the accumulated hours of excursion events occurring

exceeds 5% of the dryer/pulverizing mill’s operating time

during any quarterly reporting period, a Quality

Improvement Plan shall be developed and implemented.

If the accumulated hours of excursion events occurring

exceeds 5% of the dryer/pulverizing mill’s operating time

during any quarterly reporting period, a Quality

Improvement Plan shall be developed and implemented.


A. Data representiveness Pressure taps shall be located at the baghouse inlet and

outlet.

Observations shall be performed at the baghouse exhaust

while the dryer/pulverizing mill is operating.

B. Verification of operational Not applicable Not applicable

status

C. QA/QC practices & criteria Calibrate, maintain and operate the monitoring system

using the procedures that take into account

manufacturer’s specification.

Observations shall be performed by individuals familiar

with Method 9 &/or 22 and shall follow those procedures.

D. Monitoring frequency Continuous Daily

Observation frequency may be changed upon receiving


Observation frequency may be changed upon receiving


Data collection procedure Record hourly pressure drop Record: Daily


Record: Each occurrence Record: Each occurrence

Time, date and results of corrective actions Time, date and results of corrective actions

taken taken

Averaging period Instantaneous Six minutes