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OPERATING AIR PERMIT
Pursuant to the Regulations of the Arkansas Operating Air Permit Program, Regulation #26:
Permit #: 818-AOP-R6
Renewal #1
IS ISSUED TO:
Cooper-Standard Automotive Company NVH Division
166 Cooper Drive El Dorado, AR 71730
Union County AFIN: 70-00036
THIS PERMIT AUTHORIZES THE ABOVE REFERENCED PERMITTEE TO INSTALL,
OPERATE, AND MAINTAIN THE EQUIPMENT AND EMISSION UNITS DESCRIBED IN THE PERMIT APPLICATION AND ON THE FOLLOWING PAGES. THIS PERMIT IS
VALID BETWEEN:
May 19, 2003 and May 18, 2008
AND IS SUBJECT TO ALL LIMITS AND CONDITIONS CONTAINED HEREIN.
Signed:
_______________________ Michael Bonds Date Modified Chief, Air Division
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION I: FACILITY INFORMATION PERMITTEE: Cooper-Standard Automotive Company AFIN: 70-00036 PERMIT NUMBER: 818-AOP-R6 FACILITY ADDRESS: 166 Cooper Drive El Dorado, Arkansas 71730 COUNTY: Union CONTACT POSITION: Jason Brock, Environmental Coordinator TELEPHONE NUMBER: (870) 862-6441 REVIEWING ENGINEER: David Triplett UTM North-South (X): 3673.5 km UTM East-West (Y): 536.3 km
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION II: INTRODUCTION
Cooper-Standard Automotive Company, NVH Division (Cooper) operates a molded rubber products manufacturing facility in El Dorado, Arkansas. The molded rubber products generally consist of specifically engineered rubber compounds bonded to metal inserts. These products are typically used for vehicle vibration, noise, and harshness control. This is the sixth modification to the Title V Operating Air Permit for this facility.
Summary of Current Modification
This modification is being issued to allow for the permitting of a new emissions source, to be designated as “finishing operations.” This operation will include the currently permitted color coding and top coat operations performed at the facility. The physical locations of these sources will be relocated within the facility to allow for process streamlining within the plant. The emissions from the new source (SN-43) will be permitted at: 12.0 tpy VOC, 0.58 tpy ethylene glycol, 0.08 tpy formaldehyde, 1.35 tpy of glycol ethers, and 2.4 tpy PM/PM10. The color coating activities were previously performed at the conventional and injection presses (SN-26). There is a decrease in permitted emissions from SN-26 of 10.5 tpy VOC and 0.42 tpy of ethylene glycol associated with the removal of the color coding operations from this source. Additionally, SN-36, one of the two existing dip units in use at the facility, is no longer in use and has been removed from the permit. There are no other changes in permitted emissions at this time.
Process Description Cooper-Standard Automotive’s El Dorado, AR facility receives dry and liquid raw materials in both bulk and packaged forms. Dry materials are stored inside the building. Carbon black is received in totes, bags, and supersacs. Three process oils are stored in bulk storage tanks in the east side of the building (SN-21). Fuel oil is stored in a bulk storage tank on the southwest side of the building (SN-21a, 21b. & 21c). Solvents and cements are received and stored in drums. Rubber, carbon black, process oils, and miscellaneous dry ingredients are mixed in the Banbury Mixer (SN-06). Carbon black is handled, weighed, and fed to the mixer in enclosed systems (SN-38). Dry ingredients are weighed to specified formulations and batched in the Compounding Area (SN-14). The batches are then transported to the Banbury Mixer. Carbon black and other dry ingredients generate dust at the opening to the mixer throat and the drop mill. Three dust collectors and a Mixing Area Vacuum System (SN-40) serve this operation. All of the dust collectors and the vacuum system discharge into filter rooms that provide additional filtering for the discharged air. In addition, all mixing ventilation systems discharge into a filter room to control any fugitive emissions that may result from this operation. The mixed rubber is dropped from the Banbury Mixer onto a mill where it is milled to a specified width and thickness. Then, it is dipped in a de-tackifying solution, cooled, and layered
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 onto skids (SN-39). Some of the rubber is transported to the Pin Barrel Tuber (SN-34) where it is extruded in a specific form. The extruded form is cooled, dusted with a de-tackifier (zinc stearate), cut, and stored. The rubber pre-forms are used in the injection presses. The duster is connected to a dust collector. Some of the rubber is transported to the Preformer Extruder (SN-35) where it is extruded in preforms for use in conventional presses. Extruded rubber from SN-34 and SN-35 may also be cured in the Autoclave (SN-27). Some of the rubber is transported to the 6-Inch Tuber (SN-16) where it is extruded in specific forms. The extruded form is dusted with a de-tackifier (talc), cooled, cut, and stored. This rubber is cured in the Autoclave (SN-27). Extruded rubber from the 6-Inch Tuber (SN-16) may also be cured in the conventional and injection presses. Particulate emissions from the 6-Inch Tuber are routed to the baghouse which controls emissions from the Banbury Mixer (SN-06). Metal inserts can be cleaned by hitting them with metal shot in the Wheelabrator (SN-18). The particulate emissions from SN-18 are controlled by a control device inherent to the equipment design and then discharged inside the plant. Metal inserts for the molded rubber products are cleaned and undergo phosphate coating on the caustic cleaning/phosphate line (SN-32). Three heated tanks on the caustic line are equipped with a common roof exhaust. The acid tank is equipped with a fume scrubber and mist eliminator which discharges outside the building. Solvents, adhesives, and coatings are mixed in the required proportions to form the adhesives and coatings used on the metal inserts. The adhesives and coatings are stored and dispensed in the Cement Storage and Mixing Room (SN-11). Metal inserts are coated with adhesive coating in the Circular Paint Line (SN-01), Automatic Paint Line #1 (SN-02), Automatic Paint Line #2 (SN-03), Chain-on-Edge Paint Line #1 (SN-08), Chain-on-Edge Paint Line #2 (SN-41), Indexing Machine (SN-42), and the Dip Unit (SN-10). Each of the coating operations is equipped with exhausts that discharge outside the building. The Pyrolytic Oven (SN-33) is used to clean Chain-on-Edge fixtures. The oven is fired with natural gas and burns the dried adhesive off of the fixtures. The oven is equipped with an after-burner that operates at 1500 - 1650 deg. F. The after-burner exhausts outside the building. Rubber and metal inserts are combined on the Conventional and Injection Presses (SN-26) to produce molded rubber parts. A mold lubricant is applied to some molds. In addition, a coating and/or a color code paint is applied to some cured products at the presses. Some cured parts are also ground at the presses. Molds that become fouled through use are cleaned in the Mold
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 Cleaner (SN-17). The Mold Cleaner is equipped with a dust collector that exhausts inside the building. Finished products are inspected and stored in the warehouse prior to shipment to customers. Steam is provided to the autoclave, the conventional presses, the caustic line, and the Circular Paint Line using two 500 horsepower boilers. The York Shipley Boiler (SN-25) is natural gas fired and uses No. 2 fuel oil as a backup fuel. The Sellers Boiler (SN-24) is only capable of firing natural gas.
Regulations This facility is subject to regulation under the Arkansas Air Pollution Control Code (Regulation 18), the Arkansas Plan of Implementation for Air Pollution Control (Regulation 19), and the Regulations of the Arkansas Operating Air Permit (Regulation 26). The facility is also subject to 40 CFR Part 63 Subpart MMMM – National Emission Standards for Hazardous Air Pollutants: Surface Coating of Miscellaneous Metal Parts and Products. A copy of this federal rule has been attached as Appendix A. The facility must comply with the requirements of NESHAP MMMM by January 2, 2007. The facility is also an effected source under the provisions of 40 CFR Part 63 Subpart PPPP- National Emission Standards for Hazardous Air Pollutants: Surface Coating of Plastic Parts and Products.
Facility Emission Summary Facility wide emissions are summarized in the following table. Specific emission unit information is located at the indicated cross reference page.
CRITERIA POLLUTANT EMISSION SUMMARY
Emission Rates Source No. Description Pollutant lb/hr ton/year
Cross Reference
Page
Total Allowable Emissions
PM PM10 SO2 VOC CO NOx
5.5 5.5 12.0 124.7 7.3 8.9
16.8 16.8 51.4 428.5 26.2 32.7
N/A
Adhesive/Coating Application
01 Circular Paint Line PM
PM10 VOC
0.5 0.5 5.1
0.7 0.7
302.8** 17
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
CRITERIA POLLUTANT EMISSION SUMMARY
Emission Rates Source No. Description Pollutant lb/hr ton/year
Cross Reference
Page
02 Automatic Paint Line #1
PM PM10 VOC
0.4 0.4 10.7
1.4 1.4 **
17
03 Automatic Paint Line #2
PM PM10 VOC
0.4 0.4 10.7
1.4 1.4 **
17
08 Chain-on-Edge Paint Line #1
PM PM10 SO2 VOC CO
NOX
0.1 0.1 0.1 14.6 0.1 0.1
0.1 0.1 0.1 ** 0.3 0.4
17
41 Chain-on-Edge Paint Line #2
PM PM10 SO2 VOC CO
NOX
0.1 0.1 0.1 14.6 0.1 0.1
0.1 0.1 0.1 ** 0.3 0.4
17
42 Indexing Machine PM
PM10 VOC
0.1 0.1 5.9
0.2 0.2 **
17
10 Dip Unit #1 PM
PM10 VOC
0.2 0.2 5.8
0.7 0.7 **
17
11 Cement Mixing and Storage Room VOC 1.4 ** 17
Rubber Manufacturing
06 Banbury Mixer PM
PM10 VOC
0.1 0.1 1.1
0.4 0.4 4.4
22
26 Conventional and Injection Presses
PM PM10 VOC
0.1 0.1 53.6
0.4 0.4
106.2 28
28 Autoclave PM
PM10 VOC
0.1 0.1 0.3
0.4 0.4 0.5
32
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
CRITERIA POLLUTANT EMISSION SUMMARY
Emission Rates Source No. Description Pollutant lb/hr ton/year
Cross Reference
Page Boilers
24 Sellers Boiler
PM PM10 SO2 VOC CO NOx
0.2 0.2 0.1 0.2 1.8 2.1
0.3 0.3 0.1 0.2 2.6 3.1
25
25 York Shipley Boiler
PM PM10 SO2 VOC CO NOx
0.9 0.9 11.3 0.2 3.8 6.1
3.9 3.9 49.5 0.5 16.6 26.7
25
Other Sources
32 Caustic Cleaning/ Phosphate Line Phosphoric Acid Fumes 0.1 0.4 35
33 Pyrolytic Oven
PM PM10 SO2 VOC CO NOx
1.1 1.1 0.4 0.5 1.5 0.5
4.4 4.4 1.6 1.9 6.4 2.1
37
Overall non-criteria pollutant emissions are summarized in the following table. Specific hazardous air pollutant emission rates are identified in the specific emission unit information.
Pollutant Emission Rates lb/hr ton/year
Acetaldehyde 0.11 0.21
Acetonitrile 0.01 0.01
Acetophenone 4.28 8.55
Acrolein 0.05 0.11
Acrylonitrile 0.35 0.79
Aniline 0.11 0.19
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant Emission Rates lb/hr ton/year
Benzene 0.08 0.15
Benzidine 0.04 0.09
Bis(2-ethylhexyl) phthalate 0.19 0.37
Bromoform 0.01 0.02
1,2 Butylene Oxide 0.03 0.12
1,3 Butadiene 0.27 0.52
Carbon Disulfide 17.79 32.75
Carbon Tetrachloride 8.79 17.4
Carbonyl Sulfide 4.42 9.05
Chloroethane 0.01 0.01
Chloroform 0.12 0.24
Chloromethane 0.08 0.17
Chromium Compounds 0.18 0.42
Cumene 0.06 0.14
Di-n-butylphthalate 0.10 0.20
1,1 Dichloroethene (Vinylidene Chloride) 0.11 0.21
1,4-Dioxane 0.01 0.01
Ethyl Benzene 7.29 31.59
Ethylene Glycol 0.60 0.71
Formaldehyde 0.07 0.20
Glycol Ethers 1.51 2.48
Hexachlorobutadiene 0.02 0.02
Isooctane 0.07 0.13
Isophorone 0.02 0.03
Manganese Compounds 0.02 0.10
Methylene Chloride 1.31 1.93
Methyl Ethyl Ketone (2-Butanone) 1.14 3.69
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant Emission Rates lb/hr ton/year
Methylene Diphenyl Diisocyanate 0.053 0.10
Methyl Isobutyl Ketone (4-Methyl 2-Pentanone) 32.06 126.52
n-Hexane 3.11 6.22
Naphthalene 0.05 0.13
Nickel 0.01 0.01
o-Cresol 0.06 0.25
o-Toluidene 0.05 0.10
Phenol 0.24 0.99
Phosphoric Acid Fumes 0.10 0.40
Propylene Oxide 1.05 2.14
Selenium Compounds 0.05 0.22
Styrene 0.83 1.67
t-Butyl Methyl Ether 1.56 3.19
Tetrachloroethylene 0.40 1.18
Toluene 20.62 89.28
1,1,1- Trichloroethane 3.43 6.78
Trichloroethylene 6.21 27.21
Xylene 30.20 130.77
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION III: PERMIT HISTORY
• The facility was originally permitted under Arkansas Regulation 19. The original permit, 818-A was issued on November 10, 1987. The permit was modified and reissued as permit 818-AR-1 on September 7, 1993.
• Permit 818-AR-2 was issued on September 26, 1994, under Arkansas Regulation 19. Modifications included a production increase and several changes in the manufacturing operation which included replacement of a dip unit with a new unit, routing particulate emissions from the 6-inch tuber to the Wheelabrator dust collector, replacing the 8-inch hot feed tuber with a pin barrel tuber, and installation of a preformer extruder. Additionally several units were removed from service. Units removed from service include two degreasers, a laboratory banbury mixer, fixture cleaning drums and a rotocure operation
• Permit 818-AR-3 was issued on March 12, 1996, under Arkansas Regulation 19. Modifications included a production increase and the ability to use new coating materials.
• Cooper’s first Title V operating permit, Permit #818-AOP-R0, was issued on November 18, 1997. That modification permitted the installation of a new (second) dip unit (SN-36) and increased the overall adhesive/coating usage at the facility. Additionally, the VOC emission rates associated with the production of rubber were revised. The revised emission estimates were based on testing and emission factors developed by the Rubber Manufacturers Association. The modifications resulted in an increase in permitted volatile organic compound (VOC) emissions of 46.7 tons per year (tpy).
• Cooper’s second Title V operating permit, Permit #818-AOP-R1, was issued on January 15, 1999. Cooper replaced the existing Banbury Mixer (SN-06) and associated equipment with a new mixing system. This involved the construction of a new mixing building, the replacement of the mixer and the Compounding Area (SN-14), and the installation of a new Carbon Black Handling System and Weigh Hopper, a new Mixer Dip Mixing and Dip Tank, and a new Mixing Area Vacuum System. The maximum annual rubber throughput on the new system is the same as the existing Banbury Mixer.
These systems are served by new dust collection equipment, including a new secondary filtration system. The mixing building ventilation system is also served by a filtration system. The existing mixer dust collector was removed. Improvements in dust collection efficiency and the addition of the secondary filtration system resulted in a decrease of particulate matter emissions. In addition, since the maximum throughput did not increase, the maximum annual VOC and HAP emissions were unchanged.
The removal of the existing mixer dust collector affected the 6-inch Tuber and the Pin Barrel Tuber. These sources were connected to one of the new dust collectors.
Cooper also obtained revised physical data for several coatings and adhesives, and the plant
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 learned that several new materials will need to be introduced. As a result, there was a slight decrease in the maximum hourly VOC emission rates for each coating and adhesive application source, and an increase in the maximum hourly particulate matter emission rate for the Chain-on-Edge Paint Line (SN-08).
VOC emissions from the mold lube/coating had been omitted from the maximum VOC emission rate for the Conventional and Injection Presses in past permit modifications. These emissions were added in this modification.
• Permit #818-AOP-R2 was issued on July 26, 1999. Cooper requested to increase the rubber processing limit on the Tubers and Extruders. The Banbury Mixer and the Conventional and Injection Presses both have rubber processing limits of 14,416 tons per twelve consecutive months. In order to provide maximum flexibility for plant operations, Cooper requested an identical limit for the Tubers and Extruders. The emissions calculations for the Tubers and Extruders were based on processing 14,416 tons per year. Therefore, the requested change did not result in a change in permitted emissions.
Cooper also requested to increase the toluene and ethylene glycol emissions limits for the Surface Coating Operations. Cooper found that the current limits do not provide the desired plant operating flexibility. Cooper requested that the toluene emission limit be increased from 1.3 tons per year to 3.0 tons per year and that the ethylene glycol emission limit be increased from 0.01 tons per year to 0.04 tons per year.
Cooper also installed some additional curing presses at the plant. These presses are a part of the Conventional and Injection Presses source (SN-26). The operation of these presses did not require a change in the current rubber processing limit, mold lube/coating limit, color coding usage limit, or emission limits for the source.
The following sources have been permanently removed from service through a permit modification:
Source Description SN-04 Degreaser #1
SN-05 Degreaser #2
SN-07 Laboratory Banbury Mixer
SN-12 Coating Mixing Booth
SN-13 Fixture Cleaning Drums
SN-15 8 inch Tuber
SN-23 Trichloroethylene Storage Tank
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Source Description SN-27 Rotocure Operation
SN-29 Nitrogen Tumbler
SN-30 Nitrogen Deflasher
SN-31 Nitrogen Storage Tank
• Permit #818-AOP-R3 was issued on August 28, 2000. This modification authorized the use of new coating materials at the Surface Coating Operations portion of the plant. The permit also acknowledged new Hazardous Air Pollutant (HAP) content information recently issued for existing coating materials.
• Permit No. 818-AOP-R4 was issued on February 28, 2002. The purpose of this modification was to authorize the following changes:
• The installation of ten additional conventional and injection presses at SN-26, for a total of 64 presses at SN-26. This modification did not involve an emission increase.
• The replacement of the Caustic Cleaning/Phosphate Line (SN-32), and the addition of a Wheelabrator (SN-18) to clean metal parts. The only emission change with this modification was a 0.4 ton/yr increase in PM10.
• The incorporation of a new surface coating material at various sources. This modification resulted in the following HAP emissions: 0.03 ton/yr ethylene glycol, and 0.02 ton/yr 1,2-butylene oxide.
• The addition of an ink-jet spraying system to the permit’s list of insignificant activities.
• The replacement, modification, or addition of selected units as follows:
o An increase in rubber compound throughput at the mixers, tubers, extruders, and presses, from 14,416 ton/year to19,000 ton/year.
o A throughput increase at the Carbon Black Handling System, from 4,380 ton/yr to 5,775 ton/yr.
o An increase in rubber throughput at the Autoclave from 1,533,667 lb/yr to 2,300,000 lb/yr.
o The replacement of the existing Chain-on-Edge Paint Line, and the installation of an additional Chain-on-Edge Paint Line.
o The installation of a new Indexing Machine.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
o The replacement of existing Dip Unit No. 2.
o The replacement of existing Automatic Paint Lines 1 and 2.
The final set of changes listed above result in a potential VOC increase of 218.0 ton/yr. This permitting action was therefore reviewed under the provisions of 40 CFR 52.21, Prevention of Significant Deterioration (PSD). The total permitted plantwide VOC increase was 112.2 ton/yr, due to emission bubble limits on selected sources.
Below is a summary of the net emission increases associated with the issuance of Permit No. 818-AOP-R4.
Pollutant Surface
Coating Equipme
nt (ton/yr)
Process Equipme
nt (ton/yr)
Other Equipme
nt (ton/yr)
Boilers (ton/yr)
Total Net Change (ton/yr)
PSD Significa
nt Emission
Rate (ton/yr)
PSD Applicabilit
y
PM 2.04 0.99 -- 0.23 3.26 15 No
SO2 -- -- -- 0.02 0.02 40 No
NOX -- -- -- 3.06 3.06 40 No
CO -- -- -- 2.57 2.57 100 No
VOC 153.3 61.7 2.80 0.17 218.0 40 Yes
Several control options were considered in the VOC BACT analysis. These options included the usage of water-based solvents and/or low-VOC solvents. Due to the particular need for very high-strength metal-to-rubber bonding in the automotive industry, it was determined that the usage of such lower-VOC materials was not currently technically feasible at the Cooper facility. Add-on VOC controls with either full or partial enclosure of the new units was also considered, but ruled out as BACT due to the high dollar-per-ton cost of such control. ($5,899 per ton for partial enclosure).
BACT for Cooper’s surface coating operations was therefore selected as the following:
1) VOC content of the primer as applied shall not exceed 6.12 pounds per gallon.
2) VOC content of the adhesives as applied shall not exceed 7.13 pounds per gallon.
3) The quantity of all coatings used for surface coating operations shall not exceed 721,824 pounds per year, based on a 12-month rolling total. This limit includes water-based and solvent-based top-coats, primers, and adhesives.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 • Permit No. 818-AOP-R5 was issued to Cooper-Standard Automotive on May 19, 2003. This was the first renewal to the Title V Operating Air Permit for this facility. In addition to the Title V renewal, this modification included the following changes.
After issuance of permit No. 818-AOP-R4, Cooper discovered that it was unable to meet the 6.12 lb/gal VOC content limit for the primers, as applied. This 6.12 lb/gal limit was determined based on the assumption that Cooper would use a 75-25 primer-to-thinning solvent ratio at the facility. In order to meet operational specifications for primer viscosity, dry film thickness, and solids content, it was sometimes necessary for the facility to add additional solvent to the primer mixture, thus increasing the “as applied” VOC content above the 6.12 lb/gal permitted limit. Additionally, the facility experienced some difficulty in demonstrating full compliance with limits based on an “as applied” standard.
Based on these considerations, ADEQ revised the previous BACT determination to allow for compliance demonstration through the tracking of the “as supplied” VOC contents of the primers, adhesives, and solvents used at the facility, with the additional requirements that the facility monitor the viscosity of the final primer/solvent and adhesive/solvent mixtures to ensure that the mixing occurs at acceptable levels. If too much solvent is added to either mixture (thus increasing the VOC content), it will be detected by means of the periodic viscosity monitoring conducted by the facility. The plantwide annual emission limitation for VOC from primer and adhesive application remained unchanged at 302.8 tpy.
Several sources were determined to meet the Department’s Insignificant Activity criteria as outlined in Appendix A to Regulation 19. These sources have been removed from the Specific Conditions and listed in the Insignificant Activities List found in Section VII. The sources which have been reclassified are: SN-09, SN-13, SN-16, SN-34, SN-35, SN-17, SN-18, SN-21a, SN-21b, SN-21c, SN-32, SN-38, SN-39, and SN-40.
Additionally, there are two other changes to this permit. SN-19, formerly used as a No. 2 Fuel Oil storage tank, was removed from operation at the facility, and the emission limitations on the conventional and injection presses (SN-26) were revised to correct an error made with the issuance of Permit No. 818-AOP-R4. The correction of these emission calculations leads to increases in many of the annual HAP emission limitations at the source, as well as to the VOC emission limits.
As a result of these permit changes, total annual VOC emission limits on the facility increased by 5.8 tpy.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION IV: EMISSION UNIT INFORMATION
Surface Coating Operations: SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, SN-42
Source Description
Metal inserts are coated with top-coats, primers, and adhesives in the Circular Paint Line (SN-01), the Automatic Paint Line #1 (SN-02), the Automatic Paint Line #2 (SN-03), the Chain-on-Edge Paint Line #1 (SN-08), the Chain-on-Edge Paint Line #2 (SN-41), an Indexing Machine (SN-42) and one dip unit (SN-10). The Chain-on-Edge paint lines each use an 0.8 million Btu per hour natural gas fired dryer. Coatings are mixed in a cement mixing and storage room (SN-11). Emissions from the mixing and storage room are accounted for in the total emissions calculated for the paint lines.
Specific Conditions
1. Pursuant to §19.501 et seq of the Regulations of the Arkansas Plan of Implementation for
Air Pollution Control, effective February 15, 1999 (Regulation #19) and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates set forth in the following table.
The particulate matter emission rates are based on the assumption that the coating with the highest solid content is used exclusively. The hourly VOC emission rates are based on the assumption that the coating with the highest VOC content is used exclusively.
SN Pollutant lb/hr ton/year
01 PM10 VOC
0.5 5.1
0.7 302.8**
02 PM10 VOC
0.4 10.7
1.4 **
03 PM10 VOC
0.4 10.7
1.4 **
08
PM10 SO2 VOC CO NOx
0.1 0.1 14.6 0.1 0.1
0.1 0.1 ** 0.3 0.4
10 PM10 VOC
0.2 5.8
0.7 **
11 VOC 1.4 **
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SN Pollutant lb/hr ton/year
41
PM10 SO2 VOC CO NOx
0.1 0.1 14.6 0.1 0.1
0.1 0.1 ** 0.3 0.4
42 PM
PM10 VOC
0.1 0.1 5.9
0.2 0.2 **
**Total VOC emissions from SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, and SN-42.
2. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR 52.21, the permittee shall not exceed combined VOC emissions of 302.8 tons from sources SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, and SN-42 during any consecutive twelve month period.
3. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall maintain records which demonstrate compliance with the emission limit set in Specific Condition #2. These records may be used by the Department for enforcement purposes. Records shall be kept in a spreadsheet, database, or other well-organized format. Records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision 7.
4. Pursuant to §18.801 of the Arkansas Air Pollution Control Code, effective February 15, 1999 (Regulation #18), and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates set forth in the following table. The particulate matter emission rates are based on the assumption that the coating with the highest solid content is used exclusively.
SN Pollutant Lb/hr ton/year 01 PM 0.5 0.7
02 PM 0.4 1.4
03 PM 0.4 1.4
08 PM 0.1 0.1
10 PM 0.2 0.7
41 PM 0.1 0.1
42 PM 0.1 0.2
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
5. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates set forth in the following table for SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, and SN-42 combined. The hourly emission rates are based on the assumption that the coating with the highest non-criteria content is used exclusively.
Hazardous Air Pollutant lb/hr tons per twelve
consecutive months
1,2 Butylene Oxide 0.03 0.12
Chromium Compounds 0.17 0.40
Ethyl Benzene 7.14 31.3
Ethylene Glycol 0.10 0.13
Formaldehyde 0.03 0.12
Glycol Ethers 0.83 1.13
Manganese Compounds 0.013 0.10
Methyl Ethyl Ketone 0.56 2.47
Methylene Diphenyl Diisocyanate 0.053 0.10
Methyl Isobutyl Ketone 26.14 114.5
o-Cresol 0.06 0.25
Phenol 0.21 0.92
Selenium Compounds 0.05 0.22
Toluene 19.93 87.40
Tetrachloroethylene 0.17 0.72
Trichloroethylene 6.20 27.20
Xylene 29.50 129.10
6. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records which demonstrate compliance with the annual emission limits set in Specific Condition #5. These records may be used by the Department for enforcement purposes. Records shall be maintained in a spreadsheet, database, or other well-organized format. Records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
annual total and each individual month’s data shall be submitted to the Department in accordance with General Provision #7.
7. Pursuant to §18.501 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 5% opacity from sources SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, or SN-42 as measured by EPA Reference Method 9.
8. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall conduct weekly observations of the opacity from SN-01, SN-02, SN-03, SN-08, SN-10, SN-11, SN-41, and SN-42, and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
9. Pursuant to §19.901 et seq of the Arkansas State Implementation Plan for Air Pollution Control (Regulation 19) and 40 CFR Part 52 Subpart E, VOC content of primers, adhesives, and primer/adhesive thinning solvents, as supplied, shall not exceed the limits as listed in the following table. Compliance with this condition shall be demonstrated by compliance with Specific Condition #13.
Material Maximum Allowable VOC
Content (lb/gal) primers 5.9
primer thinning solvents 6.7
adhesives 7.1
adhesive thinning solvents 7.3
10. Pursuant to §19.901 et seq of the Arkansas State Implementation Plan for Air Pollution Control (Regulation 19) and 40 CFR Part 52 Subpart E, all primer and/or adhesive mixes shall be maintained at or above a viscosity of 17 seconds as determined by the Zahn #2 cup method. Records of viscosity measurements shall be updated daily, maintained on-site for at least 30 days, and shall be made available to Department personnel upon request.
11. Pursuant to §19.901 et seq of the Arkansas State Implementation Plan for Air Pollution Control (Regulation 19) and 40 CFR Part 52 Subpart E, the permittee shall develop and maintain work practice standards which outline the mixing process for the primers and adhesives used at the facility. These standards shall be updated as necessary, maintained on-site, and shall be made available to Department personnel upon request.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 12. Pursuant to §19.303 of the Arkansas State Implementation Plan for Air Pollution Control
(Regulation 19) and 40 CFR 52.21, the quantity of all coatings used for surface coating operations shall not exceed 721,824 pounds per year, based upon a twelve-month rolling total. This limit includes water-based and solvent-based top-coats, primers, and adhesives.
13. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, and §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records which demonstrate compliance with the limits set forth in Specific Conditions #9 and #12. The records shall be updated on a monthly basis, kept on site, and made available to Department personnel upon request.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Banbury Mixer
SN-06
Source Description Carbon black, “fillers,” curing agents, miscellaneous dry materials, rubber, and oil are combined in the Banbury Mixer in the required proportions for the desired rubber compound. Some minor curing agents and other dry materials are weighed at an operator compounding station at the mixer. All solid materials are loaded onto a charge conveyor that leads to the mixer or are charged directly to the mixer via enclosed systems. Particulates are released from the mixer, compounding station, charge conveyor, and drop mill. Two dust collectors serve the mixer. One collector serves the mixer charge door and ram chamber. The other dust collector serves the compounding station, mixer drop gate, mixer dust seal hoods, and drop mill. Both dust collectors discharge to a filter room that will provide additional air filtering capacity prior to discharge to the atmosphere. The emissions from SN-06 are discharged to Filter Room #2 where additional filtration is provided prior to discharge to the atmosphere. The emissions from SN-14 and SN-38 are also discharged to Filter Room #2. Since the emissions co-mingle in the filter room, it is not possible to observe the opacity of the emissions from each source individually. Instead, the Plantwide Conditions contain an opacity limit and an observation requirement which applies to the discharge from Filter Room #2.
Specific Conditions
14. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Condition #16.
Pollutant lb/hr ton/year
PM10 0.1 0.4
VOC 1.1 4.4
15. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Condition #16.
Pollutant lb/hr ton/year
PM 0.1 0.4
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant lb/hr ton/year 1,1 Dichloroethene 0.001 0.003
1,3 Butadiene 0.002 0.01
2-Butanone (Methyl Ethyl Ketone) 0.028 0.11
4-Methyl-2-Pentanone (Methyl Isobutyl Ketone) 0.147 0.58
Acetaldehyde 0.003 0.01
Acetophenone 0.011 0.04
Acrolein 0.004 0.02
Acrylonitrile 0.056 0.22
Aniline 0.002 0.01
Benzene 0.003 0.01
Bis(2-Ethylhexyl)phthalate 0.003 0.01
Bromoform 0.001 0.01
Carbon Disulfide 0.135 0.53
Carbon Tetrachloride 0.001 0.01
Carbonyl Sulfide 0.108 0.43
Chromium Compounds 0.001 0.01
Cumene 0.015 0.06
1,1-Dichloroethene 0.001 0.01
Ethyl benzene 0.021 0.08
Isooctane 0.004 0.02
Isophorone 0.003 0.01
Methylene Chloride 0.185 0.73
m,p Xylene 0.069 0.27
Naphthalene 0.001 0.01
n-Hexane 0.052 0.21
o-Xylene 0.037 0.15
o-Toluidine 0.001 0.01
Phenol 0.003 0.01
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant lb/hr ton/year Propylene Oxide 0.033 0.13
Styrene 0.020 0.08
t-Butyl Methyl Ether 0.038 0.15
Tetrachloroethylene 0.020 0.08
Toluene 0.111 0.44
1,1,1-Trichloroethane 0.004 0.01
16. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not exceed 19,000 tons of rubber compound produced at the banbury mixer (SN-06) for any consecutive twelve month period. (The amount of rubber processed is also limited by Specific Condition #31)
17. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, and §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records which demonstrate compliance with the limit set in Specific Condition #16. These records may be used by the Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7. (These records are also required by Specific Condition #32). One set of records may be used to demonstrate compliance with both conditions.)
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Boilers
SN-24, SN-25
Source Description Steam is provided to the autoclave, conventional presses, the Circular Paint Line Dryer, and the caustic line using a Sellers boiler (SN-24), with a heat input capacity of 20.9 mmBTU/hr, installed in 1972, and a York Shipley boiler (SN-25), with a heat input capacity of 20.9 mmBTU/hr, installed in 1974. The Sellers boiler is capable of firing natural gas only. The York Shipley boiler is capable of firing natural gas or No. 2 fuel oil. Emissions associated with the York Shipley boiler represent the worst case operating scenario.
Specific Conditions
18. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Conditions #23 through #25.
SN Pollutant lb/hr ton/year 24 PM10 0.2 0.3
SO2 0.1 0.1
VOC 0.2 0.2
CO 1.8 2.6
NOx 2.1 3.1
25 PM10 0.9 3.9
SO2 11.3 49.5
VOC 0.2 0.5
CO 3.8 16.6
NOx 6.1 26.7
19. Pursuant to §19.503 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-25 as measured by EPA Reference Method 9, while combusting fuel oil.
20. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall conduct weekly observations of the opacity from SN-25 when combusting fuel oil and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
results of these observations shall be kept on site and shall be made available to Department personnel upon request.
21. Pursuant to §18.501 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 5% opacity from SN-24 or SN-25 as measured by EPA Reference Method 9, while combusting natural gas. Compliance with the opacity limit for SN-24 and SN-25 when combusting natural gas shall be met by compliance with Specific Conditions #23 for SN-24 and the natural-gas portion of the restrictions in Specific Condition #24 for SN-25.
22. Pursuant to §18.801 et seq of Regulation #19 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Conditions #23 through #25.
SN Pollutant lb/hr ton/year 24 PM 0.2 0.3
25 PM 0.9 3.9
23. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, natural gas shall be the only fuel combusted in SN-24.
24. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, natural gas or fuel oil may be combusted in SN-25.
25. Pursuant to §19.705 of Regulation #19, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use any fuel oil which has a sulfur content in excess of 0.5% in source SN-25.
26. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the sulfur content of the fuel oil shall be verified by testing or vendors’ guarantees. The permittee shall maintain a record of each fuel shipment and the associated sulfur content. This record shall be updated with each shipment, kept on site, shall be made available to Department personnel upon request and may be used by the Department for enforcement purposes. This report shall be submitted to the Department in accordance with General Provision #7.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Conventional and Injection Presses
SN-26
Source Description Rubber preforms from the tubers and extruders are combined with metal inserts at the conventional and injection presses to form molded rubber parts. This source currently consists of 30 conventional and 32 injection presses. Since the issuance of Permit No. 818-AOP-R6, the facility is permitted to install up to 64 total presses at this source.
Specific Conditions
27. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates at source SN-26 as set forth in the following table. The emission rates are effectively limited by Specific Conditions #29, #31, #33, and #34.
Pollutant lb/hr ton/year
PM10 0.1 0.4
VOC 53.6 106.2
28. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates at source SN-26 as set forth in the following table. The emission rates are effectively limited by Specific Conditions #29, #31, #33, and #34.
Pollutant lb/hr ton/year
PM 0.1 0.4
1,1-Dichloroethene 0.10 0.20
1,1,1-Trichloroethane 3.42 6.77
1,3 Butadiene 0.25 0.49
2-Butanone (Methyl Ethyl Ketone) 0.51 1.02
4-Methyl-2-Pentanone (Methyl Isobutyl Ketone) 5.75 11.38
Acetaldehyde 0.10 0.19
Acetophenone 4.22 8.35
Acrolein 0.04 0.08
Acrylonitrile 0.29 0.57
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant lb/hr ton/year Aniline 0.09 0.16
Benzene 0.05 0.11
Benzidine 0.04 0.09
bis(2-Ethylhexyl)phthalate 0.17 0.34
Carbon Disulfide 12.69 35.11
Carbon Tetrachloride 8.78 17.38
Carbonyl Sulfide 4.21 8.34
Chloroform 0.12 0.24
Chloromethane 0.07 0.15
Cumene 0.03 0.05
Di-n-butylphthalate 0.09 0.18
Ethyl benzene 0.05 0.10
Hexachlorobutadiene 0.01 0.01
Isooctane 0.05 0.09
Methylene Chloride 0.35 0.93
m,p Xylene 0.17 0.33
Naphthalene 0.04 0.08
n-Hexane 2.88 5.69
o-Xylene 0.18 0.35
o-Toluidene 0.04 0.08
Propylene Oxide 1.00 1.98
Styrene 0.80 1.58
t-Butyl Methyl Ether 1.50 2.96
Tetrachloroethylene (Perchloroethlyene) 0.13 0.26
Toluene 0.38 0.75
29. Pursuant to §19.503 of Regulation #18 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-26 as measured by EPA Reference Method 9.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 30. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall
conduct weekly observations of the opacity from SN-26 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
31. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not exceed 19,000 tons of rubber processed in the conventional and injection presses (SN-26) during any consecutive twelve month period. (The amount of rubber processed is also limited by Specific Condition #16)
32. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records of amount of rubber processed on the conventional and injection presses which demonstrate compliance with the limit set in Specific Condition #31. These records may be used by the Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7. (These records are also required by Specific Condition #17. One set of records may be used to demonstrate compliance with both conditions.)
33. Pursuant to §19.705 of Regulation #19, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311 and 40 CFR 70.6, the permittee shall not use any mold lube/coating which contains more than 6.59 pounds VOCs per gallon.
34. Pursuant to §19.705 of Regulation #19, #18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use in excess of 5,600 gallons of mold lube/coating at (SN-26) during any consecutive twelve month period.
35. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records of amount of mold lube/coating used which demonstrate compliance with the limit set in Specific Condition #34. These records may be used by the Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Autoclave
SN-28
Source Description Some rubber pre-forms from the tubers and extruder are cured in the autoclave.
Specific Conditions 36. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee
shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Condition #40.
Pollutant lb/hr ton/year
PM10 0.1 0.4
VOC 0.3 0.5
37. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates at source SN-28 as set forth in the following table. The emission rates are effectively limited by Specific Condition #40.
Pollutant lb/hr ton/year PM 0.1 0.4
1,3 Butadiene 0.01 0.01
2-Butanone (Methyl Ethyl Ketone) 0.02 0.03
4-Methyl-2-Pentanone (Methyl Isobutyl Ketone) 0.01 0.01
Acetophenone 0.01 0.01
Aniline 0.01 0.01
Benzene 0.02 0.02
bis(2-Ethylhexyl)phthalate 0.01 0.01
Carbon Disulfide 4.89 6.82
Carbonyl Sulfide 0.04 0.06
Ethyl benzene 0.06 0.08
Isooctane 0.01 0.01
Isophorone 0.01 0.01
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pollutant lb/hr ton/year Methylene Chloride 0.02 0.02
m,p Xylene 0.20 0.28
n-Hexane 0.15 0.21
o-Xylene 0.11 0.15
Tetrachloroethylene 0.06 0.08
Toluene 0.32 0.45
38. Pursuant to §19.503 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-28. Opacity shall be measured by EPA Reference Method 9.
39. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall conduct weekly observations of the opacity from SN-28 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request. The observations shall be made at the point of greatest opacity in that portion of the plume where condensed water vapor is not present.
40. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311 and 40 CFR 70.6, the permittee shall not exceed 2,300,000 pounds of rubber processed in the autoclave (SN-28) during any consecutive twelve month period.
41. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records of rubber throughput through the autoclave which demonstrate compliance with the limit set in Specific Condition #40. These records may be used by the Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Caustic Cleaning/Phosphate Line
SN-32
Source Description
Metal inserts for the molded rubber products are cleaned and undergo phosphate coating. Three heated tanks on the caustic line are equipped with a common roof exhaust. The acid tank is equipped with a fume scrubber and mist eliminator which discharges outside the building.
Specific Conditions
42. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates set forth in the following table. The emission rates are effectively limited by Specific Condition #45 and #46.
SN Pollutant lb/hr ton/year 32 Phosphoric Acid
Fumes 0.1 0.4
43. Pursuant to §19.503 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-32 as measured by EPA Reference Method 9.
44. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall conduct weekly observations of the opacity from SN-32 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
45. Pursuant to §18.1104 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain a water flow rate of 35 gallons per minute in the scrubber (SN-32).
46. Pursuant to §18.1104 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, phosphoric acid solution in the acid bath on the caustic cleaning/phosphate line shall not exceed 15% phosphoric acid by volume.
47. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records to demonstrate compliance with Specific Conditions #45 and #46. The records for water flow rate shall be updated once per shift, and the phosphoric acid percent records updated once per month. These records shall be kept on site, and shall be provided to Department personnel upon request. Each month’s individual data shall be submitted in accordance with General Provision #7.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Pyrolytic Oven
SN-33
Source Description A Pyrolytic Oven is used to clean Chain-on-Edge fixtures. The oven burns adhesives off of the fixtures. The oven is rated at 0.40 MMBtu/hr and is fired by natural gas. Emissions from the oven are controlled by an afterburner.
Specific Conditions
48. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates at source set forth in the following table. The emission rates are effectively limited by Specific Conditions #51 and #52.
Pollutant lb/hr ton/year
PM10 1.1 4.4
SO2 0.4 1.6
VOC 0.5 1.9
CO 1.5 6.4
NOx 0.5 2.1
49. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates at source set forth in the following table. The emission rates are effectively limited by Specific Conditions #51 and #52.
Pollutant lb/hr ton/year
PM 1.1 4.4
50. Pursuant to §19.503 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-33 as measured by EPA Reference Method 9. Compliance with the opacity limit for SN-33 shall be met by compliance with Specific Condition #51.
51. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the pyrolytic oven shall only be fired by natural gas.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 52. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as
referenced by §8-4-304 and §8-4-311, and 40 CFR §70.6, the afterburner which controls emissions from the pyrolytic oven shall be maintained as a minimum temperature of 1400 degrees Fahrenheit at all times when the oven is operating.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Finishing Operations
SN-43
Source Description This source includes the color coding and top coating operations performed at the facility. These sources were relocated within the facility in 2003 in order to allow for process steamlining at the plant. The color coding emissions were formerly included at SN-26, and the top coat emissions were formerly included in the surface coating operations “bubble”.
Specific Conditions
53. Pursuant to §19.501 et seq of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall not exceed the emission rates at source set forth in the following table. The emission rates are effectively limited by Specific Conditions #55, #57, #59, #61and #63.
Pollutant lb/hr ton/year
PM10 1.2 2.4
VOC 6.0 12.0
54. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed the emission rates at source set forth in the following table. The emission rates are effectively limited by Specific Conditions #55, #58, #59, #62, and #63.
Pollutant lb/hr ton/year
PM 1.2 2.4
Formaldehyde 0.04 0.08
Glycol Ethers 0.68 1.35
Ethylene Glycol 0.29 0.29
55. Pursuant to §19.503 of Regulation #18 and 40 CFR Part 52 Subpart E, the permittee shall not exceed 20% opacity from SN-43 as measured by EPA Reference Method 9.
56. Pursuant to §19.705 of Regulation #19 and 40 CFR Part 52 Subpart E, the permittee shall conduct weekly observations of the opacity from SN-43 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
upon request.
57. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use any color coding coating which contains more than 8.34 pounds VOC per gallon.
58. Pursuant to §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not use any color coding coating which contains more than 0.33 pounds ethylene glycol per gallon.
59. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use in excess of 2,500 gallons of color coding material during any consecutive twelve month period.
60. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records of amount of color coding used which demonstrate compliance with the limit set in Specific Conditions #57, #58, and #59. These records may be used by the Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7.
61. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use any top coat coating which contains more than 0.21 pounds VOC per gallon.
62. Pursuant to §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not use any top coating which contains hazardous air pollutants (HAPs) in excess of the following amounts.
HAP Maximum Content (lb/gal)
Ethylene Glycol 0.03 Glycol Ethers 0.18 Formaldehyde 0.02
63. Pursuant to §19.705 of Regulation #19, §18.1004 of Regulation #18, A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, and 40 CFR 70.6, the permittee shall not use in excess of 15,000 gallons of top coat coating during any consecutive twelve month period.
64. Pursuant to §19.705 of Regulation #19, 40 CFR Part 52 Subpart E, §18.1004 of Regulation #18, and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records of amount of color coding used which demonstrate compliance with the limit set in Specific Conditions #61, #62, and #63. These records may be used by the
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Department for enforcement purposes. The records shall be updated on a monthly basis, shall be kept on site, and shall be provided to Department personnel upon request. An annual total and each individual month’s data shall be submitted in accordance with General Provision #7.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION V: COMPLIANCE PLAN AND SCHEDULE Cooper-Standard Automotive Company, NVH Division is in compliance with the applicable regulations cited in the permit application. Cooper-Standard Automotive Company, NVH Division will continue to operate in compliance with those identified regulatory provisions. The facility will examine and analyze future regulations that may apply and determine their applicability with any necessary action taken on a timely basis.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION VI. PLANTWIDE CONDITIONS 1. Pursuant to §19.704 of Regulation 19, 40 CFR Part 52, Subpart E, and A.C.A. §8-4-203 as
referenced by §8-4-304 and §8-4-311, the Director shall be notified in writing within thirty (30) days after construction has commenced, construction is complete, the equipment and/or facility is first placed in operation, and the equipment and/or facility first reaches the target production rate.
2. Pursuant to §19.410(B) of Regulation 19, 40 CFR Part 52, Subpart E, the Director may cancel all or part of this permit if the construction or modification authorized herein is not begun within 18 months from the date of the permit issuance if the work involved in the construction or modification is suspended for a total of 18 months or more.
3. Pursuant to §19.702 of Regulation 19 and/or §18.1002 of Regulation 18 and A.C.A. §8-4-203 as referenced by A.C.A. §8-4-304 and §8-4-311, any equipment that is to be tested, unless stated in the Specific Conditions of this permit or by any federally regulated requirements, shall be tested with the following time frames: (1) Equipment to be constructed or modified shall be tested within sixty (60) days of achieving the maximum production rate, but in no event later than 180 days after initial start-up of the permitted source or (2) equipment already operating shall be tested according to the time frames set forth by the Department. The permittee shall notify the Department of the scheduled date of compliance testing at least fifteen (15) days in advance of such test. Compliance test results shall be submitted to the Department within thirty (30) days after the completed testing.
4. Pursuant to §19.702 of Regulation 19 and/or §18.1002 of Regulation 18 and A.C.A. §8-4-203 as referenced by A.C.A. §8-4-304 and §8-4-311, the permittee shall provide:
a. Sampling ports adequate for applicable test methods
b. Safe sampling platforms
c. Safe access to sampling platforms
d. Utilities for sampling and testing equipment
5. Pursuant to §19.303 of Regulation 19 and A.C.A. §8-4-203 as referenced by A.C. A. §8-4-304 and §8-4-311, the equipment, control apparatus and emission monitoring equipment shall be operated within their design limitations and maintained in good condition at all times.
6. Pursuant to Regulation 26 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, this permit subsumes and incorporates all previously issued air permits for this facility.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 7. Pursuant to §18.801 of Regulation #18, the permittee shall not cause or permit the emission
of air contaminants, including odors or water vapor and including an air contaminant whose emission is not otherwise prohibited by Regulation #18, if the emission of the air contaminant constitutes air pollution within the meaning of A.C.A. §8-4-303.
8. Pursuant to §18.801 of Regulation #18, the permittee shall not cause or permit the emission of air contaminants, including odors or water vapor and including an air contaminant whose emission is not otherwise prohibited by Regulation #18, if the emission of the air contaminant constitutes air pollution within the meaning of A.C.A. §8-4-303.
9. Pursuant to §18.901 of Regulation #18, the permittee shall not conduct operations in such a manner as to unnecessarily cause air contaminants and other pollutants from becoming airborne.
10. Pursuant to §18.501 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 5% opacity from Filter Room #1 (SN-39 and SN-40 discharge to this filter room). Opacity shall be measured by EPA Reference Method 9.
11. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall conduct weekly observations of the opacity from Filter Room #1 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
12. Pursuant to §18.501 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 5% opacity from Filter Room #2 (SN-06, SN-14, and SN-38 discharge to this filter room). Opacity shall be measured by EPA Reference Method 9.
13. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall conduct weekly observations of the opacity from Filter Room #2 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
14. Pursuant to §18.501 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 5% opacity from Filter Room #3 (SN-39 and SN-40 discharge to this filter room). Opacity shall be measured by EPA Reference Method 9.
15. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall conduct weekly observations of the opacity from Filter Room #3 and keep a record of these observations. If visible emissions are detected, then the permittee shall conduct a 6-minute opacity reading in accordance with EPA Reference
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
Method 9. The results of these observations shall be kept on site and shall be made available to Department personnel upon request.
16. Pursuant to §18.801 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall not exceed 0.424 pounds of methylene diphenyl diisocyantate (MDI) usage during any 24-hour period.
17. Pursuant to §18.1004 of Regulation #18 and A.C.A. §8-4-203 as referenced by §8-4-304 and §8-4-311, the permittee shall maintain records to demonstrate compliance with the methylene diphenyl diisocyanate limit in Plantwide Condition #16. These records shall be updated daily, kept on site, and made available to Department personnel upon request.
18. Pursuant to §19.705 of Regulation 19 and 40 CFR Part 52 Subpart E, the semi-annual reports required by this permit shall be submitted to the Department at the address listed in General Provision #7 by July 31 and January 31 of each calendar year.
19. Pursuant to §26.1011 of Regulation 26, prior to July 1, 2005, the facility shall prepare and submit an application to the Department for the incorporation of the requirements of 40 CFR Part 63 Subpart MMMM - National Emission Standards for Hazardous Air Pollutants: Surface Coating of Miscellaneous Metal Parts and Products. This application shall also indicate whether 90% or more of the surface coating operations at the facility are metal parts surface coating rather than plastic parts coating. If less than 90% of the coating activities are performed upon metal parts, then this application shall also address the incorporation of the requirements of 40 CFR Part 63 Subpart PPPP - National Emission Standards for Hazardous Air Pollutants: Surface Coating of Plastic Parts and Products.
Title VI Provisions 20. The permittee shall comply with the standards for labeling of products using ozone
depleting substances pursuant to 40 CFR Part 82, Subpart E:
a. All containers containing a class I or class II substance stored or transported, all products containing a class I substance, and all products directly manufactured with a class I substance must bear the required warning statement if it is being introduced to interstate commerce pursuant to §82.106.
b. The placement of the required warning statement must comply with the requirements pursuant to §82.108.
c. The form of the label bearing the required warning must comply with the requirements pursuant to §82.110.
d. No person may modify, remove, or interfere with the required warning statement except as described in §82.112.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 21. The permittee shall comply with the standards for recycling and emissions reduction
pursuant to 40 CFR Part 82, Subpart F, except as provided for MVACs in Subpart B:
a. Persons opening appliances for maintenance, service, repair, or disposal must comply with the required practices pursuant to §82.156.
b. Equipment used during the maintenance, service, repair, or disposal of appliances must comply with the standards for recycling and recovery equipment pursuant to §82.158.
c. Persons performing maintenance, service repair, or disposal of appliances must be certified by an approved technician certification program pursuant to §82.161.
d. Persons disposing of small appliances, MVACs, and MVAC-like appliances must comply with record keeping requirements pursuant to §82.166. (“MVAC-like appliance” as defined at §82.152.)
e. Persons owning commercial or industrial process refrigeration equipment must comply with leak repair requirements pursuant to §82.156.
f. Owners/operators of appliances normally containing 50 or more pounds of refrigerant must keep records of refrigerant purchased and added to such appliances pursuant to §82.166.
22. If the permittee manufactures, transforms, destroys, imports, or exports a class I or class II substance, the permittee is subject to all requirements as specified in 40 CFR part 82, Subpart A, Production and Consumption Controls.
23. If the permittee performs a service on motor (fleet) vehicles when this service involves ozone-depleting substance refrigerant (or regulated substitute substance) in the motor vehicle air conditioner (MVAC), the permittee is subject to all the applicable requirements as specified in 40 CFR part 82, Subpart B, Servicing of Motor Vehicle Air Conditioners.The term “motor vehicle” as used in Subpart B does not include a vehicle in which final assembly of the vehicle has not been completed. The term “MVAC” as used in Subpart B does not include the air-tight sealed refrigeration system used as refrigerated cargo, or the system used on passenger buses using HCFC-22 refrigerant.
24. The permittee shall be allowed to switch from any ozone-depleting substance to any alternative that is listed in the Significant New Alternatives Program (SNAP) promulgated pursuant to 40 CFR part 82, Subpart G, Significant New Alternatives Policy Program.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION VII: INSIGNIFICANT ACTIVITIES Pursuant to §26.304 of Regulation 26, the following sources are insignificant activities. Any activity for which a state or federal applicable requirement applies is not insignificant even if this activity meets the criteria of §304 of Regulation 26 or is listed below. Insignificant activity determinations rely upon the information submitted by the permittee in an application dated May 14, 2003.
Description Category
Laboratory Equipment used for routine chemical or physical analysis
A-5
Cured Part Grinding A-13
Sandblaster A-13
Mold Oven (former SN-09) A-13
Compounding Area (former SN-14) A-13
Pin Barrel Tuber (former SN-34) A-13
Preformer Extruder former SN-35) A-13
Mold Cleaner (former SN-17) A-13
Wheelabrator (former SN-18) A-13
10,000 gal. process oil storage tanks (former SN-21a, 21b, 21c)
A-3
8,820 gal. waste oil storage tank (former SN-22) A-3
Caustic Cleaning/Phosphate Line (former SN-32) A-13
Carbon Black Handling System (former SN-38) A-13
Mixer Dip Mixing and Dip Tank (former SN-39) A-13
Mixing Area Vacuum System (former SN-40) A-13
Pursuant to §26.304 of Regulation 26, the emission units, operations, or activities contained in Regulation 19, Appendix A, Group B, have been determined by the Department to be insignificant activities. Activities included in this list are allowable under this permit and need not be specifically identified.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
SECTION VIII: GENERAL PROVISIONS 1. Any terms or conditions included in this permit which specify and reference Arkansas
Pollution Control & Ecology Commission Regulation 18 or the Arkansas Water and Air Pollution Control Act (A.C.A. §8-4-101 et seq.) as the sole origin of and authority for the terms or conditions are not required under the Clean Air Act or any of its applicable requirements, and are not federally enforceable under the Clean Air Act. Arkansas Pollution Control & Ecology Commission Regulation 18 was adopted pursuant to the Arkansas Water and Air Pollution Control Act (A.C.A. §8-4-101 et seq.). Any terms or conditions included in this permit which specify and reference Arkansas Pollution Control & Ecology Commission Regulation 18 or the Arkansas Water and Air Pollution Control Act (A.C.A. §8-4-101 et seq.) as the origin of and authority for the terms or conditions are enforceable under this Arkansas statute.[40 CFR 70.6(b)(2)]
2. This permit shall be valid for a period of five (5) years beginning on the date this permit
becomes effective and ending five (5) years later. [40 CFR 70.6(a)(2) and §26.701(B) of the Regulations of the Arkansas Operating Air Permit Program (Regulation 26), effective August 10, 2000]
3. The permittee must submit a complete application for permit renewal at least six (6)
months before permit expiration. Permit expiration terminates the permittee’s right to operate unless the permittee submitted a complete renewal application at least six (6) months before permit expiration. If the permittee submits a complete application, the existing permit will remain in effect until the Department takes final action on the renewal application. The Department will not necessarily notify the permittee when the permit renewal application is due. [Regulation 26, §26.406]
4. Where an applicable requirement of the Clean Air Act, as amended, 42 U.S.C. 7401, et
seq. (Act) is more stringent than an applicable requirement of regulations promulgated under Title IV of the Act, the permit incorporates both provisions into the permit, and the Director or the Administrator can enforce both provisions. [40 CFR 70.6(a)(1)(ii) and Regulation 26, §26.701(A)(2)]
5. The permittee must maintain the following records of monitoring information as required
by this permit. [40 CFR 70.6(a)(3)(ii)(A) and Regulation 26, §26.701(C)(2)] a. The date, place as defined in this permit, and time of sampling or measurements; b. The date(s) analyses performed; c. The company or entity performing the analyses; d. The analytical techniques or methods used; e. The results of such analyses; and f. The operating conditions existing at the time of sampling or measurement.
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 6. The permittee must retain the records of all required monitoring data and support
information for at least five (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 continuous monitoring instrumentation, and copies of all reports required by this permit. [40 CFR 70.6(a)(3)(ii)(B) and Regulation 26, §26.701(C)(2)(b)]
7. The permittee must submit reports of all required monitoring every six (6) months. If
permit establishes no other reporting period, the reporting period shall end on the last day of the anniversary month of the initial Title V permit. The report is due within thirty (30) days of the end of the reporting period. Although the reports are due every six months, each report shall contain a full year of data. The report must clearly identify all instances of deviations from permit requirements. A responsible official as defined in Regulation No. 26, §26.2 must certify all required reports. The permittee will send the reports to the address below: [40 C.F.R. 70.6(a)(3)(iii)(A) and Regulation 26, §26.701(C)(3)(a)]
Arkansas Department of Environmental Quality Air Division ATTN: Compliance Inspector Supervisor Post Office Box 8913 Little Rock, AR 72219
8. The permittee shall report to the Department all deviations from permit requirements,
including those attributable to upset conditions as defined in the permit. The permittee shall make an initial report to the Department by the next business day after the discovery of the occurrence. The initial report may be made by telephone and shall include:
a. The facility name and location b. The process unit or emission source deviating from the permit limit, c. The permit limit, including the identification of pollutants, from which deviation
occurs, d. The date and time the deviation started, e. The duration of the deviation, f. The average emissions during the deviation, g. The probable cause of such deviations, h. Any corrective actions or preventive measures taken or being taken to prevent
such deviations in the future, and i. The name of the person submitting the report.
The permittee shall make a full report in writing to the Department within five (5) business days of discovery of the occurrence. The report must include, in addition to the information required by the initial report, a schedule of actions taken or planned to eliminate future occurrences and/or to minimize the amount the permit’s limits were exceeded and to reduce the length of time the limits were exceeded. The permittee may
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
submit a full report in writing (by facsimile, overnight courier, or other means) by the next business day after discovery of the occurrence, and the report will serve as both the initial report and full report. [40 CFR 70.6(a)(3)(iii)(B), Regulation 26, §26.701(C)(3)(b), Regulation 19, §19.601 and §19.602]
9. If any provision of the permit or the application thereof to any person or circumstance is
held invalid, such invalidity will not affect other provisions or applications hereof which can be given effect without the invalid provision or application, and to this end, provisions of this Regulation are declared to be separable and severable. [40 CFR 70.6(a)(5), Regulation 26, §26.701(E), and A.C.A. §8-4-203 as referenced by A.C.A. §8-4-304 and §8-4-311]
10. The permittee must comply with all conditions of this Part 70 permit. Any permit
noncompliance with applicable requirements as defined in Regulation 26 constitutes a violation of the Clean Air Act, as amended, 42 U.S.C. §7401, et seq. and is grounds for enforcement action; for permit termination, revocation and reissuance, for permit modification; or for denial of a permit renewal application. [40 CFR 70.6(a)(6)(i) and Regulation 26, §26.701(F)(1)]
11. It shall not be a defense for a permittee in an enforcement action that it would have been
necessary to halt or reduce the permitted activity to maintain compliance with the conditions of this permit. [40 CFR 70.6(a)(6)(ii) and Regulation 26, §26.701(F)(2)]
12. The Department may modify, revoke, reopen and reissue the permit or terminate the
permit for cause. The filing of a request by the permittee for a permit modification, revocation and reissuance, termination, or of a notification of planned changes or anticipated noncompliance does not stay any permit condition. [40 CFR 70.6(a)(6)(iii) and Regulation 26, §26.701(F)(3)]
13. This permit does not convey any property rights of any sort, or any exclusive privilege.
[40 CFR 70.6(a)(6)(iv) and Regulation 26, §26.701(F)(4)] 14. The permittee must furnish to the Director, within the time specified by the Director, any
information that the Director may request in writing to determine whether cause exists for modifying, revoking and reissuing, or terminating the permit or to determine compliance with the permit. Upon request, the permittee must also furnish to the Director copies of records required by the permit. For information the permittee claims confidentiality, the Department may require the permittee to furnish such records directly to the Director along with a claim of confidentiality. [40 CFR 70.6(a)(6)(v) and Regulation 26, §26.701(F)(5)]
15. The permittee must pay all permit fees in accordance with the procedures established in
Regulation 9. [40 CFR 70.6(a)(7) and Regulation 26, §26.701(G)]
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036 16. No permit revision shall be required, under any approved economic incentives,
marketable permits, emissions trading and other similar programs or processes for changes provided for elsewhere in this permit. [40 CFR 70.6(a)(8) and Regulation 26, §26.701(H)]
17. If the permit allows different operating scenarios, the permittee shall, contemporaneously
with making a change from one operating scenario to another, record in a log at the permitted facility a record of the operational scenario. [40 CFR 70.6(a)(9)(i) and Regulation 26, §26.701(I)(1)]
18. The Administrator and citizens may enforce under the Act all terms and conditions in this
permit, including any provisions designed to limit a source’s potential to emit, unless the Department specifically designates terms and conditions of the permit as being federally unenforceable under the Act or under any of its applicable requirements. [40 CFR 70.6(b) and Regulation 26, §26.702(A) and (B)]
19. Any document (including reports) required by this permit must contain a certification by
a responsible official as defined in Regulation 26, §26.2. [40 CFR 70.6(c)(1) and Regulation 26, §26.703(A)]
20. The permittee must allow an authorized representative of the Department, upon
presentation of credentials, to perform the following: [40 CFR 70.6(c)(2) and Regulation 26, §26.703(B)]
a. Enter upon the permittee’s premises where the permitted source is located or emissions related activity is conducted, or where records must be kept under the conditions of this permit;
b. Have access to and copy, at reasonable times, any records required under the conditions of this permit;
c. Inspect at reasonable times any facilities, equipment (including monitoring and air pollution control equipment), practices, or operations regulated or required under this permit; and
d. As authorized by the Act, sample or monitor at reasonable times substances or parameters for assuring compliance with this permit or applicable requirements.
21. The permittee shall submit a compliance certification with the terms and conditions
contained in the permit, including emission limitations, standards, or work practices. The permittee must submit the compliance certification annually within 30 days following the last day of the anniversary month of the initial Title V permit. The permittee must also submit the compliance certification to the Administrator as well as to the Department. All compliance certifications required by this permit must include the following: [40 CFR 70.6(c)(5) and Regulation 26, §26.703(E)(3)]
a. The identification of each term or condition of the permit that is the basis of the
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
certification; b. The compliance status; c. Whether compliance was continuous or intermittent; d. The method(s) used for determining the compliance status of the source, currently
and over the reporting period established by the monitoring requirements of this permit;
e. and Such other facts as the Department may require elsewhere in this permit or by §114(a)(3) and §504(b) of the Act.
22. Nothing in this permit will alter or affect the following: [Regulation 26, §26.704(C)] The
provisions of Section 303 of the Act (emergency orders), including the authority of the Administrator under that section; the liability of the permittee for any violation of applicable requirements prior to or at the time of permit issuance; the applicable requirements of the acid rain program, consistent with §408(a) of the Act or, the ability of EPA to obtain information from a source pursuant to §114 of the Act.
23. This permit authorizes only those pollutant emitting activities addressed in this permit.
[A.C.A. §8-4-203 as referenced by A.C.A. §8-4-304 and §8-4-311]
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
APPENDIX A
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Cooper-Standard Automotive Company, NHV Division Permit No. 818-AOP-R6 AFIN: 70-00036
ATTACHMENT TWO
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