how to establish pte - mec seminars · on how to establish potential to emit (pte) for your...

Workshop E

Best Practices in Air Permitting & Compliance … Invaluable Guidance

on How to Establish Potential to Emit (PTE) for Your Facility

Wednesday, July 19, 2017 2:45 p.m. to 4:15 p.m.

Biographical Information

William J. Bruscino, C.M., Columbus Office Manager Trinity Consultants, 110 Polaris Parkway, Suite 200, Westerville, Ohio 43085

614.433.0733 Fax: 614.433.0734 [email protected] Mr. Bruscino manages air quality permitting and compliance services for industries such as refining, chemical manufacturing upstream and midstream oil and gas, and general manufacturing. His experience includes Title V and PSD permitting in EPA Regions IV, V, and VI as well as compliance assessments and implementation projects. Mr. Bruscino has recently been directing efforts for numerous energy audits required by the Boiler MACT rule as well as general 3rd party compliance audits throughout the state of Ohio. He has also assisted multiple facilities in establishing Title V and minor source air compliance programs including environmental management information system (EMIS) implementations. Mr. Bruscino currently manages Trinity’s Columbus, Ohio office and is a member of the Air & Waste Management Association. He received a Bachelor’s degree in chemical engineering from the University of Cincinnati.

Jarod W. Gregory, Consultant, Trinity Consultants 1717 Dixie Hwy. S. Ste. 900, Covington, KY 41011

859-341-8100 [email protected]

Jarod Gregory is a Consultant in Trinity Consultants’ Greater Cincinnati/Northern Kentucky office. He provides a wide array of support and solutions to both Kentucky and Ohio clients including state and federal air quality permitting, NSPS and MACT compliance assistance, emission inventory development, and TRI reporting. He focuses primarily on air quality support for the chemical manufacturing and refining industries. He holds a B.S. in Chemical Engineering and M.S. in Environmental Engineering from the University of Cincinnati.

Lisa Roberts, Environmental Manager, WILD Flavors, Inc.

1261 Pacific Ave., Erlanger, KY 41018 859-342-3778 FAX: 859-342-3795 [email protected]

Ms. Roberts is the environmental manager for the US locations of WILD Flavors, Inc., part of Archer Daniels Midland’s Wild Flavors & Specialty Ingredients Division. Prior to her role with WILD she was environmental manager of the ADM oilseed processing complex in Valdosta, GA. She started at the Valdosta location in 2007 as a production engineer, then served as the Environmental, Safety and Food Safety Coordinator before focusing on environmental compliance. Before joining ADM she was an engineer in Kentucky Division for Air Quality’s Emissions Inventory section. Ms. Roberts graduated with a B.S in Chemical Engineering from the University of Kentucky in 2005.

27th Annual Conference on Air & Water Permits –

Environmental Permitting in Ohio

Workshop E – Best Practices in Air Permitting & Compliance – Potential to Emit Focus

July 19, 2017

How fast did you drive here?

Evan Klein, Road and Trackhttp://www.roadandtrack.com/car‐culture/a25775/almost‐infamous‐2015‐lamborghini‐huracan/

How fast did you drive here?SPEEDLIMIT

35

SPEEDLIMIT

65

SPEEDLIMIT

25

SPEEDLIMIT

35 EXIT

DistanceD

(mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 35.0 0.5

195.0 65.0 3.0 17.5 35.0 0.5 12.5 25.0 0.5

242.5 53.9 4.5

Distance(mi)

Emission Factor (g/mi)

CO Emissions

(lbs)17.5 6.400 0.247

195.0 9.500 4.084 17.5 6.400 0.247 12.5 6.300 0.174

242.5 9.061 4.8 lb/yr At 4.5 hr/yrPotential Emissions => 9,250 lb/yr At 8,760 hrs/yr

4.6 tpy At 8,760 hrs/yr

What is the potential to emit (PTE)?

SPEEDLIMIT

40

SPEEDLIMIT

80

SPEEDLIMIT

35

SPEEDLIMIT

40 EXIT

How fast did you drive here?Distance

D (mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 40.0 0.4

195.0 80.0 2.4 17.5 40.0 0.4 12.5 35.0 0.4

242.5 66.1 3.7 What is the potential to emit (PTE)?

Distance(mi)


CO Emissions

(lbs)17.5 6.900 0.266

195.0 16.000 6.878 17.5 6.900 0.266 12.5 6.400 0.176



Evan Klein, Road and Trackhttp://www.roadandtrack.com/car‐culture/a25775/almost‐infamous‐2015‐lamborghini‐huracan/

SPEEDLIMIT

180

SPEEDLIMIT

180

SPEEDLIMIT

180

SPEEDLIMIT

180 EXIT


D (mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 180.0 0.1

195.0 180.0 1.1 17.5 180.0 0.1 12.5 180.0 0.1

242.5 180.0 1.3 What is the potential to emit (PTE)?

Distance(mi)


CO Emissions

(lbs)17.5 60.00 2.315

195.0 60.00 25.794 17.5 60.00 2.315 12.5 60.00 1.653



General Provisions PTE Definition

Per 3745‐15‐05(A)Potential to emit or potential emissions shall mean the amount of emissions of an air contaminant which would be emitted from a source during a 24-hour calendar day or calendar year basis, whichever is applicable, if that source were operated without the use of air pollution control equipment unless such control equipment is, aside from air pollution control requirements, necessary for the facility to produce its normal product or is integral to the normal operation of the source. Potential emissions shall be based on maximum rated capacity.

Permit to Install PTE Definition

Per 3745‐31‐01(VVVV)Potential to emit means the maximum capacity of an emissions unit or stationary source to emit an air pollutant under its physical and operational design. Any physical or operational limitation on the capacity of the emissions unit orstationary source to emit an air pollutant, which includes any federally regulated air pollutant, including air pollution control equipment and restrictions on hours of operation or on the type or amount of material combusted, stored or processed, shall be treated as part of its design if the limitation or the effect it would have on emissions is federally enforceable or legally and practicably enforceable by the state. Secondary emissions do not count in determining the potential to emit of a stationary source.

Title V Permit PTE Definition

Per 3745‐77‐01(CC)Potential to emit means the maximum capacity of a stationary source to emit any air pollutant under its physical and operational design. Any physical or operational limitation on the capacity of a source to emit an air pollutant, including air pollution control equipment and restrictions on hours of operation or on the type or amount of material combusted, stored, or processed, shall be treated as part of its design if the limitation or the effect it would have on emissions is federally enforceable or legally and practicably enforceable by the state. Secondary emissions do not count in determining the potential to emit of a stationary source.


D (mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 180.0 0.1

195.0 180.0 1.1 17.5 180.0 0.1 12.5 180.0 0.1

242.5 180.0 1.3

DistanceD

(mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 40.0 0.4

195.0 80.0 2.4 17.5 40.0 0.4 12.5 35.0 0.4

242.5 66.1 3.7

DistanceD

(mi)

SpeedR

(mi/hr)

TimeT

(hr)17.5 35.0 0.5

195.0 65.0 3.0 17.5 35.0 0.5 12.5 25.0 0.5

242.5 53.9 4.5

Distance(mi)


CO Emissions

(lbs)17.5 6.400 0.247

195.0 9.500 4.084 17.5 6.400 0.247 12.5 6.300 0.174



Distance(mi)


CO Emissions

(lbs)17.5 6.900 0.266

195.0 16.000 6.878 17.5 6.900 0.266 12.5 6.400 0.176



Distance(mi)


CO Emissions

(lbs)17.5 60.00 2.315

195.0 60.00 25.794 17.5 60.00 2.315 12.5 60.00 1.653

242.5 60.00 32.1 lb/yr At 4Potential Emissions => 208,576 lb/yr At 8

104.3 tpy At 8

What is the potential to emit (PTE)?

Importance of Source Classification Firstquestionindeterminingapplicabilitytoairregulationsand/orpermittingrequirements:“Whatismysourceclassification?”

Keyconceptstounderstandtoanswer: Meaningofterm“source” Distinguishbetweensourceclassificationbasedon♦ dateofconstruction/modification♦ emissions

Multiple Uses of Term “Source”

Differentcriteriafordifferentregulatoryprograms

Needtounderstandtheunderlyingregulationorpermittingprogrambeingconsidered Incontextofairpermittingprograms,“source”typicallyreferstothefacility

Incontextofparticularairregulations(e.g.,NSPS,NESHAP),“source”typicallyreferstospecificsubsetofequipmentatafacility

Source Classificationwith Respect to Construction Date

Sourceclassificationtiersforfacilities,processes,orindividualemissionunits: NewSource ExistingSource,NotGrandfathered ExistingSource,Grandfathered

Eachregulatoryprogramwillhaveitsowncriteriafordefiningtheseclassifications

Keydateisgenerallywhenregulationisproposed

Source Classificationwith Respect to Emissions

Threegeneralsourceclassificationtiersforfacilitiesasawhole: Major SyntheticMinor TrueMinor

Eachregulatoryprogramcanhaveitsownthresholds

“PotentialtoEmit”comparedtothresholds

Potential to Emit

Maximumcapacitytoemit Maybelimitedby:

Physicalandoperationallimits Airpollutioncontrolequipment Restrictedhoursofoperation Typeoramountofmaterialcombusted,stored,orprocessed

Limitationsmustbeenforceable

Enforceable Limitations - How?

Twoqualifiers Operatingand/oremissionlimitsinanairpermitundergoingpublicnotice

Appropriatetesting,monitoring&recordkeepingtoensurecompliancecanbedemonstrated

Potential to Emit Example - Steam Boiler (1 of 2)

Specifications Equippedtofirefueloil Maximumdesignheatinputratingof50MMBtu/hr Equippedwithacausticscrubber

Boileroperatingandtestdata PMfromstacktestingmeasuredat0.05lb/MMBtu Boilerfired2milliongallonsofoilin2010 Oilheatingvalueis0.148MMBtu/gal

Permitconditions BoilerissubjecttoaPMemissionstandardof0.1lb/MMBtu Nootherrestrictionsonoperations

Potential to Emit Example - Steam Boiler (2 of 2)

Doesactualfuelusage(utilization)ortrueemissionfactormatter?

Doesactualuptimeoperatinghoursmatter?

Doyouhavetoconsideremissionsfromotherfuels?

HowdoyouaccountforPMcontrolfromthescrubber?

Potential to Emit Example - Steam Boiler ActualPMemissionsfor2010:

PotentialtoEmitforPM:

tpy 7.4 lb 2000

tonMMBtu

lb 05.0galMMBtu 148.0

yrgal 102 6

tpy 21.9 lb 2000

ton yr

hr 8760MMBtu

lb 1.0hr

MMBtu 50

How to Calculate PTE

1. Conductafacility‐wideinventoryofemissionsources

2. Identifyanylegallyenforceablelimitations

3. Chooseemissioncalculationmethodologies

4. Gathernecessaryprocessdata5. CalculatePTEforeachemissionsource6. Calculatetotalsite‐widePTEforthefacility

“True Minor” Source

Source’sPotentialToEmitislessthanthemajorsourcethreshold,evenwithoutanyfederallyenforceablelimitsonemissionsand/oroperations Sometimesreferredtoasa“naturalminor”

“Synthetic Minor” Source

ActualemissionsarelessthanmajorsourcelevelsbutPotentialtoEmitisgreaterthanmajorsourcelevels

Asyntheticminorsourceisonethathaschosen toreduceitsPTEtominorsourcelevelsfrommajorsourcelevelsbyacceptingenforceablelimitsonemissionsand/oroperations

Major Source

Source’sPTEexceedsmajorsourcethresholds

Sourcecannotorchoosesnottoproposelimitsonemissionsand/oroperationstoreduceitsPTE

Example: Title V Program Major Source (40 CFR 70.2) MajorSourceCriteria:

Contiguous/adjacent,commoncontrol,same2‐digitSICcode

MajorSourceThresholds: >100tpyforanyairpollutant,or >10tpyforanysingleHAP,or>25tpyinaggregate

Fugitives:Includeonlyforcertainsourcecategories

Example: NESHAP Program Major Source (40 CFR 63.2) MajorSourceCriteria:

Stationarysourceorgroupofstationarysourceslocatedwithinacontiguousareaandundercommoncontrol

MajorSourceThresholds: >10tpyforanysingleHAP,or >25tpyforanycombinationofHAPs

Fugitives:Includeincalculation

Major Stationary Source Under NSR/PSD Program Stationarysourcesthathavepotentialtoemit(PTE)oneormoreregulatedNSRpollutants exceeding:

Note:Ifmajorforonepollutant,thenplantistreatedasamajorsourceforallpollutants

Threshold Criteria100 tpy If on “List of 28” named source categories

• Hard coded in Clean Air Act at 42 USC 7479• See 3745-31-01(NNN), includes “Chemical

process plants except for ethanol production facilities that produce ethanol by natural fermentation included in NAICS codes 325193 or 312140”

250 tpy If NOT on “List of 28”

List of 28 (100 tpy Threshold)1. Coal cleaning plants (with thermal dryers) 15. Coke oven batteries

2. Kraft pulp mills 16. Sulfur recovery plants

3. Portland cement plants 17. Carbon black plants (furnace process)

4. Primary zinc smelters 18. Primary lead smelters

5. Iron and steel mills 19. Fuel conversion plants

6. Primary aluminum ore reduction plants 20. Sintering plants

7. Primary copper smelters 21. Secondary metal production plants

8. Municipal incinerators capable of charging more than 250 tons of refuse per day

22. Chemical process plants

9. Hydrofluoric acid plants 23. Petroleum storage and transfer units with a total storage capacity exceeding 300,000 barrels

10. Sulfuric acid plants 24. Taconite ore processing plants

11. Nitric acid plants 25. Glass fiber processing plants

12. Petroleum refineries 26. Charcoal production plants

13. Lime plants 27. Fossil fuel-fired steam electric plants of more than 250 million British thermal units (BTU) per hour heat input

14. Phosphate rock processing plants 28. Fossil-fuel boilers (or combination thereof) totaling more than 250 million BTU/ hour heat input

PSD Applies if… NewSources:Plantwillbeanewmajorstationarysource

NewSourcePTE≥100or250tpy (dependingonListof28status) ExistingMinorSources:Makeamodificationthatinitselfis“major” Projectemissionsincreaseforonepollutant≥100or250tpy

♦ Notethatinthiscase,applicabilitythresholdforotherpollutantsdropstoSignificantEmissionRates

♦ Nonettingallowed ExistingMajorStationarySources:MakeamodificationthatexceedsPSDSignificantEmissionRates 15tpyforPM10,10tpyforPM2.5,40tpyforVOC,NOX,orSO2,100tpy

forCO,etc. Mayattempt“net‐out”ofPSDreviewwithcontemporaneous

decreases

Further Potential to Emit Examples and Case Studies

Potential to Emit Limitations

PTEmaybelimitedby: Physicalandoperationallimits Airpollutioncontrolequipment Restrictedhoursofoperation Typeoramountofmaterialcombusted,stored,orprocessed

Potential to Emit Limitations

KeyDefinitions: ContinuousOperation‐ Processesforwhichfeedandproductoutputhappensimultaneously

BatchOperation‐ Processesforwhichproductionoccursindiscretebatches

Physical and Operational Limitations Physicalandoperationallimitationsmustbeequipment‐basedandnotmarket‐based OperationalbottlenecksareajustifiablereasontolimitPTE

Nothavingenoughcustomerstooperate3shiftsperdayisnotalimittoPTE

Example 1 – PTE Limitations

Biodieselproduction(continuous)

5,000‐Gal

Glycerin Tanks

Separation Vessel

Biodiesel Pipeline

Glycerin

TransesterificationReactor

90% BD10% GLY

5,000‐Gal

Glycerin Tanks

Separation Vessel

Biodiesel Pipeline

Glycerin


90% BD10% GLY

500 GPM

200 GPM 50 GPM

˃ Based on pumping capacities alone, the transesterification reactor throughput is 750 gpm

˃ The biodiesel pipeline pump limits the transesterification reactor to 550 gpm 500 gpm biodiesel / 90% biodiesel reactor output = 550 gpm

˃ The glycerin tank loading truck limits the transesterification reactor to 500 gpm 50 gpm glycerin / 10% glycerin reactor output = 500 gpm

˃ Truck loading Including the switch-out, it takes 115 minutes to load a truck

♦ 5,000-gal truck / 50 gpm + 15 min switch-out = 115 minutes Therefore, truck loading limits the transesterification reactor to 435 gpm

♦ 5,000 gal / 115 min / 10% glycerin reactor output = 435 gpm

750 GPM

15 min truck switch‐out



Biodieselproduction(continuous)

5,000‐Gal

Glycerin Tanks

Separation Vessel

Biodiesel Pipeline

Glycerin


90% BD10% GLY

391.5 GPM

43.5 GPM 43.5 GPM

435 GPM

Batch Process Limitations

Batchprocesslimitationsareoperationallimitations i.e.,duetothenatureofbatchproduction,thereareinherentbottleneckstoaprocessorequipmenttrain

Batchprocessescannotreceiverawmaterialandproduceproductssimultaneously‐ sohowdoweaccountforthenon‐productiontime?

Example 2 - Batch Processes

Mixing Vessel20 minutes charge time

75 minutes mix time

15 minutes discharge

˃ If a batch is 500 gallons, the maximum throughput is 273 gph 500 gal batch / 110 min x 60 min/hr = 273 gph

Example 2 - Batch Processes

Mixing Vessel20 minutes charge time

75 minutes mix time

15 minutes discharge

˃ In order to produce 3 500-gal batches, 450 min is necessary 110 min x 3 + 120 min per cleaning = 450 min

˃ Thus, the production rate is 200 gph 1,500 gal in 3 batches / 450 min x 60 min/hr = 200 gph

2 hour clean time after every third batch

Batch Processes – Worst Case Emissions Batchprocesscalculationsbecomemorecomplicatedwhendealingwithvariationsthatoftenaccompanybatchproduction Howdoyouhandleprocessesthathave10,20or30+differentrawmaterialsthatchangedependingontheproduct?

Whatifdifferentproductsrequiredifferentperipheralequipmentset‐ups?

Batch Processes – Worst Case Emissions Multipleproductsthatareprocessedinthesameequipment Employthe“Frankenstein”approach

♦ i.e.,quantifyemissionsbyassumingyouruntheworst‐caseVOC‐emittingproductforeverybatch

♦ Repeatthatprocessforeachregulatedcriteriapollutant,HAP,etc.

♦ Combinethemalltogetherforaworst‐caseemissionsprofile

Batch Processes – Worst Case Emissions EquipmentUtilization

LikelythemostcomplicatedbatchprocessPTEcalculation,butcanbeperformedbyanalysisofbatchsheets

InvolvescalculatingPTEforeachcriteriapollutantandHAPbyhypotheticallyconfiguringallavailableequipmentinthewaythatwillmaximizeemissions

Batch Processes – Worst Case Emissions

3 Reactors 2 Mixers

8 Holding Tanks

Product 1

Product 1

Product 2

Real World Examples

HotAirHeater

SprayDryer

NG

Water,solids,flavorconcentrates,etc.

Pump

ProductPackOut

ProductRecoveryCyclone

ToAir

Real World ExamplesHotAirHeater

SprayDryer

NG

Water,solids,flavorconcentrates,etc.

Pump

ProductPackOut

ProductRecoveryCyclone

ToAir

“Frankenstein”ApproachatWILDFlavors Thepumphasacapacityof100gpm ofslurry(i.e.,water,solids,etc.)to

thespraydryer WILDandTrinityconductedathoroughproductformulationsheet

reviewofthehundredsofpotentialproducts Theproductswiththehighestlevelofsolidsinputwerechosento

estimatePMPTE Theproductswiththehighestlevelofsolvents(e.g.,ethanol)werechosen

toestimateVOCemissions

Real World Examples

DryBlender

BulkPowders

Wastewater

Cyclone

ToAtmosphere

SmallHandAdditions

ProductPackOut

H2O

Real World Examples

DryBlender

BulkPowders

Wastewater

Cyclone

ToAtmosphere

SmallHandAdditions

ProductPackOut

H2O

Thedryblendersmayproducemanydifferentproducts,buteachhavethesameproductionrate Thus,thePMemissionswouldnotvaryfromproducttoproduct Asabatchprocess,thenecessarycleaningtimewasincorporatedin

tothePTEproductionratecalculation Inordertoassessemissions,WILDandTrinityusedacombinationof

AP‐42andprocessdatatocreateamassbalance

Real World Examples

2FixedVesselsand

3PortableVessels

Water

SubmergedFill(LiqA&B)

DrumsofVariousIngredients Filtration

(optional)

EthanolorPropyleneGlycol

SmallHandAdditions

Real World Examples

2FixedVesselsand

3PortableVessels

Water

SubmergedFill(LiqA&B)

DrumsofVariousIngredients Filtration

(optional)

EthanolorPropyleneGlycol

SmallHandAdditions

Thewetmixingareawasassessedforworst‐caseVOCemissions Thechosenproductwas

theonewiththemostethanolasarawingredient

Therestofthecalculationprocessinvolveddeterminingtheequipmentconfigurationthatwouldresultinthemosttotalethanolpassingthroughthemixingarea

Questions?

Bill BruscinoTrinity – Columbus

(614) [email protected]

Jarod GregoryTrinity - Kentucky

(859) 341-8100 [email protected]

Lisa RobertsWILD Flavors & Specialty Ingredients

(859) [email protected]

how to establish pte - mec seminars · on how to establish potential to emit (pte) for your...

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