ALLEGHENY COUNTY HEALTH DEPARTMENTNeville Chemical Company TVOP #0060 Page 3 Technical Support Document 21. Correspondence, dated July 15, 2013 (Unit 20 feedstocks) 22. Correspondence,

ALLEGHENY COUNTY HEALTH DEPARTMENT

AIR QUALITY PROGRAM

September 28, 2015

SUBJECT: Neville Chemical Company

2800 Neville Road

Pittsburgh, PA 15225-1496

Allegheny County

Title V Operating Permit No. 0060

TO: Sandra L. Etzel

Chief Engineer

FROM: JoAnn Truchan, P.E.

Air Quality Engineer

FACILITY DESCRIPTION: ........................................................................................... 2

PERMIT APPLICATION COMPONENTS: ................................................................. 2

DETERMINATIONS ................................................................................................. 3 OLDER PERMITS .................................................................................................... 4

EMISSION SOURCES: ................................................................................................... 6

STACKS: ......................................................................................................................... 12

METHOD OF DEMONSTRATING COMPLIANCE: ............................................... 14

REGULATORY APPLICABILITY: ............................................................................ 15

EMISSION CALCULATIONS: .................................................................................... 17

HEAT POLYMERIZATION STILLS .......................................................................... 17 CATALYTIC RESIN AND POLYOIL NEUTRALIZATION – UNIT #20 ......................... 20 CATALYTIC RESIN AND POLYOIL NEUTRALIZATION – UNIT #21 ......................... 25 CONTINUOUS STILLS - #3 & #4 ............................................................................ 30 PACKAGING CENTERS.......................................................................................... 31 HEAT POLY STILL PROCESS HEATERS ................................................................. 35 CONTINUOUS STILL PROCESS HEATERS .............................................................. 36 PACKAGING CENTER HEATERS ............................................................................ 37 WASTEWATER COLLECTION, CONVEYANCE, AND TREATMENT........................... 37 RESIN REWORK TANKS ....................................................................................... 38 FINAL PRODUCT LOADING................................................................................... 40 BOILERS .............................................................................................................. 42 STORAGE TANKS ................................................................................................. 42 EQUIPMENT FUGITIVES ........................................................................................ 44 GROUNDWATER REMEDIATION ........................................................................... 45 ALTERNATIVE OPERATING SCENARIO – UNIT #20 AND UNIT #21 ....................... 47

SOURCES OF MINOR SIGNIFICANCE: .................................................................. 52

EMERGENCY GENERATORS ................................................................................. 52 OTHER SOURCES OF MINOR SIGNIFICANCE ......................................................... 53 GREENHOUSE GAS EMISSIONS ............................................................................. 54

EMISSIONS SUMMARY: ............................................................................................. 56

RECOMMENDATION: ................................................................................................. 56

APPENDIX A.1 – REGULATORY TIMELINE (GRAPH) ....................................... 57

APPENDIX A.2 – REGULATORY TIMELINE (TABLE) ........................................ 58

APPENDIX B – IMPLEMENTATION TOOL FOR THE ORGANIC LIQUIDS

DISTRIBUTION NESHAP .............................................................................. 59

Neville Chemical Company TVOP #0060 Page 2 Technical Support Document

FACILITY DESCRIPTION:

Neville Chemical Company, located at 2800 Neville Road, Pittsburgh (Neville Township),

manufactures synthetic hydrocarbon resins, plasticizers, and plasticizing oils. The facility also operates a

groundwater remediation system and wastewater treatment system. Also located at the facility are three (3)

resin flaking and packaging centers, a 49.4 MMBtu/hr and a 29.5 MMBtu/hr natural gas-fired boiler. The

facility is a major source of volatile organic compounds (VOCs); and a minor source of particulate matter (PM),

particulate matter <10 µm in diameter (PM10), particulate matter <2.5 µm in diameter (PM2.5), nitrogen oxides

(NOX), sulfur oxides (SOX), and hazardous air pollutants (HAPs), as defined in §2102.20 of Article XXI.

Prior to May 7, 2008, Neville Chemical was considered a major source of HAP. However, the facility

implemented a series of changes which both decreased the amount of HAP emissions and (in the case of

equipment leaks and fugitive emissions) allowed for more accurate accounting of HAP emissions. These

changes include:

Removal of one heat polymerization still, and connection of the remaining stills to the thermal

oxidizer;

Replacement of the clay-lime neutralization system on Unit 20 with an aqueous neutralization

system;

Switch to raw materials containing fewer HAPs, particularly benzene;

Elimination of the combustion of fuel oil in all process heaters and Boilers No. 6 and No. 8;

Replacement of the Air Stripper with a closed groundwater remediation system;

Modification of the wastewater collection system, including the installation of a roof on the surge

tank, reduction in the number of tank transfers, and a comprehensive study of fugitive emissions in

the collection, conveyance and treatment system;

Implementation of a more comprehensive LDAR program which differentiates HAP emissions and

more accurately reflects actual equipment leak emissions; and

More accurate accounting of tank throughputs, reflecting plant capabilities rather than storage

capacity.

Replaced steam ejectors with vacuum pumps at Heat Poly Stills.

PERMIT APPLICATION COMPONENTS:

1. Title V Operating Permit application, dated May 8, 2008

2. Installation Permit #0060-I001, issued April 30, 1999 (Unit #43)

3. Installation Permit #0060-I002, issued March 24, 1999 (Air Stripper – no longer in operation)

4. Installation Permit #0060-I003a, issued October 4, 2000, amended April 5, 2011 (Boiler #8)

5. Installation Permit #0060-I004a, issued August 2, 2000, amended October 21, 2003 (Tank Area “O”)

6. Installation Permit #0060-I005, withdrawn/not issued (Tank Area “Y”)

7. Installation Permit #0060-I006, issued March 7, 2005 (Connection of Unit Nos. 15, 16, 18, & 19 to the

Thermal Oxidizer)

8. Installation Permit #0060-I007a, issued October 6, 2006, amended November 3, 2006 (No. 2 Packaging

Center)

9. Installation Permit #0060-I008, issued December 16, 2010 (No. 5 Packaging Center)

10. Installation Permit #0060-I009, issued March 18, 2014 (No. 6 Boiler fuel use)

11. RACT Plan Approval and Agreement #230, dated December 13, 1996

12. Stack test report, dated October 16, 2007 (new #2 Packaging Center)

13. Stack test report, dated August 30, 2005 (old #2-2 Packaging Center)

14. Stack test report, dated July 16, 2003 (Unit #43)

15. Stack test report, dated May 17, 1999 (Air Stripper)

16. Stack test report, dated September 10-12, 1997 (Still #18)

17. Fuel analysis reports, dated January 22, 2004 through November 2, 2009 (LX®-830 sulfur content)

18. Analysis of LX®-830 fuel oil, dated June 10, 2008

19. Meeting Minutes, dated from February 24, 2010 through July 22, 2010

20. Correspondence, dated September 29, 2009 through July 26, 2010


21. Correspondence, dated July 15, 2013 (Unit 20 feedstocks)

22. Correspondence, dated April 24, 2015 (shutdown of Clay/Lime Neutralization System)

23. Permits issued prior to 1995 (See Table 1 below)

24. U.S. EPA Implementation Tool for the Organic Liquids Distribution NESHAP, September 2007

Determinations

1. October 31, 2000: Phenol emissions from Resin/Rosin Emulsion Process

Process is shut-down and no longer in operation at the facility.

2. May 11, 2004: Acrylic acid emissions from new storage tank

RFD on 03/14/03 and 04/01/03

Exempted from permitting; tank is included in the equipment list.

3. October 13, 2004: Process holding tank for Unit #20

RFD on 04/29/04 and 07/21/04

Exempted from permitting; included in section V.B of the TVOP, as part of Unit #20.

4. June 3, 2005: New flaking belt in the No. 2 Packaging Center

RFD on 05/26/05

Permit required; IP #0060-I007

5. March 29, 2007: Replacement of Clay/Lime Neutralization with Aqueous Neutralization

RFD on 11/15/06

Revised from determination letter dated 02/20/07.

Aqueous Neutralization System is included in section V.C of the TVOP, as part of Unit #21.

6. September 18, 2007: Change in Unit #20 coolant

RFD on 08/23/07.

Exempted from permitting; does not affect air emissions.

7. November 19, 2007: Temporary installation of a 14.5 MMBtu/hr boiler

RFD on 11/15/07

Short-term project that is no longer in use.

8. January 4, 2008: Replacement of tanks #2282 & 4201

RFD on 12/17/07

Tanks are included in the equipment list.

9. August 18, 2008: Use of one replacement tank for resin former

RFD on 03/18/08

Tank is included in the equipment list.

10. November 16, 2010: Units #20/#21 test trials

RFD on 03/15/10

Short-term project that is no longer in use.

11. January 24, 2012: New raw material in Unit #20

RFD on 11/21/11

Exempted from permitting; new material not being used, so not incorporated into TVOP.

12. January 27, 2012: Replacement burner on No. 3 Process Heater

RFD on 01/26/12

Exempted from permitting; new burner not installed, so not incorporated into TVOP.

13. February 15, 2013: Modification of #4 Aqueous Treater & Agitator operation

RFD on 12/19/12

Exempted from permitting; new configuration included in TVOP as an alternative operating scenario.

14. August 13, 2014: Combining of Unit #20 and Unit #21 processes

RFD on 07/23/14

Permit required; not incorporated into TVOP.

15. October 10, 2014: Replacement burner on No. 3 Process Heater (different rating than 01/26/12 RFD)

RFD on 10/09/14

Exempted from permitting; incorporated into TVOP.


Older Permits

Table 1 contains a list of permits issued prior to 1995, and if applicable, any reasons the permit was not

referenced in the Title V Operating Permit.

Table 1: Permits Issued Prior to 1995

Permit Number Issue

Date Description Reason for Exclusion from TVOP

4051008-000-28700 08/17/1973 Nevillac Reactor - Resin

Production Process no longer in operation.

73-O-0877-P 08/17/1973 No. 16 Still - Resin Production Superseded by permit #4051008-000-42505.

4051008-000-24100 05/06/1973 No. 18 Still Furnace - Oil

Heater Incorporated into the TVOP under section V.K.

73-O-2672-C 03/12/1973 No. 18 Still Furnace - Oil

Heater

73-O-0875-P 08/17/1973 No. 3 Still - Resin Production Incorporated into the TVOP under section V.D.

4051008-000-23900 03/12/1973 No. 4 Boiler Unit no longer in operation.

73-O-2671-C 05/06/1973 No. 4 Boiler

4051008-000-42504 08/17/1973 No. 4 Still - Resin Production Process is no longer in operation, but equipment is

still onsite. A maintenance plan is in place. No. 4

Continuous Still is included in the TVOP under

section V.D. 73-O-0876-P 08/17/1973 No. 4 Still - Resin Production

4051008-000-42506 08/17/1973 Unit 30 - Resin Production Process no longer in operation.

73-O-0878-P 08/17/1973 Unit 30 - Resin Production

4051008-000-76201 12/19/1974 No. 18 Still - Resin Production Connected to thermal oxidizer under IP #0060-I006.

74-O-2674-P 12/19/1974 No. 18 Still - Resin Production

4051008-000-71101 01/09/1974 No. 2 Packaging Center Replaced by IP #0060-I007.

74-O-3889-P 01/09/1974 No. 2 Packaging Center


75-O-0006-P 09/09/1975 No. 19 Still - Resin Production



75-O-0007-C 09/09/1975 No. 19 Still Furnace - Oil

Heater

74-I-0030-P 05/01/1975 C-5 Unit Process no longer in operation.

4051008-000-05901 03/24/1976 Nevtac Furnace - C-5 Unit Process no longer in operation.

75-O-0031-C 03/24/1976 Nevtac Furnace - C-5 Unit

4051008-000-05900 03/16/1976 Nevtac Unit - C-5 Unit Process no longer in operation.

75-O-0030-P 02/16/1976 Nevtac Unit - C-5 Unit

74-O-3582-P 03/22/1976 Unit 20 Process has been modified since issuance. Included

in the TVOP under section V.B.

74-O-3583-P 03/22/1976 Unit 21 Process has been modified since issuance. Included

in the TVOP under section V.C.

4051008-000-28701 12/31/1977 Nevillac Process no longer in operation.

76-I-0109-P 12/27/1976 Nevillac

77-I-0030-P 08/30/1977 Chemical Treatment of Crudes

& Solvents

Process no longer in operation; equipment currently

part of Unit #21 Aqueous Neutralization.

4051008-000-82401 08/03/1977 Chlorinated Paraffin Production Process no longer in operation.


Permit Number Issue

Date Description Reason for Exclusion from TVOP

76-I-0092-P 08/31/1977 Chlorinated Paraffin Production

4051008-000-66500 05/31/1978 No. 5 Packaging Center Flaker Incorporated into the TVOP under section V.G.

77-I-0025-P 05/23/1977 No. 5 Packaging Center Flaker

4051008-000-00901 05/31/1978 No. 5 Packaging Center Oil

Furnace Incorporated into the TVOP under section V.M.

77-I-0026-C 05/11/1977 No. 5 Packaging Center Oil

Furnace

79-I-0003-P 05/24/1979 Wastewater Treatment Plant Process has been modified since issuance. Included

in the TVOP under section V.H.

79-I-0024-C 07/05/1979 No. 6 Boiler Incorporated into the TVOP under section V.N.

4051008-000-00902 05/06/1980 No. 6 Boiler

82-I-0012-C 03/26/1982 No. 7 Boiler Unit no longer in operation.

4051008-000-00903 01/18/1983 No. 7 Boiler


82-I-0042-P 01/26/1983 No. 15 Still - Resin Production



82-I-0043-C 01/18/1983 No. 15 Still Furnace - Oil

Heater


Heater

Incorporated into the TVOP under section V.K. 4051008-000-00904 12/12/1985 No. 16 Still Furnace - Oil

Heater

85-I-0046-C 03/29/1985 No. 16 Still Furnace - Oil

Heater

86-I-0018-C 05/30/1986 Nos. 6 & 7 Boilers Boiler #7 is no longer in operation; Boiler #6 is

included in the TVOP under section V.N.

4051008-000-00905 07/21/1988 No. 3 Packaging Center

Furnace Incorporated into the TVOP under section V.M.

88-I-0022-C 06/28/1988 No. 3 Packaging Center

Furnace

89-I-0034-P 11/02/1989 Piperylene Tank Included in the tank list as Tank #5003. In the TVOP

under Section V.P.

90-I-0058-P 05/02/1991 Bio Wastewater Treatment Incorporated into the TVOP under section V.H.

90-I-0064-P 05/10/1991 Groundwater Air Stripping

Facility

Process no longer in operation; replaced by

Groundwater Remediation.

91-I-0053-P 08/07/1991 Soil Vapor Extraction Process no longer in operation.

4051008-000-42503 05/19/1992 No. 3 Still - Furnace Unit is still in operation but with a new furnace;

permitted in the TVOP under section V.L. 91-I-0051-P 07/29/1991 No. 3 Still - Furnace

4051008-000-01000 01/13/1992 Soil Vapor Extraction Process no longer in operation.

92-I-0064-P 12/08/1992 Groundwater Air Stripping

Facility

Process no longer in operation; replaced by

Groundwater Remediation System.

4051008-000-42505 08/19/1993 No. 16 Still - Resin Production

(replacement reactor) Connected to thermal oxidizer under IP #0060-I007.

4051008-000-00900 08/13/1993 Nos. 4, 6, & 7 Boilers - Use of

LX-830 (incorrect #)

Boilers #4 & #7 no longer in operation; Boiler #6 is

included in the TVOP under section V.N.

93-I-0032-P 11/17/1993 Resin & Rosin Emulsion Process no longer in operation.


EMISSION SOURCES:

Table 2: Emissions Sources

I.D. Source Description Control Device(s) Maximum

Capacity

Fuel/Raw

Material

Stack

I.D.

Heat Polymerization Stills

P001 Heat Polymerization Still - #15

Reactor 18.9 MMBtu/hr thermal

oxidizer 18,000,000 lb/yr

resin-forming

feedstock, additives

S101 2 – Distillate Receivers thermal oxidizer

2 – Ejector Vents thermal oxidizer

Decanter thermal oxidizer




resin-forming



Vacuum Pump thermal oxidizer

Decanter (shared with #18

& #19) thermal oxidizer




resin-forming









resin-forming


S101

2 – Distillate Receivers thermal oxidizer







resin-forming



2 – Ejector Vents thermal oxidizer

Decanter thermal oxidizer



Capacity

Fuel/Raw

Material

Stack

I.D.

Continuous Stills

P008 No. 3 Continuous Still

Tray Tower none 67,200,000 lb/yr polyoil, resin-forming

feedstock, additives --

Distillate Condenser none --

Decanter none S026

Batch/Flush Tank none --

Sidestream Oil Tank

(T-85) none --

P009 No. 4 Continuous Still

Tray Tower none 219,800,000 lb/yr polyoil, resin-forming

feedstock, additives --

Distillate Condenser none --

Decanter none S028

Vapor Surge Tank none --

Catalytic Resin and Polyoil Neutralization

P006 Unit 20

Reactor packed bed scrubber 66,600,000 lb/yr

ethylene-cracking

products, resin-forming


S020,

S021

2 – Mix Tanks none

2 – Decanters none

Holding Tank packed bed scrubber

P007 Unit 21

Reactor none 89,400,000 lb/yr

ethylene-cracking

products, resin-forming


4 – Holding Towers packed bed scrubber

Final Holding Tank packed bed scrubber

3 – Aqueous Treaters none S025a, b,

c

Flaking and Packaging

P011 No. 2 Packaging Center

7 – Drain Kettles none 12,500 lb/hr

86,700,000 lb/yr

liquid hydrocarbon

resins

S042-

S048

Flaking Belt none liquid hydrocarbon

resins S050a

Packaging Station fabric filter solid flaked

hydrocarbon resins S051



Capacity

Fuel/Raw

Material

Stack

I.D.


7 – Drain Kettles none 122,600,000 lb/yr liquid hydrocarbon

resins

S054-

S060


resins

S061a, b,

c



Pouring Station none liquid hydrocarbon

resins S063


3 – Drain Kettles none 78,800,000 lb/yr liquid hydrocarbon

resins

S065-

S067


resins

S068a, b,

c



Other Processes

P015 Resin Rework Tanks

Resin Rework Tanks, N2

and N4 condenser 1,800,000 gal/yr

resins, rosins, distillate

oils --

Distillate Receiver none resins, rosins, distillate

oils S079

P016 Final Product Loading

LX-830 Fuel Oil Barge

Loading none 6,000,000 gal/yr

petroleum hydrocarbon

resins, distillate fuel

oils, distillate oils

--

Final Product Tankcar &

Tankwagon Loading none 24,300,000 gal/yr

petroleum hydrocarbon

resins, distillate fuel

oils, distillate oils

--

P017 Groundwater Remediation System

7 – Groundwater Wells none 165,000 gal/yr

(recovered oil)

groundwater, recovered

oils --

7 – Oil Recovery Wells none 165,000 gal/yr

(recovered oil)


oils --

Number 2 Drywell pump

and Treat System none

165,000 gal/yr

(recovered oil)


oils --

Old Number 8 Water Well

Pump and Treat System none

165,000 gal/yr

(recovered oil)


oils --

P014 Wastewater Collection, Conveyance, and Treatment

3 – Surge Tanks (#5001,

#5251, #1004) none

105,000,000

gal/yr

(total for system)

wastewater --

3 – Batch Tanks (#2011,

#2012, #2013) none wastewater

S071-

S073

Equalization Tank

(#5002) none wastewater

2 – Biological Treatment /

Aeration Tanks (TA-2,

TA-3)

none wastewater S074-

S075



Capacity

Fuel/Raw

Material

Stack

I.D.

2 – Clarifier Tanks (TA-4,

TA-5) none wastewater

Effluent Tank (TA-7) none wastewater S076

Sludge Tank (#2010) none wastewater S077

Rotary Vacuum Filter vented to No. 6 Boiler wastewater

Oil/Water Separator none wastewater S078

Aerobic Digester Tank

(TA-6) none wastewater S078a

Still Process Heaters

B001 No. 15 Still Process

Heater none 7.5 MMBtu/hr

natural gas, liquid

propane S001



natural gas, liquid

propane S006



natural gas, liquid

propane S009



natural gas, liquid

propane S012

B015 Unit 43 Process Heater none 7.5 MMBtu/hr natural gas, liquid

propane S104

B006 No. 3 Continuous Still

Process Heater none 5.25 MMBtu/hr

natural gas, liquid

propane S027

B007 No. 4 Continuous Still

Process Heater none 10.5 MMBtu/hr

natural gas, liquid

propane S029

Packaging Center Heaters

B009 No. 2 Packaging Center


natural gas, liquid

propane S053



natural gas, liquid

propane S064



natural gas, liquid

propane S070

Boilers and Generators

B013 No. 6 Boiler none 49.4 MMBtu/hr natural gas S099

B012 No. 8 Boiler low-NOX burners, flue

gas recirculation 29.5 MMBtu/hr natural gas S098

-- 8 - Emergency Generators none natural gas --

Storage Tanks

D001 1001-1002, 1016-1017 none 101,148 gal. ea. Catalytic & Misc.

Polymer Oil --

D001 2101 none 215,777 gal. Catalytic & Misc.

Polymer Oil --

D001 2102 none 214,944 gal. Catalytic & Misc.

Polymer Oil --

D002 9 none 2,477 gal. Distillates --

D002 11-12 none 19,320 gal. ea. Distillates --



Capacity

Fuel/Raw

Material

Stack

I.D.



D002 85 (part of No. 3

Continuous Still, P008) none 3,900 gal. Distillates --





D002 308-311, 314-315 none 30,050 gal. ea. Distillates --



D002 3 Still Wash Tank none 3,900 gal. Distillates --

D003 176-177 none 16,120 gal. ea. Heat Poly Charge Stock --


D003 1014 none 100,674 gal. Heat Poly Charge Stock --


D003 2104, 2107, 2109 none 217,334 gal. ea. Heat Poly Charge Stock --

D003 1015 none 101,148 gal. Heat Poly Charge Stock --

D004 80 none 15,100 gal. LX-1144 Charge Stock --

D005 TA-13, TA-14 none 550 gal. ea. Misc. – Water

Treatment --

D005 TA-15 none 1,050 gal. Misc. – Water

Treatment --

D005 307 none 30,050 gal. Misc. --

D005 76 none 7,614 gal. Misc. – BHT --

D005 60SC none 6,016 gal. Misc. – Diesel Fuel --

D005 147 none 500 gal. Misc. – Mineral Spirits --

D005 175 none 20,347 gal. Misc. – Caustic --

D005 9 Agitator none 4,852 gal. Misc. – Emulsion

Breaker --

D005 5003 vent condenser 500,000 gal. Misc. – Piperylene --

D006 1, 2 none 19,320 gal. ea. Naphthenic/Ink/

Vegetable Oil --

D006 4 none 22,000 gal. Naphthenic/Ink/

Vegetable Oil --



Capacity

Fuel/Raw

Material

Stack

I.D.


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --


Vegetable Oil --

D006 201-204 none 20,082 gal. ea. Naphthenic/Ink/

Vegetable Oil --

D006 301-303 none 30,050 gal. ea. Naphthenic/Ink/

Vegetable Oil --

D007 82-83 none 10,000 gal. ea. NEVCHEM LR --

D007 1005 none 101,516 gal. NEVCHEM LR --

D008 1008 none 100,989 gal. Recovered Oil

D009 1012-1013 none 100,674 gal. ea. Resin Former --

D009 8501-8506 vapor return 850,000 gal. ea. Resin Former --

D009 6301-6302 none 630,000 gal. ea. Resin Former --

D010 93-94 none 28,201 gal. ea. Resin Solutions --

D010 135 none 2,010 gal. Resin Solutions --

D010 304-305, 312-313, 316-

317 none 30,050 gal. ea. Resin Solutions --



D010 331-334 none 30,000 gal. ea. Resin Solutions --

D011 252 none 24,052 gal. Unit 20 Feed Blend --

D011 271-272 none 25,974 gal. ea. Unit 20 Feed Blend --

D012 2105-2106 none 217,334 gal. ea. Unit 21 Feed Blend --

Miscellaneous Sources

F001 Roads and Vehicles none n/a n/a --

G001 Hydrolaser Water

Blasting none pressurized water --

G002 Parts Washing none 2,500 gal/yr degreasing materials --



Capacity

Fuel/Raw

Material

Stack

I.D.

G003 R&D Laboratory Hoods none

G004 Tank Cleaning and

Painting none 2,000 gal/yr

sandblasting agents,

primer, coatings --

STACKS:

Table 3: Stacks

Stack

ID Stack Name

Stack

Height

(ft)

Stack

Diameter

(ft)

Exhaust

Rate

(acfm)

Exhaust

Temp.

(ºF)

Lining/Outer

Material

S001 No. 15 Still Process Heater 70 2.8 4,000 782 carbon steel / LHV

castable

S006 No. 16 Still Process Heater 57 2.25 2,876 698 carbon steel / LHV

castable

S009 No. 18 Still Process Heater 44.25 2.0 3,830 646 carbon steel / LHV

castable

S012 No. 19 Still Process Heater 26.5 2.5 3,810 641 carbon steel / LHV

castable

S020 Unit 20/21 Scrubber Vent 12 0.33 50 70 none / pyrex glass

S021 Unit 20/21 Scrubber Vent 12 0.33 50 70 none / pyrex glass

S025a Unit 21 Aqueous Treater 1 20 0.25 1.0 68 carbon steel / none

S025b Unit 21 Aqueous Treater 2 20 0.25 1.0 68 carbon steel / none

S025c Unit 21 Aqueous Treater 3 20 0.25 1.0 68 carbon steel / none

S026 No. 3 Cont. Still & Decanter 25 0.25 2.4 80 none / carbon steel

S027 No. 3 Continuous Still

Process Heater 30 1.5 2,200 620 carbon steel / none

S028 No. 4 Cont. Still & Decanter 8 0.167 1.2 80 none / carbon steel

S029 No. 4 Continuous Still

Process Heater 58 4.3 5,200 620 carbon steel / none

S042 No. 2 Flaker Kettle 1 25 0.5 1.0 390 carbon steel / none







S050a No. 2 Flaker Belt Exhaust 15 2.0 4,850 100 steel / none

S051 No. 2 Pkg Center Dust

Collector 12 0.83 × 0.83 3,000 68 carbon steel / none

S053 No. 2 Pkg Center Heater 37 2.5 2,500 625 carbon steel / none







Stack

ID Stack Name

Stack

Height

(ft)

Stack

Diameter

(ft)

Exhaust

Rate

(acfm)

Exhaust

Temp.

(ºF)

Lining/Outer

Material



S061a No. 3 Flaker Belt Exhaust 1 15 2.0 4,850 68 carbon steel / none

S061b No. 3 Flaker Belt Exhaust 2 15 2.0 4,850 68 carbon steel / none

S061c No. 3 Flaker Belt Exhaust 3 15 2.0 4,850 68 carbon steel / none



S063 No. 3 Pkg Center Pouring

Station 15 2.0 3,300 68 carbon steel / none

S064 No. 3 Pkg Center Heater 51 2.0 1,500 626 carbon steel / LHV

castable




S068a No. 5 Flaker Belt Exhaust 1 15 2.0 4,850 68 carbon steel / none

S068b No. 5 Flaker Belt Exhaust 2 15 2.0 4,850 68 carbon steel / none

S068c No. 5 Flaker Belt Exhaust 3 15 2.0 4,850 68 carbon steel / none



S070 No. 5 Pkg Center Heater 24 1.5 1,480 640 carbon steel / none

S071 Batch Treatment Tank

T-2011 30 0.33 16 90 carbon steel / none





S074 Biological Treatment/

Aeration Tank TA-2 25 2.0 1,250 90 carbon steel / none

S075 Biological Treatment/

Aeration Tank TA-3 25 2.0 1,250 90 carbon steel / none

S076 Effluent Tank TA-7 15 0.33 1.0 90 carbon steel / none

S077 Sludge Tank T-2010 30 0.33 1.0 90 carbon steel / none

S078 API Separator 6.0 0.33 1.0 90 carbon steel / none

S078a Aerobic Digester TA-6 25 0.17 1.0 90 carbon steel / none

S079 Resin Rework Distillate

Receiver Tank 20 0.5 × 0.5 240 180 carbon steel / none

S098 No. 8 Boiler 54 4.0 10,400 540 carbon steel / LHV

castable

S099 No. 6 Boiler 35 3.0 11,600 354 carbon steel / LHV

castable

S101 Thermal Oxidizer Stack 48 2.2 23,760 1,400 cast refractory /

carbon steel

S104 Unit 43 Process Heater 65 3.0 6,700 550 carbon steel / LHV

castable


METHOD OF DEMONSTRATING COMPLIANCE:

Methods of demonstrating compliance with the emission standards set in this permit are summarized in Table 4

below.

Table 4: Method(s) of Demonstrating Compliance TVOP

Section Process Method(s) of Demonstrating Compliance

V.A Heat Polymerization Stills

15, 16, 18, 19, & 43

Testing of the thermal oxidizer at least once every 5 years

Continuous monitoring of thermal oxidizer temperature

Recordkeeping of production and raw materials per batch and batch

cycle times

Note: The reporting period is now semiannually instead of quarterly

due to all of the Heat Poly Stills now being controlled by the thermal

oxidzer. Because of the common header from all stills to the thermal

oxidizer, it is not possible to determine controlled emissions from the

individual stills. However, sample ports are available to determine

uncontrolled emissions from each still.

V.B & V.C Units #20 and #21

Recordkeeping and reporting of the number of product changes and,

if the rolling 12-month total number of product changes reaches 90%

of the maximum allowable, calculated emissions

Recordkeeping of batch temperature

Recordkeeping of monthly product changes and poly oil addition rate

Recordkeeping of water washes in the aqueous treaters per batch

Recordkeeping of scrubber flowrate and catalyst used

Analyses of materials

V.D Continuous Stills #3 and #4

Recordkeeping and reporting of the number of product changes and,

if the rolling 12-month total number of product changes reaches 90%

of the maximum allowable, calculated emissions

Recordkeeping of daily production and raw materials

V.E, V.F,

& V.G

Packaging Centers #2, #3,

and #5

Emissions testing at least once every 5 years

Continuous monitoring of baghouse pressure drop

Annual inspections of baghouse

Recordkeeping and reporting of calculated emissions from kettles

Daily, monthly, and 12-month recordkeeping of production and raw

materials

V.H Wastewater Collection,

Conveyance, and Treatment

Monthly photo ionization detector (PID) readings

Recordkeeping of flows and influent concentrations

V.I Resin Rework Tanks

One-time emissions test within 2 years of permit issuance

Monitoring of condenser coolant temperature

Recordkeeping of production and raw materials

V.J Final Product Loading

Monitoring of vapor balancing system during barge off-loading

Recordkeeping of loading operations and, if the amount of material

transferred reaches 90% of the maximum allowable, calculated

emissions

V.K, V.L,

& V.M

Heat Poly Still Heaters

Continuous Still Heaters

Packaging Center Heaters Recordkeeping of fuel use

V.N Boiler No. 6 Emissions testing at least once every 5 years for NOX

Recordkeeping of fuel use

V.O Boiler No. 8

Continuous emissions monitors (CEMs) on flue gas to measure

either O2 or CO concentration

Recordkeeping of fuel use

V.P Storage Tanks

Recordkeeping of material and throughput

Inspections of the vapor balancing system on Tanks #5003 & #8501-

8506 during barge off-loading operations

Monitoring of the coolant temperature on the outlet of the vent

condenser on Tank #5003


VI.A Groundwater Remediation

Testing of each container for vapor-tightness or for no detectable

organic emissions

Recordkeeping of materials collected

VI.B Emergency Generators Recordkeeping of hours of operation

IV.30 &

IV.31 Leak Detection and Repair

Identification of all components in VOC and HAP service

Periodic monitoring of all components

Recordkeeping of all monitor readings and repairs

See operating permit No. 0060 for the specific conditions for determining compliance with the applicable

requirements. Compliance with the short-term (lb/hr) limits must be maintained at all times, including startup

and shutdown. Any emissions due to startup, shutdown, or malfunction are included in facility’s total annual

emissions.

The reporting period requirements of §61.357 and §63.7951(a)(5) apply. However, the Department has

approved different dates for the reporting schedule in accordance with these sections, which the facility will

follow. See operating permit No. 0060, Section III.15 for the actual reporting dates.

REGULATORY APPLICABILITY:

1. Article XX1 Requirements for Issuance:

See Permit Application No. 0060, Appendix F. The requirements of Article XXI, Parts B and C for the

issuance of operating permits have been met for this facility. Article XXI, Part D, Part E & Part H will have

the necessary sections addressed individually.

The cold start notification provisions of §2108.01.d do not apply to the ten (10) process heaters. Until

terminated by written notice from the Department, the requirement to report cold starts 24-hours in advance

is waived for Boilers No. 6 and No. 8 and the facility may report all cold starts as part of the semiannual

report.

2. Testing Requirements:

Testing is required on the following once every five (5) years: thermal oxidizer, Unit #20 & #21 BF3

scrubber, the packaging centers, and the resin rework tanks. The Department reserves the right to require

additional testing if necessary in the future to assure compliance with the terms and conditions of this Title

V Operating Permit.

3. New Source Performance Standards (NSPS):

Boiler #8 is subject to 40 CFR Part 60, Subpart Dc – Standards of Performance for Small Industrial-

Commercial-Institutional Steam Generating Units. Because Boiler #6 was constructed prior to June 9,

1989, this NSPS does not apply.

Tank #601 is the only tank that meets the applicability requirements of 40 CFR Part 60, Subpart K –

Standards of Performance for Storage Vessels for Petroleum Liquids (1973-1978). However, since the

maximum vapor pressure of the material stored is less than 6.9 kPa (1.0 psi), according to §60.113, the

conditions of this subpart do not apply.

Tanks #1005 and #2102 are the only tanks that meet the applicability requirements of 40 CFR Part 60,

Subpart Ka – Standards of Performance for Storage Vessels for Petroleum Liquids (1978-1984). However,

since the maximum vapor pressure of the material stored is less than 6.9 kPa (1.0 psi), according to

§60.115a(d)(1), the conditions of this subpart do not apply.

All storage tanks constructed after 1984 with capacities between 75 m3 and 151 m3 (19,813 and 39,890

gallons) contain materials with a maximum true vapor pressure less than 15.0 kPa (2.18 psi), and those with

capacities less than 75 m3 contain materials with a maximum true vapor pressure less than 3.5 kPa (0.51


psi). Tanks #6301, #6302, and #8501-#8506, have capacities greater than 151 m3, therefore, per

§60.110b(b), 40 CFR Part 60, Subpart Kb – Standards of Performance for Volatile Organic Liquid Storage

Vessels (post-1984) only applies to tanks #6301, #6302, and #8501-#8506. The permit limits these tanks to

storing only materials with a vapor pressure less than 3.5 kPa, so there are no other applicable requirements

under this subpart.

The emergency generators are not subject to 40 CFR Part 60, Subpart JJJJ – Standards of Performance for

Stationary Spark Ignition Internal Combustion Engines, as they were all installed prior to July 1, 2007.

4. NESHAP and MACT Standards:

The facility is subject to 40 CFR Part 61, Subpart FF – National Emission Standard for Benzene Waste

Operations.

The Groundwater Remediation System is subject to 40 CFR Part 63, Subpart GGGGG – National Emission

Standards for Hazardous Air Pollutants: Site Remediation.

The emergency generators are subject to 40 CFR Part 63, Subpart ZZZZ – National Emissions Standards for

Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines. See Table 35b for

individual generator applicability.

The facility is not subject to 40 CFR Part 63, Subpart EEEE – National Emission Standards for Hazardous

Air Pollutants: Organic Liquids Distribution or Subpart FFFF – National Emission Standards for

Hazardous Air Pollutants: Miscellaneous Organic Chemical Manufacturing because the facility became a

minor source of HAP on May 7, 2008. With the original compliance date for Subpart FFFF (MON), the

facility would have had to be in compliance with the MON before needing to be in compliance with Subpart

EEEE (OLD), and therefore the OLD would not apply to the facility. However, the compliance date of the

MON was pushed back to after that of the OLD. Before that compliance date was reached, the facility

became a minor source for HAP. See Appendix A for the timeline of emissions reductions.

According to the EPA document, “Implementation Tool for the Organic Liquids Distribution NESHAP”

(#305B07002, September 2007, page 55), sources subject to the MON were not subject to the OLD during

the interim period between the compliance dates. Based on the EPA guidance memorandum “Potential to

Emit for MACT Standards – Guidance on Timing Issues” (May 16, 1995), if a facility becomes an area

source at any time before the first compliance date of the standard, it is considered an area source for that

standard. Neville Chemical became an area source on May 7, 2008. The first compliance date for the MON

was May 10, 2008.

The facility is not subject to 40 CFR Part 63, Subpart VVVVVV – National Emission Standards for

Hazardous Air Pollutants: Chemical Manufacturing Area Sources. The only applicable HAP at the facility

is 1,3-Butadiene, and it is contained in concentrations well below the applicability threshold.

The facility is not subject to 40 CFR Part 63, Subpart PPP – National Emission Standards for Hazardout Air

Pollutant Emissions for Polyether Polyols Production. Based on the definition of “polyether polyol” in

§63.1423(b), the polymerization must be with cyclic ether compounds. None of the feedstocks used in

Units 20 or 21 apply, and “polyoil” is just a term used by Neville Chemical to describe the raw material,

intermediates, and final products.

The boilers and process heaters are not subject to 40 CFR Part 63, Subpart DDDDD – National Emission

Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional

Boilers and Process Heaters. The facility became a minor source of HAP prior to the compliance date.

Boilers No. 6 and No. 8 are not subject to 40 CFR Part 63, Subpart JJJJJJ – National Emission Standards for

Hazardous Air Pollutants for Industrial, Commercial, and Institutional Boilers Area Sources. Both boilers


combust natural gas only, and are therefore exempted under §63.11195(e). Per §63.11237, the Still Process

Heaters and Packaging Center Heaters are not considered boilers, and therefore are not subject to this

subpart.

5. Risk Management Plan; CAA Section 112(r):

The facility is subject to §112(r) of the Clean Air Act due to the storage of boron trifluoride (BF3). There is

a risk management plan in place at the facility.

6. Greenhouse Gas Reporting (40 CFR Part 98):

Greenhouse gases (GHGs) from this facility come from the heat poly unit thermal oxidizer, seven process

heaters, three packaging center heaters, and two boilers. Only three (3) of the six GHG categories apply:

CO2, N2O (nitrous oxide), and CH4 (methane). Based on the calculation methodology in 40 CFR Part 98,

§98.33(a)(1), potential emissions of CO2e are 82,300 tpy. This is less than the 100,000 tpy major source

threshold, therefore the facility is not considered a major source of GHG emissions.

The requirements contained in the GHG reporting rule are not considered applicable requirements under the

Title V regulations. Furthermore, after reviewing the the actual natural gas use over the past eight (8) years

(as reported in the Emissions Inventory), the highest actual CO2e emissions, not including sources no longer

in operation at the facility, was less than 17,200 metric tons in any given year, under the 25,000 metric ton

applicability threshold for the reporting rule. Should the facility exceed 25,000 metric tons of CO2e in any

12-month period, the facility would have to submit reports in accordance with 40 CFR Part 98.

EMISSION CALCULATIONS:

All vapor pressures were calculated using Antoine Equation coefficients found in published texts.

Heat Polymerization Stills

Emissions from the Heat Polymerization Stills consists of controlled emissions from Stills #15, #16, #18, #19,

and Unit 43 from the thermal oxidizer stack, as well as emissions from combustion of natural gas from the

thermal oxidizer itself.

Thermal Oxidizer Combustion

All emissions from thermal oxidizer combustion, except for particulate matter, were based on factors found in

U.S. EPA AP-42 Section 1.4: Natural Gas Combustion (7/98) and Section 1.5: Liquified Petroleum Gas

Combustion (7/08). Particulate matter emissions limits are those found in Article XXI, §2104.02.a.1.A. A 15%

adjustment was added to all emissions calculated with AP-42 factors to account for operational variability. All

PM is assumed to be PM10, and all PM10 is assumed to be PM2.5.

The following assumptions were also used as a basis:

Natural gas rating: 1,020 Btu/scf

Hours of operation: 8,760 hours/year on natural gas


Table 5: Thermal Oxidizer Combustion Emissions

Pollutant

AP-42 Factors Thermal Oxidizer Combustion

18.9 MMBtu/hr

nat. gas propane nat. gas propane Max. Total

lb/106 scf lb/10

3 gal lb/hr lb/hr tpy

Particulate Matter1 0.0081 0.7 0.151 0.166 0.728

PM10 0.0081 0.7 0.151 0.166 0.728

PM2.5 0.0081 0.7 0.151 0.166 0.728

Nitrogen Oxides

(NOX) 100 13 2.131 3.088 13.526

Sulfur Oxides (SOX) 0.6 0.002 0.013 0.000 0.056

Carbon Monoxide

(CO) 84 7.5 1.790 1.782 7.840

VOC 5.5 1 0.117 0.238 1.040

Total HAP 1.9 0.040 0.177

Formaldeyde 7.5×10-2 0.002 0.007

1. Based on Article XXI, §2104.02.a.1.A (lb/MMBtu)

Emission Factor Derivation

Emission factors for each emission episode of the heat polymerization process were determined based on VOC

and HAP rates in the September 1997 stack test conducted on Still #18, except for atmospheric venting and

vacuum distillation. Those values were determined from the July 2003 stack test conducted on Unit 43. The

uncontrolled emission factors are summarized in Table 6a below. These factors represent the sum of emissions

from (where applicable) the ejector stack, receiver vent, and decanter vent.

Table 6a: Heat Poly Still Emission Factors (uncontrolled)

Emission Episode VOC Benzene Cumene Ethylbenzene

lb/hr lb/batch lb/hr lb/batch lb/hr lb/batch lb/hr lb/batch

Charging 0.910 1.138 0.061 0.076 0.003 0.004 0.047 0.058

Initial Heat-up 2.360 6.679 0.055 0.157 0.002 0.006 0.034 0.095

Heat to Hold Temp.

Hold

Atmospheric Venting 10.100 50.500 0.060 0.302 0.003 0.013 0.044 0.222

Vac. Dist./ Steam Strip. 27.970 237.745 0.124 1.054 0.017 0.144 0.152 1.288

Cool Down 3.120 8.518 0.003 0.010 0.000 0.000 0.000 0.000

Addition/ Cutback /

Agitation 0.900 4.122 0.063 0.288 0.003 0.013 0.047 0.214

Pump Out

Misc. Time

Total 308.701 1.886 0.178 1.877


Emission Episode Styrene Toluene Xylenes

lb/hr lb/batch lb/hr lb/batch lb/hr lb/batch

Charging 0.027 0.036 0.107 0.134 0.040 0.050

Initial

Heat-up 0.022 0.063 0.098 0.279 0.029 0.082

Heat to Hold Temp.

Hold

Atmospheric Venting 0.028 0.140 0.115 0.574 0.038 0.190

Vac. Dist./ Steam Strip. 0.057 0.486 0.000 0.000 0.163 1.383

Cool Down 0.002 0.005 0.030 0.082 0.000 0.000

Addition/ Cutback /

Agitation 0.030 0.136 0.126 0.578 0.040 0.183

Pump Out

Misc. Time

Total 0.866 1.647 1.887

Heat Polymerization Emissions Limitations

Controlled emissions from the heat polymerization process are based on the emission factors from Table 6a, the

thermal oxidizer destruction efficiency of 98%, and the following information from existing permits:

Table 6b: Heat Poly Unit Permit Summary

Unit Reference Permit Operation

(hours/year)

Max. Production

(batches/year)

No. 15 #4051008-000-42507 (06/22/84)

8,760

189

No. 16 #4051008-000-42505 (08/19/93) 258

No. 18 #4051008-000-76201 (12/19/74) 274

No. 19 #4051008-000-76202 (09/09/75) 260

Unit 43 #0060-I001 (04/30/99) 260

Short-term emissions (lb/hr) are based on the emission episode with the highest emissions rate from Table 6a.

Long-term emissions (tpy) are based on the lb/batch emission factor and maximum production from Table 6b.

Table 6c: Heat Poly Emissions (controlled)

Pollutant No. 15 Still No. 16 Still No. 18 Still

lb/hr tpy lb/hr tpy lb/hr tpy

Total VOC 0.559 0.583 0.559 0.796 0.559 0.846

Benzene 0.002 0.004 0.002 0.005 0.002 0.005

Ethylbenzene 0.003 0.004 0.003 0.005 0.003 0.005

Styrene 0.001 0.002 0.001 0.002 0.001 0.002

Xylenes 0.003 0.004 0.003 0.005 0.003 0.005

Total HAP 0.013 0.016 0.013 0.022 0.013 0.023


Pollutant No. 19 Still Unit 43 Total from T.O.

lb/hr tpy lb/hr tpy lb/hr tpy

Total VOC 0.559 0.803 0.559 0.803 2.797 3.831

Benzene 0.002 0.005 0.002 0.005 0.012 0.023

Ethylbenzene 0.003 0.005 0.003 0.005 0.015 0.023

Styrene 0.001 0.002 0.001 0.002 0.006 0.011

Xylenes 0.003 0.005 0.003 0.005 0.016 0.023

Total HAP 0.013 0.022 0.013 0.022 0.064 0.104

Catalytic Resin and Polyoil Neutralization – Unit #20

Unit 20 consists of the Unit 20 Reactor, Unit 20 Holding Tank, Neutralization Mix Tank, Neutralization

Decanter, Rinse Mix Tank, and Rinse Decanter. Emissions from all six vessels occur during material charging

operations. Emissions also occur from the reactor and Neutralization Mix Tank during heat-up operations.

Emissions were estimated using four (4) different types of poly oil charge stock: Nevchem, Nevpene, FT-11-

134, or NI-100. At the Neutralization Mix Tank phase, the charge stock is then considered Poly Oil “A”. At the

Rinse Mix Tank phase, the material is considered Poly Oil “B”. It is assumed that:

1. Vapors are saturated with either Nevchem, Nevpene, FT-11-134, or NI-100 charge stock vapors, Poly

Oil “A” vapors, or Poly Oil “B” vapors.

2. The reactor contains nitrogen as the remaining gas component.

3. All vapors from the reactor discharge to the Holding Tank, then to the scrubber.

Unit 20 Reactor – Initial Material Charging

Each time a product change occurs, the empty reactor is filled with charge stock, causing a displacement of

reactor vapors. Boron trifluoride (BF3) gas is also injected as a catalyst. After the initial charge into the reactor,

the liquid level remains constant until the next product change.

Emissions were calculated using the following equation:

E = V/RT × Ʃ(Pi)(MWi)

Where:

E = Mass of Emissions Pi = Partial Pressure

V = Volume of Gas Displaced MWi = Molecular Weight

R = Ideal Gas Constant = 10.731 cf psi/lb·mol °R


Table 7a: Unit 20 Reactor Material Charging Emissions

Constituent

Nevchem Nevpene FT-11-134 NI-100

lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

Total VOC 0.2874 0.0138 1.0109 0.0485 0.0265 0.0013 0.0268 0.0013

Benzene 0.0001 0.0000 0.0001 0.0000 0.0000 0.0000 0.0000 0.0000

Toluene 0.0003 0.0000 0.0002 0.0000 0.0001 0.0000 0.0001 0.0000

Ethylbenzene 0.0004 0.0000 0.0003 0.0000 0.0006 0.0000 0.0007 0.0000

p-Xylene 0.0006 0.0000 0.0005 0.0000 0.0014 0.0001 0.0015 0.0001

m-Xylene 0.0006 0.0000 0.0005 0.0000 0.0014 0.0001 0.0015 0.0001

o-Xylene 0.0006 0.0000 0.0005 0.0000 0.0014 0.0001 0.0015 0.0001

Cumene 0.0002 0.0000 0.0001 0.0000 0.0001 0.0000 0.0001 0.0000

Styrene 0.0013 0.0001 0.0012 0.0001 0.0053 0.0003 0.0059 0.0003

Naphthalene 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Total HAP 0.0042 0.0002 0.0034 0.0002 0.0102 0.0005 0.0113 0.0005

Unit 20 Reactor – Heat-Up

The material is heated from the reaction, causing the vapor space gas to expand. This temperature increase

occurs for every batch.


E = [(PiT1/Pa1 + PiT2/Pa2)/2] × Delta(n) × MWi

Where:

E = Mass of emissions

PiT1 = Partial pressure of constituent at T1 Pa1 = Initial gas pressure

PiT2 = Partial pressure of constituent at T2 Pa2 = Final gas pressure

MWi = Molecular weight Delta(n) = Moles of gas displaced

Delta(n) = V/R × [(Pa1/T1) – (Pa2/T2)]

R = Ideal gas constant = 10.731 cf psi/lb·mol °R

PS = System pressure V = Volume of free space

T1 = Initial temperature Pa1 = PS – ƩPiT1

T2 = Final temperature Pa2 =PS – ƩPiT2


Table 7b: Unit 20 Reactor Heat-Up Emissions


lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

Total VOC 0.0030 0.0428 0.0077 0.1109 0.0018 0.0262 0.0018 0.0263

Benzene 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Toluene 0.0000 0.0000 0.0000 0.0000 0.0000 0.0001 0.0000 0.0001

Ethylbenzene 0.0000 0.0001 0.0000 0.0000 0.0000 0.0005 0.0000 0.0005

p-Xylene 0.0000 0.0001 0.0000 0.0001 0.0001 0.0012 0.0001 0.0013

m-Xylene 0.0000 0.0001 0.0000 0.0001 0.0001 0.0012 0.0001 0.0013

o-Xylene 0.0000 0.0001 0.0000 0.0001 0.0001 0.0012 0.0001 0.0013

Cumene 0.0000 0.0000 0.0000 0.0000 0.0000 0.0001 0.0000 0.0001

Styrene 0.0000 0.0003 0.0000 0.0002 0.0003 0.0047 0.0004 0.0052

Naphthalene 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Total HAP 0.0001 0.0009 0.0001 0.0005 0.0006 0.0088 0.0007 0.0098

Unit 20 Holding Tank – Material Charging

Each time a product change occurs, the empty tank is filled with material from the Unit 20 Reactor, causing a

displacement of tank vapors. After the initial charge into the tank, the liquid level remains constant.

Emissions were calculated using the same methodology as used for the material charging of the reactor.

Table 8: Unit 20 Holding Tank Material Charging Emissions

Constituent


lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

Total VOC 10.262 0.4926 24.942 1.1972 5.0669 0.2432 5.0766 0.2437

Benzene 0.0047 0.0002 0.0030 0.0001 0.0000 0.0000 0.0000 0.0000

Toluene 0.0127 0.0006 0.0066 0.0003 0.0120 0.0006 0.0120 0.0006

Ethylbenzene 0.0238 0.0011 0.0101 0.0005 0.0905 0.0043 0.1007 0.0048

p-Xylene 0.0355 0.0017 0.0160 0.0008 0.2211 0.0106 0.2465 0.0118

m-Xylene 0.0355 0.0017 0.0160 0.0008 0.2211 0.0106 0.2465 0.0118

o-Xylene 0.0355 0.0017 0.0160 0.0008 0.2211 0.0106 0.2465 0.0118

Cumene 0.0094 0.0004 0.0051 0.0002 0.0198 0.0010 0.0221 0.0011

Styrene 0.0719 0.0035 0.0422 0.0020 0.8932 0.0429 0.9940 0.0477

Naphthalene 0.0014 0.0001 0.0006 0.0000 0.0062 0.0003 0.0069 0.0003

Total HAP 0.2304 0.0111 0.1157 0.0056 1.6850 0.0809 1.8751 0.0900

Neutralization Mix Tank – Material Charging

Each time a product change occurs, material from the Holding Tank is added to the Neutralization Mix Tank

along with caustic and solvent diluent, causing a displacement of tank vapors. After the initial charge into the

vessel, the liquid level remains constant.



Table 9a: Unit 20 Neutralization Mix Tank Material Charging Emissions


lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

lb/

product

change

tpy

Total VOC 3.7054 0.1779 8.1261 0.3901 4.6287 0.2222 4.7377 0.2274

Benzene 0.0086 0.0004 0.0061 0.0003 0.0000 0.0000 0.0000 0.0000

Toluene 0.0229 0.0011 0.0136 0.0007 0.0271 0.0013 0.0253 0.0012

Ethylbenzene 0.0428 0.0021 0.0206 0.0010 0.2042 0.0098 0.2114 0.0101

p-Xylene 0.0640 0.0031 0.0327 0.0016 0.4987 0.0239 0.5173 0.0248

m-Xylene 0.0640 0.0031 0.0327 0.0016 0.4987 0.0239 0.5173 0.0248

o-Xylene 0.0640 0.0031 0.0327 0.0016 0.4987 0.0239 0.5173 0.0248

Cumene 0.0169 0.0008 0.0103 0.0005 0.0448 0.0021 0.0463 0.0022

Styrene 0.0065 0.0003 0.0045 0.0002 0.1013 0.0049 0.1043 0.0050

Naphthalene 0.0025 0.0001 0.0011 0.0001 0.0140 0.0007 0.0144 0.0007

Total HAP 0.2922 0.0140 0.1546 0.0074 1.8875 0.0906 1.9535 0.0938

Neutralization Mix Tank – Heat-Up

Some materials are heated after charging to the mix tank, causing the vapor space gas to expand. This

temperature increase occurs for every batch.

Emissions were calculated using the same methodology as used for the heat-up of the reactor. Emissions from

polyoils FT-11-134 and NI-100 at this step of the process are zero.

Table 9e: Neutralization Mix Tank Heat-Up Emissions

Constituent

Nevchem Nevpene

lb/product

change tpy

lb/product

change tpy

Total VOC 0.0617 0.0535 0.0427 0.0370

Benzene 0.0001 0.0001 0.0000 0.0000

Toluene 0.0004 0.0003 0.0001 0.0001

Ethylbenzene 0.0008 0.0007 0.0001 0.0001

p-Xylene 0.0012 0.0011 0.0002 0.0002

m-Xylene 0.0012 0.0011 0.0002 0.0002

o-Xylene 0.0012 0.0011 0.0002 0.0002

Cumene 0.0003 0.0003 0.0001 0.0001

Styrene 0.0001 0.0001 0.0000 0.0000

Naphthalene 0.0001 0.0001 0.0000 0.0000

Total HAP 0.0056 0.0049 0.0009 0.0008

Neutralization Decanter – Material Charging

Each time a product change occurs, material from the Neutralization Mix Tank is added to the Neutralization

Decanter, causing a displacement of tank vapors. After the initial charge into the vessel, the liquid level remains

constant.



Table 10: Neutralization Decanter Emissions

Constituent


lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

Total VOC 0.1261 0.0061 0.1595 0.0077 0.0657 0.0032 0.0673 0.0032

Benzene 0.0003 0.0000 0.0001 0.0000 0.0000 0.0000 0.0000 0.0000

Toluene 0.0008 0.0000 0.0003 0.0000 0.0004 0.0000 0.0004 0.0000

Ethylbenzene 0.0017 0.0001 0.0005 0.0000 0.0029 0.0001 0.0030 0.0001

p-Xylene 0.0027 0.0001 0.0008 0.0000 0.0071 0.0003 0.0073 0.0004

m-Xylene 0.0027 0.0001 0.0008 0.0000 0.0071 0.0003 0.0073 0.0004

o-Xylene 0.0027 0.0001 0.0008 0.0000 0.0071 0.0003 0.0073 0.0004

Cumene 0.0008 0.0000 0.0002 0.0000 0.0006 0.0000 0.0007 0.0000

Styrene 0.0003 0.0000 0.0001 0.0000 0.0014 0.0001 0.0015 0.0001

Naphthalene 0.0002 0.0000 0.0000 0.0000 0.0002 0.0000 0.0002 0.0000

Total HAP 0.0121 0.0006 0.0036 0.0002 0.0268 0.0013 0.0277 0.0013

Rinse Mix Tank – Material Charging

Each time a product change occurs, material from the Neutralization Decanter is added to the Rinse Mix Tank,

along with water and distillates, causing a displacement of tank vapors. After the initial charge to the vessel, the

liquid level remains constant.


Table 11: Rinse Mix Tank Emissions

Constituent


lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

Total VOC 2.7957 0.1342 2.8479 0.1367 1.4089 0.0676 1.2933 0.0621

Benzene 0.0044 0.0002 0.0019 0.0001 0.0131 0.0006 0.0000 0.0000

Toluene 0.0164 0.0008 0.0063 0.0003 0.0603 0.0029 0.0033 0.0002

Ethylbenzene 0.0351 0.0017 0.0121 0.0006 0.0538 0.0026 0.0594 0.0029

p-Xylene 0.0441 0.0021 0.0126 0.0006 0.0858 0.0041 0.1236 0.0059

m-Xylene 0.0487 0.0023 0.0154 0.0007 0.1295 0.0062 0.1236 0.0059

o-Xylene 0.0492 0.0024 0.0159 0.0008 0.0996 0.0048 0.1969 0.0095

Cumene 0.0133 0.0006 0.0043 0.0002 0.0102 0.0005 0.0111 0.0005

Styrene 0.0058 0.0003 0.0022 0.0001 0.0226 0.0011 0.0178 0.0009

Naphthalene 0.0027 0.0001 0.0005 0.0000 0.0035 0.0002 0.0028 0.0001

Total HAP 0.2197 0.0105 0.0712 0.0034 0.4784 0.0230 0.5385 0.0258

Rinse Decanter – Material Charging

Each time a product change occurs, material from the Rinse Mix Tank is added to the Rinse Decanter, causing a

displacement of tank vapors. After the initial charge into the vessel, the liquid level remains constant.



Table 12: Rinse Decanter Emissions

Constituent


lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

Total VOC 0.1654 0.0079 0.1685 0.0081 0.0834 0.0040 0.0765 0.0037

Benzene 0.0003 0.0000 0.0001 0.0000 0.0008 0.0000 0.0000 0.0000

Toluene 0.0010 0.0000 0.0004 0.0000 0.0036 0.0002 0.0002 0.0000

Ethylbenzene 0.0021 0.0001 0.0007 0.0000 0.0032 0.0002 0.0035 0.0002

p-Xylene 0.0026 0.0001 0.0007 0.0000 0.0051 0.0002 0.0073 0.0004

m-Xylene 0.0029 0.0001 0.0009 0.0000 0.0077 0.0004 0.0073 0.0004

o-Xylene 0.0029 0.0001 0.0009 0.0000 0.0059 0.0003 0.0117 0.0006

Cumene 0.0008 0.0000 0.0003 0.0000 0.0006 0.0000 0.0007 0.0000

Styrene 0.0003 0.0000 0.0001 0.0000 0.0013 0.0001 0.0011 0.0001

Naphthalene 0.0002 0.0000 0.0000 0.0000 0.0002 0.0000 0.0002 0.0000

Total HAP 0.0130 0.0006 0.0042 0.0002 0.0283 0.0014 0.0319 0.0015

Unit 20 Summary

Emissions Limitations for Unit 20 are based on the poly oil with the highest total emissions across the process

for each pollutant.

Table 13: Unit 20 Emissions Limitations Summary

Pollutant Emissions

tpy

Total VOC 1.936

Benzene 0.001

Ethylbenzene 0.019

Naphthalene 0.001

Styrene 0.059

Xylenes 0.138

Total HAP 0.223

Catalytic Resin and Polyoil Neutralization – Unit #21

Unit 21 consists of the Unit 21 Reactor, Holding Tanks #1 and #2, Final Holding Tank T-171, and Aqueous

Treaters #4, #10, and #11. Emissions from the reactor vent to the holding tanks. Emissions from the holding

tanks occur during material charging and solvent flush operations. Emissions from the aqueous treaters occur

during material charging, water wash, and material heat-up operations.

Product changes: 52 changes per year

Sp. Gr. of poly oil: 0.922 @ 30 °C = 7.689 lb/gal

Max. poly oil throughput: 89,400,000 lbs/yr

11,626,274 gal/yr

Holding Tanks #1 & #2 and Final Holding Tank T-171 – Material Charging

Each time a product change occurs, the empty tank is filled with material, causing a displacement of tank

vapors. After the initial charge into the tank, liquid level remains constant. Assumptions include:

1. Vapors are saturated with poly oil.

2. Tanks contain nitrogen as the remaining gas component


Table 14a: Holding Tank Material Charging Parameters

Volume

Liquid

Level Volume Displaced

gallons cf % cf/batch cf/yr

Tank #1 4,100 548.1

90

493.3 25,651

Tank #2 4,100 548.1 493.3 25,651

Tank T-171 17,500 2,339.4 2,105.5 109,485



Where:




Table 14b: Holding Tank Material Charging Emissions

Pollutant

Molec. Wt. Holding Tank #1 Holding Tank #2 Final Holding Tank T-171

Emissions Emissions Emissions

lb/lb·mol lb/batch tpy lb/batch tpy lb/batch tpy

Total VOC 201.05 1.902 0.050 1.902 0.050 12.663 0.329

Benzene 78.11 0.0823 0.0021 0.0823 0.0021 0.4917 0.0128

Biphenyl 154.20 0.0001 0.0000 0.0001 0.0000 0.0005 0.0000

Toluene 92.13 0.2814 0.0073 0.2814 0.0073 1.7571 0.0457

Ethylbenzene 106.17 0.2160 0.0056 0.2160 0.0056 1.4116 0.0367

p-Xylene 106.17 0.1309 0.0034 0.1309 0.0034 0.8672 0.0225

m-Xylene 106.17 0.1309 0.0034 0.1309 0.0034 0.8672 0.0225

o-Xylene 106.17 0.1309 0.0034 0.1309 0.0034 0.8672 0.0225

Cumene 120.20 0.0436 0.0011 0.0436 0.0011 0.2975 0.0077

Styrene 104.15 0.0734 0.0019 0.0734 0.0019 0.4886 0.0127

Naphthalene 128.17 0.0067 0.0002 0.0067 0.0002 0.0541 0.0014

Total HAP 1.096 0.029 1.096 0.029 7.103 0.185

Holding Tanks #1 & #2 and Final Holding Tank T-171 – Solvent Flush

Tanks are washed with solvent flushes, which cause displacement of reactor vapors, once per product change.

The solvent is crude mix solvent (CMS). Assumptions include:

1. Vapors are saturated with CMS.


Table 14c: Holding Tank Solvent Flush Parameters

No. of Flushes Flush

Volume

Level

%

Flush Volume Pressure Temperature

flushes/

batch

flushes/

year cf/batch cf/yr psia °F °R

Holding Tank #1 1 52

100

548.1 28,501

14.696 68 527.7 Holding Tank #2 1 52 548.1 28,501

Final Holding Tank 1 52 2,339.4 121,650

Emissions were calculated using the same methodology as used for the material charging of the holding tanks.


Table 14d: Holding Tank Solvent Flush Emissions

Pollutant

Molec.

Wt.

Liq.

Wt.

Vapor

Pres.

Holding Tank #1 Holding Tank #2 Final Holding Tank

T-171


lb/lb·mol % psia lb/batch tpy lb/batch tpy lb/batch tpy

Total VOC 201.05 0.737 0.019 0.737 0.019 3.145 0.082

Benzene 78.11 0.10 1.4439 0.0167 0.0004 0.0167 0.0004 0.0714 0.0019

Biphenyl 154.20 0.00 0.0003 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Toluene 92.13 1.20 0.4226 0.0588 0.0015 0.0588 0.0015 0.2508 0.0065

Ethylbenzene 106.17 1.40 0.1364 0.0221 0.0006 0.0221 0.0006 0.0945 0.0025

p-Xylene 106.17 1.50 0.0947 0.0165 0.0004 0.0165 0.0004 0.0702 0.0018

m-Xylene 106.17 4.40 0.0965 0.0492 0.0013 0.0492 0.0013 0.2100 0.0055

o-Xylene 106.17 2.40 0.0965 0.0268 0.0007 0.0268 0.0007 0.1145 0.0030

Cumene 120.20 0.50 0.0470 0.0027 0.0001 0.0027 0.0001 0.0116 0.0003

Styrene 104.15 0.70 0.0872 0.0071 0.0002 0.0071 0.0002 0.0302 0.0008

Naphthalene 128.17 4.70 0.0008 0.0004 0.0000 0.0004 0.0000 0.0018 0.0000

Total HAP 0.200 0.005 0.200 0.005 0.855 0.022

Aqueous Treaters (#4, #10, & #11) – Material Charging





Table 15a: Aqueous Treater Material Charging Parameters

Batch Size

No. of

Batches Volume Displaced

gal/batch batches/yr cf/batch cf/yr

#4 Aqueous Treater 21,000 221 2,807.3 621,684

#10 Aqueous Treater 9,600 363 1,283.3 466,263

#11 Aqueous Treater 11,800 296 1,577.4 466,263



Where:





Table 15b: Aqueous Treater Material Charging Emissions

Pollutant

Molec. Wt. Aqueous Treater #4 Aqueous Treater #10 Aqueous Treater #11


lb/lb·mol lb/charge tpy lb/charge tpy lb/charge tpy

Total VOC 201.05 16.884 1.869 7.718 1.402 9.487 1.402

Benzene 78.11 0.656 0.073 0.300 0.054 0.368 0.054

Biphenyl 154.20 0.001 0.000 0.000 0.000 0.000 0.000

Toluene 92.13 2.343 0.259 1.071 0.195 1.316 0.195

Ethylbenzene 106.17 1.882 0.208 0.860 0.156 1.058 0.156

p-Xylene 106.17 1.156 0.128 0.529 0.096 0.650 0.096

m-Xylene 106.17 1.156 0.128 0.529 0.096 0.650 0.096

o-Xylene 106.17 1.156 0.128 0.529 0.096 0.650 0.096

Cumene 120.20 0.397 0.044 0.181 0.033 0.223 0.033

Styrene 104.15 0.651 0.072 0.298 0.054 0.366 0.054

Naphthalene 128.17 0.072 0.008 0.033 0.006 0.041 0.006

Total HAP 9.470 1.049 4.329 0.786 5.321 0.486

Aqueous Treaters (#4, #10, & #11) – Water Washes

For each batch, there are three (3) water washes. The first is water/caustic wash, where the water/caustic

mixture is added to the first vessel. No volatile emissions are expected during this wash. Two (2) more washes

are performed after the poly oil addition, where volatile emissions may be expected due to displacement. It is

assumed that the volume of gas displaced during the last two washes is equal to the volume of water added.



Table 15c: Aqueous Treater Water Wash Parameters

Vol. per

Wash Washes

per

Batch

No. of


gal/batch batches/

yr cf/batch cf/yr

#4 Aqueous Treater 3,100 2 221 828.8 183,545

#10 Aqueous Treater 1,500 2 363 401.0 145,707

#11 Aqueous Treater 2,100 2 296 561.5 165,958

Emissions were calculated using the same methodology as used for the material charging of the aqueous

treaters.


Table 15d: Aqueous Treater Water Wash Emissions

Pollutant

Molec. Wt. Aqueous Treater #4 Aqueous Treater #10 Aqueous Treater #11


lb/lb·mol lb/charge tpy lb/charge tpy lb/charge tpy

Total VOC 201.05 4.985 0.552 2.412 0.438 3.377 0.499

Benzene 78.11 0.194 0.021 0.094 0.017 0.131 0.019

Biphenyl 154.20 0.000 0.000 0.000 0.000 0.000 0.000

Toluene 92.13 0.692 0.077 0.335 0.061 0.469 0.069

Ethylbenzene 106.17 0.556 0.062 0.269 0.049 0.376 0.056

p-Xylene 106.17 0.341 0.038 0.165 0.030 0.231 0.034

m-Xylene 106.17 0.341 0.038 0.165 0.030 0.231 0.034

o-Xylene 106.17 0.341 0.038 0.165 0.030 0.231 0.034

Cumene 120.20 0.117 0.013 0.057 0.010 0.079 0.012

Styrene 104.15 0.192 0.021 0.093 0.017 0.130 0.019

Naphthalene 128.17 0.021 0.002 0.010 0.002 0.014 0.002

Total HAP 2.796 0.310 1.353 0.246 1.894 0.280

Aqueous Treaters (#4, #10, & #11) – Material Heat-Up

When the heated water from the last two water washes is added to the vessels, it increases the temperature of the

intermediate, causing the vapor space to expand. This temperature increase occurs for every batch for the

second and third water washes.



Table 15e: Aqueous Treater Material Heat-Up Parameters

Vessel

Vol.

Batch

Size

Water

Vol.

Total

Vol.

Free

Space Heat-ups

per

Batch gal. gal/batch gal/batch gal/batch gal.

#4 Treater 27,000 21,000 3,100 24,100 2,900 2.0

#10 Treater 12,500 9,600 1,500 11,100 1,400 2.0

#11 Treater 15,200 11,800 2,100 13,900 1,300 2.0


E = [(PiT1/Pa1 + PiT2/Pa2)/2] × Delta(n) × MWi × H

Where:

E = Mass of emissions H = Number of heat-ups




Delta(n) = V/R × [(Pa1/T1) – (Pa2/T2)]





Note: Batches per year can be found in Table 15c.


Table 15f: Aqueous Treater Material Heat-Up Emissions

Pollutant

Molec

Wt.

Aqueous Treater #4 Aqueous Treater #10 Aqueous Treater #11


lb/lb·mol lb/

charge tpy

lb/

charge tpy

lb/

charge tpy

Total VOC 201.05 0.255 0.028 0.123 0.022 0.114 0.017

Benzene 78.11 0.009 0.001 0.004 0.001 0.004 0.001

Biphenyl 154.20 0.000 0.000 0.000 0.000 0.000 0.000

Toluene 92.13 0.034 0.004 0.016 0.003 0.015 0.002

Ethylbenzene 106.17 0.028 0.003 0.014 0.002 0.013 0.002

p-Xylene 106.17 0.017 0.002 0.008 0.002 0.008 0.001

m-Xylene 106.17 0.017 0.002 0.008 0.002 0.008 0.001

o-Xylene 106.17 0.017 0.002 0.008 0.002 0.008 0.001

Cumene 120.20 0.006 0.001 0.003 0.001 0.003 0.000

Styrene 104.15 0.010 0.001 0.005 0.001 0.004 0.001

Naphthalene 128.17 0.001 0.000 0.001 0.000 0.001 0.000

Total HAP 0.141 0.016 0.068 0.012 0.063 0.009

Continuous Stills - #3 & #4

The only emission points for the No. 3 and No. 4 Continuous Stills are the respective decanters. The only

emission episode would be the initial filling of distillate to the still column, decanter, heater tube, piping, and

overheads condenser. The liquid level of the decanter is then maintained at a constant level after the initial fill.

The still is operated at or near atmospheric conditions (there are no vacuum pumps or steam ejectors for these

stills). The following assumptions are used:

1. Vapors are saturated with distillate (the overheads from the still).

2. The decanter contains nitrogen as the remaining gas component.

3. All vapors discharge to the atmosphere.

Table 16a: Continuous Still Dimensions & Operating Parameters

No. 3 Continuous Still No. 4 Continuous Still

Column Volume 157.1 cubic feet 1,156.1 cubic feet

Decanter Volume 62.8 cubic feet 175.9 cubic feet

Heater Tube Volume 65.0 cubic feet 84.0 cubic feet

Side Stripper Volume n/a 29.2 cubic feet

SS Tank Volume n/a 15.7 cubic feet

Piping Volume 7.3 cubic feet 53.6 cubic feet

Condenser Volume 144.0 cubic feet 180.0 cubic feet

Normal Operating Liquid Level

(column & decanter) 90 % 90 %

Duration for Startup 2 hours 4 hours

Max. Number of Startups 1 start-up/day 1 start-up/day

365 start-ups/year 365 start-ups/year

Volume of Gas Displaced 414.2 cf/start-up 1561.4 cf/start-up

207.1 cf/hour 390.3 cf/hour

151,194 cf/year 569,899 cf/year


No. 3 Continuous Still No. 4 Continuous Still

System Pressure 0 psig 0 psig

System Temperature 131 °F 131 °F

590.67 °R 590.67 °R



Where:




Table 16b: Continuous Still No. 3 & No. 4 Emissions

Constituent

M.W. No. 3 Continuous Still No. 4 Continuous Still

lb/lb·mol lb/product

change tpy

lb/product

change tpy

Total VOC 112.55 13.996 2.554 75.998 13.870

Benzene 78.11 0.018 0.003 0.068 0.012

Biphenyl 154.20 0.000 0.000 0.000 0.000

Toluene 92.13 0.562 0.103 2.075 0.379

Ethylbenzene 106.17 0.315 0.058 1.165 0.213

Xylenes 106.20 0.692 0.126 2.554 0.466

Cumene 120.20 0.026 0.005 0.096 0.018

Styrene 104.15 0.043 0.008 0.160 0.029

Naphthalene 128.17 0.003 0.001 0.013 0.002

Total HAP 1.660 0.303 6.130 1.119

Packaging Centers

Emissions from the packaging centers consist of those emissions from the kettles, the flaker belts, and the

baghouses. The #3 Packaging Center also has emissions from pouring stations. Emissions factors were

determined from the October, 2007 stack test on the new #2 Packaging Center (for the #2 and #5 pkg. centers)

and the August 2005 stack test on the old #2-2 Packaging Center (for the #3 pgk. center). It is assumed that the

vapor composition in the flaking belt exhaust is the same as that in the kettle exhaust.

The No. 2 Packaging Center was originally permitted under Installation Permit #0060-I007, and the No. 5

Packaging Center Flaker Belt under Installation Permit #0060-I008. A 10% adjustment factor was added to the

kettle and flaker belt emissions from the No. 3 Packaging Center to account for variability in the test results.

Maximum throughputs:

No. 2 pkg. center: 87,600,000 lb/yr of resin



Hours of operation: 8,760 hours/year


Kettle Emissions

VOC emissions factors for kettle emissions were determined by organic vapor analyzer (OVA) readings:

Blowing into empty kettles = 0.05 lb/100,000 lbresin

Pumping into kettles = 1.35 lb/100,000 lbresin

Line blowing of empty kettles = 0.21 lb/100,000 lbresin

Nitrogen blanket on resin drain kettles = 28.0 lb/100,000 lbresin

Nitrogen blanketing on solution kettles = 2.7 lb/100,000 lbresin

Total VOC = 32.31 lb/100,000 lbresin

Table 17a: Kettle Emissions

Process Pollutant

Emission Factor Emissions

lb/lb VOC1,2 lb/hr tpy

No. 2 Kettles3

(7 kettles) Total VOC 3.23×10-4 3.553 15.562

Benzene 1.08×10-4 0.0004 0.002

Ethylbenzene 3.05×10-3 0.0108 0.047

Naphthalene 7.89×10-3 0.0280 0.123

Styrene 3.14×10-3 0.0112 0.049

Xylenes 6.99×10-3 0.0248 0.109

Total HAP 2.31×10-2 0.082 0.359

No. 3 Kettles


Benzene 8.13×10-5 0.0004 0.002

Ethylbenzene 1.55×10-3 0.0077 0.034

Naphthalene 2.50×10-2 0.1243 0.544

Styrene 1.23×10-3 0.0061 0.027

Xylenes 2.43×10-3 0.0121 0.053

Total HAP 3.24×10-2 0.161 0.706

No. 5 Kettles


Benzene 8.13×10-5 0.0003 0.001

Ethylbenzene 1.55×10-3 0.0050 0.022

Naphthalene 2.50×10-2 0.0799 0.350

Styrene 1.23×10-3 0.0039 0.017

Xylenes 2.43×10-3 0.0078 0.034

Total HAP 3.24×10-2 0.104 0.454

1. The VOC emission factor is in lb/lb of resin.

2. Since the HAP factors are based on VOC, the 10% adjustment factor was added only to the VOC emissions numbers.

3. Calculated numbers for the No. 2 Packaging Center were not used in the TVOP; the IP #0060-I007 limits were used

instead.


Flaking Belt Emissions

Table 17b: Flaking Belt Emissions

Process Pollutant


lb/lb resin lb/hr tpy

No. 2 Belt1 Total VOC 0.338 1.859 8.142

Benzene 3.64×10-5 0.001 0.001

Ethylbenzene 1.03×10-3 0.006 0.025

Naphthalene 2.67×10-3 0.015 0.064

Styrene 1.06×10-3 0.006 0.026

Xylenes 2.36×10-3 0.013 0.057

Total HAP 7.82×10-3 0.043 0.188

No. 3 Belt Total VOC 0.507 3.903 17.094

Benzene 4.12×10-5 0.001 0.001

Ethylbenzene 7.87×10-4 0.006 0.027

Naphthalene 1.27×10-2 0.098 0.428

Styrene 6.25×10-4 0.005 0.021

Xylenes 1.23×10-3 0.009 0.041

Total HAP 1.64×10-2 0.126 0.553

No. 5 Belt Total VOC 0.338 1.672 7.324

Benzene 3.64×10-5 0.000 0.001

Ethylbenzene 1.03×10-3 0.002 0.007

Naphthalene 2.67×10-3 0.005 0.022

Styrene 1.06×10-3 0.013 0.058

Xylenes 2.36×10-3 0.005 0.023

Total HAP 7.82×10-3 0.039 0.169

1. Calculated numbers for the No. 2 Packaging Center were not used in the TVOP; the IP #0060-

I007 limits were used instead.

No. 3 Pouring Stations

VOC emissions from the pouring stations were based on the methodology found in U.S. EPA AP-42 Section

5.2, Transportation and Marketing of Petroleum Liquids (6/08):

LL = 12.46 × (SPM ÷ T)

Where:

S = saturation factor = 1.45 for splash loading

P = true vapor pressure of liquid loaded, psia = 0.097 psia

M = molecular weight of vapors, lb/lb·mol = 120 lb/lb·mol

T = temperature of bulk liquid loaded, °R = 888 °R

LL = loading loss, lb/103 gallons of liquid loaded = 0.237 lbVOC/103 gal

Maximum Throughputs:

Portable Station No. 3 Station

Max. throughput, lb/yr: 1,000,000 122,000,000

Density: 8.5 lb/gal

Pour rate: 30 gal/min

Max. throughput, gal/yr: 117,647 14,352,941

Max. throughput, gal/hr: 1,800 1,800


Table 17c: No. 3 Pouring Station Emissions

Process Pollutant


lb/lb VOC1,2 lb/hr tpy

Portable Pouring

Station Total VOC 0.237 lb/103 gal 0.469 0.015

Benzene 8.13×10-5 0.000 0.000

Ethylbenzene 1.55×10-3 0.001 0.000

Naphthalene 2.50×10-2 0.012 0.001

Styrene 1.23×10-3 0.001 0.000

Xylenes 2.43×10-3 0.001 0.000

Total HAP 3.24×10-2 0.015 0.001

No. 3 Pouring

Station Total VOC 0.237 lb/103 gal 0.469 1.870

Benzene 8.13×10-5 0.000 0.000

Ethylbenzene 1.55×10-3 0.001 0.003

Naphthalene 2.50×10-2 0.012 0.051

Styrene 1.23×10-3 0.001 0.003

Xylenes 2.43×10-3 0.001 0.005

Total HAP 3.24×10-2 0.015 0.067

1. The VOC emission factor is in lb/lb of resin.

2. Since the HAP factors are based on VOC, the 10% adjustment factor was added only to the

VOC emissions numbers.

Bagging Emissions

Particulate emissions from the packaging center baghouses are based on the following information. All PM is

assumed to be PM10, and all PM10 is assumed to be PM2.5.

Table 17d: Bagging Emissions

No. 2 Packaging

Center Baghouse

No. 3 Packaging

Center Baghouse

No. 5 Packaging

Center Baghouse

Flow: 4,850 acfm 3,000 acfm 3,000 acfm

4,445 dscfm 2,905 dscfm 2,905 dscfm

Temperature: 560 °R 530 °R 530 °R

Moisture: 2.8 % 2.8 % 2.8 %

Loading: 0.01 gr/dscf 0.01 gr/dscf 0.01 gr/dscf

Emissions: 0.381 lb/hr 0.249 lb/hr 0.249 lb/hr

1.669 tpy 1.091 tpy 1.091 tpy


Packaging Center Summary

Table 18: Summary of Packaging Center Emissions

Summary of Packaging Center Emissions – tpy

PM Total

VOC

Total

HAP Benzene

Ethyl-

benzene

Naph-

thalene Styrene Xylenes

No. 2

Packaging

Center1

Kettles -- 15.562 0.359 0.002 0.047 0.123 0.049 0.109

Flaking/

Bagging 1.669 8.142 0.188 0.001 0.025 0.064 0.026 0.057

Total 1.669 23.705 0.548 0.003 0.072 0.187 0.074 0.166

No. 3

Packaging

Center

Kettles -- 21.780 0.706 0.002 0.034 0.544 0.027 0.053

Flaking/

Bagging 1.091 17.094 0.553 0.001 0.027 0.428 0.021 0.041

Pouring -- 1.870 0.067 0.000 0.003 0.051 0.003 0.005

Total 1.091 38.873 1.259 0.003 0.060 0.937 0.048 0.094

No. 5

Packaging

Center

Kettles -- 13.999 0.454 0.001 0.022 0.350 0.017 0.034

Flaking/

Bagging 1.091 7.324 0.169 0.001 0.022 0.058 0.023 0.051

Total 1.091 21.323 0.623 0.002 0.044 0.408 0.040 0.085

1. Emissions from the No. 2 Packaging Center are based on the limits from IP #0060-I007.

Heat Poly Still Process Heaters

All emissions from the Heat Poly Still Process Heaters, except for particulate matter, were based on factors

found in U.S. EPA AP-42 Section 1.4: Natural Gas Combustion (7/98) and Section 1.5: Liquified Petroleum

Gas Combustion (7/08). Particulate matter emissions limits are those found in Article XXI, §2104.02.a.1.A. A

15% adjustment was added to all emissions calculated with AP-42 factors to account for operational variability.

All PM is assumed to be PM10, and all PM10 is assumed to be PM2.5.




500 hours/year on propane

Table 19: Heat Poly Still Process Heater Emissions Limitations

Pollutant

AP-42 Factors1

No. 15 Still Heater No. 16 Still Heater

7.5 MMBtu/hr 6.1 MMBtu/hr

nat. gas propane n.g. prop. max. n.g. prop. max.

lb/106 scf lb/10

3 gal lb/hr lb/hr tpy lb/hr lb/hr tpy

PM1 0.0081 0.7 0.060 0.066 0.264 0.049 0.054 0.215

PM101 0.0081 0.7 0.060 0.066 0.264 0.049 0.054 0.215

PM2.51 0.0081 0.7 0.060 0.066 0.264 0.049 0.054 0.215

NOX 100 13 0.846 1.225 3.799 0.688 0.997 3.090

SOX 0.6 0.002 0.005 0.000 0.021 0.004 0.000 0.017

CO 84 7.5 0.710 0.707 3.110 0.578 0.575 2.530

VOC 5.5 1 0.047 0.094 0.216 0.038 0.077 0.175

HAP 1.9 -- 0.016 0.066 0.013 0.054

Formald. 7.5×10-2 -- 0.001 0.003 0.001 0.002


Pollutant

No. 18 Still Heater No. 19 Still Heater No. 43 Still Heater

8.0 MMBtu/hr 7.5 MMBtu/hr 7.5 MMBtu/hr

n.g. prop. max. n.g. prop. max. n.g. prop. max.

lb/hr lb/hr tpy lb/hr lb/hr tpy lb/hr lb/hr tpy

PM1 0.064 0.070 0.282 0.060 0.066 0.264 0.060 0.066 0.264

PM101 0.064 0.070 0.282 0.060 0.066 0.264 0.060 0.066 0.264

PM2.51 0.064 0.070 0.282 0.060 0.066 0.264 0.060 0.066 0.264

NOX 0.902 1.307 4.052 0.846 1.225 3.799 0.846 1.225 3.799

SOX 0.005 0.000 0.022 0.005 0.000 0.021 0.005 0.000 0.021

CO 0.758 0.754 3.318 0.710 0.707 3.110 0.710 0.707 3.110

VOC 0.050 0.101 0.230 0.047 0.094 0.216 0.047 0.094 0.216

HAP 0.017 0.071 0.016 0.066 0.016 0.066

Formald. 0.001 0.003 0.001 0.003 0.001 0.003

1. Emission factors for PM, PM10, and PM2.5 are from Article XXI, §2104.02.a.1.A (lb/MMBtu).

Continuous Still Process Heaters

All emissions from the No. 3 and No 4 Continuous Still Process Heaters, except for particulate matter, were

based on factors found in U.S. EPA AP-42 Section 1.4: Natural Gas Combustion (7/98) and Section 1.5:

Liquefied Petroleum Gas Combustion (7/08). Particulate matter emissions limits are those found in Article XXI,

§2104.02.a.1.A. A 15% adjustment was added to all emissions calculated with AP-42 factors to account for

operational variability. All PM is assumed to be PM10, and all PM10 is assumed to be PM2.5.



Propane rating: 91,500 Btu/gallon



Table 20: No. 3 & No. 4 Continuous Still Process Heater Emission Limitations

Pollutant

AP-42 Factors1

No. 3 Continuous Still Process

Heater

No. 4 Continuous Still Process

Heater

Natural

Gas

Liquid

Propane 5.25 MMBtu/hr 10.5 MMBtu/hr

lb/106 scf lb/10

3 gal lb/hr NG lb/hr LPG tpy lb/hr NG lb/hr LPG tpy

PM1

0.008

lb/MMBtu 0.7 0.042 -- 0.184 0.084 0.092 0.370

PM101

0.008

lb/MMBtu 0.7 0.042 -- 0.184 0.084 0.092 0.370

PM2.51

0.008

lb/MMBtu 0.7 0.042 -- 0.184 0.084 0.092 0.370

NOX 100 13 0.592 -- 2.593 1.184 1.716 5.318

SOX 0.6 0.002 0.004 -- 0.016 0.007 0.001 0.029

CO 84 7.5 0.497 -- 2.178 0.994 0.990 4.354

VOC 5.5 1 0.033 -- 0.143 0.065 0.132 0.302

HAP 1.9 -- 0.011 -- 0.049 0.001 0.004

Formaldeyde 7.5×10-2 -- 0.000 -- 0.049 0.022 0.093

1. Emission factors for PM, PM10, and PM2.5 are from Article XXI, §2104.02.a.1.A (lb/MMbtu).


Packaging Center Heaters

All emissions from the Packaging Center Heaters, except for particulate matter, were based on factors found in

U.S. EPA AP-42 Section 1.4: Natural Gas Combustion (7/98) and Section 1.5: Liquefied Petroleum Gas

Combustion (7/08). Particulate matter emissions limits are those found in Article XXI, §2104.02.a.1.A. A 15%

adjustment was added to all emissions calculated with AP-42 factors to account for operational variability.




Propane rating: 91,500 Btu/gallon



Table 21: Packaging Center Heater Emissions Limitations

Pollutant

AP-42 Factors1

No. 2 Packaging Center

Heater


Heater


Heater

Natural

Gas

Liquid

Propane 5.0 MMBtu/hr 3.91 MMBtu/hr 3.0 MMBtu/hr

lb/106 scf lb/103

gal lb/hr

nat. gas

lb/hr propane

tpy lb/hr

nat. gas

lb/hr propane

tpy lb/hr

nat. gas

lb/hr propane

tpy

PM 0.008

lb/MMBtu 0.7 0.040 0.044 0.176 0.031 0.034 0.138 0.024 0.026 0.106

PM10 0.008

lb/MMBtu 0.7 0.040 0.044 0.176 0.031 0.034 0.138 0.024 0.026 0.106

PM2.5 0.008

lb/MMBtu 0.7 0.040 0.044 0.176 0.031 0.034 0.138 0.024 0.026 0.106

NOX 100 13 0.564 0.817 2.532 0.441 0.639 1.980 0.338 0.490 1.519

SOX 0.6 0.002 0.003 0.001 0.014 0.003 0.000 0.011 0.002 0.001 0.008

CO 84 7.5 0.474 0.471 2.074 0.370 0.369 1.621 0.284 0.283 1.244

VOC 5.5 1 0.040 0.044 0.176 0.024 0.049 0.112 0.024 0.026 0.106

HAP 1.9 -- 0.011 0.044 0.001 0.035 0.001 0.001

Formal-

dehyde 7.5×10-2 -- 0.001 0.002 0.008 0.001 0.006 0.027

1. Emission factors for PM, PM10, and PM2.5 are from Article XXI, §2104.02.a.1.A (lb/MMBtu).

Wastewater Collection, Conveyance, and Treatment

In January 2008, a comprehensive review of the Wastewater Collection, Conveyance, and Treatment System

was conducted by Malcolm Pirnie, Inc. The study, titled Hazardous Air Pollutants (HAPs) and Volatile

Organic Compounds (VOCs) Emission Estimate for Wastewater Conveyance and Treatment, can be found in the

Title V Operating Permit application under Appendix A. Emission factors for the wastewater conveyance

system and the wastewater treatment system were taken directly from that study.

Wastewater Conveyance

Hours of operation = 8,760 hours/year


Table 22: Wastewater Conveyance System

PID1

Units Qty.

Emission Factors – lb/hr/source Total HAP

Emissions

Benzene Toluene Ethyl-

Benzene Styrene Cumene Xylenes

Total

HAP lb/hr tpy

10 40 8.92×10-8 1.04×10-6 2.48×10-6 4.10×10-6 1.68×10-6 2.00×10-5 2.94×10-5 0.001 0.005

50 44 4.46×10-7 5.20×10-6 1.24×10-5 1.66×10-5 8.39×10-6 9.98×10-5 1.43×10-4 0.006 0.028

100 20 8.92×10-7 1.04×10-5 2.48×10-5 3.04×10-5 1.68×10-5 2.00×10-4 2.83×10-4 0.006 0.025

500 30 4.46×10-6 5.20×10-5 1.24×10-4 1.23×10-4 8.39×10-5 9.98×10-4 1.39×10-3 0.042 0.182

1,000 26 8.92×10-6 1.04×10-4 2.48×10-4 2.25×10-4 1.68×10-4 2.00×10-3 2.75×10-3 0.072 0.313

2,000 15 1.78×10-5 2.08×10-4 4.97×10-4 4.12×10-4 3.36×10-4 3.99×10-3 5.46×10-3 0.082 0.359

3,000 3 2.68×10-5 3.12×10-4 7.45×10-4 5.86×10-4 5.03×10-4 5.99×10-3 8.16×10-3 0.024 0.107

4,000 0 3.57×10-5 4.16×10-4 9.94×10-4 7.53×10-4 6.71×10-4 7.99×10-3 1.09×10-2 0.000 0.000

5,000 1 4.46×10-5 5.20×10-4 1.24×10-3 9.15×10-4 8.39×10-4 9.98×10-3 1.35×10-2 0.014 0.059

Total HAP Emissions: 0.246 1.078

Total VOC Emissions2: 0.767 3.360

1. Photo Ionization Detector (PID) readings (ppm).

2. Calculated in the Malcolm Pirnie Report using the same methodology as for HAP emissions.

Wastewater Treatment


Total flow = 105,000,000 gallons/year

Table 23: Wastewater Treatment System

Pollutant

Factor Batch Tanks

Emissions

Equalization Tank

Emissions

Biological System

Emissions Total Emissions

lbs/106

gal lb/hr tpy lb/hr tpy lb/hr tpy lb/hr tpy

1,3-Butadiene 0.098 0.0012 0.005 0.0000 0.000 0.0000 0.000 0.001 0.005

Benzene 0.068 0.0008 0.004 0.0003 0.001 0.0002 0.001 0.001 0.006

Carbon

Disulfide 0.119 0.0014 0.006 0.0000 0.000 0.0000 0.000 0.001 0.006

Cumene 0.833 0.0100 0.044 0.0008 0.004 0.0004 0.002 0.011 0.050

Ethylbenzene 4.42 0.0530 0.232 0.0179 0.078 0.0092 0.040 0.080 0.350

Hexane 0.137 0.0016 0.007 0.0000 0.000 0.0000 0.000 0.002 0.007

Methylene

Chloride 0.094 0.0011 0.005 0.0000 0.000 0.0000 0.000 0.001 0.005

Naphthalene 0.014 0.0002 0.001 0.0188 0.082 0.0013 0.005 0.020 0.088

Phenol 0.0000 0.000 0.0004 0.002 0.0000 0.000 0.000 0.002

Styrene 1.95 0.0234 0.102 0.0192 0.084 0.0829 0.363 0.125 0.549

Toluene 0.511 0.0061 0.027 0.0021 0.009 0.0017 0.007 0.010 0.043

Xylenes 20.6 0.2469 1.082 0.1075 0.471 0.1017 0.445 0.456 1.998

Total HAP 0.3457 1.514 0.167 0.731 0.197 0.863 0.710 3.108

Total VOC 195.8 2.3469 10.280 0.409 1.790 0.313 1.370 3.068 13.440

Resin Rework Tanks

Emissions from the Resin Rework Tanks are controlled by a double-pipe surface condenser with a control

efficiency of 80%. Total VOC emissions estimates were determined using the following equation:

VOClb/hr = (Cppm × MWpropane × Qcfm × 60min/hr) ÷ 385.3 ÷ 106


Where:

C = measured concentration (ppm) = 2,500 ppm (at the condenser vent)

MW = molecular weight of propane = 44.1 lb/lb·mol

Q = volumetric flow rate = 200 dscfm

Conversion factor = 385.3 ft3/lb·mol


A 10% adjustment factor was added to account for variability in the volumetric flowrate and measured

concentration.

Total VOC = (2,500 ppm × 44.1 lb/lb·mol × 200 scfm × 60 min/hr) ÷ 385.3 ft3/lb·mol ÷ 106 × (1 + 0.1)

= 3.777 lb/hr of VOC (controlled)

= 16.544 tpy of VOC (controlled)

HAP emissions were calculated as a percentage of the total VOC emissions using the maximum weight percent

concentration and the vapor pressure. The following totals were calculated:

Total moles (liquid phase) = 0.966 lb·mol

Total pressure = 0.151 psia

Total molecular weight (vapor phase) = 101.965 lb/lb·mol

Sample Calculation for Benzene:

Maximum concentration = 0.040%wt

Molecular weight = 78.12 lb/lb·mol

True Vapor pressure = 1.522 psia

Mole fraction (liquid phase), Xi = (0.040 ÷ 78.12 lb/lb·mol) ÷ 0.966 lb·mol = 5.30×10-4

Partial pressure = 1.522 psia × 5.30×10-4 = 8.07×10-4 psia

Mole fraction (vapor phase), Yi = 8.07×10-4

psia ÷ 0.151 psia = 5.36×10-3

Vapor molecular weight = 5.36×10-3 × 78.12 lb/lb·mol = 0.417 lb/lb·mol

Vapor weight fraction = 0.417 lb/lb·mol ÷ 101.965 lb/lb·mol = 4.10×10-3

Benzene emissions = 4.10×10-3 × 3.434 lb/hrVOC × (1 + 0.1) = 0.015 lb/hr of benzene

= 4.10×10-3 × 15.040 tpyVOC × (1 + 0.1) = 0.068 tpy of benzene

Table 24: Resin Rework Tank HAP Emissions

Compound

Maximum

Concentration

Molecular

Weight

True Vapor

Pressure Controlled Emissions

wt. % lb·mol psia lb/hr tpy

1,3-Butadiene 0.003 54.09 23.162 0.018 0.077

Benzene 0.040 78.12 1.522 0.015 0.068

Biphenyl 0.000 154.21 0.000 0.000 0.000

Cumene 0.010 120.20 0.051 0.000 0.001

Ethylbenzene 0.047 106.17 0.146 0.002 0.008

Naphthalene 5.000 128.17 0.001 0.001 0.006

n-Hexane 0.000 86.18 2.445 0.000 0.001

Styrene 0.145 104.15 0.093 0.003 0.015

Toluene 0.261 92.14 0.448 0.030 0.130

Xylenes 0.118 106.17 0.101 0.003 0.013

Unidentified 94.494 102.60 0.154 3.704 16.225

Total HAP: 0.073 0.319


Final Product Loading

The Final Product Loading consists of two types of loading: Barge Loading and Tankcar/Tankwagon Loading.

Emissions were estimated using the saturation factor method found in U.S. EPA AP-42 Section 5.2:

Transportation and Marketing of Petroleum Liquids (6/08). A saturation factor of 0.5 (submerged fill) was used

for barge loading, and the loading loss emission factor was calculated using the following equation:

LL = 12.46 × (SPM ÷ T)

Where:

LL = loading loss, lb/103 gallons of liquid loaded

S = saturation factor

P = true vapor pressure of liquid loaded, psia

M = molecular weight of vapors, lb/lb·mol

T = temperature of bulk liquid loaded, °R

Barge Loading – LX-830

Emissions from the barge loading were determined using the following basis:

Transfer rate to barges = 850 gal/min = 51,000 gal/hr

Annual quantity transferred = 6,000,000 gal/year

Loading temperature = 60 °F = 520 °R

VOC and HAP emissions were calculated using the maximum weight percent concentration and the vapor

pressure. The following totals were calculated:


True vapor pressure = 0.274 psia


Loading loss factor LL = 12.46 × (0.5 × 0.274 × 79.366 ÷ 520) = 0.261 lb/103 gal

Sample Calculation for Benzene:

Maximum concentration = 0.070%wt

Molecular weight = 78.12 lb/lb·mol

True Vapor pressure = 1.163 psia

Mole fraction (liquid phase), Xi = (0.070 ÷ 78.12 lb/lb·mol) ÷ 0.811 lb·mol = 1.10×10-3

Partial pressure = 1.163 psia × 1.10×10-3 = 1.28×10-3 psia

Mole fraction (vapor phase), Yi = 1.28×10-3 psia ÷ 0.274 psia = 4.67×10-3

Vapor molecular weight = 4.67×10-3 × 78.12 lb/lb·mol = 0.366 lb/lb·mol

Vapor weight fraction = 0.366 lb/lb·mol ÷ 79.366 lb/lb·mol = 4.60×10-3

Benzene emissions = 0.261 lb/103 gal × 51,000 gal/hr ÷ 1,000 gal/103 gal × 4.60×10-3

= 0.061 lb/hr of benzene

= 0.261 lb/103gal × 6,000,000 gal/yr ÷ 1,000 gal/103 gal × 4.60×10-3

÷ 2,000lb/ton

= 0.004 tpy of benzene


Table 25: Barge Loading Emissions

Concentration

Molecular

Weight

Vapor

Pressure Vapor Wt.

Fraction

Emissions

wt. % lb/lb·mol psia lb/hr tpy

Total VOC 100.00 1.000 13.300 0.782

Benzene 0.07 78.1 1.163 0.005 0.061 0.004

Toluene 0.22 92.1 0.332 0.004 0.055 0.003

Ethylbenzene 1.80 106.2 0.104 0.011 0.141 0.008

Xylenes 6.00 106.2 0.072 0.024 0.323 0.019

Cumene 0.60 120.2 0.035 0.001 0.016 0.001

Styrene 0.80 104.2 0.066 0.003 0.040 0.002

Naphthalene 3.20 106.2 0.001 0.001 0.001 0.001

Total HAP 0.636 0.037

Tankcar & Tankwagon Loading – NCLR

Emissions from the barge loading were determined using the same method as for barge loading with a saturation

factor of 1.0 and the following basis:

Transfer rate to tankcars = 250 gal/min = 15,000 gal/hr

Annual quantity transferred = 24,300,000 gal/year

Loading temperature = 200 °F = 660 °R

VOC and HAP emissions were calculated using the maximum weight percent concentration and the vapor

pressure. The following totals were calculated:


True vapor pressure = 0.613 psia


Loading loss factor LL = 12.46 × (1.0 × 0.613 × 129.68 ÷ 660) = 1.501 lb/103 gal

Table 26: Tankcar & Tankwagon Loading Emissions

Concentration

Molecular

Weight

Vapor

Pressure Vapor Wt.

Fraction

Emissions

wt. % lb/lb·mol psia lb/hr tpy

Total VOC 100.000 1.0000 22.518 18.240

Biphenyl 0.005 154.2 2.682 0.0002 0.005 0.004

Naphthalene 0.050 106.2 13.705 0.0112 0.252 0.204

Unidentified 99.945 130.0 0.605 0.9886 22.261 18.031

Total HAP 0.257 0.208


Boilers

All emissions from Boiler #6, except for particulate matter were based on factors found in U.S. EPA AP-42

Section 1.4: Natural Gas Combustion (7/98). Particulate matter emissions limits are those found in Article XXI,

§2104.02.a.1.A. A 15% adjustment was added to all emissions calculated with AP-42 factors to account for

operational variability.

Emissions from Boiler #8 are based on the amended existing permit (IP #0060-I003a). However, the facility no

longer burns LX®-830 fuel oil in Boiler #8, so only the emissions from natural gas combustion are used.


Boiler #6 Permit #0060-I009 (issued 03/18/14)

Boiler #8 Permit #0060-I003a (issued 10/04/00, amended 04/05/11)



Hours of operation: 8,760 hours/year

Table 27: Boiler #6 & Boiler #8 Emissions

Pollutant AP-42

Factors

Boiler #6 Boiler #8

47.5 MMBtu/hr 29.5 MMBtu/hr

lb/106 scf lb/hr tpy lb/hr tpy

PM1 0.0081 0.395 1.731 0.236 1.034

PM101 0.0081 0.395 1.731 0.236 1.034

PM2.51 0.0081 0.395 1.731 0.236 1.034

NOX 100 5.411 23.698 1.663 7.284

SOX 0.6 0.033 0.142 0.020 0.087

CO 84 4.545 19.906 2.794 12.237

VOC 5.5 0.280 1.303 0.183 0.801

Total HAP 1.9 0.103 0.450 0.063 0.277

Formaldehyde 7.5×10-2 0.004 0.018 0.003 0.011

1. Article XXI, §2104.02.a.1.A, (lb/MMBtu).

Storage Tanks

Emissions from the tanks were estimated using the USEPA Tanks 4.0.9d program for each storage tank. Each

tank was then grouped by category. Total throughput emissions represent the maximum based on plant

production capacity, and not necessarily storage capacity.


Table 28: Storage Tank Emissions

Category

Max.

Thru-put

MMgal/yr

Potential Emissions – lbs/yr

Total

VOC Benzene Cumene

Ethyl-

Benzene

Naph-

thalene Styrene Toluene Xylenes

Total

HAP

Catalytic &

Misc. Poly Oil 22.0 7,570 7.31 13.06 23.94 2.73 4.34 12.99 116.15 180.52

Distillates 10.0 10,735 39.93 40.15 437.58 7.35 57.80 137.20 1,090.1 1,810.12

Heat Poly

Charge Stock 25.0 8,966 2.50 1.68 58.46 1.53 241.32 45.83 121.36 472.68

LX-1144

Charge Stock 0.1 25 0.06 0.02 0.04 0.00 19.77 0.06 0.18 20.13

Naphthenic/

Ink/ Veg. Oils 16.0 249 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Nevchem LR 3.2 131 0.59 0.00 0.00 0.11 0.00 0.00 0.00 0.70

Recovered Oil 1.2 222 5.50 1.11 8.21 0.11 0.70 2.17 25.19 42.99

Resin Former

(uncontrolled) 9.0 1,634 3.04 1.84 66.59 0.70 79.17 20.88 165.89 338.11

Resin Former

(controlled) 28.3 1,468 50.65 1.36 29.60 0.62 29.33 46.41 31.96 189.93

Resin

Solutions 24.3 43,186 0.00 0.00 0.00 14.66 0.00 0.00 0.00 14.66

Unit 20 Feed

Blend 9.0 1,462 2.79 1.71 61.65 0.65 73.32 19.26 153.65 313.03

Unit 21 Feed

Blend 13.0 5,482 4.21 7.28 13.48 1.47 56.10 7.41 65.32 155.27

Miscellaneous 2.3 2,898 0.13 0.05 0.30 0.02 0.09 0.13 0.03 0.75

Storage Tank

Totals 193.3 84,028 116.71 68.26 699.85 29.95 561.94 292.34 1,769.84 3,538.89

Category

Max.

Thru-put

MMgal/yr

Potential Emissions – tpy

Total

VOC Benzene Cumene

Ethyl-

Benzene

Naph-

thalene Styrene Toluene Xylenes

Total

HAP

Catalytic &

Misc. Poly Oil 22.0 3.79 0.004 0.007 0.012 0.001 0.002 0.006 0.058 0.090

Distillates 10.0 5.37 0.020 0.020 0.219 0.004 0.029 0.069 0.545 0.905

Heat Poly

Charge Stock 25.0 4.48 0.001 0.001 0.029 0.001 0.121 0.023 0.061 0.236

LX-1144

Charge Stock 0.1 0.01 0.000 0.000 0.000 0.000 0.010 0.000 0.000 0.010

Naphthenic/

Ink/ Veg. Oils 16.0 0.12 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.001

Nevchem LR 3.2 0.07 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.001

Recovered Oil 1.2 0.11 0.003 0.001 0.004 0.000 0.000 0.001 0.013 0.021

Resin Former

(uncontrolled) 9.0 0.82 0.002 0.001 0.033 0.000 0.040 0.010 0.083 0.169

Resin Former

(controlled) 28.3 0.73 0.025 0.001 0.015 0.000 0.015 0.023 0.016 0.095

Resin

Solutions 24.3 21.59 0.000 0.000 0.000 0.007 0.000 0.000 0.000 0.007

Unit 20 Feed

Blend 9.0 0.73 0.001 0.001 0.031 0.000 0.037 0.010 0.077 0.157

Unit 21 Feed

Blend 13.0 2.74 0.002 0.004 0.007 0.001 0.028 0.004 0.033 0.078

Miscellaneous 2.3 1.45 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.001

Storage Tank

Totals 193.3 42.01 0.058 0.034 0.350 0.015 0.281 0.146 0.885 1.769


Equipment Fugitives

Calculations for equipment leak fugitive emissions were based on the US EPA document Protocol for

Equipment Leak Emissions Estimates (November 1995, EPA-453/R-95-017), and components identified in a

comprehensive LDAR study conducted by Air/Compliance Consultants, Inc. in 2007. The study may be found

in Appendix B of the Neville Chemical Title V Operating Permit Application. Leak threshold values for each

type of component were taken from 40 CFR Part 63, Subpart UU – National Emission Standards for Equipment

Leaks – Control Level 2 Standards.

Components Above Leak Threshold: 2%

Components Below Leak Threshold: 98% (“default zero”)

Hours of Operation: 8,760 hours/year

The percent of HAP in the fugitive emissions was estimated by taking the five largest emitting processes

(Continuous Stills, Heat Polymerization Stills, Unit 20, and Unit 21), and calculating a mean-weighted average

of HAP emissions. Table 29a shows this estimation.

Table 29a: Fugitive HAP % Estimate

Process

Max.

Production

(MMlbs/yr

)

% of Total

Production

VOC PTE1

(tpy)

HAP PTE1

(tpy) % HAP

Adjusted

% HAP

No. 3 Cont. Still 67.2 12.0% 2.554 0.303 11.9% 0.0143

No. 4 Cont. Still 219.8 39.4% 13.871 1.119 8.1% 0.0318

Heat Poly. Stills 115.3 20.7% 191.549 5.176 2.7% 0.0056

Unit 20 66.6 11.9% 2.0951 0.223 10.6% 0.0127

Unit 21 89.4 16.0% 6.779 3.768 55.6% 0.0890

Est. HAP Percent: 558.3 15.33% 1. Potential-to-Emit prior to control.


Table 29b: HAP Emissions From Equipment Leaks

Equipment

Type Service Number

Screening

Value1

Emission Factor

Above Leak

Threshold2

“Default Zero”3

Emission Factor

Maximum

Emissions

ppmv kg/hr/

source

lb/hr/

source

kg/hr/

source

lb/hr/

source lb/hr tpy

Valves gas 147 500 4.25E-04 9.36E-04 6.60E-07 1.46E-06 2.96E-03 0.0130

Valves lt. liquid 1,697 500 9.08E-04 2.00E-03 4.90E-07 1.08E-06 6.97E-02 0.3053

Pump Seals lt. liquid 68 1,000 5.63E-03 1.24E-02 7.50E-06 1.65E-05 1.80E-02 0.0788

PRV gas 99 500 3.18E-03 7.02E-03 7.50E-06 1.65E-05 1.55E-02 0.0679

Agitator Seals gas 79 10,000 3.76E-02 8.28E-02 7.50E-06 1.65E-05 1.32E-01 0.5787

Agitator Seals lt. liquid 20 10,000 3.76E-02 8.28E-02 7.50E-06 1.65E-05 3.34E-02 0.1465

Flanges gas 592 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 2.03E-02 0.0887

Flanges lt. liquid 4,125 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 1.41E-01 0.6183

Screw Conn. gas 191 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 6.54E-03 0.0286

Screw Conn. lt. liquid 1,896 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 6.49E-02 0.2842

Manways gas 63 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 2.16E-03 0.0094

Manways lt. liquid 101 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 3.46E-03 0.0151

Gauge

Hatches gas

62 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 2.12E-03 0.0093

Instruments gas 80 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 2.74E-03 0.0120

Instruments lt. liquid 235 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 8.04E-03 0.0352

Open-Ended gas 42 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 1.44E-03 0.0063

Open-Ended lt. liquid 484 500 7.46E-04 1.65E-03 6.10E-07 1.34E-06 1.66E-02 0.0725

VOC Total: 2.370

HAP Total: 0.363

1. Definition of “leak” in 40 CFR Part 63, Subpart UU.

2. USEPA Protocol for Equipment Leak Emission Estimates, November 1995, Table 2-9.

3. USEPA Protocol for Equipment Leak Emission Estimates, November 1995, Table 2-11. Assumes all readings below leak threshold

are at or below background (i.e., “default zero”).

Groundwater Remediation

The Groundwater Remediation System consists of the following emission sources: oil recovery container

filling, No. 2 drywell, old No. 8 well, backwash tank, and fugitive emissions.

Oil Recovery Wells – Container Filling Emissions

Total VOC emissions were calculated using the following :

Vapor MW = 78.12 lb/lb·mol

Vapor pressure = 1.2 psia

Hourly volume = 315 gal/hr (7 wells at 45 gal/hr each)

Annual volume = 164,400 gal/yr

VOC emissions = (gallons) × (1 ft3/7.48 gal) × (1 mole/379 ft3) × (MW) × (vap. pres/14.7)


Table 30a: Oil Recovery Container Emissions

Compound

Vapor

Concentration Tote-Filling Tote-Filling Drum-Filling Total

% by wt. lbs/hr tpy tpy tpy

Total VOC 100.00 0.7085 0.1849 0.1849 0.3698

Benzene 1.92 0.0136 0.0036 0.0036 0.0071

Toluene 1.32 0.0094 0.0024 0.0024 0.0049

Styrene 0.08 0.0006 0.0001 0.0001 0.0003

Ethylbenzene 0.39 0.0028 0.0007 0.0007 0.0014

Xylenes 1.15 0.0081 0.0021 0.0021 0.0043

Cumene 0.06 0.0004 0.0001 0.0001 0.0002

Naphthalene 0.03 0.0002 0.0001 0.0001 0.0001

No. 2 Drywell and Old No. 8 Water Well Emissions

Emissions from these two systems were calculated using the U.S. EPA WATER 9 program and the following

flowrates:

No. 2 Drywell Old No. 8 Well

1,200 gal/hr 12,000 gal/hr

1,500,000 gal/year 520,000 gal/year

Table 30b: No. 2 Drywell & Old No. 8 Well Emissions

Compound No. 2 Drywell Old No. 8 Well

g/sec lb/gal lb/hr tpy g/sec lb/gal lb/hr tpy

Total VOC 2.39×10-4 1.58×10-6 0.0019 0.0012 2.39×10-3 1.58×10-6 0.0190 0.0004

Benzene 8.02×10-5 5.30×10-7 0.0006 0.0004 8.01×10-4 5.30×10-7 0.0064 0.0001

Toluene 1.95×10-5 1.29×10-7 0.0002 0.0001 1.95×10-4 1.29×10-7 0.0015 0.0000

Styrene 3.18×10-6 2.10×10-8 0.0000 0.0000 3.17×10-5 2.10×10-8 0.0003 0.0000

Ethylbenzene 2.84×10-5 1.88×10-7 0.0002 0.0001 2.84×10-4 1.88×10-7 0.0023 0.0000

Xylenes 3.30×10-5 2.18×10-7 0.0003 0.0002 3.30×10-4 2.18×10-7 0.0026 0.0001

Cumene 1.24×10-5 8.20×10-8 0.0001 0.0001 1.24×10-4 8.20×10-8 0.0010 0.0000

Naphthalene 7.17×10-6 4.74×10-8 0.0001 0.0000 7.16×10-5 4.74×10-8 0.0006 0.0000

Total HAP 0.0019 0.0012 0.0189 0.0004

Groundwater Remediation System Equipment Leaks

SOCMI emission factors used for calculating equipment leak emissions were taken from U.S. EPA’s “Protocol

for Equipment Leak Emission Estimates”, 1995.


Table 30c: Groundwater Remediation Equipment Leak Emissions

Valves Press.

Relief Pumps Flanges

Screwed

Connect. Hours

per year

VOC Emissions SOCMI Factor

(lb/hr/source) 0.000363 0.0983 0.00411 0.000178 0.000178

Equipment Count lb/hr tpy

Carbon

Adsorption 82 1 3 41 9

8,760

0.149 0.654

Water Wells 55 0 7 2 1 0.049 0.216

Oil Recovery

Wells 55 0 7 2 1 0.049 0.216

Totals 192 1 17 45 11 0.248 1.086

Groundwater Remediation System Summary

Table 31: Summary of Groundwater Remediation System Emissions

Compound

Oil Recovery

Wells

Backwash

Tank

No. 2

Drywell No. 8 Well

Equipment

Leaks

Total

Emissions

tpy tpy tpy tpy tpy tpy

Total VOC 0.3698 0.0010 0.0012 0.0004 1.086 1.458

Benzene 0.0071 0.0004 0.0001 0.008

Toluene 0.0049 0.0001 0.0000 0.005

Styrene 0.0003 0.0000 0.0000 0.000

Ethylbenzene 0.0014 0.0001 0.0000 0.002

Xylene 0.0043 0.0002 0.0001 0.004

Cumene 0.0002 0.0001 0.0000 0.000

Naphthalene 0.0001 0.0000 0.0000 0.000

Unidentified1 0.3501 0.350

Total HAP 0.370

1. Unidentified components are assumed to be polyaromatic hydrocarbons (PAH).

Alternative Operating Scenario – Unit #20 and Unit #21

There is an alternative operating scenario for Unit 20 and Unit 21where the #4 Aqueous Treater and Agitator is

moved from Unit 21 and placed in operation after the Rinse Decanter in Unit 20. The #4 Aqueous Treater is

not heated in this alternative scenario.

Unit #20 – Alternative Operating Scenario

Emissions calculations for the Unit 20 Reactor, Unit 20 Holding Tank, Neutralization Mix Tank, Rinse Mix

Tank, and Rinse Decanter are the same as with normal operation. See section titled “Catalytic Resin and Polyoil

Neutralization – Unit #20” above. Emissions from the #4 Agitator are as follows:

#4 Aqueous Treater/Agitator – Material Charging

Each time a product change occurs, material from the Rinse Decanter is added to the #4 Aqueous

Treater/Agitator, causing a displacement of tank vapors. After the initial charge into the vessel, the liquid level

remains constant.


Table 32a: #4 Aqueous Treater/Agitator Emissions

(Alternative Operating Scenario)

Constituent


lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

lb/product

change tpy

Total VOC 25.3028 1.2145 37.9589 1.8220 9.4686 0.4545 8.1919 0.3932

Benzene 0.0385 0.0018 0.0257 0.0012 0.1144 0.0055 0.0000 0.0000

Toluene 0.1263 0.0061 0.0893 0.0043 0.4630 0.0222 0.0251 0.0012

Ethylbenzene 0.2319 0.0111 0.1446 0.0069 0.3559 0.0171 0.3925 0.0188

p-Xylene 0.3465 0.0166 0.1819 0.0087 0.6746 0.0324 0.9715 0.0466

m-Xylene 0.3651 0.0175 0.2126 0.0102 0.9691 0.0465 0.9266 0.0445

o-Xylene 0.2970 0.0143 0.1753 0.0084 0.6007 0.0288 1.1880 0.0570

Cumene 0.1024 0.0049 0.0649 0.0031 0.0784 0.0038 0.0855 0.0041

Styrene 0.0346 0.0017 0.0259 0.0012 0.1343 0.0064 0.1059 0.0051

Naphthalene 0.0315 0.0015 0.0157 0.0008 0.0408 0.0020 0.0326 0.0016

Total HAP 1.5740 0.0756 0.9361 0.0449 3.4311 0.1647 3.7277 0.1789

Unit 20 Summary – Alternative Operating Scenario

Emissions Limitations for Unit 20 under the alternative operating scenario are based on the poly oil with the

highest total emissions across the process for each pollutant.

Table 33: Unit 20 Emissions Limitations Summary


Pollutant Emissions

tpy

Total VOC 3.758

Benzene 0.006

Ethylbenzene 0.038

Naphthalene 0.003

Styrene 0.064

Xylenes 0.286

Total HAP 0.402

Unit #21 – Alternative Operating Scenario

Under the alternative operating scenario, the maximum amount of poly oil throughput through the aqueous

treaters due to the reduced capacity from moving the #4 Aqueous Treater/Agitator. However, the emissions

from Holding Tanks #1 & #2 and the Final Holding Tank T-171 (including material charging and solvent flush)

are the same as with normal operation. See section titled “Catalytic Resin and Polyoil Neutralization – Unit

#21” above. The maximum throughput is:

Product changes: 52 changes per year

Sp. Gr. of poly oil: 0.922 @ 30 °C = 7.689 lb/gal

Max. poly oil throughput: 53,640,000 lbs/yr

6,975,765 gal/yr

Aqueous Treaters (10 & #11) – Material Charging






Table 34a: Aqueous Treater Material Charging Parameters


Batch Size

No. of


gal/batch batches/yr cf/batch cf/yr

#10 Aqueous Treater 9,600 363 1,283.3 466,263

#11 Aqueous Treater 11,800 296 1,577.4 466,263



Where:




Table 34b: Aqueous Treater Material Charging Emissions


Pollutant

Molec.

Wt.

Aqueous Treater #10 Aqueous Treater #11

Emissions Emissions

lb/lb·mol lb/charge tpy lb/charge tpy

Total VOC 201.05 7.718 1.402 9.487 1.402

Benzene 78.11 0.300 0.054 0.368 0.054

Biphenyl 154.20 0.000 0.000 0.000 0.000

Toluene 92.13 1.071 0.195 1.316 0.195

Ethylbenzene 106.17 0.860 0.156 1.058 0.156

p-Xylene 106.17 0.529 0.096 0.650 0.096

m-Xylene 106.17 0.529 0.096 0.650 0.096

o-Xylene 106.17 0.529 0.096 0.650 0.096

Cumene 120.20 0.181 0.033 0.223 0.033

Styrene 104.15 0.298 0.054 0.366 0.054

Naphthalene 128.17 0.033 0.006 0.041 0.006

Total HAP 4.329 0.786 5.321 0.786

Aqueous Treaters (#10 & #11) – Water Washes

For each batch, there are three (3) water washes. The first is water/caustic wash, where the water/caustic

mixture is added to the first vessel. No volatile emissions are expected during this wash. Two (2) more washes

are performed after the poly oil addition, where volatile emissions may be expected due to displacement. It is

assumed that the volume of gas displaced during the last two washes is equal to the volume of water added.




Table 34c: Aqueous Treater Water Wash Parameters


Vol. per

Wash Washes

per

Batch

No. of


gal/batch batches/

yr cf/batch cf/yr

#10 Aqueous Treater 1,500 2 363 401.0 145,707

#11 Aqueous Treater 2,100 2 296 561.5 165,958

Emissions were calculated using the same methodology as used for the material charging of the aqueous

treaters.

Table 34d: Aqueous Treater Water Wash Emissions


Pollutant

Molec.

Wt.


Emissions Emissions

lb/lb·mol lb/charge tpy lb/charge tpy

Total VOC 201.05 2.412 0.438 3.377 0.499

Benzene 78.11 0.094 0.017 0.131 0.019

Biphenyl 154.20 0.000 0.000 0.000 0.000

Toluene 92.13 0.335 0.061 0.469 0.069

Ethylbenzene 106.17 0.269 0.049 0.376 0.056

p-Xylene 106.17 0.165 0.030 0.231 0.034

m-Xylene 106.17 0.165 0.030 0.231 0.034

o-Xylene 106.17 0.165 0.030 0.231 0.034

Cumene 120.20 0.057 0.010 0.079 0.012

Styrene 104.15 0.093 0.017 0.130 0.019

Naphthalene 128.17 0.010 0.002 0.014 0.002

Total HAP 1.353 0.246 1.894 0.280

Aqueous Treaters (#10 & #11) – Material Heat-Up

When the heated water from the last two water washes is added to the vessels, it increases the temperature of the

intermediate, causing the vapor space to expand. This temperature increase occurs for every batch for the

second and third water washes.



Table 34e: Aqueous Treater Material Heat-Up Parameters


Vessel

Vol.

Batch

Size

Water

Vol.

Total

Vol.

Free

Space Heat-ups

per

Batch gal. gal/batch gal/batch gal/batch gal.

#10 Treater 12,500 9,600 1,500 11,100 1,400 2.0

#11 Treater 15,200 11,800 2,100 13,900 1,300 2.0



E = [(PiT1/Pa1 + PiT2/Pa2)/2] × Delta(n) × MWi × H

Where:

E = Mass of emissions H = Number of heat-ups




Delta(n) = V/R × [(Pa1/T1) – (Pa2/T2)]





Note: Batches per year can be found in Table 15c.

Table 34f: Aqueous Treater Material Heat-Up Emissions


Pollutant

Molec

Wt.


Emissions Emissions

lb/lb·mo

l

lb/

charge tpy

lb/

charge tpy

Total VOC 201.05 0.123 0.022 0.114 0.017

Benzene 78.11 0.004 0.001 0.004 0.001

Biphenyl 154.20 0.000 0.000 0.000 0.000

Toluene 92.13 0.016 0.003 0.015 0.002

Ethylbenzene 106.17 0.014 0.002 0.013 0.002

p-Xylene 106.17 0.008 0.002 0.008 0.001

m-Xylene 106.17 0.008 0.002 0.008 0.001

o-Xylene 106.17 0.008 0.002 0.008 0.001

Cumene 120.20 0.003 0.001 0.003 0.000

Styrene 104.15 0.005 0.001 0.004 0.001

Naphthalene 128.17 0.001 0.000 0.001 0.000

Total HAP 0.068 0.012 0.063 0.009


SOURCES OF MINOR SIGNIFICANCE:

Emergency Generators

All emissions, except for particulate matter, are based on US EPA AP-42 factors, Section 3.2: Natural Gas-

Fired Reciprocating Engines (10/96). A 15% adjustment was added to all emissions calculated with AP-42

factors to account for operational variability. Particulate matter emissions limits are those found Article XXI,

§2104.02.a.1.A. All PM is assumed to be PM10, and all PM10 is assumed to be PM2.5.

Basis:


Hours of Operation: 500 hours/year

Table 35a: Emergency Generator Emissions

Pollutant

AP-42 WWTP Unit 43 BH Building 50

Factor1 600 hp 691 hp 242 hp 31 hp

4SLB 1.53 MMBtu/hr 1.76 MMBtu/hr 0.62 MMBtu/hr 0.08 hp

lb/MMBtu lb/hr tpy lb/hr tpy lb/hr tpy lb/hr tpy

PM 0.012 0.018 0.005 0.021 0.005 0.007 0.002 0.001 0.001

PM10 0.012 0.018 0.005 0.021 0.005 0.007 0.002 0.001 0.001

PM2.5 0.012 0.018 0.005 0.021 0.005 0.007 0.002 0.001 0.001

NOX 8.47 × 10-1 1.488 0.372 1.714 0.429 0.600 0.150 0.077 0.019

SOX 5.88 × 10-4 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001

CO 5.57 × 10-1 0.979 0.245 1.127 0.282 0.395 0.099 0.051 0.013

VOC 1.18 × 10-1 0.207 0.052 0.239 0.060 0.084 0.021 0.011 0.003

Pollutant

AP-42 Building 19A QTL Building 50 ICT

Factor1 10 hp 12 hp 29.5 hp

4SLB 0.03 MMBtu/hr 0.03 MMBtu/hr 0.08 MMBtu/hr

lb/MMBtu lb/hr tpy lb/hr tpy lb/hr tpy

PM 0.012 0.001 0.001 0.001 0.001 0.001 0.001

PM10 0.012 0.001 0.001 0.001 0.001 0.001 0.001

PM2.5 0.012 0.001 0.001 0.001 0.001 0.001 0.001

NOX 8.47 × 10-1 0.025 0.006 0.030 0.007 0.073 0.018

SOX 5.88 × 10-4 0.001 0.001 0.001 0.001 0.001 0.001

CO 5.57 × 10-1 0.016 0.004 0.020 0.005 0.048 0.012

VOC 1.18 × 10-1 0.003 0.001 0.004 0.001 0.010 0.003

Pollutant

AP-42 Heat Poly Total

(for 8 generators) Factor

1 600 hp

4SRB 1.53 MMBtu/hr

lb/MMBtu lb/hr tpy tpy

PM 0.012 0.018 0.005 0.017

PM10 0.012 0.018 0.005 0.017

PM2.5 0.012 0.018 0.005 0.017

NOX 2.27 × 100 3.989 0.997 1.999

SOX 5.88 × 10-4 0.001 0.001 0.001

CO 3.72 × 100 6.537 1.634 2.293

VOC 2.96 × 10-2 0.052 0.013 0.153

1. Emission factors for PM, PM10, and PM2.5 are from Article XXI, §2104.02.a.1.A.


The emergency generators are subject to 40 CFR Part 63, Subpart ZZZZ under the following applicability

sections:

Table 35b: Emergency Generator Subpart ZZZZ Applicability

WWTP Unit 43 BH Bldg. 50

§63.6590(a)(1)(iii) §63.6590(a)(1)(iii) §63.6590(a)(1)(iii) §63.6590(a)(1)(iii)

Bldg. 19A QTL Bldg. 50 ICT Heat Poly

§63.6590(a)(1)(iii) §63.6590(a)(2)(iii)

§63.6590(c)(1)

§63.6590(a)(2)(iii)

§63.6590(c)(1) §63.6590(a)(1)(iii)

Other Sources of Minor Significance

Hydrolaser Water Blasting/Cleaning

Emissions from the Hydrolaser Water Blasting/Cleaning operations are worst-case estimates based on

engineering judgment and past numbers used by the facility

Table 36: Hydrolaser Water Blasting & Cleaning Emissions Estimate

PM PM10 PM2.5 VOC

tpy tpy tpy tpy

1.0 0.5 0.5 1.0

Parts Washing

Annual usage of cleaning solvent is based on the actual 2009 usage, scaled up (based on engineering judgment)

to reflect a worst-case scenario.

Annual usage: 2,500 gallons/year

Solvent density1: 6.60 lb/gal

Table 37: Parts Washing Emissions Estimate

Pollutant MSDS

Amount1

Annual Usage Amount

Recycled

Total Emissions

lb/yr tpy lb/yr tpy

VOC 97% 16,005 8.0025 75% 4,001.43 2.001

Benzene 0.04 mg/L 0.0008 4.17 × 10-7 75% 0.0002 1.04 × 10-7

p-Dichlorobenzene 5.00 mg/L 0.1043 5.22 × 10-5 75% 0.0261 1.30 × 10-5

Toluene 30.00 mg/L 0.6259 0.0003 75% 0.1565 7.82 × 10-5

Total HAP 9.14 × 10-5

1. From Safety-Kleen Premium Solvent / Premium Gold Solvent, MSDS #82658.

R&D Laboratory Hoods

Emissions from the R&D Laboratory Hoods are worst-case estimates based on engineering judgment and past

numbers used by the facility. Hours of operation are assumed to be 8,760 hours per year.

VOC Emissions = 0.457 lb/hr = 2.000 tpy

Tank Cleaning & Painting

Annual usage of coatings and solvents are based on the actual 2009 usage, scaled up (based on engineering

judgment) to reflect a worst-case scenario.

Total Usage: 2,000 gallons/year

Thinner (20%): 400 gal/yr

Base Coat (40%): 800 gal/yr

Top Coat (40%): 800 gal/yr


Table 38: Tank Cleaning & Painting Emissions Estimate

Material Description

VOC Content VOC Emissions

gr/L lb/gal lb/yr tpy

Low VOC Epoxy Thinner (025T000) 838.20 6.995 2,798.0 1.399

White Base Coat (220B3501) 327.10* 2.730* 2,183.8 1.092

White Enamel Top Coat (379B9500) 372.70* 3.110* 2,488.3 1.244

Total VOC: 3.735

* VOC content as-applied

Greenhouse Gas Emissions

Emissions of greenhouse gases (GHG) are from combustion of natural gas from the boilers, process heaters, and

the thermal oxidizer, and consist of carbon dioxide (CO2), methane (CH4), and nitrous oxide (N2O). Calculations

of greenhouse gas and CO2-equivalent (CO2e) emissions are based on the methodology found in 40 CFR Part

98, Subpart C, §98.33(a)(1), and factors found in Table A-1, Table C-1, and Table C-2 of that subpart.

Note: Emergency generators, as defined in §98.6, are not considered part of the source category for

greenhouse gas reporting (per §98.30(a)(2)), and are therefore not included in the total GHG estimate.

Emission Factors (from Part 98, Subpart C, Tables C-1 & C-2):

CO2 = 53.06 kg/MMBtu

N2O = 1.0 × 10-4 kg/MMBtu

CH4 = 1.0 × 10-3 kg/MMBtu

Global Warming Potential (GWP) Factors (from Part 98, Subpart A, Table A-1):

CO2 = 1

N2O = 298

CH4 = 25

Table 39: Rated Heat Input of Combustion Equipment

Combustion Equipment Rating

MMBtu/hr

Thermal Oxidizer 18.9

#15 Still Process Heater 7.5





#3 Continuous Still Process Heater 2.25

#4 Continuous Still Process Heater 10.5

No. 2 Packaging Center Heater 5.0



No. 6 Boiler 49.4

No. 8 Boiler 29.5

Total Rated Heat Input 161.27


161.27 MMBtu/hr × 8,760 hrs/yr = 1,412,725 MMBtu/yr

CO2: 1,412,725 MMBtu/yr × 53.06 kg/MMBtu ÷ 1,000 kg/metric ton = 74,959 metric tons/year

NO2: 1,412,725 MMBtu/yr × 1×10-4 kg/MMBtu ÷ 1,000 kg/metric ton = 0.141 metric tons/year

CH4: 1,412,725 MMBtu/yr × 1×10-3 kg/MMBtu ÷ 1,000 kg/metric ton = 1.413 metric tons/year

CO2e = (74,959 × 1) + (0.141 × 298) + (1.413 × 25) = 75,037 metric tons/year of CO2e

= 82,713 tpy of CO2e


EMISSIONS SUMMARY:

Table 40: Emissions Summary for Neville Chemical Company

Pollutant Total

(tpy*)

Particulate Matter 13.981

Particulate Matter <10 μm 10.941

Particulate Matter <2.5 μm (PM2.5) 10.091

Nitrogen Oxides (NOX) 78.526

Sulfur Oxides (SOX) 0.465

Carbon Monoxide (CO) 68.548

Volatile Organic Compounds (VOC) 224.924

Hazardous Air Pollutants (HAP) 16.676

Benzene 0.468

Ethylbenzene 2.095

Naphthalene 1.956

Styrene 1.495

Xylenes 6.322

Greenhouse Gases (CO2e) 83,119

* A year is defined as any consecutive 12-month period.

RECOMMENDATION:

All applicable Federal, State, and County regulations have been addressed in the permit application and the

facility was found to be in compliance. The Title V Operating Permit for the Neville Chemical Company,

Neville Island facility should be approved with the emission limitations and terms & conditions in Permit No.

0060.


APPENDIX A.1 – Regulatory Timeline (graph)

0.00010.00020.00030.00040.00050.00060.000

Jan-03

Mar-03

May-03

Jul-03

Sep-03

Nov-03

Jan-04

Mar-04

May-04

Jul-04

Sep-04

Nov-04

Jan-05

Mar-05

May-05

Jul-05

Sep-05

Nov-05

Jan-06

Mar-06

May-06

Jul-06

Sep-06

Nov-06

Jan-07

Mar-07

May-07

Jul-07

Sep-07

Nov-07

Jan-08

Mar-08

May-08

C-5 Unit Shutdown

Installation of Groundwater Remediation

Unit #15 Connected to RTO

Air Stripper Removed Units #18 & #19 Connected to RTO

Shutdown of NDD Process

Unit #16 Connected to RTO

Unit #30 Shutdown

LDAR Study Conducted Boiler #7 Shutdown

Wastewater Treatment Study Conducted Clay/Lime Neutralization Shutdown

Initial Notification for FFFF

11/10/03 FFFF Promulgation (68FR, 63888)

02/03/04 EEEE Promulgation (69FR, 5063)

03/01/06 FFFF Amendment (71FR, 10439)

11/10/06 FFFF Orig. Comp. Date (68FR, 63888)

02/05/07 EEEE Comp. Date (69FR, 5064)

05/10/08 FFFF Comp. Date (71FR, 10442)

05/07/08 NCC Letter of Minor Source Status

10

9

8

7

6

5

4

3

2

1


APPENDIX A.2 – Regulatory Timeline (table)

Emission Source

Point #1

(tpy)

Point #2

(tpy)

Point #3

(tpy)

Point #4

(tpy)

Point #5

(tpy)

Point #6

(tpy)

Point #7

(tpy)

Point #8

(tpy)

Point #9

(tpy)

Point #10

(tpy)

No. 3 Cont. Still 0.303 0.303 0.303 0.303 0.303 0.303 0.303 0.303 0.303 0.303

No. 4 Cont. Still 1.119 1.119 1.119 1.119 1.119 1.119 1.119 1.119 1.119 1.119

No. 15 Heat Poly Still 0.788 0.788 0.788 0.016 0.016 0.016 0.016 0.016 0.016 0.016





Unit 20 5.781 5.781 5.781 5.781 5.781 5.781 5.781 5.781 0.399 0.399

Unit 21 3.768 3.768 3.768 3.768 3.768 3.768 3.768 3.768 3.768 3.768

C-5 Process 0.339

Unit 30 0.880 0.880 0.880 0.880 0.880 0.880

No. 2 Packaging Center 0.772 0.772 0.772 0.772 0.772 0.772 0.772 0.772 0.772 0.772



No. 3 Process Heater 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034







Heat Poly Thermal Oxidizer 0.142 0.142 0.142 0.142 0.142 0.142 0.142 0.142 0.142 0.142

No. 2 PC Heater 0.039 0.039 0.039 0.039 0.039 0.039 0.039 0.039 0.039 0.039

No. 3 PC Heater 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030

No. 5 PC Heater 0.023 0.023 0.023 0.023 0.023 0.023 0.023 0.023 0.023 0.023

C-5 Process Heater 0.036

Unit 30 Process Heater 0.039 0.039 0.039 0.039 0.039 0.039

Wastewater Treatment 9.470 9.470 9.470 9.470 9.470 9.470 9.470 9.470 9.470 9.470

No. 6 Boiler (nat. gas) 0.368 0.368 0.368 0.368 0.368 0.368 0.368 0.368 0.368 0.368

No. 6 Boiler (oil) 2.180 2.180 2.180 2.180 2.180 2.180 2.180 2.180 2.180

No. 7 Boiler (oil) 1.890 1.890 1.890 1.890 1.890 1.890 1.890

No. 8 Boiler (nat. gas) 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230

No. 8 Boiler (oil) 1.400 1.400 1.400 1.400 1.400 1.400 1.400 1.400 1.400

Resin Rework Tanks 0.319 0.319 0.319 0.319 0.319 0.319 0.319 0.319 0.319 0.319

Air Stripper 9.380 9.380

Groundwater Remediation

(including the Air Stripper) 12.990 12.990 0.370 0.370 0.370 0.370 0.370 0.370

NDD Process 0.090 0.090 0.090 0.090

Barge Loading 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065

Tankcar/Tankwagon Loading 0.279 0.279 0.279 0.279 0.279 0.279 0.279 0.279 0.279 0.279

Storage Tanks 1.769 1.769 1.769 1.769 1.769 1.769 1.769 1.769 1.769 1.769

Fugitives 0.224 0.224 0.224 0.224 0.224 0.224 0.224 0.224 0.224 0.224

Total: 47.507 47.132 50.742 49.970 35.078 34.024 33.105 31.215 25.833 22.253


APPENDIX B – Implementation Tool For the Organic Liquids Distribution NESHAP

(selected pages)



Documents

ALLEGHENY COUNTY HEALTH DEPARTMENTNeville Chemical Company TVOP #0060 Page 3 Technical Support Document 21. Correspondence, dated July 15, 2013 (Unit 20 feedstocks) 22. Correspondence,