Appendix I 09.05.06 - web.epa.ohio.govweb.epa.ohio.gov/dapc/transfer/ptiApplication/aep/Appendix_I_OEPA... · Prepared by AEP – New Generation Licensing Section September 2006 APPENDIX

Prepared by AEP – New Generation Licensing Section September 2006

APPENDIX I

AEP – Great Bend IGCC Facility

Ohio EPA Permit Application Forms

Ohio EPA, Division of Air Pollution Control Page 1 General Cover SheetAEP – Great Bend IGCC Facility Prepared by AEP-New Generation Licensing

Ohio Environmental Protection Agency Lazarus Government Center P.O. Box 1049 Columbus, Ohio 43216-1049 GENERAL COVER SHEET 1. Facility Information Core Place ID

Not yet assigned by OEPA.

Legal Name

Columbus Southern Power Company & Ohio Power Company (dba American Electric Power)

Alternate Name

Great Bend IGCC Project

Street Address

State Route 33

City/State/Zip

Great Bend, OH

Location

The proposed project in located on State Route 33 along the Ohio River (between river mile markers 222

& 224) near the town of Ravenswood, WV.

County

Meigs County

2. Owner Information Owner Name


Effective Date

Upon Construction.

Mailing Address

1 Riverside Plaza – Floor 10

c/o Great Bend IGCC Project

City/State/Zip

Columbus, OH 43215

Phone Number

(614) 716-1238

Billing Address



City/State/Zip

Columbus, OH 43215

For EPA Use Only Application Or ID Number________________________________________ Date Received ________________________________________ Check No. _________________ Check ID No. ______________ Check Date ___________________ Amount ________________ Revenue ID No. ______________________________________

DAPC DDAGW DHWM DSW DSIWM RTK DEFA TRI __________

Ohio EPA, Division of Air Pollution Control Page 2 General Cover SheetAEP – Great Bend IGCC Facility Prepared by AEP-New Generation Licensing

3. Operator Information Operator Name


Effective Date

Upon Construction.

Mailing Address



City/State/Zip

Columbus, OH 43215

Phone Number

(614) 716-1238

Billing Address



City/State/Zip

Columbus, OH 43215

4. Division/Program Specific Secondary ID Numbers (for existing facilities only)

DAPC

Facility ID

DAPC

TRI ID

DDAGW

PWS ID

DHWM

RCRA ID

DSW

NPDES ID

DSIWM

Facility ID

RTK

RTK ID

Other

(________)

5. Supplemental Information

Primary SIC Code

4911 (Electric Services)

Primary NAICS Code

221112 (Fossil Fuel Electric Power Generation)

D&B D-U-N-S No.

NA

Lat./Long.

N339000; E2175000 (NAD 83 based coordinates)

Point Description

Center of proposed project area.

Section I - General Permit To Install (PTI) Application Information

Ohio EPA, Division of Air Pollution Control Page 3 Section IAEP – Great Bend IGCC Facility Prepared by AEP – New Generation Licensing

This section should be filled out for each permit to install (PTI) application. A PTI is required for all air contaminant sources (emissions units) installed or modified after 1/1/74. See the line by line PTI instructions for additional information. 1. State the reason(s) for the application.

new installation (for which construction has not yet begun) initial application for an air contaminant source already installed or under construction modification to an existing air contaminant source/facility - List previous PTI number(s) for air contaminant sources included

in this application, if applicable, and describe requested modification (attach an additional sheet, if necessary): _______________________________________________________________________________________

reconstruction of an existing air contaminant source/facility. Please explain:

___________________________________________ startup of an air contaminant source/facility that has been shutdown for ______ years. other, please explain: ___________________________________________

2. Please check the appropriate boxes below. If you check exempt/not subject, explain why.

not affected subject to Subpart: * New Source Performance Standards (NSPS) exempt/not subject - explain below New Source Performance Standards are listed under 40 CFR 60 unknown - Standards of Performance for New Stationary Sources.

not affected subject to Subpart: National Emission Standards for Hazardous Air exempt/not subject - explain below Pollutants (NESHAPS) unknown National Emissions Standards for Hazardous Air Pollutants are

listed under 40 CFR 61. (These include asbestos, benzene, beryllium, mercury, and vinyl chloride).

not affected subject to Subpart: Maximum Achievable Control Technology (MACT) exempt/not subject - explain below The Maximum Achievable Control Technology standards are unknown listed under 40 CFR 63 and OAC rule 3745-31-28.

not affected subject to regulation * Prevention of Significant Deterioration (PSD) unknown These rules are found under OAC rule 3745-31-10

through OAC rule 3745-31-20.

not affected subject to regulation Non-Attainment New Source Review unknown These rules are found under OAC rule 3745-31-21

through OAC rule 3745-31-27.

Please describe any of the above applicable rules and/or exemptions. Identify whether they apply to the entire facility and/or to specific air contaminant sources included in this PTI application (attach additional page if necessary): *Please see Section 3.0 (Regulatory Analysis) of the PTI application.

3. Do you qualify for permit to install registration status as determined by Ohio Administrative Code(OAC) rule 3745-31-05? yes no

If yes, are you requesting registration status per OAC rule 3745-31-05?

yes no

4. Is any information included in this application being claimed as a trade secret per Ohio Revised Code (ORC) 3704.08?

yes (A “non-confidential” version must be submitted in order for this application to be deemed complete.) no

Section II - Specific Air Contaminant Source Information

Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility P001 – Combustion Turbine #1

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Combustion Turbine #1 2. List all equipment that are part of this air contaminant source: Gasifier; Water Scrubber; Hg Control System; Acid Gas Removal System; Syngas Saturator; Nitrogen Diluent;

Combustion Turbine #1; Heat Recovery Steam Generator #1; Thermal Oxidizer; Flare; 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or

modification): When did/will you begin to install or modify the air contaminant source? (month/year) After receipt of PTI and other necessary regulatory approvals.

When did/will you begin to operate the air contaminant source? (month/year) Approximately 48 months after beginning actual construction.

4. Emissions Information: The following table requests information needed to determine the applicable requirements and the compliance status of this air contaminant source with those requirements. Suggestions for how to estimate emissions may be found in the instructions to the Emissions Activity Category (EAC) forms required with this application. If you need further assistance, contact your Ohio EPA permit representative.

• If total potential emissions of HAPs or any Air Toxic is greater than 1 ton/yr, fill in the table for that (those) pollutant(s). For all other pollutants, if “Emissions before controls (max), lb/hr” multiplied by 24 hours/day is greater than 10 lb/day, fill in the table for that pollutant.

• If you have no add-on control equipment, “Emissions before controls= will be the same as “Actual emissions” • Annual emissions should be based on operating 8760 hr/yr unless you are requesting operating restrictions to limit

emissions in line # 8 or have described inherent limitations below. • If you use units other than lb/hr or ton/yr, specify the units used (e.g., gr/dscf, lb/ton charged, lb/MMBtu, ton/12-

months). • Requested Allowable (ton/yr) is often equivalent to Potential to Emit (PTE) as defined in OAC rule 3745-31-01 and

OAC rule 3745-77-01.

Pollutant Emissions before controls (max) (lb/hr)

1Actual emissions

(lb/hr)

2Actual emissions(ton/year)

1,3Requested Allowable

(lb/hr)

2,3RequestedAllowable (ton/year)

Particulate emissions (PE) (formerly particulate matter, PM) NK NK NK NK NK

PM10 (PM < 10 microns in diameter) NK 18

(filterable) 79

(filterable) 18

(filterable) 79

(filterable)

Sulfur dioxide (SO2) NK 51.3 225 51.3 225

Nitrogen oxides (NOx) NK 188.9 746 188.9 746

Carbon monoxide (CO) NK 93.3 409 93.3 409

Volatile organic compounds (VOC) NK 3.2 39 3.2 39

H2SO4 NK 11.3 49 11.3 49

HAPs / Air Toxics NA NA NA NA NA

1Short-term emission rates represent normal operations, and exclude startup, shutdown, & malfunction operations. 2Ton/year emission rates include normal, startup, shutdown and malfunction operations that are expected to occur. 3Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for P001.



Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emissions Inventory) and Appendix E (IGCC Process Potential Emission Calculations).

5. Does this air contaminant source employ emissions control equipment?

Yes - fill out the applicable information below.

No - proceed to item # 6. Note: Pollutant abbreviations used below: Particulates = PE; Organic compounds = OC; Sulfur dioxide = SO2;

Nitrogen oxides = NOx; Carbon monoxide = CO

Cyclone/Multiclone Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%): _________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Type: Cyclone Multiclone Rotoclone Other ________________________________

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: ___________________________________________________________________________________________

Fabric Filter/Baghouse

Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Operating pressure drop range (inches of water): Minimum: _________Maximum: _________ Pressure type: Negative pressure Positive pressure Fabric cleaning mechanism: Reverse air Pulse jet Shaker Other _____________

Lime injection or fabric coating agent used: Type: _________ Feed rate: _________ This is the only control equipment on this air contaminant source

If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment:

___________________________________________________________________________________________

Wet Scrubber Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Type: Spray chamber Packed bed Impingement Venturi Other ______________ Operating pressure drop range (inches of water): Minimum: _________ Maximum: _________ pH range for scrubbing liquid: Minimum: _________ Maximum: _________ Scrubbing liquid flow rate (gal/min): ____________ Is scrubber liquid recirculated? Yes No Water supply pressure (psig): _____________ NOTE: This item for spray chambers only.




Electrostatic Precipitator

Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Type: Plate-wire Flat-plate Tubular Wet Other ____________ Number of operating fields: ____________


Concentrator

Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design regeneration cycle time (minutes): ____________ Minimum desorption air stream temperature (oF): _________ Rotational rate (revolutions/hour): ____________


Catalytic Incinerator

Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Minimum inlet gas temperature (oF): ____________ Combustion chamber residence time (seconds): ____________ Minimum temperature difference (oF) across catalyst during air contaminant source operation: _______


Thermal Incinerator/Thermal Oxidizer

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Thermal Oxidizer (C001) Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Minimum operating temperature (oF) and location: TBD (See line by line instructions.) Combustion chamber residence time (seconds): TBD

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: Combustion Turbine #2 (P002); Sulfur Recovery System (P003);



Flare

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Flare (C002) Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Type: Enclosed Elevated (open) Ignition device: Electric arc Pilot flame Flame presence sensor: Yes No


Condenser Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Type: Indirect contact Direct contact Maximum exhaust gas temperature (oF) during air contaminant source operation: _______ Coolant type: ________________________ Design coolant temperature (oF): Minimum ____________ Maximum ____________ Design coolant flow rate (gpm): ________________________


Carbon Adsorber (Hg Control System) Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Hg Control System Pollutant(s) controlled: PE OC SO2 NOx CO Other Hg Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK Type: On-site regenerative Disposable Maximum design outlet organic compound concentration (ppmv): NA Carbon replacement frequency or regeneration cycle time (specify units): TBD Maximum temperature of the carbon bed, after regeneration (including any cooling cycle): NA

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: Combustion Turbine #2 (P002)

Dry Scrubber

Manufacturer: ________________________ Year installed: ________________________ What do you call this control equipment: ________________________ Pollutant(s) controlled: PE OC SO2 NOx CO Other _______________ Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Reagent(s) used: Type: ________________________ Injection rate(s): ________________________ Operating pressure drop range (inches of water): Minimum: _________ Maximum: _________


Paint booth filter



Type: Paper Fiberglass Water curtain Other _________________________________ Design control efficiency (%):____________ Basis for efficiency: _____________________

Other, describe: Water Scrubber

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Water Scrubber Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): 100% Basis for efficiency: Design Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Acid Gas Removal System

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: AGR Pollutant(s) controlled: PE OC SO2 NOx CO Other H2SO4 Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Syngas Saturator

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Syngas Saturator Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Nitrogen Diluent

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Nitrogen Diluent Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


6. Attach a Process or Activity Flow Diagram to this application for each air contaminant source included in the application. The

diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information. Please see the process flow diagram for P001 provided on the following page.



Gasifiers

Coal; Oxygen

C001 - Thermal Oxidizer

Water Scrubber

Slag By-Product

P001 – Combustion Turbine #1

Syngas

Hg Control

Acid GasRemoval System

SyngasSaturator

Acid Gas to P003

C002 - Flare

C002 - Flare

C002 - Flare

Combustion Turbine #1

C002 - Flare

Heat Recovery Stem Generator #1

Exhaust thru CT/HRSG Stack #1

Steam to Steam Generator

N2 Diluent



7. Emissions egress point(s) information: PTIs which allow total emissions in excess of the thresholds listed below will be subject

to an air quality modeling analysis. This analysis is to assure that the impact from the requested project will not exceed Ohio=s Acceptable Incremental Impacts for criteria pollutants and/or Maximum Allowable Ground Level Concentrations (MAGLC) for air toxics. Permit requests that would have unacceptable impacts can not be approved as proposed. See the line by line PTI instructions for additional information. Complete the tables below if the requested allowable annual emission rate for this PTI exceeds any of the following:

• Particulate Matter (PM10): 10 tons per year • Sulfur Dioxide (SO2): 25 tons per year • Nitrogen Oxides (NOx): 25 tons per year • Carbon Monoxide (CO): 100 tons per year • Air Toxic: 1 ton per year. An air toxic is any air pollutant for which the American Council of Governmental Industrial

Hygienists (ACGIH) has established a Threshold Limit Value (TLV).

Complete Table 7-A below for each stack emissions egress point. An egress point is a point at which emissions from an air contaminant source are released into the ambient (outside) air. List each individual egress point on a separate line.

Table 7-A, Stack Egress Point Information Company Name or ID for the Egress Point (examples: Stack A; Boiler Stack; etc.)

Type Code

*

Stack Egress Point

Shape and Dimensions (in) (examples: round

10 inch ID; rectangular 14 X 16 inches; etc.)

Stack Egress Point

Height from the Ground

(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max.

Capacity (ACFM)

Minimum Distance to

the Property Line (ft)

P001: CT/HRSG Stack #1 A Round: 18.6 ft Diameter 175 ft 275 F 1,298,702 775 ft

C001: Thermal Oxidizer A Round: 4 ft Diameter 198 ft 1300 F 3,813 875 ft

C002: Flare A Round: 3.5 ft Diameter 200 ft (structure)

See Appendix H & I. Calculated values for flare flame based on operating

condition

950 ft

*Type codes for stack egress points:

A. vertical stack (unobstructed): There are no obstructions to upward flow in or on the stack such as a rain cap. B. vertical stack (obstructed): There are obstructions to the upward flow, such as a rain cap, which prevents or

inhibits the air flow in a vertical direction. C. non-vertical stack: The stack directs the air flow in a direction which is not directly upward.



Complete Table 7-B below for each fugitive emissions egress point. List each individual egress point on a separate line. Refer to the description of the fugitive egress point type codes below the table for use in completing the type code column of the table. For air contaminant sources like roadways and storage piles, only the first 5 columns need to be completed. For an air contaminant source with multiple fugitive emissions egress points, include only the primary egress points.

Table 7-B, Fugitive Egress Point Information Company ID for the Egress Point (examples; Garage Door B, Building C; Roof Monitor; etc.)

Type Code*

Egress Point Description (examples: garage door, 12 X 30 feet, west wall; outside gravel storage piles; etc.)

Fugitive Egress Point Height from the Ground (ft)

Minimum Distance to the Property Line (ft)

Exit Gas

Temp. (F)

Not Applicable to P001.

*Type codes for fugitive egress point:

D. door or window E. other opening in the building without a duct F. no stack and no building enclosing the air contaminant source (e.g., roadways)

Complete Table 7-C below for each Stack Egress Point identified in Table 7-A above. In each case, use the dimensions of the largest nearby building, building segment or structure. List each individual egress point on a separate line. Use the same Company Name or ID for the Egress Point in Table 7-C that was used in Table 7-A. See the line by line PTI instructions for additional information.

Table 7-C, Egress Point Additional Information (Add rows as necessary)

Company ID or Name for the Egress Point

Building Height (ft)

Building Width

(ft)

Building

Length (ft)

Please see Good Engineering Practice (GEP) stack height analysis provided in Appendix H (Air Dispersion Modeling Final Report) of the application.

8. Request for Federally Enforceable Limits

As part of this permit application, do you wish to propose voluntary restrictions to limit emissions in order to avoid specific requirements listed below, (i.e., are you requesting federally enforceable limits to obtain synthetic minor status)?

yes no

not sure - please contact me if this affects me

If yes, why are you requesting federally enforceable limits? Check all that apply.

a. to avoid being a major source (see OAC rule 3745-77-01) b. to avoid being a major MACT source (see OAC rule 3745-31-01) c. to avoid being a major modification (see OAC rule 3745-31-01) d. to avoid being a major stationary source (see OAC rule 3745-31-01) e. to avoid an air dispersion modeling requirement (see Engineering Guide # 69) f. to avoid another requirement. Describe: ________________________________

If you checked a., b. or d., please attach a facility-wide potential to emit (PTE) analysis (for each pollutant) and synthetic minor strategy to this application. (See line by line instructions for definition of PTE.) If you checked c., please attach a net emission change analysis to this application.



9. If this air contaminant source utilizes any continuous emissions monitoring equipment for indicating or demonstrating compliance, complete the following table. This does not include continuous parametric monitoring systems.

Company ID for Egress Point

Type of Monitor

Applicable performance specification (40 CFR 60, Appendix B)

Pollutant(s) Monitored

P001 – CT/HRSG Stack #1 TBD 40 CFR 60, Appendix B; 40 CFR Part 75. SO2; NOx; CO; Hg;

C001 – Thermal Oxidizer TBD 40 CFR 60, Appendix B; 40 CFR Part 75.

SO2

C002 – Flare TBD TBD TBD. Ongoing evaluation of feasibility and options for potentially measuring sulfur in gas streams to the flare.

10. Do you wish to permit this air contaminant source as a portable source, allowing relocation within the state in accordance with

OAC rule 3745-31-03 or OAC rule 3745-31-05?

yes - Note: notification requirements in rules cited above must be followed. no

11. The appropriate Emissions Activity Category (EAC) form(s) must be completed and attached for each air contaminant source.

At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following EAC form applicable to P001: Fuel Burning Operations EAC (P001 – Combustion Turbine #1)

EPA FORM 3101 – REV2005 Page P001 – Combustion Turbine #1 1

FOR OHIO EPA USE FACILITY ID: ___________________________ EU ID: _______________ PTI #:__________________

EMISSIONS ACTIVITY CATEGORY FORM

FUEL BURNING OPERATION P001 – Combustion Turbine #1

This form is to be completed for each fuel burning operation. State/Federal regulations which may apply to fuel burning operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list 1. Reason this form is being submitted (check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. B001)________ 2. Maximum Operating Schedule: 24 hours per day; 365 days per year

If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples. ______________________________

3. Input Capacity (million Btu/hr):

Rated (Indicate units if other than mmBtu/hr)

Maximum (Indicate units if other than mmBtu/hr)

Normal (Indicate units if other than mmBtu/hr)

3878 mmBTU/hr LHV (syngas) 3878 mmBTU/hr LHV (syngas) 3878 mmBTU/hr LHV (syngas)

3359 mmBTU/hr LHV (natural gas) 3359 mmBTU/hr LHV (natural gas) 3359 mmBTU/hr LHV (natural gas)

*Rated, Maximum, and Normal input capacity values represent nominal estimates. 4. Output Capacity:

Rated (lb steam/hr)

Maximum (lb steam/hr)

Normal (lb steam/hr)

1,808,000 (syngas) 1,808,000 (syngas) 1,808,000 (syngas)

759,000 (natural gas) 759,000 (natural gas) 759,000 (natural gas)

*Rated, Maximum, and Normal output capacity values represent nominal estimates.

Not applicable - operation does not produce steam. 5. Percent of Operating Time Used for: Process: 100 %

Space Heat: _______% 6. Type of Draft (check one):

Natural Induced Forced 7. Type of combustion monitoring (check one):

Fuel/Air Ratio Oxygen None Other (describe) TBD

EPA FORM 3101 – REV2005 Page P001 – Combustion Turbine #1

2

8. Type of Fuel Fired (complete all that apply):

Fuel* Fired as... Min. Heat Content

(Btu/unit)

Max. % Ash

Max. % Sulfur

Max. Annual Fuel Use

Average Hourly Fuel

Use

Maximum Hourly Fuel Use

Coal Primary Backup

NA NA NA NA NA NA

No. 2 Fuel Oil Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA

Other** Oil Primary Backup

NA NA NA NA NA NA

Natural Gas Primary Backup

20,874 (BTU/lb)

LLV negligible 0.00083 TBD 180,700

lb/hr 180,700

lb/hr

Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA

Other** Syngas

Primary Backup

3511 (BTU/lb)

LLV negligible 40 ppmvd 9,793,680,000

lb/yr 1,118,000

lb/hr 1,118,000

lb/hr

* Please identify all combinations of fuels that are co-fired: Natural Gas and Syngas ** Identify other fuel(s): Syngas

Coal-Fired Units 9. Type of Coal Firing (check one):

Pulverized-Wet Bottom Hand-Fired Chain Grate Traveling Grate Pulverized-Dry Bottom Cyclones Spreader Stoker Fluidized Bed Underfeed Stoker Other (describe) _________________________________

10. Flyash Reinjection:

Yes No 11. Overfire Air:

Yes No

Oil-Fired Units 12. Oil Preheater:

Yes - Indicate Temperature deg. F No



NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Combustion Turbine #2 2. List all equipment that are part of this air contaminant source: Gasifier; Water Scrubber; Hg Control System; Acid Gas Removal System; Syngas Saturator; Nitrogen Diluent;

Combustion Turbine #2; Heat Recovery Steam Generator #2; Thermal Oxidizer; Flare; 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or








OAC rule 3745-77-01.


1Actual emissions

(lb/hr)


1,3Requested Allowable

(lb/hr)



PM10 (PM < 10 microns in diameter) NK 18

(filterable) 79

(filterable) 18

(filterable) 79

(filterable)

Sulfur dioxide (SO2) NK 51.3 225 51.3 225

Nitrogen oxides (NOx) NK 188.9 746 188.9 746

Carbon monoxide (CO) NK 93.3 409 93.3 409

Volatile organic compounds (VOC) NK 3.2 39 3.2 39

H2SO4 NK 11.3 49 11.3 49


1Short-term emission rates represent normal operations, and exclude startup, shutdown, & malfunction operations. 2Ton/year emission rates include normal, startup, shutdown and malfunction operations that are expected to occur. 3Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for P002.














___________________________________________________________________________________________








Concentrator







Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Thermal Oxidizer (C001) Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Minimum operating temperature (oF) and location: TBD (See line by line instructions.) Combustion chamber residence time (seconds): TBD




Flare

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Flare (C002) Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Type: Enclosed Elevated (open) Ignition device: Electric arc Pilot flame Flame presence sensor: Yes No




Carbon Adsorber (Hg Control System) Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Hg Control System Pollutant(s) controlled: PE OC SO2 NOx CO Other Hg Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK Type: On-site regenerative Disposable Maximum design outlet organic compound concentration (ppmv): NA Carbon replacement frequency or regeneration cycle time (specify units): TBD Maximum temperature of the carbon bed, after regeneration (including any cooling cycle): NA


Dry Scrubber



Paint booth filter



Type: Paper Fiberglass Water curtain Other _________________________________ Design control efficiency (%):____________ Basis for efficiency: _____________________

Other, describe: Water Scrubber

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Water Scrubber Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): 100% Basis for efficiency: Design Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Acid Gas Removal System

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: AGR Pollutant(s) controlled: PE OC SO2 NOx CO Other H2SO4 Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Syngas Saturator

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Syngas Saturator Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


Other, describe: Nitrogen Diluent

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Nitrogen Diluent Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK



diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information. Please see the process flow diagram for P002 provided on the following page.



Gasifiers

Coal; Oxygen


Water Scrubber

Slag By-Product

P002 – Combustion Turbine #2

Syngas

Hg Control

Acid GasRemoval System

SyngasSaturator

Acid Gas to P003

C002 - Flare

C002 - Flare

C002 - Flare

Combustion Turbine #2

C002 - Flare

Heat Recovery Stem Generator #2

Exhaust thru CT/HRSG Stack #2

Steam to Steam Generator

N2 Diluent









Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max.

Capacity (ACFM)

Minimum Distance to


P002: CT/HRSG Stack #2 A Round: 18.6 ft Diameter 175 ft 275 F 1,298,702 900 ft

C001: Thermal Oxidizer A Round: 4 ft Diameter 198 ft 1300 F 3,813 875 ft



condition

950 ft








Type Code*




Exit Gas

Temp. (F)








Building Width

(ft)

Building

Length (ft)




yes no









Type of Monitor



P002 – CT/HRSG Stack #1 TBD 40 CFR 60, Appendix B; 40 CFR Part 75. SO2; NOx; CO; Hg;


SO2






At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following EAC form applicable to P002: Fuel Burning Operations EAC (P002 – Combustion Turbine #2)

EPA FORM 3101 – REV2005 Page P002 – Combustion Turbine #2 1



FUEL BURNING OPERATION P002 – Combustion Turbine #2

This form is to be completed for each fuel burning operation. State/Federal regulations which may apply to fuel burning operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list 1. Reason this form is being submitted (check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. B001)________ 2. Maximum Operating Schedule: 24 hours per day; 365 days per year






3878 mmBTU/hr LHV (syngas) 3878 mmBTU/hr LHV (syngas) 3878 mmBTU/hr LHV (syngas)

3359 mmBTU/hr LHV (natural gas) 3359 mmBTU/hr LHV (natural gas) 3359 mmBTU/hr LHV (natural gas)


Rated (lb steam/hr)



1,808,000 (syngas) 1,808,000 (syngas) 1,808,000 (syngas)

759,000 (natural gas) 759,000 (natural gas) 759,000 (natural gas)






EPA FORM 3101 – REV2005 Page P002 – Combustion Turbine #2

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


20,874 (BTU/lb)

LLV negligible 0.00083 TBD 180,700

lb/hr 180,700

lb/hr

Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA

Other** Syngas

Primary Backup

3511 (BTU/lb)

LLV negligible 40 ppmvd 9,793,680,000

lb/yr 1,118,000

lb/hr 1,118,000

lb/hr

* Please identify all combinations of fuels that are co-fired: Natural Gas and Syngas ** Identify other fuel(s): Syngas





Yes No




Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility P003 – Sulfur Recovery System

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Sulfur Recovery System 2. List all equipment that are part of this air contaminant source: Sulfur Recovery Units; Tail Gas Treatment Unit; Flare; Thermal Oxidizer 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or








OAC rule 3745-77-01.

Pollutant Emissions

before controls (max) (lb/hr)

1Actual emissions

(lb/hr)

2Actual emissions (ton/year)

1,2RequestedAllowable

(lb/hr)



PM10 (PM < 10 microns in diameter) NK 0.9

(filterable) 1.1

(filterable) 0.9

(filterable) 1.1

(filterable)

Sulfur dioxide (SO2) NK 836 135 836 135

Nitrogen oxides (NOx) NK 69 16 69 16

Carbon monoxide (CO) NK 321 54 321 54

Volatile organic compounds (VOC) NK 0.7 0.5 0.7 0.5


1Short-term emission rates represent startup and shutdown operations. 2Ton/year emission rates include normal, startup, shutdown and malfunction operations that are expected to occur. 3Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for P003.














___________________________________________________________________________________________








Concentrator







Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Thermal Oxidizer Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Minimum operating temperature (oF) and location: TBD (See line by line instructions.) Combustion chamber residence time (seconds): TBD

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: Combustion Turbine #1 (P001); Combustion Turbine #2 (P002);



Flare

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Flare Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC, H2SO4 Estimated capture efficiency (%): TBD Basis for efficiency: TBD Design control efficiency (%): TBD Basis for efficiency: TBD Type: Enclosed Elevated (open) Ignition device: Electric arc Pilot flame Flame presence sensor: Yes No

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: Combustion Turbine #1 (P001); Combustion Turbine #2 (P002);



Carbon Adsorber Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________ Type: On-site regenerative Disposable Maximum design outlet organic compound concentration (ppmv): _______________ Carbon replacement frequency or regeneration cycle time (specify units): _______________ Maximum temperature of the carbon bed, after regeneration (including any cooling cycle): _________


Dry Scrubber





Paint booth filter Type: Paper Fiberglass Water curtain Other _________________________________ Design control efficiency (%):____________ Basis for efficiency: _____________________

Other, describe:

Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%):_________ Basis for efficiency: _____________________ Design control efficiency (%):____________ Basis for efficiency: _____________________



diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information.

Sulfur Recovery

Units

IGCC Process

Gas Streams


C002 - Flare


C002 - Flare


C002 - Flare

Tail GasTreatment

Unit

IGCC Process

Sulfur By-Product

P003 – Sulfur Recovery System









Type Code

*

Stack Egress Point

Shape and Dimensions (in) (examples: round 10 inch ID; rectangular 14

X 16 inches; etc.)

Stack Egress Point Height

from the Ground (ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max.

Capacity (ACFM)

Minimum Distance to


C001: Thermal Oxidizer A Round: 4 ft Diameter 198 ft 1300 F 3813 ACFM 875 ft



condition

950 ft








Type Code*




Exit Gas

Temp. (F)








Building Width

(ft)

Building

Length (ft)




yes no





9. If this air contaminant source utilizes any continuous emissions monitoring equipment for indicating or demonstrating



compliance, complete the following table. This does not include continuous parametric monitoring systems.


Type of Monitor




SO2






At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following EAC form applicable to P003: Process Operations EAC (P003 – Sulfur Recovery Process)

EPA FORM 3100 – REV2005 P003 – Sulfur Recovery System 1 of 2

FOR OHIO EPA USE FACILITY ID:_____________________________________ EU ID: PTI #:


GENERAL PROCESS OPERATION P003 – Sulfur Recovery System

This form is to be completed for each process operation when there is no specific emissions activity category (EAC) form applicable. If there is more than one end product for this process, copy and complete this form for each additional product (see instructions). Several State/Federal regulations which may apply to process operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list. 1. Reason this form is being submitted (Check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. P001)_______________ 2. Maximum Operating Schedule: 24 hours per day ; 365 days per year

If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples. _______________________________

3. End product of this process: Sulfur By-Product 4. Hourly production rates (indicate appropriate units). Please see the instructions for clarification of

“Maximum” and “Average” for new versus existing operations:

Hourly Rate Units (e.g., widgets)

Average production 32 tons/hr

Maximum production 32 tons/hr 5. Annual production rates (indicate appropriate units) Please see the instructions for clarification of

“Maximum” and “Actual” for new versus existing operations:

Annual Rate Units (e.g., widgets)

Actual production 280,320 tons/year

Maximum production 280,320 tons/year

EPA FORM 3100 – REV2005 2 of 2 P003 – Sulfur Recovery System

6. Type of operation (please check one):

Continuous Batch (please complete items below)

Minimum cycle* time (minutes): _________ Minimum time between cycles (minutes): _________ Maximum number of cycles per daily 24 hour period: _________

(Note: include cycle time and set up/clean up time.) *”Cycle” refers to the time the equipment is in operation.

7. Materials used in process at maximum hourly production rate (add rows/pages as needed):

Material Physical State at Standard Conditions

Principle Use Amount**

IGCC Process Gas Gas sulfur by-product production NK

** Please indicate the amount and rate (e.g., lbs/hr, gallons/hr, lbs/cycle, etc.). 8. Please provide a narrative description of the process below (e.g., coating of metal parts using high VOC

content coatings for the manufacture of widgets; emissions controlled by thermal oxidizer...): Acid gas from the AGR and ammonia acid gas from various systems are is processed by the sulfur recovery unit (SRU) that utilizes the Claus process to convert H2S into an elemental sulfur by-product.


Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility P004 – Cooling Tower

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Cooling Tower 2. List all equipment that are part of this air contaminant source: Cooling Tower 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or

modification):

When did/will you begin to install or modify the air contaminant source? (month/year) After receipt of PTI and other necessary regulatory approvals.



• If total potential emissions of HAPs or any Air Toxic is greater than 1 ton/yr, fill in the table for that (those)

pollutant(s). For all other pollutants, if “Emissions before controls (max), lb/hr” multiplied by 24 hours/day is greater than 10 lb/day, fill in the table for that pollutant.




OAC rule 3745-77-01.

Pollutant Emissions


Actual emissions

(lb/hr)

Actual emissions(ton/year)

1Requested Allowable

(lb/hr)

1Requested Allowable (ton/year)


PM10 (PM < 10 microns in diameter) NK 6.4

(filterable) 28

(filterable) 6.4

(filterable) 28

(filterable)

Sulfur dioxide (SO2) NA NA NA NA NA

Nitrogen oxides (NOx) NA NA NA NA NA

Carbon monoxide (CO) NA NA NA NA NA

Volatile organic compounds (VOC) NA NA NA NA NA


1Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for P004. Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emissions Inventory) and Appendix E (IGCC Process Potential Emission Calculations).













___________________________________________________________________________________________








Concentrator







Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency: Minimum operating temperature (oF) and location: (See line by line instructions.) Combustion chamber residence time (seconds):

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment:



Flare

Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency: Type: Enclosed Elevated (open) Ignition device: Electric arc Pilot flame Flame presence sensor: Yes No




Carbon Adsorber Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency: Type: On-site regenerative Disposable Maximum design outlet organic compound concentration (ppmv): Carbon replacement frequency or regeneration cycle time (specify units): Maximum temperature of the carbon bed, after regeneration (including any cooling cycle):


Dry Scrubber






Other, describe: Drift Elimination System Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Drift Elimination System Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): 100% Basis for efficiency: Design Design control efficiency (%): 0.001% Drift Basis for efficiency: Design



diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information.

P004 – Cooling Tower

Steam PlumeExhaust

Steam Turbine Condenser

Clarified River Water

CoolingTower

Cooled Water

Heated Water



7. Emissions egress point(s) information: PTIs which allow total emissions in excess of the thresholds listed below will be subject to an air quality modeling analysis. This analysis is to assure that the impact from the requested project will not exceed Ohio=s Acceptable Incremental Impacts for criteria pollutants and/or Maximum Allowable Ground Level Concentrations (MAGLC) for air toxics. Permit requests that would have unacceptable impacts can not be approved as proposed. See the line by line PTI instructions for additional information. Complete the tables below if the requested allowable annual emission rate for this PTI exceeds any of the following:

• Particulate Matter (PM10): 10 tons per year • Sulfur Dioxide (SO2): 25 tons per year • Nitrogen Oxides (NOx): 25 tons per year • Carbon Monoxide (CO): 100 tons per year • Air Toxic: 1 ton per year. An air toxic is any air pollutant for which the American Council of Governmental

Industrial Hygienists (ACGIH) has established a Threshold Limit Value (TLV).



Type Code

*

Stack Egress Point





Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max. Capacity (ACFM)

Minimum Distance

to the Property Line (ft)







Type Code

*




Exit Gas

Temp. (F)

P004: Cooling Tower F Round: 32.8 ft diameter (22 individual cells)

61 feet 1,150 ft 95.1 F









Building Width

(ft)

Building

Length (ft)




yes no


If yes, why are you requesting federally enforceable limits? Check all that apply. a. to avoid being a major source (see OAC rule 3745-77-01) b. to avoid being a major MACT source (see OAC rule 3745-31-01) c. to avoid being a major modification (see OAC rule 3745-31-01) d. to avoid being a major stationary source (see OAC rule 3745-31-01) e. to avoid an air dispersion modeling requirement (see Engineering Guide # 69) f. to avoid another requirement. Describe: ________________________________




Type of Monitor








At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following EAC form applicable to P004: Process Operations EAC (P004 – Cooling Tower)

EPA FORM 3100 – REV2005 P004 – Cooling Tower

1 of 2

FOR OHIO EPA USE FACILITY ID:_____________________________________ EU ID: PTI #:


GENERAL PROCESS OPERATION P004 – Cooling Tower

This form is to be completed for each process operation when there is no specific emissions activity category (EAC) form applicable. If there is more than one end product for this process, copy and complete this form for each additional product (see instructions). Several State/Federal regulations which may apply to process operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list. 1. Reason this form is being submitted (Check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. P001)_______________ 2. Maximum Operating Schedule: 24 hours per day ; 365 days per year


3. End product of this process: Cooled Water 4. Hourly production rates (indicate appropriate units). Please see the instructions for clarification of

“Maximum” and “Average” for new versus existing operations:

Hourly Rate Units (e.g., widgets)

Average production 6,120,000 gallons/hr

Maximum production 6,120,000 gallons/hr

5. Annual production rates (indicate appropriate units) Please see the instructions for clarification of

“Maximum” and “Actual” for new versus existing operations:

Annual Rate Units (e.g., widgets)

Actual production 53,611 million gallons/year

Maximum production 53,611 million gallons/year

EPA FORM 3100 – REV2005 2 of 2 P004 – Cooling Tower

6. Type of operation (please check one):

Continuous Batch (please complete items below)

Minimum cycle* time (minutes): _________ Minimum time between cycles (minutes): _________ Maximum number of cycles per daily 24 hour period: _________

(Note: include cycle time and set up/clean up time.) *”Cycle” refers to the time the equipment is in operation.

7. Materials used in process at maximum hourly production rate (add rows/pages as needed):

Material Physical State at Standard Conditions

Principle Use Amount**

Cooling Water liquid cooling water 6,120,000 gallons/hour

Clarified River Water liquid cooling water 6,120,000 gallons/hour

** Please indicate the amount and rate (e.g., lbs/hr, gallons/hr, lbs/cycle, etc.). 8. Please provide a narrative description of the process below (e.g., coating of metal parts using high VOC

content coatings for the manufacture of widgets; emissions controlled by thermal oxidizer...):

IGCC process heat loads are cooled by a wet evaporative mechanical draft cooling tower.


Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility B001 – Auxiliary Boiler

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Auxiliary Boiler 2. List all equipment that are part of this air contaminant source: Auxiliary Boiler 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or








OAC rule 3745-77-01.

Pollutant Emissions


Actual emissions

(lb/hr)



(lb/hr)

1, 2Requested Allowable (ton/year)

Particulate emissions (PE) (formerly particulate matter, PM) NA NK NK NK NK

PM10 (PM < 10 microns in diameter) NA 2.2

(filterable) 6

(filterable) 2.2

(filterable) 6

(filterable)

Sulfur dioxide (SO2) NA 0.22 1 0.22 1

Nitrogen oxides (NOx) NK 15 39 15 39

Carbon monoxide (CO) NA 24.7 64 24.7 64

Volatile organic compounds (VOC) NA 1.6 4 1.6 4

HAPs / Air Toxics NA NA NA NA NA 1Ton/year estimates based on auxiliary boiler use during startup and shutdown. 2Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for B001. Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emissions Inventory) and Appendix E (IGCC Process Potential Emission Calculations).













___________________________________________________________________________________________








Concentrator











Flare







Dry Scrubber






Other, describe: ________

Manufacturer: ________ Year installed: _______ What do you call this control equipment: _______ Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): _____ Basis for efficiency: _______ Design control efficiency (%): _____ Basis for efficiency: _______

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: _______

6. Attach a Process or Activity Flow Diagram to this application for each air contaminant source included in the application. The diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information.

B001 – Auxiliary Boiler

CombustionExhaust

Natural Gas AuxiliaryBoiler

Steam









Type

Code*

Stack Egress Point

Shape and Dimensions (in)

(examples: round 10 inch ID; rectangular 14 X 16 inches; etc.)



Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max

Capacity (ACFM)

Minimum Distance


B001: Auxiliary Boiler A Round: 6 ft diameter 75 feet 500 F 105,177 950 ft






Type Code*




Exit Gas

Temp. (F)

Not Applicable to B001.









Building Width

(ft)

Building

Length (ft)




yes no






Type of Monitor



B001 – Auxiliary Boiler TBD 40 CFR 60, Appendix B; 40 CFR 75 NOx





At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following EAC form applicable to B001: Process Operations EAC (B001 – Auxiliary Boiler)

EPA FORM 3101 – REV2005 Page B001 – Auxiliary Boiler 1



FUEL BURNING OPERATION B001 – Auxiliary Boiler

This form is to be completed for each fuel burning operation. State/Federal regulations which may apply to fuel burning operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list 1. Reason this form is being submitted (check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. B001)________ 2. Maximum Operating Schedule: 24 hours per day; TBD days per year

If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples. The auxiliary boiler is in service during startup and shutdown operation.





300 mmBTU/hr 300 mmBTU/hr 300 mmBTU/hr


Rated (lb steam/hr)



220,000 220,000 220,000






EPA FORM 3101 – REV2005 Page B001 – Auxiliary Boiler

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


927 (BTU/scf) negligible 0.00083 TBD 323,625

scf/hr 323,625 scf/hr

Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA

Other** Primary Backup

NA NA NA NA NA NA

* Please identify all combinations of fuels that are co-fired: NA ** Identify other fuel(s):





Yes No




Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility F001 – Material Handling System

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): F001 – Material Handling Activities 2. List all equipment that are part of this air contaminant source: Material Handling System; Coal Storage Pile; Haul Roads; Parking Lots/Misc. Unit 1 Traffic; 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or

modification):

When did/will you begin to install or modify the air contaminant source? (month/year) After receipt of PTI and other regulatory approvals.








OAC rule 3745-77-01.

Pollutant

Emissions


Actual

emissions (lb/hr)

Actual

emissions (ton/year)


(lb/hr)

1Requested Allowable (ton/year)

Particulate emissions (PE) (formerly particulate matter, PM)

116 (TSP)

6.4 (TSP)

28 (TSP)

6.4 (TSP)

28 (TSP)

PM10 (PM < 10 microns in diameter)

39 (filterable)

2.3 (filterable)

10 (filterable)

2.3 (filterable)

10 (filterable)

Sulfur dioxide (SO2) NA NA NA NA NA Nitrogen oxides (NOx) NA NA NA NA NA Carbon monoxide (CO) NA NA NA NA NA Volatile organic compounds (VOC) NA NA NA NA NA HAPs / Air Toxics NA NA NA NA NA Highest single HAP: NA NA NA NA NA Air Toxics (see instructions): NA NA NA NA NA

1Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for F001.



Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emission Inventory) and Appendix F (Material Handling Potential Emission Calculations).











___________________________________________________________________________________________








Concentrator







Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other VOC Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency: Minimum operating temperature (oF) and location: (See line by line instructions.) Combustion chamber residence time (seconds):




Flare







Dry Scrubber






Other, describe: Forced Air Dust Collection

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Forced Air Dust Collector Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): 100% Basis for efficiency: Design Design control efficiency (%): 99% Basis for efficiency: Design

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: Forced Air Dust Collection applied as necessary to the Material Handling System.

Other, describe: Dust Suppression System

Manufacturer: TBD Year installed: Upon Issuance of PTI What do you call this control equipment: Dust Suppression System Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): NK Basis for efficiency: NK Design control efficiency (%): NK Basis for efficiency: NK


Dust Suppression supplied as necessary to the Material Handling System.

6. Attach a Process or Activity Flow Diagram to this application for each air contaminant source included in the application. The diagram should indicate their relationships to one another. See the line by line PTI instructions for additional information. Please see the process flow diagram for F001 provided on the following page.



Great Bend IGCC Project Material Handling Block Flow Diagram

Coal Pile 2

Barge Unloader 1

Transfer House 1A

Transfer House 3

Transfer House 4

Coal Pile 1

Sulfur By-Product

IGCCProcess

Trucks to Offsite Location

Trucks to Landfill

Conveyor A1 (2,100 tph)

Stacking Tube

(4,200 tph)

Coal Pile 3

Transfer House 5

Transfer House 6

Coal ReclaimSystem

TransferHouse 7

Coal Slurry PrepBuilding

Conveyor A2 (2,100 tph)

Conveyor C (4,200 tph)

Conveyor D1 (4,200 tph)

Conveyor D2 (4,200 tph)

Stacking Tube

(4,200 tph)

Stacking Tube

(4,200 tph)

Conveyor E (800 tph)

Conveyor F (800 tph)

Transfer House 8

Conveyor G (800 tph)

Conveyor H (800 tph)

Conveyor K (800 tph)

Conveyor L (800 tph)

Conveyor N(800 tph)

Conveyor M(800 tph)

CrusherStation

Slag By-Product

Slag Loading to Trucks

Trucks to Offsite Location

Trucks to Landfill

Future Barge Unloader

Conveyor (2,100 tph)

Parking Lots & Misc. Unit 1 Traffic



7. Emissions egress point(s) information: PTIs which allow total emissions in excess of the thresholds listed below will be subject to an air quality modeling analysis. This analysis is to assure that the impact from the requested project will not exceed Ohio=s Acceptable Incremental Impacts for criteria pollutants and/or Maximum Allowable Ground Level Concentrations (MAGLC) for air toxics. Permit requests that would have unacceptable impacts can not be approved as proposed. See the line by line PTI instructions for additional information. Complete the tables below if the requested allowable annual emission rate for this PTI exceeds any of the following:





Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max.

Capacity (ACFM)

Minimum Distance to


Material Handling EAC:

Reclaim Station Baghouse TBD TBD TBD TBD TBD 1,500 ft

Crusher Station Baghouse TBD TBD TBD TBD TBD 1,500 ft








Type Code

*


Fugitive Egress

Point Height from the Ground

(ft)

Minimum

Distance to the Property Line

(ft)

Exit Gas

Temp. (F)

Material Handling EAC:

Barge Unloader #1 F Unloading from Barge NK At Property Line NA

Transfer House 1A E Building NK 50 NA

Transfer House 3 E Building NK 700 NA






Coal Slurry Prep Building E Building NK 1100 NA

Roadways EAC:

Road Segment A F Paved Road NK At Property Line NA

Road Segment B F Paved Road NK At Property Line NA

Road Segment C F Paved Road NK 450 NA

Road Segment D F Paved Road NK 800 NA

Road Segment E F Unpaved Road NK TBD NA

Coal Pile Traffic F Storage Pile Traffic NK 400 NA

Parking Lots/Misc Traffic F Paved Road NK At Property Line NA

Storage Pile EAC:

Coal Storage Pile F Storage Pile NK 400 NA

*Type codes for fugitive egress point: D. door or window

E. other opening in the building without a duct F. no stack and no building enclosing the air contaminant source (e.g., roadways)




Table 7-C, Egress Point Additional Information (Add rows as necessary) Company ID or Name for the Egress Point


Building Width

(ft)

Building

Length (ft)




yes no







Type of Monitor



Not applicable to F001 – Material Handling System.

10. Do you wish to permit this air contaminant source as a portable source, allowing relocation within the state in accordance with OAC rule 3745-31-03 or OAC rule 3745-31-05?


11. The appropriate Emissions Activity Category (EAC) form(s) must be completed and attached for each air contaminant source. At least one complete EAC form must be submitted for each air contaminant source for the application to be considered



complete. Refer to the list attached to the PTI instructions. Please see the following EAC forms applicable to F001: Material Handling: Fugitive Dust Emissions EAC Form Roadways and Parking Areas: Fugitive Dust Emissions EAC Form Storage Piles EAC Form

EPA FORM 3113 - REV2005 Page 1

EMISSIONS ACTIVITY CATEGORY FORM MATERIAL HANDLING: FUGITIVE DUST EMISSIONS

This form is to be completed for any material handling operation with fugitive dust emissions. State/Federal regulations which may apply to material handling operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list. 1. Reason this form is being submitted (Check one)

New Permit Renewal or Modification of Air Permit Number(s) (e.g. F001)__________

2. Maximum Operating Schedule: 24 hours per day; 365 days per year


3. What is the material being handled? coal; slag by-product; sulfur by-product; 4. Mean wind speed at or near facility 6.3 miles per hour 5. Complete the following table for all unloading operations.

ID

Type of Unloading

(see examples below)

Material

Unloaded

Annual

Quantity Unloaded (tons/yr)

Hourly

Maximum Unloading Rate

(tons/hr)

Avg. Moisture

Content, as Unloaded

(%)

Barge unloader 1

Truck: dump pneumatic Vessel: clamshell bucket ladder Rail car: side dump bottom dump rotary dump pneumatic Other: __________________

Coal 18,396,000 2,100 5%

FOR OHIO EPA USE FACILITY ID:_____________________EU ID:__________ PTI#:___________


6. Complete the following table for all loading operations.

ID

Type of Loading (see examples below)

Material Loaded

Annual Quantity Loaded (tons/yr)

Hourly Maximum Loading Rate

(tons/hr)

Avg. Moisture Content, as Loaded (%)

Coal Reclaim

front end loader under pile load out bucket well reclaimer rake reclaimer other: under pile reclaim

Coal 14,016,000 1,600 5%


7. Complete the following table for all transfer operations.

ID Type of Transfer Point (see examples below)

Number of Such Points

Type of Material Handled

Max. Transfer Rate

(tons/hr)

Transfer House 1A

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor Other:

1 Coal 2,100

Transfer House 3


1 Coal 4,200

Transfer House 4

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor (optional) Other: optional: conveyor to storage pile

1 Coal 4,200

Transfer House 5

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor (optional) Other: optional: conveyor to storage pile

1 Coal 4,200

Transfer House 6

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor Other: conveyor to storage pile

1 Coal 4,200

Crusher Station

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor Other: conveyor to crusher bin;

crusher activities;

2 of each Coal 1,600

Transfer House 7


2 Coal 1,600

Transfer House 8


2 Coal 1,600

Coal Slurry Prep Building

Load/unload conveyor: vibrating belt screw bucket elevator belt conveyor to belt conveyor Other: TBD

4 of each Coal 1,600


8. Summarize the material handling operations covered in items 5 through 7 above and identify the applicable control method(s) from available

options. Complete the remaining table based upon the selected control method(s).

ID Enclosure, Control Equipment (describe)

Chemical Stabilization

Application Frequency Overall Control Eff. (%) Basis for Overall Control Efficiency

Barge Unloader #1 Water Spray (80%) Precautionary Measures (25%)

water dust suppressant other: ________

As necessary. 85%

Transfer House 1A Chute Enclosure (90%) Building Enclosure (90%)


Year-round. 99%

Transfer House 3 Chute Enclosure (90%) Building Enclosure (90%)


Year-round. 99%

Transfer House 4 Chute Enclosure (90%) Building Enclosure (90%) Stacking Tube (80%)


Year-round.

99% (enclosures)

80%

(if transferred to storage pile)

Transfer House 5 Chute Enclosure (90%) Building Enclosure (90%) Stacking Tube (80%)


Year-round.

99% (enclosures)

80%

(if transferred to storage pile)

Transfer House 6 Stacking Tube (80%) water dust suppressant other: ________

Year-round 80%

Reclaim Station Under Pile Loadout (90%) Forced Air Dust Collector (99+%)


Year-round 99+%

OEPA RACM Document (1980) per Fugitive Dust Control Technology; 1983 by Orlemann et al EPA Document EPA-450/3-88-008 (Control of Open Fugitive Dust Sources)


ID Enclosure, Control Equipment (describe)

Chemical Stabilization Application Frequency Overall Control Eff.

(%) Basis for Overall Control Efficiency

Crusher Station Chute Enclosure (90%) Forced Air Dust Collector (99+%)


As necessary. 99+%



Year-round. 99%



Year-round. 99%

Coal Slurry Prep Building

Chute Enclosure (90%) Building Enclosure (90%)


Year-round. 99%


EPA FORM 3111 - REV2005

FOR OHIO EPA USE FACILITY ID __________________________ EU ID _____________ PTI# _____________

Page 1

EMISSIONS ACTIVITY CATEGORY FORM ROADWAYS AND PARKING AREAS: FUGITIVE DUST EMISSIONS

This form is to be completed for all Roadways and Parking Areas. State/Federal regulations which may apply to Roadways and Parking Areas are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list. 1. Reason this form is being submitted (Check one)

New Permit Renewal or Modification of Air Permit Number(s) (e.g. F001) __________



3. Complete the table below for each road segment or parking area. Please see the following page.

EPA FORM 3111 - REV2005

FOR OHIO EPA USE FACILITY ID __________________________ EU ID _____________ PTI# _____________

Page 2

ID

Road Segment or Parking

Area Description

Length

(miles) or Area (ft2)

Year

Installed

Surface

Type (check one)

Surface Composition

(check one)

Segment A Road Segment A

(Sulfur Recovery System to Plant Gate)

0.74 miles

After Issuance of PTI

paved unpaved

asphalt gravel concrete dirt chip & seal other

Segment B Road Segment B

(Route 33 to Intersection 1) 0.48 miles


paved unpaved


Segment C Road Segment C

(Slag Pile to Intersection 1) 0.07 miles


paved unpaved


Segment D Road Segment D

(Intersection 1 to Segment E) 0.28 miles


paved unpaved


Segment E Road Segment E

(Segment D to Landfill) 0.43 miles


paved unpaved


Coal Pile Traffic

Coal Pile Traffic 3 miles traveled per hour


paved unpaved


coal



5 miles traveled per hour


paved unpaved



4. Complete the table below for each paved road segment or parking area.

ID

Silt Loading (g/m2)

Vehicle Type

Avg.

Weight (tons)

Avg. Speed (mph)

Vehicle Miles

Traveled (vmt/yr)

Control Method(s)

Application or Usage Frequency

Segment A 1.26 Heavy-Duty (gasoline) Heavy-Duty (diesel)

Haul Truck 27.5 15 26,280

sweeping flushing watering good housekeeping other: Speed Reduction

Watering: as necessary Speed Reduction: year-round

Segment B 1.26 Heavy-Duty (gasoline) Heavy-Duty (diesel)

Haul Truck 27.5 15 50,808



Segment C 1.26 Heavy-Duty (gasoline) Heavy-Duty (diesel)

Haul Truck 27.5 15 4,380



Segment D 1.26 Heavy-Duty (gasoline) Heavy-Duty (diesel)

Haul Truck 27.5 15 29,784



Segment E NA NA NA NA NA

sweeping flushing watering good housekeeping other:

NA

Coal Pile Traffic NA NA NA NA NA

sweeping flushing watering good housekeeping other:

NA

Parking Lots & Misc. Traffic

1.26 Light-Duty (gasoline) 2 5 miles traveled per hour

43,800




5. Identify all the places that the permittee roadways and parking lots meet a public road. Use the Road Segment or Parking Area ID from the table above to identify the permittee roadway and parking lots that are involved.

1. Segment A (Plant Gate and Township Road 371) 2. Segment B (Beginning of Segment B and State Route 33)

Describe how any foreign materials deposited on public paved roadways will be removed.

Flushing with water Wet sweeping Sweeping with vacuum truck Other. Describe ________________________________

6. Complete the table below for each unpaved road segment or parking area.

ID

Silt Content

(%)

Surface Material Moisture Content

(%)

Vehicle Type

Avg.

Weight (tons)

Avg. Speed

(mph)

Vehicle Miles

Traveled (vmt/yr)

Control Method(s)

Application or Usage

Frequency

Segment A NA NA NA NA NA NA NA NA

Segment B NA NA NA NA NA NA NA NA

Segment C NA NA NA NA NA NA NA NA

Segment D NA NA NA NA NA NA NA NA

Segment E 4.9 NK

(not used in PTE calculation)

Heavy-Duty (gasoline)Heavy-Duty (diesel)

Haul Truck 27.5 15 44,676

oiling watering surface improvement chemical stabilization other: Speed Reduction

Watering: as necessary Speed Reduction: yr-rd

Coal Pile Traffic

2.0 NK

(not used in PTE calculation)

Heavy-Duty (gasoline)Heavy-Duty (diesel)

Pile Management Vehicle(s)

25 3 mph

(assumed distance traveled on pile/hour)

26,280

oiling watering surface improvement

(precautionary measures) chemical stabilization

Watering: as necessary Precautionary Measures: year-round


7. The use of used oil for dust suppression is prohibited. Used oil is any oil that has been refined from crude oil, or any synthetic oil, that has been used, and, as a result of that use, is contaminated by physical or chemical impurities. See OAC rule 3745-279-01. Used oil does not include oils that have been refined from crude oil that have not been used or any synthetic oil that has not been used.

If oiling is being used for dust suppression, is only virgin oil being used?

Yes No Not using oil

EPA Form 3112 – REV 2005 Page 1

EMISSIONS ACTIVITY CATEGORY FORM STORAGE PILES

This form is to be completed for each storage pile. State/Federal regulations which may apply to storage piles are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list.

1. Reason this form is being submitted (Check one)

New Permit Renewal or Modification of Air Permit Number(s) (e.g. F001) ____________



3. Meteorological data at or near storage pile area:

a. mean number of days per year in which >0.01 inch of precipitation occurred 146 days b. percentage of time wind speed exceeds 12 miles per hour: 30 % c. mean wind speed: 6.3 miles per hour d. source of meteorological data: (a) National Climatic Data Center

(b) OEPA Storage Pile EAC Instructions (c) National Climatic Data Center

4. Description of storage pile activities: ID

Type of Material Stored

Method of Load-in (check one or more)

Method of Load-out (check one or more)

Coal Pile Coal conveyor/stacker: front-end loader other (describe): Stacking Tube

bucket wheel reclaimer under pile feed rake reclaimer pan scraper front-end loader other: ________

FOR OHIO EPA USE FACILITY ID: ______________________EU ID: __________ PTI#: ___________


5. STORAGE PILE ACTIVITIES:

ID Number of Separate Piles

Average Silt Content (wt %)

Average Moisture Content (wt %)

Average Pile Surface Area

(acres)

Max. Load-in Rate

(tons/hr)

Max. Load-in Rate

(tons/yr)

Max. Load-out Rate

(tons/hr)

Max. Load-out Rate

(tons/yr)

Coal Pile 3 2.0 5 31 acres (3 piles combined) 4,200 36,792,000 1,600 14,016,000

6. WIND EROSION CONTROL METHODS

ID Enclosure, Covering, and/or Operating Practices (describe)


(check one or more) Application Frequency

Overall Control Eff. (%)

Basis for Overall Wind Erosion Control Efficiency

Coal Pile Pile Management Compaction Water Spray

water crusting agents other:________

Year-round; Water Spray as necessary NK NA


7. LOAD-IN CONTROL METHODS



(check one or more)

Application Frequency Overall Control Eff. (%) Basis for Overall Wind Erosion Control

Efficiency

Coal Pile Stacking Tube water crusting agents other:________

Year-round 80


8. LOAD-OUT CONTROL METHODS



(check one or more) Application Frequency

Overall Control Eff. (%)

Basis for Overall Wind Erosion Control Efficiency

Coal Pile Under pile Loadout (90%) Forced Air Dust Collection (99+%)

water crusting agents other:________

Year-round 99+%



Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility Z001 – Gasifier #1 Preheater

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Gasifier #1 Preheater 2. List all equipment that are part of this air contaminant source: Gasifier #1 Preheater 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or








OAC rule 3745-77-01.

Pollutant Emissions


Actual emissions

(lb/hr)



(lb/hr)



NK NK NK NK NK


NA 0.14 (filterable)

0.2 (filterable)

0.14 (filterable)

0.2 (filterable)

Sulfur dioxide (SO2) NA 0.01 0.02 0.01 0.02 Nitrogen oxides (NOx) NK 1.87 2 1.87 2 Carbon monoxide (CO) NA 1.57 2 1.57 2 Volatile organic compounds (VOC) NA 0.1 0.1 0.1 0.1 HAPs / Air Toxics NA NA NA NA NA

1Ton/year estimates based on gasifier #1 preheater use during startup. 2Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for Z001. Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emissions Inventory) and Appendix E (IGCC Process Potential Emission Calculations).













___________________________________________________________________________________________








Concentrator











Flare







Dry Scrubber






Other, describe: ________ Manufacturer: _____ Year installed: _____ What do you call this control equipment: _____ Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): _____ Basis for efficiency: _____ Design control efficiency (%): _____ Basis for efficiency: _____

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: _____


Z001 – Gasifier #1 Preheater

CombustionExhaust

Natural Gas Gasifier #1 Preheater

Heat









Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max

Capacity (ACFM)

Minimum Distance


Z001: Gasifier #1 Preheater A Round: 0.83 ft diameter 290 feet 200 F 20,127 1,100 ft






Type Code*




Exit Gas

Temp. (F)

Not Applicable to Z001.









Building Width

(ft)

Building

Length (ft)




yes no






Type of Monitor








At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following forms applicable to Z001: Fuel Burning Operations EAC (Z001 – Gasifier #1 Preheater) Permit By Rule Form - Boiler and Heater (Z001 – Gasifier #1 Preheater)

EPA FORM 3101 – REV2005 Page Z001 – Gasifier #1 Preheater 1



FUEL BURNING OPERATION Z001 – Gasifier #1 Preheater


If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples Gasifier #1 Preheater is in service during startup operations.





19.1 19.1 19.1


Rated (lb steam/hr)



NA NA NA






EPA FORM 3101 – REV2005 Page Z001 – Gasifier #1 Preheater

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA




Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA






Yes No





NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Gasifier #2 Preheater 2. List all equipment that are part of this air contaminant source: Gasifier #2 Preheater 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or








OAC rule 3745-77-01.

Pollutant Emissions


Actual emissions

(lb/hr)



(lb/hr)



NK NK NK NK NK


NA 0.14 (filterable)

0.2 (filterable)

0.14 (filterable)

0.2 (filterable)

Sulfur dioxide (SO2) NA 0.01 0.02 0.01 0.02 Nitrogen oxides (NOx) NK 1.87 2 1.87 2 Carbon monoxide (CO) NA 1.57 2 1.57 2 Volatile organic compounds (VOC) NA 0.1 0.1 0.1 0.1 HAPs / Air Toxics NA NA NA NA NA

1Ton/year estimates based on gasifier #2 preheater use during startup. 2Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for Z002. Provide your calculations as an attachment and explain how all process variables and emission factors were selected. Note the emissions factor(s) employed and document the origin. Example: AP-42, Table 4.4-3 (8/97); stack test, Method 5, 4/96; mass balance based on MSDS; etc. Please see Section 4.0 (Emissions Inventory) and Appendix E (IGCC Process Potential Emission Calculations).













___________________________________________________________________________________________








Concentrator











Flare







Dry Scrubber






Other, describe: ________ Manufacturer: _____ Year installed: _____ What do you call this control equipment: _____ Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): _____ Basis for efficiency: _____ Design control efficiency (%): _____ Basis for efficiency: _____

This is the only control equipment on this air contaminant source If no, this control equipment is: Primary Secondary Parallel List any other air contaminant sources that are also vented to this control equipment: _____


Z002 – Gasifier #2 Preheater

CombustionExhaust

Natural Gas Gasifier #2 Preheater

Heat









Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max

Capacity (ACFM)

Minimum Distance


Z002: Gasifier #2 Preheater A Round: 0.83 ft diameter 290 feet 200 F 20,127 1,100 ft






Type Code*




Exit Gas

Temp. (F)










Building Width

(ft)

Building

Length (ft)




yes no






Type of Monitor








At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following forms applicable to Z002: Fuel Burning Operations EAC (Z002 – Gasifier #2 Preheater) Permit By Rule Form - Boiler and Heater (Z002 – Gasifier #2 Preheater)

EPA FORM 3101 – REV2005 Page Z002 – Gasifier #2 Preheater 1



FUEL BURNING OPERATION Z002 – Gasifier #2 Preheater


If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples Gasifier #2 Preheater is in service during startup operations.





19.1 19.1 19.1


Rated (lb steam/hr)



NA NA NA






EPA FORM 3101 – REV2005 Page Z002 – Gasifier #2 Preheater

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA




Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA






Yes No




Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility Z003 – Emergency Generator

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Emergency Generator 2. List all equipment that are part of this air contaminant source: Emergency Generator 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or

modification):









OAC rule 3745-77-01.


Actual emissions

(lb/hr)



(lb/hr)

1,2Requested Allowable (ton/year)


NK NK NK NK NK


NA 1.5

(filterable) 0.4

(filterable) 1.5

(filterable) 0.4

(filterable) Sulfur dioxide (SO2) NA 0.9 0.2 0.9 0.2 Nitrogen oxides (NOx) NK 28.6 7.2 28.6 7.2 Carbon monoxide (CO) NA 12.1 3 12.1 3 Volatile organic compounds (VOC) NA 1.5 0.4 1.5 0.4 HAPs / Air Toxics NA NA NA NA NA

1Ton/year estimates based on emergency generator in service 500 hours per year. 2Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for Z003.














___________________________________________________________________________________________








Concentrator











Flare





Carbon Adsorber (Hg Control System) Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency: Type: On-site regenerative Disposable Maximum design outlet organic compound concentration (ppmv): Carbon replacement frequency or regeneration cycle time (specify units): Maximum temperature of the carbon bed, after regeneration (including any cooling cycle):


Dry Scrubber






Other, describe: Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency:



Z003 – Emergency Generator

CombustionExhaust

Low Sulfur Diesel Fuel

EmergencyGenerator

Electricity









Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max

Capacity (ACFM)

Minimum Distance


Z003: Emergency Generator A Round: 1.16 ft diameter 14 feet 800 F 10,600 1,100 ft






Type Code*




Exit Gas

Temp. (F)










Building Width

(ft)

Building

Length (ft)




yes no






Type of Monitor








At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following forms applicable to Z003: Fuel Burning Operations EAC (Z003 – Emergency Generator) Permit By Rule Form – Emergency Generator/Pump/Compressor (Z003 – Emergency Generator)

EPA FORM 3101 – REV2005 Page Z003 – Emergency Generator 1



FUEL BURNING OPERATION Z003 – Emergency Generator

This form is to be completed for each fuel burning operation. State/Federal regulations which may apply to fuel burning operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list 1. Reason this form is being submitted (check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. B001)________ 2. Maximum Operating Schedule: 24 hours per day; (<500 hours/year) days per year

If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples Emergency Generator to support emergency operating conditions.





16.77 16.77 16.77


Rated (lb steam/hr)



NA NA NA






EPA FORM 3101 – REV2005 Page Z003 – Emergency Generator

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA

Natural Gas Primary Backup NA NA NA NA NA NA

Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA

Other** Diesel Fuel

Primary Backup

130,000 BTU/gal 1.5 0.05 64,500 gal/yr 129 gal/hr 129 gal/hr






Yes No




Ohio EPA, Division of Air Pollution Control Page 1 Section IIAEP - Great Bend IGCC Facility Z004 – Emergency Fire Pump

NOTE: One copy of this section should be filled out for each air contaminant source covered by this PTI application. See the line by line PTI instructions for additional information. 1. Company identification (name for air contaminant source for which you are applying): Emergency Fire Pump 2. List all equipment that are part of this air contaminant source: Emergency Fire Pump 3. Air Contaminant Source Installation or Modification Schedule (must be completed regardless of date of installation or

modification):









OAC rule 3745-77-01.


Actual emissions

(lb/hr)



(lb/hr)

1,2Requested Allowable (ton/year)


NK NK NK NK NK


NA 0.9

(filterable) 0.2

(filterable) 0.9

(filterable) 0.2

(filterable) Sulfur dioxide (SO2) NA 0.9 0.2 0.9 0.2 Nitrogen oxides (NOx) NK 13 3.3 13 3.3 Carbon monoxide (CO) NA 2.8 0.7 2.8 0.7 Volatile organic compounds (VOC) NA 1.1 0.3 1.1 0.3 HAPs / Air Toxics NA NA NA NA NA

1Ton/year estimates based on emergency fire pump in service 500 hours per year. 2Please see Section 6.0 (Proposed Emission Limits) for the proposed emission limits for Z004.














___________________________________________________________________________________________








Concentrator











Flare







Dry Scrubber






Other, describe: Manufacturer: Year installed: What do you call this control equipment: Pollutant(s) controlled: PE OC SO2 NOx CO Other Estimated capture efficiency (%): Basis for efficiency: Design control efficiency (%): Basis for efficiency:



Z004 – Emergency Fire Pump

CombustionExhaust

Low Sulfur Diesel Fuel

EmergencyFire Pump

Power









Type Code

*

Stack Egress Point



Stack Egress Point


(ft)

Stack Temp.

at Max. Capacity

(F)

Stack Flow

Rate at Max

Capacity (ACFM)

Minimum Distance


Z004: Emergency Fire Pump A Round: 0.33 ft diameter 12 feet 790 F 2,080 1,100 ft






Type Code*




Exit Gas

Temp. (F)










Building Width

(ft)

Building

Length (ft)




yes no






Type of Monitor








At least one complete EAC form must be submitted for each air contaminant source for the application to be considered complete. Refer to the list attached to the PTI instructions. Please see the following forms applicable to Z004: Fuel Burning Operations EAC (Z004 – Emergency Fire Pump) Permit By Rule Form – Emergency Generator/Pump/Compressor (Z004 – Emergency Fire Pump)

EPA FORM 3101 – REV2005 Page Z004 – Emergency Fire Pump 1



FUEL BURNING OPERATION Z004 – Emergency Fire Pump

This form is to be completed for each fuel burning operation. State/Federal regulations which may apply to fuel burning operations are listed in the instructions. Note that there may be other regulations which apply to this emissions unit which are not included in this list 1. Reason this form is being submitted (check one) New Permit Renewal or Modification of Air Permit Number(s) (e.g. B001)________ 2. Maximum Operating Schedule: 24 hours per day; (<500 hours/year) days per year

If the schedule is less than 24 hours/day or 365 days/year, what limits the schedule to less than maximum? See instructions for examples Emergency fire pump to support emergency operating conditions.





3.12 3.12 3.12


Rated (lb steam/hr)



NA NA NA






EPA FORM 3101 – REV2005 Page Z004 – Emergency Fire Pump

2



(Btu/unit)

Max. % Ash

Max. % Sulfur


Average Hourly Fuel

Use


Coal Primary Backup

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA

Natural Gas Primary Backup NA NA NA NA NA NA

Wood Primary Backup

NA NA NA NA NA NA

LPG Primary Backup

NA NA NA NA NA NA

Other** Diesel Fuel

Primary Backup

130,000 BTU/gal 1.5 0.05 12,000 gal/yr 24 gal/hr 24 gal/hr






Yes No



Documents

Appendix I 09.05.06 - web.epa.ohio.govweb.epa.ohio.gov/dapc/transfer/ptiApplication/aep/Appendix_I_OEPA... · Prepared by AEP – New Generation Licensing Section September 2006 APPENDIX