FET Environmental Primer Air Regulations: Permitting Basics Steven Klafka, P.E. Wingra Engineering, S.C. Madison, Wisconsin

FET Environmental Primer

Air Regulations: Permitting Basics

Steven Klafka, P.E.Wingra Engineering, S.C.Madison, Wisconsinwww.wingraengineering.com

Wingra Engineering, S.C. 2

Air Quality Permit Overview

WDNR responsible for permit issuanceUSEPA oversightConstruction permits for new sourcesOperation permits for existing sources


Air Pollution “Sources”

Operations Issued Air Quality Permits1. Stationary - Process or Point2. Stationary - Factory or Facility3. Portable - Asphalt Plant4. Indirect - Parking Lots and Highways

Not Issued Air Quality Permits1. Area - Small Boilers, Wildfires2. Mobile - Cars, Trucks, Busses3. Off Road – Lawn mowers, Snowmobiles


Wisconsin VOC Emissions

05

101520253035404550

Contribution (% )

Point SourcesMobile SourcesArea Sources


Air Pollution Sources Issued Permits

Burning of fuels or wastes.Conveying or handling of dusty materials like sand, wood shavings, etc.Evaporation of solvents from painting, printing, cleaning, gluing, storage, etc.Chemical processing and reactions.


Types of Emission Estimates

MTE or Uncontrolled – Need for Permit Full capacity; 8,760 hrs/yr; 0% collection

Potential – Determines Compliance Full capacity; 8,760 hrs/yr; Required %

Actual – Reported for Annual Fees Actual capacity, hrs/yr and % collection


Sample Permit Calculations #1

Shotblasting Operation with 99% Efficient BaghouseCapacity = 2 tons per hour of metalUSEPA Emission Factor = 17 lbs TSP/ton of metalApplicable Discharge Limit = NR 415.05(2) = 3.59 P 0.62

Comparison with General Permit Exemption ThresholdsMTE = 2 tph x 17 lbs of TSP/ton = 34 lbs of TSP/hr > 5.7 lbs TSP/hr, NR 406 construction permit requiredActual = 34 lbs/hr x (1 – 0.99) = 0.34 lbs TSP/hrPotential = 3.59 (2) 0.62 = 5.5 lbs TSP/hr


Types of Emission Estimates

0

5

10

15

20

25

30

35

Emissions (lbs/ hr)

MTE/ UncontrolledPotential/ AllowableActual


CONSTRUCTION PERMITS

Must be issued prior to construction or modification of regulated sources.NR 406 - Exemptions and SchedulesNR 405 - PSD rules for Large ProjectsNR 410 – FeesNR 411 – Parking Lots and RoadsNR 150 – Environmental Assessment & EIS


Types of Specific Exemptions

Natural gas-fired boilers < 25 mmbtu/hrWood-fired boilers < 5 mmbtu/hrPaint/ink usage < 1,666 lbs VOC/monthVOC storage tanks < 10,000 gallonsEmergency generators < 3,000 kilowattsEach state has own specific exemptions.


Types of General Exemptions

Uncontrolled emissions < all permit thresholds5.7 lbs/hr of total suspended particles (TSP)3.4 lbs/hr of particles < 10 microns (PM10)

9.0 lbs/hr of sulfur dioxide (SO2)

9.0 lbs/hr of nitrogen oxides (NOx)Thresholds for >500 air toxics under NR 445Use specific exemption first, then general.



Paint Spray Booth with 95% Efficient FiltersActual paint usage = 600 gallons per monthMaximum paint usage = 1.5 gallons per hourMaximum VOC content = 3.5 lbs VOC per gallonMaximum solids content = 6.0 lbs solids per gallonSpray gun transfer efficiency = 70%

Comparison with Specific Permit Exemption ThresholdsActual = 600 gpm x 3.5 lbs/gal = 2,100 lbs/month VOC> 1,666 lbs of VOC/month exemption threshold



Comparison with General Permit Exemption Thresholds

VOC Emission EstimateMTE = 1.5 gph x 3.5 lbs/gal = 5.3 lbs/hr< 5.7 lbs/hr general exemption threshold for VOC

PM10 Emission EstimateMTE = 1.5 gph x 6.0 lbs/gal x (1 - 0.7) = 2.7 lbs/hr< 3.4 lbs/hr general exemption threshold for PM10

Conclusion:No NR 406 construction permit is required based on the general permit exemption thresholds.


Schedule and Fees

Permit issuance within 2 to 12 months.30-day public comment period.Public hearing if requested by public or applicant.$1,350 initial application fee$2,300 to $85,000 permit issuance feeNR 438 annual emission fee ($35/ton)


Criteria for Permit Approval

Comply with emission limitations.Comply with air quality standards using dispersion modeling analysis.Standards include the NR 404 National Ambient Air Quality Standards or NR 445 Acceptable Air Concentrations for hazardous air pollutants.Comply with current policies.


Typical Permit Schedule

Week 1 – Submit application to DNRWeek 5 – Receive DNR request for information.Week 7 – Respond to request for information.Week 11 – DNR issues draft permit and PD.Week 12 – Publish notice for public comments.Week 16 – Public comment period ends.Week 18 – DNR issues final permit and invoice.


Expedited Permit Issuance

Pre-application meeting with DNR.Submit a complete application.Anticipate DNR application review needs.Provide emission calculations.Comply with applicable requirements.Conduct DNR modeling & risk analyses.Prepare environmental assessment.Anticipate public involvement.


Recent Air Permit Enforcement

$45,000 – Failure to obtain permit.$45,600 – Exceeded emission limits.$60,000 – Failure to maintain records.$65,000 – Failure to obtain permit.$71,820 – Failure to maintain records.$86,450 – Failure to raise stack.http://www.doj.state.wi.us/dls/environpro/news/


Keys to Successful Air Permits

Stay involved in review process.Review preliminary permit prior to official “draft” permit.Anticipate future production needs and provide flexibility in permit.Minimize unnecessary requirements.


PSD Rules Add ComplexityNR405-Prevention of Significant DeteriorationApplies to new large sourcesApplies to modifications of large sourcesAdditional permit issuance timeBest Available Control Techology or BACTPre-construction ambient monitoringDispersion modeling for increments & NAAQSVisibility, growth and vegetation analyses


PSD Thresholds (tons/year)

Air Pollutant

New Plant Modification

PM10 100/250 15

SO2 100/250 40

NOx 100/250 40

CO 100/250 100

VOC 100/250 40

Pb 100/250 0.6


PSD Avoidance

PSD rules uses “potential” emissions.Permit restrictions on capacity,operating hours, or collection % are considered.PSD avoided to save permit issuance complexity or processing time, or eliminate control requirements.Balance restrictions and future growth.


Anatomy of an Air Permit

Description of source or process.Emission limitations.Wis. Adm. Code citations.Record keeping requirements.Monitoring requirements.Testing and certification requirements.Reporting requirements.


Sample Air Permit


Construction Permit References

Jeff Hanson, Construction Permit Leader [email protected] and (608) 267-6876

Regional DNR Office Air Staff

Air Permit Web Site http://www.dnr.state.wi.us/org/aw/air/reg/regs.htm

Provides application forms, instructions, issued and pending construction permits, and modeling guidance.

Application Forms & Instructions:

ftp://www.dnr.state.wi.us/DAW/AM/permits/AppForms/

Issued & Pending Operation Permits:ftp://www.dnr.state.wi.us/DAW/AM/permits/OpPermit/PmtDocs/


OPERATION PERMITS

Application must be filed for existing regulated sources or prior to expiration of construction permits.Title V of 1990 Clean Air Act Amendments (Congress)40 CFR Part 70 (USEPA)NR 407 - Exemptions & Schedules (WI)


Processes included in Permit

Similar exemption thresholds as provided for construction permits.Includes processes which require a construction permit if built today.Includes minor processes which exceed NR 407 Table 2 inclusion thresholds (i.e. 2,000 lbs/yr).


Types of Operation Permits

FOP or Title V or Part 70 Permit

100 TPY PM, SO2, NOx, CO, VOC, Pb, Lower TPY for VOC if located in ozone nonattainment area (SE Wisconsin)

10 TPY Federal Air Toxic or 25 TPY Combined Air Toxics

Subject to most thorough review and compliance demonstration.

Subject to MACT, if available.

All applications for existing WI sources were due by 1995.


Types of Operation Permits Cont’d

Federally Enforceable Synthetic Minor Permit

Limits potential emissions by using operating hours or production restrictions to remain below thresholds.

Avoids MACT or other FOP requirements.

All WI applications were due by 1995.

Balance FESOP restrictions and future growth.



SOP – State Only Permit

Required by state not federal rules.

Potential emissions less than FOP thresholds (i.e. 100 TPY)

Only annual compliance reports.

All applications for existing WI sources were due by 1998.



Applications for all existing sources in Wisconsin have been submitted to DNR.

Construction permits for new or modified processes are replaced with operation permits prior to expiration or incorporated into the facility-wide operation permit.


Operation Permit References

Keith Pierce, Operation Permit Leader [email protected] and (608) 267-0562

Regional DNR Office Air Staff

DNR Air Permit Web Site http://www.dnr.state.wi.us/org/aw/air/reg/regs.htm Provides application forms, instructions, issued and

pending operation permits, permit application software.

USEPA MACT Web Sitehttp://www.epa.gov/ttn/atw/eparules.html


Air Permits in a Nutshell

NR 406 construction permits required prior to the start of construction or modification.

NR 407 operation permits are for existing processes, or replace construction permits.

Review permits thoroughly before issuance to assure accuracy and flexibility.

Documents

FET Environmental Primer Air Regulations: Permitting Basics Steven Klafka, P.E. Wingra Engineering, S.C. Madison, Wisconsin