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Adeq Draft Operating Air Permit ADEQ DRAFT OPERATING AIR PERMIT Pursuant to the Regulations of the Arkansas Operating Air Permit Program, Regulation 26: Permit No. : 0801-AOP-R10 IS ISSUED TO: Blue Cube Operations LLC 3230 Dow Drive Russellville, AR 72802 Pope County AFIN: 58-00011 THIS PERMIT AUTHORIZES THE ABOVE REFERENCED PERMITTEE TO INSTALL, OPERATE, AND MAINTAIN THE EQUIPMENT AND EMISSION UNITS DESCRIBED IN THE PERMIT APPLICATION AND ON THE FOLLOWING PAGES. THIS PERMIT IS VALID BETWEEN: AND THE PERMITTEE IS SUBJECT TO ALL LIMITS AND CONDITIONS CONTAINED HEREIN. Signed: Stuart Spencer Date Associate Director, Office of Air Quality Blue Cube Operations LLC Permit #: 0801-AOP-R10 AFIN: 58-00011 Table of Contents SECTION I: FACILITY INFORMATION .............................................................................. 4 SECTION II: INTRODUCTION ............................................................................................... 5 Summary of Permit Activity .................................................................................................... 5 Process Description ................................................................................................................... 5 Regulations .............................................................................................................................. 12 Emission Summary ................................................................................................................. 13 SECTION III: PERMIT HISTORY ........................................................................................ 16 SECTION IV: SPECIFIC CONDITIONS .............................................................................. 19 Production Unit Operations .......................................................................................................... 19 SN-07 Production Unit #5 Operations ...................................................................................... 19 SN-02A and SN-03A Silo and Sand Transfer System .............................................................. 21 SN-13 Anode Bake Oven.......................................................................................................... 22 SN-15 and SN-16 Transfer System and Coating Operation ..................................................... 24 Dip Tanks ...................................................................................................................................... 25 SN-12 Anode Dip Tank ............................................................................................................ 25 SN-20 and SN-21 Membrane Cell Components Dip Tank and Electric Bake Oven ............... 26 Tanks ............................................................................................................................................. 27 SN-08R, SN-08A, and SN-09A Casting Resin Storage Tank, Day Tank, and Containers ...... 27 SN-22 and SN-23 Mix Tank Exhaust Vent and Mix Room Exhaust Vent .............................. 29 SN-26 Isopropanol Tank ........................................................................................................... 30 SN-28 Coating Solvent Storage Mix Tanks and Day Tanks .................................................... 31 Grinding Operations...................................................................................................................... 32 SN-04, SN-17, and SN-25 Grinding Operations #1, #2, and #3 ............................................... 32 Grit Blasting Operations ............................................................................................................... 34 SN-06, SN-11, SN-14, and SN-19 Grit Blasting Operations #1, #2, #3, and #4 ...................... 34 SN-38 Fueling Station............................................................................................................... 36 SN-39 Gasket Glue Removal Operation ................................................................................... 38 SN-40 Cell Putty ....................................................................................................................... 39 SECTION V: COMPLIANCE PLAN AND SCHEDULE ..................................................... 42 SECTION VI: PLANTWIDE CONDITIONS ........................................................................ 43 Title VI Provisions .................................................................................................................... 45 Permit Shield ............................................................................................................................. 47 SECTION VII: INSIGNIFICANT ACTIVITIES................................................................... 49 SECTION VIII: GENERAL PROVISIONS ........................................................................... 50 Appendix A: 40 CFR Part 63, Subpart CCCCCC Appendix B: 40 CFR Part 61, Subpart M 2 Blue Cube Operations LLC Permit #: 0801-AOP-R10 AFIN: 58-00011 List of Acronyms and Abbreviations Ark. Code Ann. Arkansas Code Annotated AFIN ADEQ Facility Identification Number C.F.R. Code of Federal Regulations CO Carbon Monoxide HAP Hazardous Air Pollutant lb/hr Pound Per Hour MVAC Motor Vehicle Air Conditioner No. Number NOx Nitrogen Oxide PM Particulate Matter PM10 Particulate Matter Smaller Than Ten Microns SNAP Significant New Alternatives Program (SNAP) SO2 Sulfur Dioxide SSM Startup, Shutdown, and Malfunction Plan Tpy Tons Per Year UTM Universal Transverse Mercator VOC Volatile Organic Compound 3 Blue Cube Operations LLC Permit #: 0801-AOP-R10 AFIN: 58-00011 SECTION I: FACILITY INFORMATION PERMITTEE: Blue Cube Operations LLC AFIN: 58-00011 PERMIT NUMBER: 0801-AOP-R10 FACILITY ADDRESS: 3230 Dow Drive Russellville, AR 72802 MAILING ADDRESS: 3230 Dow Drive Russellville, AR 72802 COUNTY: Pope County CONTACT NAME: Jonathan Hawkins CONTACT POSITION: Environmental, Health & Safety Technician TELEPHONE NUMBER: (479) 968-0832 REVIEWING ENGINEER: Franck Houenou UTM North South (Y): Zone 15: 3899572.59 m UTM East West (X): Zone 15: 486371.35 m 4 Blue Cube Operations LLC Permit #: 0801-AOP-R10 AFIN: 58-00011 SECTION II: INTRODUCTION Summary of Permit Activity The Blue Cube Operations LLC operates an industrial plant located in Russellville, Arkansas. This is the third Title V Renewal permit for this facility. With the renewal, the facility requested to delete four discontinued production operations from the air permit coverage. The facility is removing sources SN-27, SN-30, SN-36 and SN-37. The total permitted emission rate limit changes associated with this activity includes -0.10 tpy PM, -0.10 tpy PM10, -4.40 tpy VOCs, - 0.44 tpy Acetone and -3.80 tpy Ammonia. Process Description Blue Cube Operations LLC (Blue Cube) operates an industrial facility located in Russellville, Arkansas. The physical address of the site is 3230 Dow Drive. Cathode and anode electrodes for chlorine (“chlor-alkali”) production cells are made and refurbished at the plant. The polymer concrete components for these units are also fabricated onsite. The manufacturing operations at the Russellville facility are properly categorized using Standard Industrial Classification (SIC) Code #3559 (special industrial machinery, not elsewhere classified). The corresponding North American Industry Classification System (NAICS) Code is #333298 (all other industrial machinery manufacturing). Blue Cube is a wholly owned subsidiary of Olin Corporation (Olin). Blue Cube Operations LLC merged with Olin on October 5, 2015. The production activities at the Blue Cube facility include the following: the casting of polymer concrete frames, covers and other parts for chlorine cells; the fabrication of cathode and anode electrodes; the refurbishing of certain anode units; several electrode-coating processes; numerous grit blasting and grinding operations; and, a variety of miscellaneous industrial activities. CASTING OF REINFORCED POLYMER CONCRETE COMPONENTS FOR DIAPHRAGM CELLS (PRODUCTION UNIT #5) Blue Cube makes frames, covers and other components for chlorine production cells (“diaphragm” -type units). These reinforced “polymer concrete” parts are made in Production Unit #5. The manufacturing operations are described below: The raw materials for the batch casting operations include several styrene-based “epoxy vinyl ester resins”, sand, chopped fiberglass, and miscellaneous ingredients. The primary casting material is a styrene-based resin. This product is delivered in bulk by truck. The material is stored in the casting resin tank (SN-08R). This aboveground, vertical vessel has a storage capacity of 14,300 gallons. The insulated tank is chilled to maintain the stability of the styrene-based resin and pumped into a 500-gallon “day tank” (SN-08A) that supplies the casting operations. 5 Blue Cube Operations LLC Permit #: 0801-AOP-R10 AFIN: 58-00011 Four additional casting compounds are received in 350-gallon tote bins and/or 55-gallon drums (SN-09A). Sand for the casting operations is delivered in bulk by truck. The material is pneumatically unloaded into a large storage silo (SN-02A). The silo is equipped with a baghouse. It is used to control the dust emissions generated during the unloading operations. The material is subsequently transferred to a bulk resin mixer located inside Production Unit #5. The sand transfer system (SN-03A) encompasses all of the conveying and handling equipment from the storage silo to the mixer. These units include a bucket elevator, two belt conveyors, a screener, a weigh
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