MPCA Air Quality Permits Guide Part 1 Defining Your Facility Prepared by: Air Quality Staff Minnesota Pollution Control Agency 520 Lafayette Road St. Paul, MN 55155 March 1994 Revised September 1998 Printed on paper containing at least 20 percent fibers from paper recycled from consumers. Part 1 Acknowledgments March 1994 version: Author: Barbara Conti Contributors: Lori Bartels Leo Raudys Dick Cordes Kathy Seeburger Bernadette Halverson Toni Stevens Julie Hendricks Mark Strange Mary Hoffman Phyllis Strong Barb Loida Neesha Wolf MPCA Air Quality Division Minnesota Office of the Attorney General Project Manager: Leo Raudys Editor: Valerie Williams, VKW Consulting Graphic Design and Layout: Dick Garrison, Garrison Design (March 1994 version only) Additional assistance provided Rust Environment & Infrastructure by: 1998 revision: Coordinator: Toni Volkmeier Contributors: Peggy Bartz Bonnie Nelson The MPCA would also like to thank the following individuals and organizations for provided advice and assistance during initial development of this document: MPCA Small Business Compliance Advisory Council William R. McMurtry, Honeywell, Inc. Tim Casey, HDR Engineering, Inc. Mike Medina, Unisys Karl DeWahl, Minnesota Technical Assistance Program Craig Moody, University of Minnesota Duane Dittberner, Unisys Mark Sytsma, Woodcraft Industries, Inc. James N. Friedman, Interpoll Laboratories, Inc. Mike Valentine, Braun Intertec Stephen F. Haselmann, Waldorf Corporation Lee Walz, DeZurik Elizabeth Henderson, Wenck Associates, Inc. Richard Svanda, Jostens Gary Kaziukewicz, Waldorf Corporation Paul Kramer, Rahr Malting Company Richard T. Kennealy, Jr., United Defense, L.P. Ahto Niemioja, Braun Intertec Allan Kremer, Hennepin Energy Resource Company Mary Sands, DPRA Incorporated Mary Kruger, Department of Trade and Economic Development Richard D. Lowe, American Engineering Testing, Inc. Gary J. Nierengarten, Frigidaire Company - Freezer Products Michael K. Vennewitz, Capsule Environmental Engineering, Inc. Bill Wall, ENSR Consulting and Engineering Table of Contents Preface To The Guide......................................................................................v Focus Of Part 1 .............................................................................................vii 1.0 What Is A Permit?....................................................................................1-1 2.0 What Air Pollutants Are Regulated By The MPCA?..............................2-1 2.1 Criteria pollutants................................................................................................... 2-1 2.2 Volatile Organic Compounds (VOCs) ................................................................... 2-2 2.3 Hazardous Air Pollutants (HAPs) .......................................................................... 2-4 2.4 Other regulated pollutants ...................................................................................... 2-4 3.0 Steps For Completing A Permit Application .........................................3-1 4.0 How Is Your Facility Defined? ................................................................4-1 4.1 What are your emission points? ............................................................................. 4-1 4.2 What are your emission units? ............................................................................... 4-2 4.3 How should you describe your operations?............................................................ 4-3 5.0 What Is Potential To Emit (PTE)?...........................................................5-1 5.1 How do you calculate Potential to Emit (PTE)? .................................................... 5-1 5.1.1 What references can you use to calculate PTE?......................................... 5-2 5.1.2 Examples of potential emissions calculations............................................ 5-3 5.1.3 What is the next step after calculating the PTE of your emission units? ... 5-8 5.1.4 What about fugitive emissions? ................................................................. 5-9 5.1.5 What if your PTE is below the thresholds?................................................ 5-10 5.2 Do you need any other emissions data? ................................................................. 5-11 5.2.1 What are your actual emissions?................................................................ 5-11 5.3 How can you limit your Potential to Emit (PTE)? ................................................. 5-12 5.3.1 What about your air pollution control equipment? .................................... 5-12 5.3.2 What if you do not want to be subject to federal regulations? ................... 5-12 5.3.2.1 What are acceptable options for synthetic minor limits? ............... 5-13 6.0 What Rules And Regulations Apply To You? ........................................6-1 6.1 What are the federal regulations?........................................................................... 6-1 6.1.1 National Ambient Air Quality Standards (NAAQS).................................. 6-1 6.1.1.1 State Implementation Plan ............................................................. 6-2 6.1.2 National Emission Standards for Hazardous Air Pollutants (NESHAPs)............................................................................... 6-2 6.1.3 New Source Review (NSR)........................................................................ 6-3 6.1.3.1 Does NSR apply to your facility?................................................... 6-4 6.1.3.2 What is required for NSR?............................................................. 6-5 6.1.4 New Source Performance Standards (NSPS)............................................. 6-6 6.1.4.1 An example of an NSPS................................................................. 6-7 MPCA Air Quality Permits Guide Part 1: Defining Your Facility -- Revision 1, September 1998 Page i 6.1.5 Acid rain..................................................................................................... 6-7 6.1.6 Stratospheric ozone protection................................................................... 6-7 6.1.7 Compliance assurance monitoring ............................................................. 6-8 6.2 What are the Minnesota rules?............................................................................... 6-8 6.2.1 Air Quality permit rule............................................................................... 6-9 6.2.2 Environmental review program.................................................................. 6-9 6.2.3 Standards of performance for stationary sources ....................................... 6-10 6.2.4 Emission inventory and air quality emission fees ...................................... 6-10 6.2.5 Performance testing for emissions ............................................................. 6-11 7.0 How Do You Maintain Flexibility In Your Operations?.........................7-1 7.1 What is operational flexibility?.............................................................................. 7-1 7.1.1 Alternative operating scenarios.................................................................. 7-1 7.1.2 Emission trading......................................................................................... 7-2 8.0 What If You Have Confidential Material In An Application? ................8-1 9.0 What Is In A Complete Permit Application?..........................................9-1 9.1 Why is a "complete" application important?.......................................................... 9-1 9.2 When were complete permit applications due?...................................................... 9-2 9.3 What happens to your application at the MPCA? .................................................. 9-3 10.0 Case Study -- Blue Ox Woodworks........................................................10-1 10.1 History of Blue Ox Woodworks............................................................................. 10-1 10.2 Blue Ox Woodworks Emission Unit Information.................................................. 10-2 10.2.1 Boilers ........................................................................................................ 10-2 10.2.2 Milling operations ...................................................................................... 10-3 10.2.3 Painting operations..................................................................................... 10-6 10.2.4 Diesel generator.......................................................................................... 10-7 10.2.5 Fugitive dust emissions .............................................................................. 10-7 10.2.6 Insignificant activities ................................................................................ 10-7 10.3 Blue Ox Woodworks emission calculations........................................................... 10-7 10.3.1 Wood boiler #1 calculations....................................................................... 10-8 10.3.2 New boiler #2 calculations......................................................................... 10-9 10.3.3 Milling equipment calculations.................................................................. 10-11 10.3.4 Painting equipment calculations................................................................. 10-11 10.3.5 Diesel generator calculations...................................................................... 10-19 10.3.6 Summary of all potential to emit calculations...........................................