TECHNICAL SUPPORT DOCUMENT FOR THE BOEING COMPANY BOEING EVERETT 777X PROJECT Prepared by Air Quality Program Washington State Department of Ecology Olympia, Washington September 9, 2014 TABLE OF CONTENTS 1. EXECUTIVE SUMMARY .................................................................................................................................. 1 2. INTRODUCTION................................................................................................................................................ 3 2.1. The Permitting Process ................................................................................................................................ 3 2.1.1. The PSD Process ................................................................................................................................. 3 2.1.2. The NOC Process ................................................................................................................................ 3 2.2. Site and Project Description ......................................................................................................................... 4 2.2.1. Site Description ................................................................................................................................... 4 2.2.2. Project Description .............................................................................................................................. 5 3. PSD APPLICABILITY REVIEW ..................................................................................................................... 15 3.1. Overview and Permitting History .............................................................................................................. 15 3.2. Emissions Calculation ................................................................................................................................ 17 3.2.1. Significant Emissions Increases ........................................................................................................ 17 4. BACT ................................................................................................................................................................. 23 4.1. Definitions and Policy Concerning BACT ................................................................................................. 23 4.2. BACT Analysis .......................................................................................................................................... 25 4.2.1. Prep and Spray Paint Booths BACT Analysis ................................................................................... 25 4.2.2. Available Control Technologies ........................................................................................................ 26 4.2.3. BACT Feasibility Review ................................................................................................................. 27 4.2.4. Ranking of BACT by Control ........................................................................................................... 28 4.2.5. Cost-Effectiveness Evaluation ........................................................................................................... 28 4.2.6. Thermal Oxidizer .............................................................................................................................. 28 4.2.7. Carbon Adsorption ............................................................................................................................ 29 4.2.8. Regenerative Thermal Oxidizer......................................................................................................... 29 4.2.9. RTO with Concentrator ..................................................................................................................... 29 4.2.10. Low VOC Coatings, High Transfer Efficiency Coating Techniques, and Good Work Practices ..... 29 4.2.11. Summary of Cost-Effectiveness Analysis ......................................................................................... 30 4.2.12. Comparison with Other Aerospace BACT Determinations............................................................... 33 4.2.13. BACT Selection ................................................................................................................................ 38 4.3. BACT for Natural Gas Combustion ........................................................................................................... 39 4.3.1. Available Control Technologies ........................................................................................................ 41 4.3.2. BACT Selection ................................................................................................................................ 41 4.4. BACT for Emergency Generators .............................................................................................................. 42 4.4.1. Available Control Technologies ........................................................................................................ 42 4.4.2. BACT Selection ................................................................................................................................ 42 4.5. BACT for Wing Composite Layup and Curing ......................................................................................... 42 4.5.1. Available Control Technologies ........................................................................................................ 43 4.5.2. BACT Feasibility Review ................................................................................................................. 44 ii 4.5.3. RTO with Concentrator ..................................................................................................................... 44 4.5.4. Thermal Incineration ......................................................................................................................... 45 4.5.5. Carbon Adsorption ............................................................................................................................ 45 4.5.6. Ranking of BACT by Control ........................................................................................................... 45 4.5.7. Cost-Effectiveness Evaluation ........................................................................................................... 46 4.6. BACT for Crush Core Press ....................................................................................................................... 46 4.6.1. Available Control Technologies ........................................................................................................ 46 4.6.2. BACT Feasibility Review ................................................................................................................. 47 4.6.3. RTO with Concentrator ..................................................................................................................... 47 4.6.4. Thermal Incineration ......................................................................................................................... 48 4.6.5. Carbon Adsorption ............................................................................................................................ 48 4.6.6. Ranking of BACT by Control ........................................................................................................... 48 4.6.7. Cost-Effectiveness Evaluation ........................................................................................................... 49 4.6.8. BACT Selection ................................................................................................................................ 49 4.7. BACT for Open Floor Emissions ............................................................................................................... 49 4.7.1. Wing Component Fabrication ........................................................................................................... 50 4.7.2. Available Control Technologies ........................................................................................................ 50 4.7.3. BACT Feasibility Review ................................................................................................................. 51 4.7.4. BACT Selection ................................................................................................................................ 51 4.8. Toxic Air Pollutants ................................................................................................................................... 52 5. AMBIENT AIR QUALITY IMPACTS ANALYSIS ........................................................................................ 52 5.1. Regulatory Requirements ........................................................................................................................... 52 5.2. Impacts on Class I Areas ............................................................................................................................ 52 5.3. Ozone Impacts ............................................................................................................................................ 54 6. ADDITIONAL IMPACTS ANALYSIS ............................................................................................................ 55 6.1. Air Quality Related Values (AQRV) ........................................................................................................