Oakville Health Protection Air Quality By-Law Application for Approval Submitted by: Ford Motor Company of Canada Limited Oakville Assembly Complex The Canadian Road Oakville, ON L6J 5C9 Prepared by: Horizon Environmental Corporation 4771 – 50th Street SE, Suite 100 Grand Rapids, Michigan 49512 September 28, 2012 TABLE OF CONTENTS PUBLIC SUMMARY ............................................................................................................................................... IV 1 EXECUTIVE SUMMARY ................................................................................................................................ 1 2 INTRODUCTION .............................................................................................................................................. 2 3 FACILITY DESCRIPTION ............................................................................................................................. 4 3.1 OVERVIEW ....................................................................................................................................................... 4 3.2 LOCATION ........................................................................................................................................................ 4 3.3 BUILDINGS ....................................................................................................................................................... 5 3.4 RAW MATERIALS, PRODUCTS AND PROCESSES ................................................................................................ 5 3.4.1 COMFORT AND PROCESS HEATING ......................................................................................................... 5 3.4.2 PEAK SHAVE GENERATORS .................................................................................................................... 5 3.4.3 VEHICLE BODY PAINTING ...................................................................................................................... 5 3.5 EMISSION SOURCES AND PROCESSES ............................................................................................................... 6 3.5.1 COMFORT AND PROCESS HEATING ......................................................................................................... 6 3.5.2 PEAK SHAVE GENERATORS .................................................................................................................... 6 3.5.3 VEHICLE BODY PAINTING ...................................................................................................................... 6 3.6 EMISSION CONTROL EQUIPMENT, PROCEDURES AND EMISSIONS MONITORING ............................................... 8 3.6.1 COMFORT AND PROCESS HEATING ......................................................................................................... 8 3.6.2 DIESEL-FIRED PEAK SHAVE GENERATORS ............................................................................................. 8 3.6.3 VEHICLE BODY PAINTING ...................................................................................................................... 8 3.7 IDENTIFICATION AND QUANTIFICATION OF SUBSTANCES RELEASED TO THE AIR ............................................ 8 3.7.1 NATURAL GAS COMBUSTION ................................................................................................................. 8 3.7.2 DIESEL-FIRED PEAK SHAVE GENERATORS ............................................................................................. 9 3.7.3 VEHICLE BODY PAINTING ...................................................................................................................... 9 4 EVALUATION ................................................................................................................................................. 11 4.1 MODELLING APPROACH AND MODEL SELECTION .......................................................................................... 11 4.2 MODEL INPUTS .............................................................................................................................................. 11 4.2.1 FACILITY EMISSIONS ESTIMATE REQUIREMENTS / ESTIMATION METHODS .......................................... 11 4.2.2 MODEL INPUT CHECKLIST .................................................................................................................... 12 4.3 MODEL-PREDICTED FPM CONCENTRATIONS ................................................................................................. 17 4.3.1 TOTAL FACILITY INDUCED CONCENTRATIONS ..................................................................................... 17 4.3.2 CUMULATIVE CONCENTRATIONS .......................................................................................................... 20 5 MAPPING ........................................................................................................................................................ 21 6 HEALTH-RISK ASSESSMENT .................................................................................................................... 23 6.1 NUMERIC PROCEDURE ................................................................................................................................... 23 6.2 GRAPHIC PROCEDURE .................................................................................................................................... 24 7 APPRAISAL ..................................................................................................................................................... 25 7.1 EMISSION CONTROL TECHNOLOGIES ............................................................................................................. 25 Ford Motor Company of Canada Limited i Horizon Environmental Corporation Oakville Assembly Complex Technical Support Document Application for Town Approval September 28, 2012 7.1.1 TALL STACK AND VENTURI SCRUBBER ................................................................................................ 25 7.1.2 REGENERATIVE THERMAL OXIDIZER (RTO) ........................................................................................ 25 7.2 OAKVILLE ASSEMBLY COMPLEX APPRAISAL AND MITIGATION PLANS ......................................................... 26 7.2.1 PAINTING OPERATIONS ......................................................................................................................... 26 7.2.2 NATURAL GAS COMBUSTION ............................................................................................................... 26 7.2.3 PEAK SHAVE GENERATORS .................................................................................................................. 28 8 ADDITIONAL INFORMATION ................................................................................................................... 29 FIGURES 2-1 LOCATION OF THE OAKVILLE ASSEMBLY COMPLEX 3-1 LAND USE AND SENSITIVE RECEPTORS WITHIN A THREE KILOMETER RADIUS OF THE OAKVILLE ASSEMBLY COMPLEX 3-2 PLANAR VIEW OF BUILDING PROJECTIONS IN RELATION TO EMISSION POINTS 3-3 3-D DEPICTION OF BUILDING PROJECTIONS IN RELATION TO EMISSION POINTS 3-4 PROCESS FLOW DIAGRAM – VEHICLE BODY PAINTING 4-1 CARTESIAN RECEPTOR POINTS ASSOCIATED WITH THE 100 BY 100 KILOMETER CALMET METEOROLOGICAL GRID 4-2 FINE RESOLUTION RECEPTOR POINTS WITHIN THE TOWN OF OAKVILLE 5-1 TOTAL FACILITY INDUCED FPM CONCENTRATIONS, MAXIMAL EMISSIONS SCENARIO 5-2 TOTAL FACILITY INDUCED FPM CONCENTRATIONS, AVERAGE EMISSIONS SCENARIO 5-3 CUMULATIVE FPM CONCENTRATIONS (FACILITY + BACKGROUND), MAXIMAL EMISSIONS SCENARIO 5-4 CUMULATIVE FPM CONCENTRATIONS (FACILITY + BACKGROUND), AVERAGE EMISSIONS SCENARIO 6-1 TOTAL FACILITY INDUCED RISK MAP, MAXIMAL EMISSIONS SCENARIO 6-2 TOTAL FACILITY INDUCED RISK MAP, AVERAGE EMISSIONS SCENARIO 6-3 CUMULATIVE RISK MAP (FACILITY + BACKGROUND), MAXIMAL EMISSIONS SCENARIO 6-4 CUMULATIVE RISK MAP (FACILITY + BACKGROUND), MAXIMAL EMISSIONS SCENARIO TABLES 6 3-1 NATURAL GAS CONSUMPTION (10 CUBIC METRE) BY MONTH AND YEAR 3-2 FPM AND NOX ANNUALIZED EMISSION RATES BY NG COMBUSTION SOURCE - MAXIMAL AND AVERAGE EMISSIONS SCENARIOS 3-3 FPM AND NOX ANNUALIZED EMISSION RATES FOR PEAKING UNITS – MAXIMAL AND AVERAGE EMISSIONS SCENARIOS Ford Motor Company of Canada Limited ii Horizon Environmental Corporation Oakville Assembly Complex Technical Support Document Application for Town Approval September 28, 2012 3-4 FPM ANNUAL EMISSION RATES FOR PAINTING – MAXIMAL AND AVERAGE EMISSIONS SCENARIOS 4-1 STACK LOCATION AND EXHAUST PARAMETERS 4-2 MODELLED EMISSION RATES – MAXIMAL AND AVERAGE EMISSIONS SCENARIOS 4-3 TOTAL FACILITY INDUCED AND CUMULATIVE CONCENTRATION ASSESSMENT 4-4 TOTAL FACILITY INDUCED AND CUMULATIVE CONCENTRATION ASSESSMENT – ON-SITE DAYCARE CENTER 6-1 HEALTH RISK ASSESSMENT – NUMERIC PROCEDURE APPENDICES A DISPERSION MODELLING INPUT/OUTPUT FILES AND RELATED DATABASES (DVD-ROM) B MODEL INPUT CHECKLIST Ford Motor Company of Canada Limited iii Horizon Environmental Corporation Oakville Assembly Complex Technical Support Document Application for Town Approval September 28, 2012 PUBLIC SUMMARY Introduction: Ford Motor Company of Canada, Limited (“Ford”) owns and operates the Oakville Assembly Complex located on The Canadian Road in the Town of Oakville, Ontario. The site is comprised of a large vehicle assembly complex that currently produces cross-over utility vehicles including the Ford Edge, Ford Flex, Lincoln MKX and Lincoln MKT and employs approximately 2,900