NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION

DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES

DIVISION OF AIR QUALITY

AIR PERMIT NO. 03642R18

Issue Date: December 14, 2005

Effective Date: December 14, 2005

Expiration Date: July 31, 2009

Replaces Permit: 03642R17

 

To construct and operate air emission source(s) and/or air cleaning device(s), and for the discharge of the associated air contaminants into the atmosphere in accordance with the provisions of Article 21B of Chapter 143, General Statutes of North Carolina (NCGS) as amended, and other applicable Laws, Rules and Regulations,

Alamac American Knits, LLC
1885 Alamac Road
Lumberton, Robeson County, North Carolina
Fee Class: Title V
Site Number: 06/78/00003

(the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenances described below:

Emission
Source ID

Emission Source
Description

Control System ID /Control System Description

Four Textile Finishing Open Width Dryers:

16

One natural gas/propane-fired open width tenter frame dryer with coating/resin applicator (9.6 million Btu per hour maximum heat input and maximum throughput of 1000 lbs of cloth per hour, [Stentex #1])

N/A

2F and 3F

Two natural gas/propane-fired open width tenter frame dryers, with a coating/resin applicator (8.0 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour each, [Famatex])

1K

One natural gas/propane-fired open width tenter frame dryer, with a coating/resin applicator (7.2 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour, [Krantz #4]),

Eight Textile Finishing Tubular Dryers:

1

One natural gas/propane-fired textile finishing tubular dryer (8.0 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour [Fabcon #1])

N/A

2

One natural gas/propane-fired textile finishing tubular dryer (8.1 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour, [Tube-Tex #2]),

5

One (1) natural gas / propane-fired textile finishing tubular dryer with coating/resin applicator (9.96 million Btu per hour maximum heat input , and maximum throughput of 500 lbs of cloth per hour, [Tube-Tex])

6

One natural gas/propane-fired textile finishing dryer with coating/resin applicator (6.0 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour, [Fabcon]),

8

One natural gas/propane-fired textile finishing dryer with coating/resin applicator (9.0 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour, [Fabcon #8])

9

One (1) natural gas / propane-fired textile finishing tubular dryer with coating/resin applicator (9.96 million Btu per hour maximum heat input , and maximum throughput of 800 lbs of cloth per hour, [Tube-Tex])

10

One natural gas / propane-fired textile finishing tubular dryer with coating/resin applicator (9.96 million Btu per hour maximum heat input , and maximum throughput of 750 lbs of cloth per hour, [Tube-Tex])

15

One natural gas/propane-fired textile finishing tubular dryer with coating/resin applicator (12 million Btu per hour maximum heat input, and maximum throughput of 1000 lbs of cloth per hour, [Tube-Tex #4])

One Textile Finishing Loop Dryer:

12

One natural gas/propane-fired textile finishing #2 Loop Dryer (2.4 million Btu per hour maximum heat input, and maximum throughput of 750 lbs of cloth per hour

N/A

One Textile Finishing Dryer with Coating/Resin Applicator:

14

One natural gas/propane-fired textile finishing dryer with coating/resin applicator (7.446 million Btu per hour maximum heat input, and maximum throughput of 800 lbs of cloth per hour, [Santex]),

N/A

TDP1

One textile dye process

17a and 17b

Two bleach ranges

18

One acetic acid tank (7,500 gallon capacity)

Two Process Boilers

ESB-1

One No. 6/No. 4/No. 2 fuel oil/NG fired 1988 Cleaver Brooks 33.5MBtu/hr max. heat input dryback firetube boiler model CB 400-800; s/n L84652; NB # 66104

N/A

ESB-2

One No. 6/No. 4/No. 2 fuel oil/NG fired 1986 Cleaver Brooks 33.5MBtu/hr max. heat input dryback firetube boiler; model CB 400-800; s/n L82724; NB # 63294


in accordance with the completed application 7800003.05D received November 21, 2005 including any plans, specifications, previous applications, and other supporting data, all of which are filed with the Department of Environment and Natural Resources, Division of Air Quality (DAQ) and are incorporated as part of this permit.
            This permit is subject to the following specified conditions and limitations including any TESTING, REPORTING, OR MONITORING REQUIREMENTS:

A. SPECIFIC CONDITIONS AND LIMITATIONS

  1. Any air emission sources or control devices authorized to construct and operate above must be operated and maintained in accordance with the provisions contained herein. The Permittee shall comply with applicable Environmental Management Commission Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0202, 2D .0503, 2D .0515, 2D .0516, 2D .0521, 2D .0535, 2D .0958, 2D .1100, 2D .1806, 2Q .0317 avoidance conditions, 2Q .0711, and 2Q .0507.
  2. EMISSION INVENTORY REQUIREMENT - At least 90 days prior to the expiration date of this permit, the Permittee shall submit the air pollution emission inventory report in accordance with 15A NCAC 2D .0202, pursuant to N.C. General Statute 143 215.65. The report shall be submitted to the Regional Supervisor, DAQ. The report shall document air pollutants emitted for the 2008 calendar year. The Regional Office will send information on how to submit the emissions inventory, along with a reminder to renew your permit, about six months prior to your permit expiration. If you do not receive this information, please contact the Regional Supervisor, DAQ.
  3. PARTICULATE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0503 "Particulates from Fuel Burning Indirect Heat Exchangers," particulate matter emissions from the fuel burning indirect heat exchangers shall not exceed the allowable emission rates listed below:

Source

Emission Limit (lbs/million Btu)

1988 Cleaver Brooks 33.5MBtu/hr max. heat input dryback firetube boiler model CB 400-800; s/n L84652; NB # 66104 (ESB-1)

0.33 lbs/MBtu

1986 Cleaver Brooks 33.5MBtu/hr max. heat input dryback firetube boiler; model CB 400-800; s/n L82724; NB # 63294 (ESB-2)

0.33lbs/MBtu
  1. PARTICULATE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the emission sources shall not exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC 2D .0515, a function of the process weight rate and shall be determined by the following equation(s), where P is the process throughput rate in tons per hour (tons/hr) and E is the allowable emission rate in pounds per hour (lbs/hr).

E = 4.10 * (P) 0.67           

for P <= 30 tons/hr, or

E = 55 * (P) 0.11 - 40     

for P >30 tons/hr
  1. SULFUR DIOXIDE CONTROL REQUIREMENT - As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from 1988 CB Boiler 33.5MBtu/hr (ID No. ESB-1) and 1986 CB Boiler 33.5MBtu/hr (ID No. ESB-2) shall not exceed 2.3 pounds per million Btu heat input.
  2. VISIBLE EMISSIONS CONTROL REQUIREMENT - As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein.
  3. VISIBLE EMISSIONS CONTROL REQUIREMENT - As required by 15A NCAC 2D .0521 "Control of Visible Emissions," visible emissions from the emission sources  manufactured as of July 1, 1971, shall not be more than 40 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 90 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein.
  4. NOTIFICATION REQUIREMENT - As required by 15A NCAC 2D .0535, the Permittee of a source of excess emissions that last for more than four hours and that results from a malfunction, a breakdown of process or control equipment or any other abnormal conditions, shall:
    1. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the occurrence and describe:
      1. the name and location of the facility,
      2. the nature and cause of the malfunction or breakdown,
      3. the time when the malfunction or breakdown is first observed,
      4. the expected duration, and
      5. an estimated rate of emissions.
    2. Notify the Director or his designee immediately when the corrective measures have been accomplished.

This reporting requirement does not allow the operation of the facility in excess of Environmental Management Commission Regulations.

  1. WORK PRACTICES REQUIREMENTS - As required by 15A NCAC 2D .0958(c) "Work Practices for Sources of Volatile Organic Compounds," the Permittee shall adhere to the following required work practices:
    1. The Permittee shall store all VOC-containing material not in use (including waste material) in containers covered with a tightly fitting lid that is free of cracks, holes, or other defects.
    2. The Permittee shall clean up spills as soon as possible following proper safety procedures.
    3. The Permittee shall store wipe rags in closed containers.
    4. The Permittee shall not clean sponges, fabric, wood, paper products, and other absorbent materials.
    5. The Permittee shall drain solvents used to clean supply lines and other coating equipment into closable containers and close containers immediately after each use.
    6. The Permittee shall clean mixing, blending, and manufacturing vats and containers by adding cleaning solvent, closing the vat or container before agitating the cleaning solvent.
    7. The Permittee shall pour spent cleaning solvent into closable containers and close containers immediately after each use.

10. TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND REPORTING REQUIREMENT - Pursuant to 15A NCAC 2D .1100 "Control of Toxic Air Pollutants," and in accordance with the approved application for an air toxic compliance demonstration, the following permit limits shall not be exceeded:

Affected Source(s)

Toxic Air Pollutant

Emission Limit

Facility Wide

Acetic acid

16.4 lbs/hr

Formaldehyde

12.4 lbs/hr

a.   Reporting Requirements - For compliance purposes, within 30 days after each calendar year, regardless of the actual emissions, the following shall be reported to the Regional Supervisor, DAQ:

      1. The actual maximum hourly facility-wide emission rate for acetic acid during the previous calendar year; and
      2. the actual maximum hourly facility-wide emission rate for formaldehyde during the previous calendar year

b.   Recordkeeping Requirements - The following recordkeeping requirements apply:

Recordkeeping Requirements - To ensure compliance with the above limits, the Permittee shall maintain records of material usage, formulation data, hours of operation, and any other operational data needed to calculate the actual maximum hourly facility-wide emission rates for acetic acid and formaldehyde.

i.    Availability of Records - The records specified in this permit condition shall be kept on site and made available to DAQ personnel for inspection upon request.

11. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS - As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions" the Permittee shall not operate the facility without implementing management practices or installing and operating odor control equipment sufficient to prevent odorous emissions from the facility from causing or contributing to objectionable odors beyond the facility's boundary.

      12. 15A NCAC 2Q. 0317: AVOIDANCE CONDITIONS for

            15A NCAC 2D .0530:  PREVENTION OF SIGNIFICANT DETERIORATION

           

            a.   In order to avoid applicability of 15A NCAC 2D .0530(g), the boilers (ID Nos. ESB-1 & 2) shall discharge into the atmosphere less than 250 tons of sulfur dioxide per consecutive 12-month period.  [15A NCAC 2D .0530]

                 

                  Monitoring/Recordkeeping [15A NCAC 2Q .0508 (f)]

            b.   The Permittee shall keep monthly records of the amount of fuel used and the sulfur content, including certification of the fuel, in a log (written or in electronic format). The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the sulfur content of the fuel is not monitored.

 

                  Monitoring/Recordkeeping [15A NCAC 2Q .0508 (f)]

c.       The use of fuel in both boilers shall be limited such that sulfur dioxide emissions shall not exceed 250 tons for any consecutive 12-month period.  The following limits apply to ensure sulfur dioxide emissions stay below 250 tons per year:

 

i.                    the amount of fuel oil burned in the boilers shall not exceed 1,500,000 gallons per consecutive 12-month period,

ii.         the sulfur content of the fuel oil shall not exceed 2.1 % by weight.

           

      The Permittee shall be deemed in noncompliance with 15A NCAC 2D .0530 if the above records are not kept or if sulfur dioxide emissions exceed the limit.

             

                  Reporting [15A NCAC 2Q .0508(f)]

d.      The Permittee shall submit a semi-annual summary report, acceptable to the Regional Air Quality Supervisor, of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December, and July 30 of each calendar year for the preceding six-month period between January and June.  The report shall contain the following:

 

      i. The monthly quantities of fuel oil consumed for the previous 17 months; and

                        ii. The average sulfur content of the fuel oil.

13. TOXIC AIR POLLUTANT EMISSIONS LIMITATION REQUIREMENT - Pursuant to 15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," for each of the below listed toxic air pollutants (TAPs), the Permittee has made a demonstration that facility-wide actual emissions do not exceed the Toxic Permit Emission Rates (TPERs) listed in 15A NCAC 2Q .0711. The facility shall be operated and maintained in such a manner that emissions of any listed TAPs from the facility, including fugitive emissions, will not exceed TPERs listed in 15A NCAC 2Q .0711.

a.       A permit to emit any of the below listed TAPs shall be required for this facility if actual emissions from all sources will become greater than the corresponding TPERs.

b.      PRIOR to exceeding any of these listed TPERs, the Permittee shall be responsible for obtaining a permit to emit TAPs and for demonstrating compliance with the requirements of 15A NCAC 2D .1100 "Control of Toxic Air Pollutants".

c.       In accordance with the approved application, the Permittee shall maintain records of operational information demonstrating that the TAP emissions do not exceed the TPERs as listed below:

Pollutant

(CAS)

Carcinogens (lb/yr)

Chronic Toxicants (lb/day)

Acute Systemic Toxicants (lb/hr)

Acute Irritants (lb/hr)

Acetaldehyde (75-07-0)

 

 

 

6.8

Ethyl acetate (141-78-6)

 

 

36

 

Toluene (108-88-3)

 

98

 

14.4

14. Pursuant to 15A NCAC 2Q .0507(a), the owner or operator shall have one year from the date of beginning operation under this permit to file a complete application for a permit or permit revision.  To obtain a Title V permit, the owner or operator shall follow the procedures set forth in 2Q .0507.

      15. LIMITATION TO AVOID BEING MAJOR FOR HAZARDOUS AIR POLLUTANTS

 

            a.   In order to remain classified a minor source for hazardous air pollutants and avoid applicability of this regulation, facility emissions  shall be less than:

 

            i.    10  tons per year of each individual hazardous air pollutant, and

            ii.   25  tons per year of all hazardous air pollutants combined.

 

            Monitoring/Recordkeeping

            In order to demonstrate compliance with the above limits, the Permittee shall maintain monthly consumption records of each material used containing volatile organic compounds as follows:

           

            i.    quantity of all hazardous air pollutants in pounds used on individual equipment and for the plant each month and for the 12-month period ending on that month,

            ii.   quantity of individual hazardous air pollutants in pounds used by the plant each month and for the 12‑month period ending on that month,

            These records shall be kept on-site and made available to DAQ personnel upon request.