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ESSENTIALS OF
AIR PERMITTING FOR
CHEMICAL PLANTS
Presented by:
Kevin Moin, P.E.
Principal
RECES Environmental Consulting
4C Conference – San Antonio, TX – April 2018
Introduction
Kevin Moin
 Chemical Engineer – University of Houston
 Texas Registered P.E.
 28 Years of experience in air quality consulting & Engineering
 Radian Corporation: 1990-1998
 Jacobs Engineering: 1998-2000
 TRC Solutions: 2000-2003
 RECES Environmental: 2003-Present
Background:
RECES (Reliant Environmental Consulting & Engineering Services)
 Established 2003
 Houston, TX & Irvine, CA
Expertise:
 Air Permitting (NSR, Title V, PSD, PBR)
 Compliance & Recordkeeping
 Air Dispersion Modeling
Industries:
 Chemical & Petrochemical
 Upstream (O&G)
 Midstream (Transfer Operations)
 Downstream (Refining)
 24 States
Operational flexibility
Operational flexibility to handle existing chemicals
Ability to introduce new chemicals (self authorize)
Permit Condition: Flexibility Clause
Ease of Compliance Demonstration
WHAT TO ACHIEVE WITH AN
AIR PERMIT
Addition of new chemicals:
Create Master Chemical List (MCL)
 Molecular weight (M)
 Vapor pressures (P)
Create Max MxP product group(s) from MCL
May have multiple groups of MxPs
Calculate emissions based on this max MxP product
Establish an allowable emission rate (PTE)
Create an annual not-to-exceed throughput rate for the entire plant
Maintain Minor Source status
 Remain below Title V major source thresholds, specifically for non-attainment areas
 Recent Re-Classifications: Opportunity to become minor for plants that are already
major
 Severe to Moderate
 Ability to add new chemicals without adding to overall PTE
 BACT Requirements
Fugitive Emissions
 LDAR Program to reduce fugitive emissions
Fugitive BACT Considerations
 Hassle-free compliance demonstration / record keeping
Evaluate the need for emission controls
BACT Requirements
Further reduce PTE
Stay out of Title V
INFO NEEDS - DATA ACQUISITION
Products/Chemicals (raw materials and products)
Chemical properties (molecular weight, vapor pressures)
SDS
Create MxP product for added flexibility
Batch sizes and total batches per year
INFO NEEDS - DATA ACQUISITION
Total annual throughput to be permitted (per source)
IN: Storage tanks, reactors, blenders, etc
OUT: Tank trucks, drums, totes, etc
Max hourly fill rates (gal/hr)
INFO NEEDS - DATA ACQUISITION
List of all equipment to be permitted
 Reactors and blenders
Vessel sizes
 Storage tanks
Number of tanks to be permitted
Capacity
Dimensions
Material, construction, color, etc
 Control devices, if necessary
INFO NEEDS - DATA ACQUISITION
Fugitive component counts for process equipment
LDAR program to be instituted across the entire plant
 Process description
 Process flow diagram
 EPNs (Stack Parameters and Locations)
 Plot Plan
 List of all equipment, EPNs, buildings, property lines, etc
 Drawings
 PIDs of equipment
INFO NEEDS - DATA ACQUISITION
INFO NEEDS - DATA ACQUISITION
MSS Activities
 Vessel cleanings, Degassing, line purgings, etc
PERMIT APPLICATION
Latest version of TCEQ Forms
 PI-1
 Equipment tables
 Table 2 (Material Balance)
 Table 30 (Application Fee)
PERMIT APPLICATION
Emissions calculations/methodology
 MxP Product – generic VOC product
Best used for plants with a large master chemical list
Use MxP Product to calculate PTE based on proposed
throughputs
 May have multiple MxP groups to keep PTE down
PERMIT APPLICATION
Regulatory Requirements
 State
 Federal
 BACT Analysis
 Submittal
 DRAFT Review and revisions
 FINAL Submittal
 Complete permit application
 Permit application fee
PERMIT APPLICATION
POST-SUBMITTAL
1st 30-day Public Notice (if triggered)
 Technical Review Process
TCEQ Notice of Deficiency (NOD)
 Address any issues with representations, methodologies,
etc.
 Opportunity to incorporate any changes at this time
 MERA request
Health Effects Review – Air Dispersion Modeling
Off-site Impacts determination
NAAQS Analysis
Model post-processing
Air Quality Analysis (AQA) report
POST-PERMIT APPLICATION
SUBMITTAL
HEALTH EFFECTS REVIEW
AIR DISPERSION MODELING
Complete MERA to determine what is to be modeled
 Effort to reduce the mass quantity of chemicals to be modeled
 Site-wide modeling vs increase only modeling
 ESL Requests
Modeling Protocol
 Project description
 Identifies sources and source types to be modeled
Proposed model and modeling options
 AERMOD
 EPN Locations & Stack Parameters
 Off-site Receptor Grid
 Downwash Analysis
 Meteorological
HEALTH EFFECTS REVIEW
AIR DISPERSION MODELING
Modeling Data Needs
 Locations, parameters and modeled emission rates
for each stack (EPN)
 Locations and heights of building and structures
(downwash)
 Location of property line
HEALTH EFFECTS REVIEW
AIR DISPERSION MODELING
AERMOD Runs
Generate receptor grid
Generate property line receptors
BPIP
Determines building/structure downwash
Downwash to be included in AERMOD runstream
AERSURFACE
Determines meteorological data set
HEALTH EFFECTS REVIEW
AIR DISPERSION MODELING
Unit emission rate modeling (short-term and long-term)
Initially based on chemical flexibility across the entire plant
1 gr/sec emission rate
Best for modeling large number of chemicals
Post-processing
Determine unit emission rate impacts
 Unit impacts x actual ER of each chemical
Compare impacts ESLs for each chemical
Chemical Specific Modeling
 Chemicals that do not pass unit emission rate modeling
 Compare chemicals specific impacts to applicable ESL
 Determine exceedances for those chemicals with impacts above
ESLs
 Impose restrictions and limitations, as necessary
 Multiple iterations of modeling
NAAQS Modeling (if applicable)
 Model emissions for products of combustion (SO2, NOx, CO, PM)
 Determine emission rates for each averaging periods
 DeMinimis analysis to determine if full NAAQS is required. If so…
Determine background concentrations
Run AERMOD
Compare to applicable NAAQS
AQA Report
Details what was modeled
Lists all modeling options used
Summarizes results of all modeling performed
Lists all operational restrictions taken
POST-PERMIT APPLICATION
SUBMITTAL
DRAFT Conditions Issued
 Review and request any changes to conditions at this
time
2nd 30-day Public Notice (if triggered)
PERMIT ISSUED
Life after permit…
CHEMICAL FLEXIBILITY CLAUSE
Incorporated into permit
 Allows self authorization of new chemicals
Does not add to PTE
Does not require authorization (e.g. PBR)
 Unit impact multipliers from modeling included in clause
Readily Evaluate if proposed chemical will “pass”
RECORD KEEPING
RECORD KEEPING
RECORD KEEPING
Create a streamlined process to maintain and demonstrate
compliance with the permit
 12-month rolling totals to show that the plant is operating
below the permitted allowables (MAERT)
 Based on the same methodologies used in the permit
application
RECORD KEEPING
Minimize burden to maintain & Demonstrate compliance
 Use single front-end spreadsheet workbook
 Only required input would be monthly throughputs
 Automate emission calculations
 Automatically compare calculated emissions to PTE
Alerts when approaching PTE limit in order to avoid exceedances
New Chemical Authorization (NCA) Tool
Spreadsheet automatically evaluates off-site impacts without
further modeling
Determines if chemical will “pass”
Alter spreadsheet to allow chemical to “pass”
Reduce loading rates
Reduce simultaneous loading spots
Authorization to handle chemical, as long as…
Remain below PTE
Remain below MxP Product
Impact below ESL
Contact Info:
Kevin Moin
Email: KMoin@RECES-LLC.com
Phone: (281) 529-5087

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Essentials of Air Permitting for Chemical Plants with Kevin Moin, P.E.

  • 1. ESSENTIALS OF AIR PERMITTING FOR CHEMICAL PLANTS Presented by: Kevin Moin, P.E. Principal RECES Environmental Consulting 4C Conference – San Antonio, TX – April 2018
  • 2. Introduction Kevin Moin  Chemical Engineer – University of Houston  Texas Registered P.E.  28 Years of experience in air quality consulting & Engineering  Radian Corporation: 1990-1998  Jacobs Engineering: 1998-2000  TRC Solutions: 2000-2003  RECES Environmental: 2003-Present
  • 3. Background: RECES (Reliant Environmental Consulting & Engineering Services)  Established 2003  Houston, TX & Irvine, CA Expertise:  Air Permitting (NSR, Title V, PSD, PBR)  Compliance & Recordkeeping  Air Dispersion Modeling Industries:  Chemical & Petrochemical  Upstream (O&G)  Midstream (Transfer Operations)  Downstream (Refining)  24 States
  • 4. Operational flexibility Operational flexibility to handle existing chemicals Ability to introduce new chemicals (self authorize) Permit Condition: Flexibility Clause Ease of Compliance Demonstration WHAT TO ACHIEVE WITH AN AIR PERMIT
  • 5. Addition of new chemicals: Create Master Chemical List (MCL)  Molecular weight (M)  Vapor pressures (P) Create Max MxP product group(s) from MCL May have multiple groups of MxPs Calculate emissions based on this max MxP product Establish an allowable emission rate (PTE) Create an annual not-to-exceed throughput rate for the entire plant
  • 6. Maintain Minor Source status  Remain below Title V major source thresholds, specifically for non-attainment areas  Recent Re-Classifications: Opportunity to become minor for plants that are already major  Severe to Moderate  Ability to add new chemicals without adding to overall PTE  BACT Requirements
  • 7. Fugitive Emissions  LDAR Program to reduce fugitive emissions Fugitive BACT Considerations  Hassle-free compliance demonstration / record keeping
  • 8. Evaluate the need for emission controls BACT Requirements Further reduce PTE Stay out of Title V
  • 9. INFO NEEDS - DATA ACQUISITION Products/Chemicals (raw materials and products) Chemical properties (molecular weight, vapor pressures) SDS Create MxP product for added flexibility Batch sizes and total batches per year
  • 10. INFO NEEDS - DATA ACQUISITION Total annual throughput to be permitted (per source) IN: Storage tanks, reactors, blenders, etc OUT: Tank trucks, drums, totes, etc Max hourly fill rates (gal/hr)
  • 11. INFO NEEDS - DATA ACQUISITION List of all equipment to be permitted  Reactors and blenders Vessel sizes  Storage tanks Number of tanks to be permitted Capacity Dimensions Material, construction, color, etc  Control devices, if necessary
  • 12. INFO NEEDS - DATA ACQUISITION Fugitive component counts for process equipment LDAR program to be instituted across the entire plant
  • 13.  Process description  Process flow diagram  EPNs (Stack Parameters and Locations)  Plot Plan  List of all equipment, EPNs, buildings, property lines, etc  Drawings  PIDs of equipment INFO NEEDS - DATA ACQUISITION
  • 14. INFO NEEDS - DATA ACQUISITION MSS Activities  Vessel cleanings, Degassing, line purgings, etc
  • 15. PERMIT APPLICATION Latest version of TCEQ Forms  PI-1  Equipment tables  Table 2 (Material Balance)  Table 30 (Application Fee)
  • 16. PERMIT APPLICATION Emissions calculations/methodology  MxP Product – generic VOC product Best used for plants with a large master chemical list Use MxP Product to calculate PTE based on proposed throughputs  May have multiple MxP groups to keep PTE down
  • 18.  BACT Analysis  Submittal  DRAFT Review and revisions  FINAL Submittal  Complete permit application  Permit application fee PERMIT APPLICATION
  • 19. POST-SUBMITTAL 1st 30-day Public Notice (if triggered)  Technical Review Process TCEQ Notice of Deficiency (NOD)  Address any issues with representations, methodologies, etc.  Opportunity to incorporate any changes at this time  MERA request
  • 20. Health Effects Review – Air Dispersion Modeling Off-site Impacts determination NAAQS Analysis Model post-processing Air Quality Analysis (AQA) report POST-PERMIT APPLICATION SUBMITTAL
  • 21. HEALTH EFFECTS REVIEW AIR DISPERSION MODELING Complete MERA to determine what is to be modeled  Effort to reduce the mass quantity of chemicals to be modeled  Site-wide modeling vs increase only modeling  ESL Requests Modeling Protocol  Project description  Identifies sources and source types to be modeled
  • 22. Proposed model and modeling options  AERMOD  EPN Locations & Stack Parameters  Off-site Receptor Grid  Downwash Analysis  Meteorological HEALTH EFFECTS REVIEW AIR DISPERSION MODELING
  • 23. Modeling Data Needs  Locations, parameters and modeled emission rates for each stack (EPN)  Locations and heights of building and structures (downwash)  Location of property line HEALTH EFFECTS REVIEW AIR DISPERSION MODELING
  • 24. AERMOD Runs Generate receptor grid Generate property line receptors BPIP Determines building/structure downwash Downwash to be included in AERMOD runstream AERSURFACE Determines meteorological data set HEALTH EFFECTS REVIEW AIR DISPERSION MODELING
  • 25. Unit emission rate modeling (short-term and long-term) Initially based on chemical flexibility across the entire plant 1 gr/sec emission rate Best for modeling large number of chemicals Post-processing Determine unit emission rate impacts  Unit impacts x actual ER of each chemical Compare impacts ESLs for each chemical
  • 26. Chemical Specific Modeling  Chemicals that do not pass unit emission rate modeling  Compare chemicals specific impacts to applicable ESL  Determine exceedances for those chemicals with impacts above ESLs  Impose restrictions and limitations, as necessary  Multiple iterations of modeling
  • 27. NAAQS Modeling (if applicable)  Model emissions for products of combustion (SO2, NOx, CO, PM)  Determine emission rates for each averaging periods  DeMinimis analysis to determine if full NAAQS is required. If so… Determine background concentrations Run AERMOD Compare to applicable NAAQS
  • 28. AQA Report Details what was modeled Lists all modeling options used Summarizes results of all modeling performed Lists all operational restrictions taken
  • 29. POST-PERMIT APPLICATION SUBMITTAL DRAFT Conditions Issued  Review and request any changes to conditions at this time 2nd 30-day Public Notice (if triggered)
  • 32. CHEMICAL FLEXIBILITY CLAUSE Incorporated into permit  Allows self authorization of new chemicals Does not add to PTE Does not require authorization (e.g. PBR)  Unit impact multipliers from modeling included in clause Readily Evaluate if proposed chemical will “pass”
  • 33. RECORD KEEPING RECORD KEEPING RECORD KEEPING Create a streamlined process to maintain and demonstrate compliance with the permit  12-month rolling totals to show that the plant is operating below the permitted allowables (MAERT)  Based on the same methodologies used in the permit application
  • 34. RECORD KEEPING Minimize burden to maintain & Demonstrate compliance  Use single front-end spreadsheet workbook  Only required input would be monthly throughputs  Automate emission calculations  Automatically compare calculated emissions to PTE Alerts when approaching PTE limit in order to avoid exceedances
  • 35. New Chemical Authorization (NCA) Tool Spreadsheet automatically evaluates off-site impacts without further modeling Determines if chemical will “pass” Alter spreadsheet to allow chemical to “pass” Reduce loading rates Reduce simultaneous loading spots Authorization to handle chemical, as long as… Remain below PTE Remain below MxP Product Impact below ESL
  • 36.
  • 37. Contact Info: Kevin Moin Email: KMoin@RECES-LLC.com Phone: (281) 529-5087