Download - 2228-A-REG315 - Arkansas Division of Environmental Quality

ADEQARK A N S A SDepartment of Environmental Quality

June 16, 2011

Cecil HutchinsPlant ManagerArkgalv, Inc.998 Escue DrivePrairie Grove, AR 72753

RE: Application for RegistrationAFIN: 72-00236 Registration No.: 2228-A-REG315

Dear Mr. Hutchins:

The Department has reviewed your facility's application for registration for the facility located at998 Escue Drive, Prairie Grove in Washington County, Arkansas.

The Department has determined that the information certified in the application fulfills therequired criteria for registration as specified in Arkansas Air Pollution Control Code (Regulation18), Section 18.315 and other applicable regulations. Your registration number has beenassigned as 2228-A-REG315.

This registration is your authority to construct, operate, and maintain the equipment and/orcontrol apparatus as set forth in your registration request received on May 16, 2011. Arkgalv,Inc. is required to update this registration should the facility operations or emissions change sothat the current registration no longer reflects actual operations.

Please maintain a copy of this letter and the application at the facility.

Sincerely,

~Thomas RheaumePermit Branch Manager, Air Division

c: Compliance Monitoring

ARKANSAS DEPARTMENT OF ENVIRONMENTAL QUALITY5301 NORTHSHORE DRIVE / NORTH UTILE ROCK / ARKANSAS 72118-5317 / TELEPHONE 501-682-0744 / FAX 501-682-0880

www.adeq.state.ar.us

incorporated

May 12,2011

Tom RheaumeADEQ-Air Division5301 Northshore Dr.North Little Rock, AR 72118

RE: Arkansas Galvanizing

Dear Mr. Rheamue,

I am writing on behalf of our galvanizing plant located in Prairie Grove, Ark. ArkansasGalvanizing is planning to install an abrasive blasting operation and we are not certain if theoperation requires an air permit. The operation will emit 22 tons per year of total particulatesand 7 tons per year of PM10 particulates. My calculations are attached with this letter and arebased on a blasting operation that averages 4 hours per day for 220 days per year.

The blast operation will be located outside in a comer of the plant's yard. There will be nocontrol system associated with the blasting. I have also attached technical information on theblast machine.

Arkansas regulation 18.301(A) says that a stationary source does not require a permit if theemissions are less than 25 tons of particulate matter and 15 tons per year of PM10

particulates. Please confirm that a permit is not required and, if possible, please respond inwriting so that we may have your opinion in a written record.

Sincerely,

~~Frank Gaudet, PEEnvironmental Engineer

Enclosure (2)

cc: Kevin Fleming, Regional ManagerCecil Hutchins, Arkansas Galvanizing

AZZ incorporated www.azz.com

REGISTRATION FORM

AFIN I I DATE 15/10/2011

FACILITY PHYSICAL LOCATION

Facility Name Arkgalv, Inc. (The facility also does business under the names of AZZ GalvanizingArkansas and Arkansas Galvanizing, Inc.)

Physical Address or998 Escue Dr.Location

Physical City Prairie Grove

Physical Zip 72753

UTMZone 15SUTMWesting

3796000.44 m E VTM Northing3982192.91 niN(nearest meter) (nearest meter)

NAICS Code 332812 NAICS Description Coating

FACILITY AIR CONTACT

Technical Contact Frank Gaudet, PE Environmental Engineer

Site Contact Cecil Hutchins, Plant Manager

Technical Contact Address AZZ incorporated, 3100 West 7th St, #500

Fort Worth, TX 76107

Site Contact Address Same as Facility Location address

Tech Contact Phone # 817-810-0095 Contact Mailing Zip

Site Contact Phone # 479-846-4500 Contact FAX 479-846-3119

Contacts Email Addresses [email protected]; [email protected]

INVOICE MAILING ADDRESS

Organization Name Same as Plant Location Address

Invoice Contact First Name

Invoice Contact Last Name

Mailing Address

Invoice Mailing State Invoice Mailing Zip

Invoice Contact Phone Invoice Contact FAX

1

1. Organization Status of Applicant

Please check the box which appropriately describes the legal organization of the applicant.

Solely Owned Proprietorship 0 Corporation ~ Limited Partnership I0

General Partnership D OTHER: D Please Specify:I2. If the applicant is a corporation, indicate ifit is a domestic (Arkansas) corporation or a foreign

(chartered outside of Arkansas) corporation. Domestic ~ Foreign D3. If the applicant is a corporation, is it currently registered to do business with the Arkansas Secretary of

State? Yes~ No 04. Registration Information

New Facility D !Existing Facility [81

Existing Facility with an Air Permit 0 List Current Permit No. The permit will be voided with this registration.

Modification of Current Registration 0 List Current Registration No.

5. Attach a brief description of the facility, processes and sources of air pollution emissions.

6. What are the estimated total actual emissions from this facility?

Pollutant Tons/year

PM 24.35

PMlO 8.81

S02 0.5

VOC 0.1

CO 3

NOx 2.5,

Single HAP* 0

Combination HAP* 0

Air Contaminants**

HAP* - Hazardous Air Pollutant**Cannot exceed 25 tons per year

7. Attach an explanation of how the emissions estimate was determined e.g. AP-42, test information, etc.

8. Has a Disclosure Statement been submitted to the Department previously? Yes ~ No D(Ifno, please attach a disclosure statement)ATTACHED

9. Do you wish to be added the Air Permits Newsletter email list? Yes ~ No 0If yes, list the email address(es)youwishtouse:[email protected](or you can email [email protected] with "subscribe" (no quotation marks) in the subjectbox.

2

10. The registration requires an annual fee of $200. The Department will send an invoice when the annualfee is due. Submit this Registration to:

Arkansas Department of Environmental QualityAir Permitting Section5301 Northshore DriveNorth Little Rock, AR 72118

PROCESS DESCRIPTION

AZZ Galvanizing Arkansas provides hot dip galvanizing services to customers who fabricate steel parts that need acorrosion resistant coating. Customers deliver uncoated steel to the facility where forklifts unload the steel and lay it in theyard to await processing. Forklifts move the steel to the head of the process where workers chain the steel to hoists thatwill move the steel through the process. The process consists of three basic steps: a) surface preparation by causticcleaning and acid pickling, b) preflux, c) galvanizing and quench. Each step is necessary to provide a uniform highquality galvanized coating. The steps are performed in open top tanks containing either chemical mixtures or rinsewaters. The caustic tank is a 1% solution of sodium hydroxide heated to 160°F and it removes oil and grease from thesteel. The four acid tanks are operated at 8-15% hydrochloric. Normally the acid remains at ambient temperature exceptduring winter months when the acid is warmed to approximately 80°F. Steel is immersed into the pickling solution andremains for 15 minutes to 12 hours until all rust and mill scale is removed. The preflux solution consists of approximately15% zinc ammonium chloride and 85% water and is heated to approximately 160°. After prefluxing, the steel isimmersed in the kettle. The kettle consists of approximately 600,000 pounds of molten zinc heated to 845°F. Aftergalvanizing, the steel is immersed in a water to cool it. When cooled, the steel is touched-up to remove zinc burrs and tocover chain marks. The completed steel product is placed in the laydown yard to await pickup by the customer.

AZZ Galvanizing Arkansas proposes a sandblasting operation to provide additional services to customers. Blasting isanother way to prepare the surface of steel for galvanizing. It will also be used to remove paint coatings and mil finishcoatings that are on the steel. The process may not be used very much at first, but our company will be solicitingcustomers and eventually the process could operate 4 hours a day each work day.

Air emissions are generated by several of the processes. Minor amounts of fugitive acid emissions are generated by theacid tanks. The kettle is heated by a furnace that generates products of natural gas combustion. Natural gas heating for thecaustic and preflux tanks also generates products of natural gas combustion. The kettle itself emits fugitive emissions asthe preflux coating burns off in the kettle.

Particulate emissions are the only pollutant that will require registration. Particulate emissions will derive from threesources:

II PM PM10

TonsNr TonsNr

I 1. Abrasive Blast Fugitive Emissions, 22.40 6.862. Kettle Fugitive Emissions, 1.95 1.953. Natural Gas Combustion Stack Emissions 0.08 0.08

TOTAL 24.43 8.89

Calculations for each source are provided in the attached spread sheets. All calculations are based on AP-42 factors.Blasting will generate most of the particulate emissions, about 22.4 tons per year. Kettle emissions and natural gascombustion will contribute to the overall site emissions but the total particulate emissions will remain below 25 tons peryear and PM IO emissions will total less than 10 tons per year.

3

-+ PRODUCTS OF GASCOMBUSTION

PRODUCTS OF GASCOMBUSTION

-+PARTICULATEFUGITIVE EMISSIONS

STEELPART

FUGITIVE ACIDEMISSIONS AND

STEAMKETILE

EMISSIONS

STEELPART

GASBURNERS

GALVANIZEDSTEEL PARTS

BOILER

AZZ GALVANIZING ARKANSASPROCESS FLOW SCHEMATIC

4

EMISSIONS FROM PROPOSED ABRASIVE BLAST OPERATIONSAZZ GALVANIZING ARKANSAS

Given:The plant will use a CEMCO 6 cu ft Classic Blast Machine, Model 2452, that is capable of using 6 cubic feet of abrasive in 30 minutes at100 psi with a No. 6(3/8 inch) nozzle. The technical data sheet specifies that 6 cu ft of abrasive weighs 600 Ibs.Ref: CLEMCO, Technical Data Sheet 2009.

Blasting will not be a continuous operation. Maximum blasting operations will average 4 hours per day and total 880 hours per yr. The average windspeed in Arkansas is 7.8 mph. The AP-42 factors are interpolated to estimate a factor for this average wind speed.

Rating, Abrasive in 30 minutesHourly RatingDaily with avg of 4 hour/work dayAnnual, 220 Days in Year

ABRASIVE USAGEIbs tons600 0.301200 0.604800 2.40

1056000 528

AIR EMISSIONS·

TOTAL PM,S mph WindIbs tons16 0.0132 0.02130 0.06

28512 14.3

AIR EMISSIONS*·TOTAL PM, 7.8 mph

WindIbs tons26 0.0151 0.03

204 0.1044891 22.4

AIREMISSIONS···

PM-10Ibs tons8 0.00416 0.00862 0.031

13728 6.86

Air emissions are calculated using AP-42 Factors. Example Calculation:Annual Emissions =1056000 Ibs x (42.51/1000)/2000 Ibs/ton =22.4 tons per year of PM emissions.

Particle Size*Total PM, 5 mph windTotal PM, 10 mph windTotal PM, 15 mph wind

***PM-10PM-2.5

Air EmissionFactors: Ib/1000 Ibsof Abrasive Used

27559113

1.30

AP-42 Factor: Section 13.2.6( Sept 1997): Table 13.26-1: Sand Blasting of Mild Steel Panels

**Total PM @ 7.8 mph is anInterpolation between factors for 5 '42.51

and 10 mph5

*Emission Factor of 0.52 Ibs of PM air emissions/ton of productionfrom "Emissions from Hot Dip Galvanizing Processes" EPA March1976. Particulate is assumed to be 100% PM10.

Note; The calculation assumes that some of the particulateemissions are captured inside the building and fugitive emissionsoutside the building are 50% of emissions off the kettle.

AZZ GALVANIZING ARKANSASKETTLE AIR EMISSIONS

FUGITIVE PARTICULATE EMISSIONS

Annual Production in TonsNrAnnual Operating Hours, hrs/yr

Kettle Emission Factor, Ibs/ton*Annual Uncontrolled PM10 Emissions, Ibs/yrAnnual Uncontrolled PM10 Emissions, tons/yr

CONTROLLED EMISSIONSBuilding Capture Efficiency%

Annual Controlled PM10 Emissions, tons/yr

FUGITIVE EMISSIONSAnnual Fugitive PM10 Emissions Rate, tons/yr

AU GALVANIZING ARKANSASSPECIATED KETTLE AIR EMISSIONS

Annual Fugitive PM10 Emissions Rate,TonsNr

150002080

Annual Fugitive0.52 Emissions, tpy % of Total78003.90 PM10 100%

NH4CI 68%50% ZnO 16%

ZnCI2 4%1.950 NH3 1%

Zn 5%

1.950

6

1.950

TonsNr

1.9501.3260.3120.0780.0200.098

AZZ GALVANIZING ARKANSASNATURAL GAS COMBUSTION EMISSIONS

NATURAL GAS USAGEAvg MMBTU per MonthMMBTU per YearAvg Heat content, BTU/SCFMillion SCFI year

EMISSIONS

PMS02CONOxVOC

FactorsIbs/mmscf

7.60.6

84.0100.05.5

190022800105022

Emssions, tons/yr0.080.010.911.090.06

Factors from AP-42, Section 1.4-1 Natural Gas Combustion.July 1998.

CERTIFICATION OF APPLICATION"Responsible Official" means one of the following:

1) For a corporation: a president, secretary, treasurer, or vice-president ofthe corporation in charge of aprincipal business function, or any other person who performs similar policy or decision-makingfunctions for the corporation, or a duly authorized representative of such person if the representative isresponsible for the overall operation of one or more manufacturing, production, or operating facilitiesapplying for or subject to a permit and either:

A) the facilities employ more than 250 persons or have gross annual sales or expenditures exceeding$25 million (in second quarter 1990 dollars); or

B) the delegation of authority to such representative is approved in advance by the permittingauthority.

2) For a partnership or sole proprietorship: a general partner or the proprietor, respectively;

3) For a municipality, State, Federal, or other public agency: either a principal executive officer or rankingelected official. For the purposes of this part, a principal executive officer ofa Federal agency includesthe chief executive officer having responsibility for the overall operations of a principal geographic unitof the agency (e.g., a Regional Administrator of EPA).

8

June 8, 2011

Mr. Phillip Murphy, P.E., Engineer SupervisorArkansas Department of Environmental QualityAir Division5301 Northshore Drive

. North Little Rock, AR 72118-5317

Re: Minor Source Permit Application, AFIN: 72-00236

Mr. Murphy:

hAllARKANSAS

In response to your letter dated May 26, 2011, I submit the following information:

• HCl emissions calculations are attached along with the guidance package used toestimate them.

• Arkansas Galvanizing will comply with Regulation 18, §18.501(A)(2) byo Maintaining a 10' solid wood barrier fence at the property line ando Performing the blasting operation at least 40' from the property line ando Using sound operating procedures to minimize media usage and dust

generation ando Using a low dust blasting media approved by the California Air Resources

Board (CARB) for outdoor blasting (see attached May 6, 2011 CARB listof certified abrasives).

• Arkansas Galvanizing will use the measures listed above for compliance withRegulation 18, §18.501(A)(2) to prevent unnecessary amounts of particulatematter from becoming airborne as required by Regulation 18, §18.901(B).

If you have any questions, please contact me at 479-846-4500.

Sincerely,

Uill~Cecil HutchinsPlant Manager

Enclosures: 3

Cc: Frank GaudetKevin Halstead

AU Galvanizing. Arkansas www.azzgalvanizing.com

998 Escue 0,. • Prairie Grove, ;,rkaI1SClS 72753 • 479.846.4500 Phone • 479.846.3119 Fax

ARKANSAS GALVANIZING, INC,

HCI Emissions

Pickl~ Tanks - No AP-42 emission factor is available. Therefore, the factor provided by the TexasCommission on Environmental Quality, "Calculations Guidance PackageHot Dip Galvanizing" will be used.

Temperature of 30 C (86 F), represents a conservative average temperature of the ambient tanks.Air velocity is an estimate. The tanks are operated 10" below the lip providing an inherent velocity barrier.HCI concentrations typically vary between 6-12%, thus, these are maximum emissions estimates.A fume suppressant is used in the HCI tanks that is not accounted for in these calculations.

Temperature, C = 30 Air velocity, fps =Vapor Pressure, mm Hg = 0.05 Max. HCI cone. =Emission factor = 0.000412165 Ibs./hr. - sq. ft.

14 %wtIwt

Tanks3456

L, ft.26263834

W, ft.6666

Area, sq. ft.156156228204

Potential Emissions, Ibs./hour =

Potential Emissions, TPY =

0.307

1.343

Air Permits Division

CalculationsGuidancePackage

Hot Dip Galvanizing

Compiled, published, and distributed by theAir Permits DivisionTexas Commission on Environmental QualityPost Office Box 13087 - MC 163Austin, Texas 78711-3087(512) 239-1250

-----------

HOT DIP GALVANIZING

I. INSTRUCTIONSThis manual was developed for the purpose of providing a guide for calculatingemissions at hot-dip galvanizing facilities. Tables are provided for identifying the inputdata required and the emission calculation results. In most cases, the upper portions of thetables are used to record input data/calculation parameters. Use the equations whichfollow the table to perform the emission calculations and record the results in the lowerportion of the table.

NOTE: Some of the calculations are made using data from TCEQ Tables 6, 11, and 13. Youshould complete these forms for maximum operating conditions and actual equipmentspecifications for your facility.

The information provided below will be used throughout the calculations and establisheslimitations for the permit.

A. GALVANIZING FACILITY CAPACITY DATA

AP = Maximum annual production (tons/year) _OP = Maximum daily production (tons/year) _HO = Hours of operation per day _OW = Number of days operated per week _WY = Number of weeks operated per year _HY = Maximum number of hours operated per year _ZN = Tons of zinc used per year _

B. DEGREASING/CLEANING OPERATIONS

1. Number of degreasing tanks _2. Degreasing Tank ParametersTank #1: feet (ft) wide X feet (ft) longTank #2: feet (ft) wide X feet (ft) longType of degreasing compound used: _Concentration of degreasing compound: _Temperature of degreasing tank solution: _Type of heat source: _

NOTE: The permit engineer will review the above data and determine if degreasing tankemissions will be considered.

C. ACIDfPICKLE TANK EMISSIONS

INSTRUCTIONS: Acid/pickle tank emissions are calculated using the procedure below.If the applicant chooses to not calculate the pickle tank emissions, then all the operatingparameters must be provided with the permit application so that the permit engineer cancalculate the emissions.

- 2 -

1. Acid Tank Data

Number of pickle tanks at facility: _Tank #1: feet (ft) wide X feet (ft) longTank #2: feet (ft) wide X feet (ft) longType acid used: _Maximum acid concentration: % weight/weight (w/w)Minimum acid concentration: % w/w. (concentration at recharge)Temperature of acid tanks: degrees F.Fume suppressant used? __Yes; __No

Submit a copy of the Material Safety Data Sheet (MSDS) for the acid, the fumesuppressant, and any other chemicals or additives used.

Are capture hoods used over the acid tanks? __Yes; __NoAre any exhaust fans located near the tanks? __ Yes; No

If yes, show their location on the plot plan and indicate the fan size (diameter), flow rate(CFM), and the height of the fan discharge point above the ground where it exhausts tothe atmosphere.

2. Acid Pickle Tank Emission Calculation Procedure.

- 3 -

HYDROCHLORIC (BCI) ACID TANK TABLETABLE 2

HCI Pickle Tanks 1 2 3 4 5

A = Surface area of tank (ih)

T = Operating temperature (CO)

Cone. = Percent concentration of HCL by weight (%w/w)

V = Air velocity across surface of tank (fps)

Pv= Vapor pressure ofHCI (mmHg from Table 3-1thru 3-4 in the Appendix)

E = Evaporation rate from tank (Ib/hr-fh)

ERI = Emission rate Uncontrolled (Ib/hr)

FE = Suppressant efficiency 1 - (%)/1 00

CE = Hood capture efficiency (%)

AE= Abatement device efficiency 1 - (%)/100

ER4= Emission rate Controlled (lb/hr)

FUG = Fugitive emissions (Ib/hr)

OY= Annual operating hours

AFUG = Annual HCI fugitive emission rate(tons/year)

AER = Annual HCI emission rate (tons/year)

SUPPLEMENTARY INFORMATIONTABLE2a

HCI Pickle Tanks 1 2 3 4 5

ERI (enter into TABLE 2) (Ibs/hr)

ERz(lbs/hr)

ER3 (Ibs/hr)

(ER2- ERJ) (Ibs/hr)

ER4 (enter into TABLE 2) (Ibs/hr)

- 4 -

D. HYDROCHLORIC (HCl) ACID TANK EMISSIONS CALCULATIONSThe following calculations are made with data provided by the applicant. To assist inthese calculations, TABLE 2, TABLE 2a, and TABLEs 3-1 thru 3-4 (regarding partialpressures of HCl over aqueous solutions of HCl located in the Appendix) are provided foryour use. A completed TABLE 2 and TABLE 2a, in addition to the applicant'scalculations, will serve to expedite the permit review process.

E. CALCULATION STEPS1. Calculate the surface area (A) of each tank in square feet and enter the value of A intoTABLE 2.

2. Enter the operating temperature (T) in degrees centigrade (CO), acid concentration(cone.) by weight percent, and air velocity (V) in feet per second (fps) across the surfaceof each tank into TABLE 2.

3. Determine the vapor pressure (py) of the HCI solution from the appropriate TABLEs 31 thru 3-4 (Appendix). Using the temperature (T, CO) and the percent acid concentration(Cone.) determine the partial pressure of the solution in mmHg and enter the value ofPyinto TABLE 2.

4. Calculate the evaporation rate of HCI from the tank using the following equation andenter the value of E (Ib/hr-ftz) into TABLE 2 (Requires a calculator with logarithmicfunctions ):

E = 25[0.46 + 0.117(V)]log[(760 - Pa)/(760 - py)] (lb/hr-ftz)Pa = 0 for this calculation.

5. Calculate and enter into TABLEs 2 and 2a the uncontrolled emission rate,

ERI = E x A (lb/hr)

6. Do you use a suppressant (foam, fume, or mechanical) in your HCl tank? If yes,complete the following then go to 7.

FE = [I - (%)/100], where % is the efficiency of the suppressant.

The efficiency of the suppressant can usually be found in the manufacturer's literature orby contacting the manufacturer of your particular suppressant.

Enter the value of FE into TABLE 2, then calculate the following (enter the value ofERz into TABLE 2a):

ERz = ERI x FE (Ibs/hr)

- 5 -

If you do not use a fume suppressant, complete the following (enter the value ofER2 intoTABLE 2a) then go to 7.

ER2= ERI

7. Do you use a capture hood on your HCl tank? If yes, complete the followingappropriate calculation, then go to 10. If no, skip to 8.

If you use a hood, and do not use a fume suppressant, calculate the following (enter thevalue of ER3 into TABLE 2a), then go to 10:

ER3 = ER2 x CEil 00 (lbs/hr) (Hood, no fume suppressant)

Note: CE is the percent capture efficiency of your hood design. Hoods designed in accordancewith the Industrial Ventilation, A Manual of Recommended Practice, can be conservativelyconsidered to have 98% capture efficiency.

If you use a hood, and also use a fume suppressant, calculate the following (enter thevalue ofER3 into TABLE 2a), then go to 10:

ER3 = ER2 x CEil 00 (lbs/hr) (Hood and a fume suppressant)

8. If you do not use a capture hood, but use a fume suppressant use the following (enterthe value ofER3 into TABLE 2a), then go to 12.

ER3 = ER2 (lbs/hr) (No hood, use a fume suppressant)

If you do not use a capture hood, and also do not use a fume suppressant, then go to 9.

9. You will not be authorized to operate a HCI pickle tank without the use of, as aminimum, a fume suppressant or a capture hood.

10. Do you have an abatement device that controls the emissions from your hoodexhaust? If yes, complete the following calculations, enter the values of AE and ER4 intoTABLE 2, then go to 13. Ifnot, then go to 11.

The efficiency of the abatement device you propose to use, or you are using, can bedetermined from the manufacturers literature or by contacting the manufacturer directly.

AE = [1-(%)11 00], where % is the abatement device efficiency.ER4 = ER3 x AE (lbs/hr)

11. Without an abatement device your hourly emission rate is the same as calculated in 7.Complete the following, enter the value ofER4 into TABLEs 2 and 2a, then go to 13:ER4 = ER3 (lbs/hr)

12. Calculate the hourly fugitive emission rate from the tank and enter the value of FUGinto TABLE 2, then go to 14:

- 6 -

Fugitive emissions are those emissions that escape into the building. These emissions areeventually emitted to the atmosphere through a building vent (exhaust fan, open door,window, etc.). You are given a 50% capture efficiency for the building.

FUG = (ER3) (0.5) (Ibs/hr) (Fume suppressant only)

13. Calculate the fugitive emission rate from the tank and enter the value of FUG intoTABLE 2, then go to 15:

Fugitive emissions are those emissions that are not captured by the hood system and;therefore, escape into the building. These emissions are eventually emitted to theatmosphere through a building vent (exhaust fan, open door, window, etc.). You aregiven a 50% capture efficiency for the building.

FUG = (ER2 - ER3)(0.5) (Ibs/hr)

14. Calculate your annual fugitive emission rate (AFUG) and enter the value of AFUGinto TABLE 2:

AFUG = (FUG x OY)/2000 (tons/year)

15. Calculate your annual emission rate (AER) and the annual fugitive rate (AFUG) andenter the values of AER and AFUG into TABLE 2.

AER =(ER4 x OY)/2000 (tons/year)AFUG = (FUG x OY)/2000 (tons/year)

SULFURIC ACID EMISSION CALCULAnONSIf sulfuric acid is used as a pickling agent, use the above Steps 5 through 15 and TABLEs2 and 2a. Begin with Step 5 and use 0.00015 lbs/hr-ftl for "E," the emission factor forsulfuric acid.

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F. GALVANIZING/ZINC KETTLE UNCONTROLLED EMISSIONSalvanizin'\FacJll .

Zinc Kettle2

HP = Maximum Hourly Productionin PoundslHour of GalvanizedProduct Ibs/hr

3

AP = Maximum Annual ,Productionin TonslYear of Galvanized Productt

AH = Maximum Annual OperatingHours Per Year hrs! rEF = Zinc Kettle Emission Factorlbs/hr

EH = Hourly Uncontrolled PM\oEmissions lbs/hr *EA = Actual Uncontrolled PM lO

Emissions (t **

* EH= HP!2000 X EF** EA= AP/2000 X EF

0.52 0.52 0.52

Note: The above calculations must be completed for each galvanizing kettle that exhausts to its own controldevice. For all kettles exhausting to a common control device, then this calculation may be made only onceusing an AP and HP for all kettles exhausting to the same control device.

EH = See Previous TableEA == See Previous TableCE == Kettle Hood CaptureEfficienc %AE = Control Device EfficiencEHC == Hourly Controlled PM lO

Emissions Ibs/hr *EAC = Annual Control1ed PM lO

Emissions t **FH = Hourly Fugitive PM 10

Emissions Ibs/hr ***FA = Actual Fugitive PM lO

Emissions t ****

* EHC= EH X CEI100 X [1- (AEIlOO)] =** EAC= EA X CEil 00 X [l-(AEIlOO)] =

*** FH= EH X [1-(CEI100)] =**** FA= EA X [l-(CEIlOO)] =

Note: This quantity must be completed for each galvanizing kettle that exhausts to its own control device.For all kettles exhausting to a common control device, then this calculation may be made only once usingan AP and HP for all kettles exhausting to the same control device.

- 8 -

1. Speciated Zinc Kettle Emissions

(a) Hourly Controlled Emissions (lbs/hr)

Contaminant

PM 10 =

NH4Cl =ZnO=ZnCh=Zn =

NH3=

%

1.00 x EAC =---0.68 x EAC =---0.16 x EAC =---0.04 x EAC = _0.05 x EAC = _0.01 x EAC = _

(b) Hourly Fugitive Emissions (Ibslhr)

Contaminant

PM10=NH4CI =ZnO=ZnCh=Zn =

NH3=

%

1.00 x EHC = _0.68 x EHC =---0.16xEHC= _0.04 x EHC =---0.05 x EHC = _0.01 xEHC= _

(c) Annual Controlled Emissions (tpy)

Contaminant %

PMIO=NH4CI =ZnO=ZnCh=Zn =NH3=

1.00 x FH = _0.68 x FH = _0.16xFH= _0.04 x FH = _0.05 x FH = _

0.01 x FH = _

(d) Annual Fugitive Emissions (Ibslhr)

Contaminant %

PM10=NH4CI =ZnO=ZnCh=Zn =NH3=

1.00 X FA = _0.68XFA= _0.16XFA= _0.04XFA= _0.05XFA= ~

0.01 XFA= _

- 9-

E. HEAT SOURCE EMISSIONSThe following calculations must be completed for each heat source, i.e. zinc kettleburner, boiler, tank heater, etc.

1. Heat Source Parameters (From the completed TCEQ Table 6 to be filled out by theapplicant)

Parameter Design Max Annual Average

Total Flow Rate (SFM)

FRH = Total Flow Rate (SCF/hr)

Avg. Heat Content (BTUlSCF)

Total Heat Rate (BTUthr)

2. Emission Factors (Refer to AP-42 natural gas Chapter 1.4)

Contaminant

PMS02CONOxVOC

Emission Factor

____ (EPM)____ (ES02)____ (ECO)____ (ENOx)____ (EVOC)

3. Emission Calculation (lbs/hr)

Use FRH (from above) at design maximums (FRHmax) in the following calculations:

PM = EPM x FRHmaxS02 = ES02 x FRHmaxCO = ECO x FRHmaxNOx= ENOxx FRHmaxVOC = EVOC X FRHmax

4. Emission Calculation (tons/yr)

Use FRHavg in the following calculations.

HY (Hours of operation per year) =

PM = EPM x FRHavg x HY 12000S02 = ES02 x FRHavg x HY 12000CO = ECO x FRHavg x HY 12000NOx= ENOx x FRHavgX HY 12000VOC = EVOC X FRHavg x HY 12000

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HOT DIP GALVANIZING FACILITYEXAMPLE CALCULATIONS

I. INSTRUCTIONS

This manual was developed for the purpose of providing a guide for calculatingemissions at hot-dip galvanizing facilities. Tables are provided for identifying the inputdata required and the emission calculation results. In most cases, the upper portions of thetables are used to record input data/calculation parameters. Use the equations whichfollow the table to perform the emission calculations and record the results in the lowerportion of the table.

NOTE: Some of the calculations are made using data from TCEQ Tables 6, 11, and 13. Youshould complete these forms for maximum operating conditions and actual equipmentspecifications for your facility.

The information provided below will be used throughout the calculations and establisheslimitations for the permit.

A. GALVANIZING FACILITY CAPACITY DATAAP = Maximum annual production (tons/year) 20,000DP = Maximum daily production (tons/year) 100HD = Hours of operation per day 24DW = Number of days operated per week _-,5,--_WY = Number of weeks operated per year 52HY = Maximum number of hours operated per year 6,240ZN = Tons of zinc used per year 1,200

B. DEGREASING/CLEANING OPERATIONS1. Number of degreasing tanks _2_.2. Degreasing Tank ParametersTank #1 :_5_feet (ft) wide X ---.1L feet (ft) longTank #2:_5_feet (ft) wide X ---.1L feet (ft) longType of degreasing compound used: Sodium HydroxideConcentration of degreasing compound: 10%Temperature of degreasing tank solution: 200 degrees FType of heat source: NG Fired Tube Heater

NOTE: The permit engineer will review the above data and determine if degreasing tankemissions will be considered.

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C. ACIDIPICKLE TANK EMISSIONSINSTRUCTIONS: Acid/pickle tank emissions are calculated using the procedure below.If the applicant chooses to not calculate the pickle tank emissions, then all the operatingparameters must be provided with the permit application so that the permit engineer cancalculate the emissions.

1. Acid Tank DataNumber of pickle tanks at facility: _-=2=-_Tank #1: 5 feet (ft) wide X __....:..4=--5__feet (ft) longTank #2: 5 feet (ft) wide X 45 feet (ft) longType acid used: Hydrochloric (HC])Maximum acid concentration: 16 % weight/weight (w/w)Minimum acid concentration: _8_ % w/w. (concentration at recharge)Temperature of acid tanks: ambient degrees F.Fume suppressant used?_X_ Yes; __ No

Submit a copy of the Material Safety Data Sheet (MSDS) for the acid, the fumesuppressant, and any other chemicals or additives used.

Are capture hoods used over the acid tanks? __Yes;~ NoAre any exhaust fans located near the tanks? X Yes; No

If yes, show their location on the plot plan and indicate the fan size (diameter), flow rate(CFM), and the height of the fan discharge point above the ground where it exhausts tothe atmosphere.

2. Acid Pickle Tank Emission Calculation Procedure.

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HYDROCHLORIC (HCl) ACID TANK TABLETABLE 2

Hel Pickle Tanks 1 2 3 4 5

A == Surface area of tank (ftz) 225 225

T == Operating temperature (CO) 30 30

Cone. == Percent concentration ofHCL by weight (%16 16w/w)

V == Air velocity across surface of tank (fps) 1.0 1.0

Pv== Vapor pressure ofHCI (mmHg from Table 3-1 thru0.106 0.106

3-4 in the Appendix)

E == Evaporation rate from tank (lb/hr-ftz) 0.0009 0.0009

ERI = Emission rate Uncontrolled (lb/hr) 0.196 0.196

FE == Suppressant efficiency 1 - (%)/100 0.05 0.05

CE = Hood capture efficiency (%) N/A N/A

AE== Abatement device efficiency 1 - (%)/100 N/A NIA

ER4= Emission rate Controlled (lb/hr) 0.0098 0.0098

FUG = Fugitive emissions (lb/hr) 0.0049 0.0049

OY== Annual operating hours 8760 8760 Tanks Emit All theTime

AFUG == Annual Hel fugitive emission rate (tons/year) 0.021 0.021

AER == Annual HCI emission rate (tons/year) NIA NIA

SUPPLEMENTARY INFORMATIONTABLE2a

He) Pickle Tanks 1 2 3 4 5

ERI (enter into TABLE 2) (lbs/hr) 0.196 0.196

ERz (lbs/hr) 0.0098 0.0098

ER3 (lbs/hr) 0.0098 0.0098

(ERz- ER3) (lbs/hr) NIA N/A

ER4 (enter into TABLE 2) (lbs/hr) 0.0098 0.0098

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D. HYDROCHLORIC (HCI) ACID TANK EMISSIONS CALCULATIONSThe following calculations are made with data provided by the applicant. To assist inthese calculations, TABLE 2, TABLE 2a, and TABLEs 3-1 thru 3-4 (regarding partialpressures of HCI over aqueous solutions of Hel located in the Appendix) are provided foryour use. A completed TABLE 2 and TABLE 2a, in addition to the applicant'scalculations, will serve to expedite the permit review process.

E. CALClTLATION STEPS1. Calculate the surface area (A) of each tank in square feet and enter the value of A intoTABLE 2.

2. Enter the operating temperature (T) in degrees centigrade (CO), acid concentration(cone.) by weight percent, and air velocity (V) in feet per second (fps) across the surfaceof each tank into TABLE 2.

3. Determine the vapor pressure (Pv) of the HCl solution from the appropriate TABLEs 31 thru 3-4 (Appendix). Using the temperature (T, CO) and the percent acid concentration(Cone.) determine the partial pressure of the solution in mmHg and enter the value ofPvinto TABLE 2.

4. Calculate the evaporation rate ofHCI from the tank using the following equation andenter the value ofE (Ib/hr-fe) into TABLE 2 (Requires a calculator with logarithmicfunctions):

E = 25[0.46 + 0.117(V)]log[(760 - Pa)/(760 - Pv)] (lb/hr-fe)Pa = 0 for this calculation.

5. Calculate and enter into TABLEs 2 and 2a the uncontrolled emission rate,

ERI: ERI = E x A (lb/hr)

6. Do you use a suppressant (foam, fume, or mechanical) in your HCI tank? If yes,complete the following then go to 7.

FE = [1 - (%)/1 00], where % is the efficiency of the suppressant.

The efficiency of the suppressant can usually be found in the manufacturer's literature orby contacting the manufacturer of your particular suppressant.

Enter the value of FE into TABLE 2, then calculate the following (enter the value ofER2 into TABLE 2a):

ER2 = ERI x FE (lbs/hr)

If you do not use a fume suppressant, complete the following (enter the value of ERz intoTABLE 2a) then go to 7.

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7. Do you use a capture hood on your HCI tank? If yes, complete the followingappropriate calculation, then go to 10. If no, skip to 8.

If you use a hood, and do not use a fume suppressant, calculate the following (enter thevalue of ER3 into TABLE 2a), then go to 10:

ER3 = ER2 x CEil 00 (lbs/hr) (Hood, no fume suppressant)

Note: CE is the percent capture efficiency of your hood design. Hoods designed in accordancewith the Industrial Ventilation, A Manual of Recommended Practice, can be conservativelyconsidered to have 98% capture efficiency.

If you use a hood, and also use a fume suppressant, calculate the following (enter thevalue ofER3 into TABLE 2a), then go to 10:

ER3 = ER2 x CEil 00 (lbs/hr) (Hood and a fume suppressant)

8. If you do not use a capture hood, but use a fume suppressant use the following (enterthe value of ER3 into TABLE 2a), then go to 12.

ER3 =ER2 (lbs/hr) (No hood, use a fume suppressant)

If you do not use a capture hood, and also do not use a fume suppressant, then go to 9.

9. You will not be authorized to operate a HCI pickle tank without the use of, as aminimum, a fume suppressant or a capture hood.

10. Do you have an abatement device that controls the emissions from your hoodexhaust? If yes, complete the following calculations, enter the values of AE and ER4 intoTABLE 2, then go to 13. If not, then go to 11.

The efficiency of the abatement device you propose to use, or you are using, can bedetermined from the manufacturers literature or by contacting the manufacturer directly.

AE = [1-(%)11 00], where % is the abatement device efficiency.ER4 = ER3 x AE (lbs/hr)

11. Without an abatement device your hourly emission rate is the same as calculated in 7.Complete the following, enter the value of ER4 into TABLEs 2 and 2a, then go to 13:

ER4 = ER3 (lbs/hr)

12. Calculate the hourly fugitive emission rate from the tank and enter the value ofFUGinto TABLE 2, then go to 14:

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Fugitive emissions are those emissions that escape into the building. These emissions areeventually emitted to the atmosphere through a building vent (exhaust fan, open door,window, etc.). You are given a 50% capture efficiency for the building.

FUG = (ER3) (0.5) (Ibs/hr) (Fume suppressant only)

13. Calculate the fugitive emission rate from the tank and enter the value ofFUG intoTABLE 2, then go to 15:

Fugitive emissions are those emissions that are not captured by the hood system and;therefore, escape into the building. These emissions are eventually emitted to theatmosphere through a building vent (exhaust fan, open door, window, etc.). You aregiven a 50% capture efficiency for the building.

FUG =(ER2 - ER3) (0.5) (Ibs/hr)

14. Calculate your annual fugitive emission rate (AFUG) and enter the value of AFUGinto TABLE 2:

AFUG = (FUG x OY)/2000 (tons/year)

15. Calculate your annual emission rate (AER) and the annual fugitive rate (AFUG) andenter the values of AER and AFUG into TABLE 2.

AER =(ER4 x OY)/2000 (tons/year)AFUG = (FUG x OY)/2000 (tons/year)

SULFURIC ACID EMISSION CALCULATIONSIf sulfuric acid is used as a pickling agent, use the above Steps 5 through 15 and TABLEs2 and 2a. Begin with Step 5 and use 0.00015 lbs/hr-ftz for "E", the emission factor forsulfuric acid.

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3

10,000DP = Maximum Hourly Productionin Pounds/Hour of GalvanizedProduct Ibs/hr

F. GALVANIZING/ZINC KETTLE UNCONTROLLED EMISSIONSGalvaniZinFaeili

AP = Maximum Annual Productionin TonslYear of Galvanized Productt

20,000

AD = Maximum Annual OperatingHours Per Year hrs/ r

6,240

EF = Zinc Kettle Emission Factor(Ibs/hr

0.52 0.52 0.52

ED = Hourly Uncontrolled PM 10

Emissions Ibs/hr *2.6

EA = Annual Uncontrolled PM 10

Emissions t **5.2

* EH= 10,000/2000 X 0.52 = 2.6 Ibs/hr** EA= 20,000/2000 X 0.52 = 5.2 tons/yr

Note: The above calculations must be completed for each galvanizing kettle that exhausts to its own controldevice. For all kettles exhausting to a common control device, then this calculation may be made only onceusing an AP and HP for all kettles exhausting to the same control device.

G. GALVANIZING/ZINC KETTLE CONTROLLED EMISSIONS

ED = See Previous TableEA = See Previous TableCE = Kettle Hood CaptureEfficienc %AE = Control Device EfficiencEDC = Hourly Controlled PMIO

Emissions Ibs/hr *

2.65.2

98%

99%

0.03

Zinc Kettle2 3

EAC = Annual Controlled PM IO

Emissions t ** 0.05

FD = Hourly Fugitive PM 10

Emissions Ibs/hr *** 0.05

FA = Actual Fugitive PM 10

Emissions t **** 0.104

* EHC= 2.6 X 0.98 X 0.01 = 0.02 Ibs/hr** EAC= 5.2 X 0.98 x 0.01 = 0.05 tons/yr

*** FH= 2.6 X 0.02 = 0.05 Ibs/hr**** FA= 5.2 X 0.02 = 0.104 tons/yr

Note: This quantity must be completed for each galvanizing kettle that exhausts to its own control device.For all kettles exhausting to a common control device, then this calculation may be made only once usingan AP and HP for all kettles exhausting to the same control device.

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1. Speciated Zinc Kettle Emissions

(a) Hourly Controlled Emissions (Ibs/hr)

Contaminant %

PMlo=NH4CI =ZnO=ZnCh=Zn =NH3=

1.00 x 0.03 = 0.030.68 x 0.03 = 0.020.16 x 0.03 = 0.0050.04 x 0.03 = 0.00120.05 x 0.03 = 0.00450.01 x 0.03 = 0.0003

(b) Hourly Fugitive Emissions (Ibslhr)

Contaminant %

PM 10 =NH4Cl =ZnO=ZnCh=Zn=NH3=

1.00 x 0.OS = =0.=05"------ _0.68 x 0.05 = =0.=03"-4'----__0.16 x 0.05 = =0.=00=8'----__0.04 x 0.05 = =0.=00=2=---__0.05 x 0.05 = =0.=00=3:......-__0.01 x 0.05 = =0.=00",-,0=5 _

(c) Annual Controlled Emissions (tpy)

Contaminant %

PMJo=NH4Cl =ZnO=ZnCh=Zn =NH3=

1.00 x 0.OS = =0.=05"------ _0.68 x 0.05 = =0.=03"-4'----__0.16 x 0.05 = =0.=00=8'----__0.04 x 0.05 = =0.=00=2=---__0.05 x 0.05 = =0.=00=3:......-__0.01 x 0.05 = -,,-,0.=00.::..,:0:..:;.5 _

(d) Annual Fugitive Emissions (Ibs/hr)

Contaminant %

PMlo=NH4Cl =ZnO=ZnCh=Zn=NH3=

1.00 X 0.104 = =0.~10::....:.4__0.68 X 0.104 = =0...::....:07--=-1__0.16 X 0.104 = =0...::....:01:....:...7__0.04 X 0.104 = 0.00420.05 X 0.104 = =0.-,,-,00=5__0.01 X 0.104 = =0.-,,-,00,-,,1__

- 18 -


1. Tube Heater Parameters (From the completed TCEQ Table 6 to be filled out by theapplicant)


Total Flow Rate (SFM) 10 5

FRH = Total Flow Rate (SCF/hr) 600 300

Avg. Heat Content (BTU/SCF) 1,050

Total Heat Rate (BTU/hr) 630,000


Contaminant

PMS02CONOxVOC

Emission Factor

12 (EPM)0.6 (ES02)21 (ECO)100 (ENOx)5.8 (EVOC)

3. Emission Calculation (Ibslhr)

Use FRHmax in the following calculations:

PM = 12 x 0.0006 = 0.007S02 = 0.6 x 0.0006 =0.0004CO = 21 x 0.0006 = 0.013NOx = 100 x 0.0006 = 0.06VOC = 5.8 X 0.0006 = 0.0035



HY (Hours of operation per year) = 6,240

PM = 12 x 0.0003 x 6,240 /2,000 = 0.011S02 = 0.6 x 0.0003 x 6,240 /2,000 = 0.00056CO = 21 x 0.0003 x 6,240 /2,000 = 0.0197NOx = 100 x 0.0003 x 6,240/ 2,000 = 0.094VOC = 5.8 X 0.0003 x 6,240 /2,000 = 0.0054

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1. Kettle Heater Parameters (From the completed TCEQ Table 6 to be filled out by theapplicant)


Total Flow Rate (SFM) 120 60

FRH = Total Flow Rate (SCFIHr) 7,200 3,600

Avg. Heat Content (BTU/SCF) 1,050

Total Heat Rate (BTUIHr 7,560,000


Contaminant

PMSOzCONOxVOC

Emission Factor

_------'-'12=--_ (EPM)__0::....:..6""--_ (ESOz)_---'2::..:1'--_ (ECO)_~10,-,,-0_ (ENOx)_---'5::....:.."'--8_ (EVOC)

3. Emission Calculation (lbslhr)

Use FRHmax in the following calculations:

PM = 12 x 0.0072 = 0.086SOz = 0.6 x 0.0072 =0.004CO = 21 x 0.0072 = 0.15NOx= 100x 0.0072 = 0.72VOC = 5.8 X 0.0072 = 0.042



HY (Hours of operation per year) = 6,240

PM = 12 x 0.0036 x 6,240 / 2,000 = 0.135SOz = 0.6 x 0.0036 x 6,240 /2,000 = 0.0067CO = 21 x 0.0036 x 6,240 /2,000 = 0.24NOx= lOOx 0.0036 x 6,240 / 2,000 = 1.12VOC = 5.8 X 0.0036 x 6,240 / 2,000 = 0.07

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APPENDIX:PARTIAL PRESSlTRES (Pv) OF HCI OVER AQUEOUSSOLUTIONS OF HCI

- 21 -

PARTIAL PRESSURES (Pv) OF HCI OVER AQUEOUS SOLUTIONS OF HCITable 3-4~ ._-_ .. -----, .. -- --- -- - ----, - ---- ---_ ••• -;> - ----- -._-- ~ ..- - --- -- --, - ------

0/00° 5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 60° 70° 80° 90° 100° 110°

Hel

2 ,ii., ... 0.0000117 0.000023 0.000044 0.000084 0.000151 0.000275 0.00047 0.00083 0.00104 0.0038 0.01 0.0245 0.058 0.132 0.28

4 0.000018 0.000036 0.000069 0.000131 0.00024 0.00044 0.00077 0.00134 0.0023 0.00385 0.0064 0.0165 0.0405 0.095 0.21 0.46 0.93

6 O:oOod66 0.000125 0.000234 0.000425 0.00076 0,00131 0.00225 0.0038 0.0062 0.0102 0.0163 0.04 0.094 0.206 0.44 0,92 1.78

8 0.000118 0.000323 0.000583 0.00104 0.00178 0.0031 0.00515 0.0085 0.0136 0.022 0.0344 0.081 0.183 0.39 0.82 1.64 3.1

10 0.00042 0.00075 0.00134 0.0232 0.00395 0.0067 0.0111 0.0178 0.0282 0.045 0.069 0.157 0.35 0.73 1,48 2.9 5.4

12 0.00099 0.00175 0.00305 0.0052 0.008 0.0145 0.0234 0.037 0.058 0.091 0.136 0,305 0.66 1.34 2.65 5.1 9.3

14 0;0024 0.00415 0;0071 0.0118 0.0196 0.0316 0.05 0.078 0.121 0.185 0.275 0.6 1.25 2.5 4.8 9 16

16 0.0056 0.0095 0:0016 0.0265 0;0418 0.0685 0.106 0.163 0.247 0.375 0.55 1.17 2.4 4.66 8.8 16.1 28

18 0.0135 0.0225 0.037 0.06 0.095 0.148 0.228 0.345 0.515 0.77 1.11 2.3 4.55 8.6 15.7 28 48

20 0.0316 0.052 0.084 0.132 0.205 0.32 0.48 0,72 1.06 1.55 2.21 4.4 8.5 15.6 28.1 49 83

22 0.0734 0.119 0.187 0.294 0.45 0.68 1.02 1.5 2.18 3.14 4.42 8.6 16.3 29.3 52 90 146

24 0.175 0.277 0.43 0.66 1 1.49 2.17 3.14 4.5 6.4 8.9 16.9 31 54.5 94 157 253

26 0.41 0.64 0.98 1.47 2.17 3.2 4.56 6.5 9.2 12.7 17.5 32.5 58.5 100 169 276 436

28 1 1.52 2.27 3.36 4.9 7.05 9.9 13.8 19.1 26.4 35.7 64 112 188 309 493 760

30 2.4 3.57 5.23 7.6 10.6 15.1 21 28,6 39.4 53 71 124 208 340 542 845 •....

32 /'15.7 8.3 'i~1,8 16.8 23.5 32.5 44.5 60 81 107 141 238 390 623 970 ...

34 iili.a~,~ 18.8 26.4 36.8 50.5 68.5 92 122 161 211 273 450 720 ... ..... ... ·'i·36 :29 41 56.4 78 105.5 142 188 246 322 416 535 860 ." ... ... ... ...38 63 87 •!. 158 210 277 360 464 598 758 955 ... ... ... ... ... ..,

40 'i 176 233 307 399 515 627 830 .... ... ... ... ... ... ... ... ..'.

42 253 332 430 560 709 900 ..... .., ... ... ... '" '" ... '" ... ...

44 510 655 840 ... ... ... ... ... ... ... .... ... ... ... ... .. . ...

46 940 ... '"... ... ... ... '" ... ... .... ... ... ... ... .. . ...

22

State of CaliforniaAIR RESOURCES BOARD

EXECUTIVE ORDER G-11-014

Relating to Certification of Abrasives for Permissible Outdoor Blasting underCalifornia Code of Regulations, Title 17, Section 92530

WHEREAS, Pursuant to California Health and Safety Code Division 26, Article 4,Chapter 3, Part 4 of the Air Resources Board (ARB) has adopted abrasive blastingstandards;

WHEREAS, in California Code of Regulations, title 17, section 92000 et seq., ARB hasestablished abrasive blasting standards;

WHEREAS, California Code of RegUlations, title 17, section 92500 (c), provides in partthat any abrasive blasting operation conducted outside a permanent building must useexclusively wet abrasive blasting, hydroblasting, vacuum blasting, or abrasives certifiedby ARB for permissible dry outdoor blasting;

WHEREAS, Exhibit A to this Executive Order lists abrasives that have been tested inaccordance with "Method of Test for Abrasive Media Evaluation," Test MethodNo. California 371-A, dated May 15, 1975, including the "Visible Emission EvaluationTest Method for Selected Abrasives Used in Permissible Dry Outdoor Blasting," asadopted by ARB on April 1, 1991, for some selected abrasives, and all have been foundto comply with the abrasive certification performance standards set forth in CaliforniaCode of Regulations, title 17, section 92530 (b);

WHEREAS, Exhibit A may be amended from time to time to remove abrasives nolonger certified for use and to add new abrasives that have been tested and found tocomply with the abrasive certification performance standards set forth in California Codeof Regulations, title 17, section 92530 (b); and

WHEREAS, ARB's Executive Officer pursuant to California Health and Safety Code,section 39516, issued Executive Order G-02-007 delegating to the Chief of ARB'sMonitoring and Laboratory Division the authority to certify abrasives in accordance withCalifornia Code of RegUlations, title 17, section 92530(a).

NOW, THEREFORE, I, Alberto Ayala, Chief of ARB's Monitoring and LaboratoryDivision, order certified the abrasives listed in Exhibit A for permissible dry outdoorblasting pursuant to California Code of Regulations, title 17, section 92530.

-2-

IT IS FURTHER ORDERED pursuant to California Code of Regulations, title 17,section 92530 (a), that the certifications granted by this Executive Order will expire onthe respective dates listed in Exhibit A and subsequent addendums, and thereafter nopreviously listed abrasive will be permissible for dry outdoor blasting until recertified inaccordance with California Code of Regulations, title 17, section 92530.

IT IS FURTHER ORDERED that Executive Order G-1 0-053 is superseded by this order.

Executed at Sacramento, California this 6th day of May 2011.

Original signed by

Alberto Ayala, Ph.D., M.S.E.Chief, Monitoring and Laboratory Division

Attachment

Exhibit A: Abrasives Certified for Permissible Dry Outdoor Blasting

ABRASIVES CERTIFIED FOR PERMISSIBLE OUTDOOR BLASTING - G-11-014

Executive Order G-11-014 Exhibit A

EXECUTIVE ORDER G-11-014

STATE OF CALIFORNIAAIR RESOURCES BOARD

Page 1 of 15

ABRASIVES CERTIFIED FOR PERMISSIBLE DRY OUTDOOR BLASTING pursuant to CaliforniaCode of Regulations, title 17, section 92530 Unless otherwise noted, the cut-point for fineness (cpff) is#70 sieve.

Abrasive Technologies. Inc.499 Settlers Ridge ParkwayWoodbury, Minnesota 55129

Plant: 499 Settlers Ridge ParkwayWoodbury, Minnesota

Brand Name or Grade:Black Diamond Grit Blasting Abrasive

Abrasives. Incorporated4090 Highway 49Glen Ullin, North Dakota 58631

Plant: 4090 Highway 49Glen Ullin, North Dakota

Brand Name or Grade:Black Magic 8-20Black Magic 16-40Black Magic 20-40Black Magic 40-60

www.ati-blackdiamond.comAlbie Kraemer(651) 436-6071Fax: (320) 597-2002

Expires:8/31/11

www.abrasivesinc.comRussell Raad(701) 348-3610Fax: (701) [email protected]

Expires:8/31/128/31/128/31/128/31/12

Executive Order G-11-014

Arden Incorporated DBAGreen Diamond Sands Products

Post Office Box DRiddle, Oregon 97469

Exhibit A

Brian Rebuck(541) 874-3111x18Fax: (541) [email protected]

Page 2 of 15

Plant: Corner of 6th and E StreetRiddle, Oregon

Brand Name or Grade:Green Diamond 1636Green Diamond 2050

Barton Mines Company. L.L.C.Six Warren StreetGlens Falls, New York 12801

Plant: 17-C KeeraikaranthattuTisiayanvilai, Tamil NaduIndia

Brand Name or Grade:Barton Garnet #36Barton Garnet #30x40Barton Garnet #80

(cpff=#100)

Plant: Hudson River Plant Rd.North River, NY

Brand Name or Grade:Barton Garnet #36 CGBarton Garnet #50 HPXBarton Garnet #80HPX

(cpff=#200)Barton Garnet #120HPX

(cpff=#270)

Plant: 1960 Diamond Hill Rd.Chesapeake, VA

Brand Name or Grade:Barton Garnet #30x60 Plus

(cpff=#100)

Expires:8/31/128/31/12

www.barton.comScott Trom(832) 233-4272Fax: (832) [email protected]

Expires:8/31/128/31/128/31/12

Expires:8/31/128/31/128/31/12

8/31/12

Expires:8/31/12


BCJ Sand & Rock, Incorporated3388 Regional Park Way, Suite ASanta Rosa, California 95403

Exhibit A

www.bcjunlimited.comBrad Slender(707) 544-0303Fax: (707) 544-8274bcj [email protected]

Page 3 of 15

Plant: 4970 Slickens RoadOroville, California

Brand Name or Grade:BCJ #30BCJ Unlimited - Sand Blasting Sand / Blasting Sand#30 Blasting SandBlasting Sand30x50 Blasting Sand20x30 Blasting SandPremium Blasting Sand

Expires:8/31/128/31/128/31/128/31/128/31/128/31/128/31/12

Bell & MacKenzie Co., Ltd.Post Office Box 844, LCD #1Hamilton, Ontario L8N 3N9Canada

Plant: 500 Sherman Avenue, NorthHamilton, OntarioCanada

Brand Name or Grade:Black Shot Granulated Slag #12Black Shot Granulated Slag #20

California Silica Products LLCP.O. Box 4225Ontario, California 91761

Plant: 12808 Rancho RoadAdelanto, California

Brand Name or Grade:#16 Blast off Sand#20 Blast off Sand#30 Blast off SandCal-Silica Grade 16Cal-Silica Grade 20Cal-Silica Grade 30

Richard Bell(888) 794-5665Fax: (888) [email protected]

Expires:8/31/118/31/11

Randall Humphreys(909) 938-6505Fax: (909) 947-7929

Expires:8/31/118/31/118/31/118/31/118/31/118/31/11


Carmeuse Industrial SandsPost Office Box 249San Juan Capistrano, California 92693

Plant: 31302 Ortega HighwaySan Juan Capistrano, California

Brand Name or Grade:Dust Net #12Dust Net #16Dust Net #20Dust Net #30

Exhibit A Page 4 of 15

Michael Michlette(951) 440-0913Fax: (949) [email protected]

Expires:8/31/128/31/128/31/128/31/12

CemexUSAPost Office Box 337Marina, California 93933

Plant: Lapis RoadTwo miles north of Marina, California

Brand Name or Grade:Lapis Lustre, NO.3Lapis Lustre, No. 0/30Lapis Lustre, No. 1/20Lapis Lustre, No. 1CLapis Lustre, No. 2/12Lapis Lustre, No. 2/16

E. I. DuPont de Nemours and Company4641 County Road 230Starke, Florida 32091

Plant: 4641 County Road 230Starke, Florida

Brand Name or Grade:Starblast®

(cpff=#140)Starblast® XL

(cpff=#140)

Dale Kendall(831) 883-3709Fax: (831) 883-3703dalew.kenda [email protected]

Expires:8/31/128/31/128/31/128/31/128/31/128/31/12

www.titanium.dupont.comLuther B. Carter(904) 276-6239Fax: (904) [email protected]

Expires:8/31/11

8/31/11

Executive Order G-11-014 Exhibit A Page 5 of 15

Energized Substation Maintenance, IncorporatedPost Office Box 2345Apple Valley, California 92307

Plant: Mt. Pulaski Products908 North VineMt Pulaski, Illinois

Brand Name or Grade:#3 (20/40) Processed Corn Cobs#3 Processed Corn Cobs(20/40) Processed Corn Cobs

www.esminc.infoRonald R. Goss(800) 959-5589Fax: (760) 247-2915esm1 @aol.com

Expires:8/31/118/31/118/31/11

Glass Recyling Technologies, Incorporated493 State Route 28Richfield Springs, New York 13439

Plant: 493 State Route 28Richfield Springs, New York

Brand Name or Grade:SunBlast Extra-CoarseSunBlast MediumSunBlast Fine

(cpff=#100)

Gordon Sand Company28310 Industrial Boulevard, Suite FHayward, California 94545

Plant: West End of Main StreetGuadalupe, California

Brand Name or Grade:Golden Flint G-16*Golden Flint G-20*Golden Flint G-30*

www.grtcleanglass.comBrett Wilhelm(607) 218-1430Fax: (607) [email protected]

Expires:8/31/128/31/128/31/12

George E. Gordon [email protected] P. [email protected](510) 782-5640Fax: (510) 782-5694

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Executive 0 rder G-11-014

Harsco Minerals5000 Ritter RoadMechanicsburg, Pennsylvania 17055

Exhibit A

www.reedmin.comAnthony J. Budzinski(717) 506-7157Fax: (717) [email protected]

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Plant: 240 Baldwin RoadSatsuma, Alabama

Brand Name or Grade:Black Beauty - MediumBlack Beauty - Fine

Plant: 600 - 800 Outer DriveLaCygne, Kansas

Brand Name or Grade:Black Beauty - MediumBlack Beauty - FineBlack Beauty - XFine

Plant: 9001 State Route 176 EastDrakesboro, Kentucky


Plant: Highway 104, Across from Kinkaid Power StationPawnee, Illinois


Plant: 7100 West 9th Ave.Gary, Indiana


Plant: 2170 Plant RoadMemphis, Tennessee


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Harsco MineralsPlant: 13040-A Market Street

Houston, TexasBrand Name or Grade:

Black Beauty - MediumBlack Beauty - Fine


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Plant: Rt 2 South of Mitchell Generating StationMoundsville, West Virginia


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Industrial Mineral CompanyPost Office Box NO.6Muthiahpuram, Tuticorin 628 005India

Plant: AvudaiyalpuramVijayapathi VillageRadhapuram TalukTirunelveli DistrictIndia

Brand Name or Grade:Garnet Abrasive Grit A (Mesh 12-25)Supreme Garnet Grade A (Mesh 12-25)Garnet Abrasive Grit Mesh B (20-40)Supreme Garnet Grade B (Mesh 20-40)Garnet Abrasive Grit C (Mesh 30-60)Supreme Garnet Grade C (Mesh 30-60)

International Materials &Supplies Incorporated56 Industrial Park RoadKeeseville, New York 12944

Plant: 56 Industrial Park RoadKeeseville, New York

Brand Name or Grade:International Garnet #16International Garnet #36

www.supremegarnet.comMadhavan.K0091-461-2357221Fax: [email protected]

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www.optaminerals.comMartin Caouette(800) 252-9288Fax: (800) [email protected]

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Kleen Blast Division - CanAm Minerals50 Oak Court #210Danville, California 94526

Exhibit A

www.kleenblast.comFionn O'Neill(925) 831-9800Fax: (925) 831-9183fion [email protected]

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Plant: Pacific Abrasives & Supply, Incorporated2465 Carson RoadGrand Forks, British ColumbiaCanada

Brand Name or Grade:Kleen Blast #16/30Kleen Blast #35Kleen Blast #30/60

Plant: 676-B Moss StreetChula Vista, California

Brand Name or Grade:Kleen Blast #16-30 15% BlastoxKleen Blast #35 15% Blastox

Plant: 30028 Industrial Parkway. Hayward, CABrand Name or Grade:

Kleen Blast Royal Garnet #30/60

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Les Sables Olimag. Incorporated163, rue PIE XI Street, C.P.276Thetford Mines, Quebec G6G 5T1Canada

Plant: 725 Boul Caouette C.P. 276Thetford Mines, QuebecCanada

Brand Name or Grade:Jetmag 30-60

www.olimag.comJean Yves Angers(418) 338-3562Fax: (418) [email protected]

Expires:8/31/12


LVH Industries, Incorporated220 South Hancock StreetMcAdoo, Pennsylvania 18237

Exhibit A

www.lvhindustriesinc.comLori A. VanHoekelen(570) 366-0950Fax: (570) 366-0948

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Plant: 49 Pinedale Industrial RoadOrwigsburg, Pennsylvania

Brand Name or Grade:MediumCoarse

Minerals Research & Recovery, Incorporated4620 South Coach DriveTucson, Arizona 85714

Plant: 1/8 mile from Fire StationNorth Side of Highway 85South of Ajo, Arizona

Brand Name or Grade:Sharpshot 12x30Sharpshot 20x50Sharpshot 30x60

(cpff=#140)

Mohawk Garnet Incorporated808 Highway 17 EastWahnapitae, Ontario POM 3COCanada

Plant: Street TownshipOff Kukagami Lake RoadCity of Greater Sudbury, OntarioCanada

Brand Name or Grade:Mohawk Garnet XB16Mohawk Garnet XB30

Expires:8/31/128/31/12

www.mrrinc.comMichael D. Vick(520) 748-9362Fax: (520) [email protected]

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www.mohawkgarnet.comBob McMurdy(705) 694-5783Fax: (705) [email protected]

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Nevada Slag. Inc.P.O. Box 1314McGill, Nevada 89318

Plant: 55 North 4th StreetMcGill, Nevada

Brand Name or Grade:Nevada Black 8/20Nevada Black 16/30Nevada Black 30/60


Meloney Roberts(775) 235-7500Fax: (775) 235-7119Email: [email protected]

Expires:8/31/118/31/118/31/11

Novetas Solutions. LLC4900 South Broad StreetCommandants Building, Suite 310Philadelphia, Pennsylvania 19112

Plant: 2 Enterprise CourtSewell, New Jersey

Brand Name or Grade:New Age Blast Media CoarseNew Age Blast Media MediumEco Blast Media CoarseEco Blast Media Medium

Plant: 13101 Enon Church RoadChester, Virginia

Brand Name or Grade:New Age Blast Media CoarseNew Age Blast Media MediumEco Blast Media CoarseEco Blast Media Medium

www.newageblastmedia.comStephen R. Swartz, Jr.(215) 551-3070Fax: (215) [email protected]

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Opta Minerals, Inc.407 Parkside DriveWatertown, Ontario LOR 2HOCanada

Exhibit A

www.optaminerals.comJohn Papaioannou(905) 689-6661 x335Fax: (905) [email protected]

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Plant: 407 Parkside DriveWatertown, OntarioCanada

Brand Name or Grade:, Ebony Grit 14

Opta Minerals Baltimorec/o Virginia Materials, Incoporated407 Parkside DriveWatertown, Ontario LOR 2HOCanada

Plant: 4500 East Fayette StreetBaltimore, Maryland

Brand Name or Grade:Black Blast Coal SlagUltrablast Nickel Slag

Opta Minerals Hardeevillec/o Virginia Materials, Incoporated407 Parkside DriveWatertown, Ontario LOR 2HOCanada

Plant: 715 Industrial Park RoadHardeeville, South Carolina

Brand Name or Grade:Black Blast Coal Slag

Expires:8/31/12

www.optaminerals.comJohn Papaioannou(905) 689-6661x335Fax: (905) [email protected]

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www.optaminerals.comJohn Papaioannou(905) 689-6661 x335Fax: (905) [email protected]

Expires:8/31/11

Iixecutive Order G-11-014

P.W. Gillibrand:4537 Ish Drive'Simi Valley, California 93063

Plant: 5810 Bennett RoadSimi Valley, California

Brand Name or Grade:Silver Sand #12Silver Sand #16Silver Sand #20Silver Sand #30

Servicios Mineros del Noroeste S.A. de C.V.Reform 1507-ACol NuevaMexicali, BC 91100Mexico

Plant: Col MarianaGPE Victoria, BCMexico

Brand Name or Grade:Almandite Garnet 36Dark Red 20/30Red 30/40Almandite GarnetSelect GarnetKleen Blast Select Garnet

Silica Resources Incorporated4553 Hammonton RoadMarysville, California 95901

Plant: 4553 Hammonton RoadMarysville, California

Brand Name or Grade:SRI Supreme #12SRI Supreme #20SRI Supreme #30

Exhibit A

Gary Shockley(805) 520-8731x416Fax: (805) [email protected]

Robert Mark Anthony52-686-548-7654FAX: [email protected]

www.sri-sand.comDustin Parsons(530) 741-0290Fax: (530) [email protected]

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Executive Order G-11-014 Exhibit A Page 13 of 15

Sponge-Jet, Inc.235 Heritage Avenue, Suite 2Portsmouth, New Hampshire 03801

Plant: RR6 Box 6243Montrose, Pennsylvania

Brand Name or Grade:Sponge-Jet Silver 16Sponge-Jet Silver 30Sponge-Jet Silver 30-DGSponge-Jet Silver 60Sponge-Jet Silver 320

Teichert Aggregates8760 Kiefer BoulevardSacramento, California 95826

Plant: 8760 Kiefer Blvd.Sacramento, California

Brand Name or Grade:Black Talon

(cpff=#140)

TriVitro Corporation18420 - 68th Avenue South, #101Kent, Washington 98032

Plant: 18420 - 68th Avenue South, #101Kent, Washington

Brand Name or Grade:Vitro Grit VG #30/50

www.spongejet.comMr. William F. McLaughlin, Jr.(603) 610-7950Fax: (603) 431-6043Email: [email protected]

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www.teichert.comRon Stickel(916) 484-3363Fax: (916) 484-7012Email: [email protected]

Expires:8/31/12

www.trivitro.comDonald H. Freas(425) 251-8340Fax: (425) 251-8301Email: [email protected]

Expires:8/31/11


u.s. Minerals LLC2105 North Winds DriveDyer, Indiana 46311

Exhibit A

www.us-minerals.comVincent J. Piccirilli(219) 864-0909x18Fax: (219) [email protected]

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Plant: 3860 Peters RoadHarvey, Louisiana

Brand Name or Grade:Black Magnum

Virginia Materials Incorporated,An Optaminerals Company

407 Parkside DriveWatertown, Ontario LOR 2HOCanada

Plant: 3306 Peterson StreetNorfolk, Virginia

Brand Name or Grade:Beach Minerals GarnetBlack BlastAdmirals Garnet

(cpff=#140)Powerblast LS

(cpff=#270)

Expires:8/31/12

www.optaminerals.comJohn Papaioannou(905) 689-6661x335Fax: (905) [email protected]

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8/31/11

I

IExecutiv~ Order G-11-014

IV. v. MineraiIttamozhi RoadKeeraikaranthattuTisaiyanvilai- 627 657TamilnaduIndia

Exhibit A

www.vvmineral.com

00-91-4637-272360Fax: 00-91-4637-271802Fax: 00-91-4637-271802

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Plant: No.1, M.L.Theri RoadKeeraikaranthattuTisaiyanvilai-627657Tirunelveli DistrictTamilnaduIndia

Brand Name or Grade:Garnet Abrasive Grit Grade-B (20-40 mesh)Sg. Super Garnet Grade-B (20-40 mesh)

Plant: No.75,K.Pudur VillageValianvilai,Navalady postTirunelveli DistrictTamilnaduIndia

Brand Name or Grade:Garnet Abrasive Grit Grade-C (30-60 mesh) 8/31/12Sg. Super Garnet Grade-C (30-60 mesh)

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WGI Heavy Minerals Inc.P. O. Box 190Fernwood, Idaho 83830

Plant: 4 miles south of Fernwood, HWY 3 IdahoBrand Name or Grade:

Emerald Creek Garnet # 16Emerald Creek Garnet # 36Emerald Creek Garnet # 30/40

Plant: HeLinGe Er CountyHuhhot City, Inner MongoliaChina

Brand Name or Grade:Western Garnet #20/40

www.wgiheavyminerals.comSandy Stamper(208) 245-2096Fax: (208) 245-5309Email: [email protected]

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Expires:8/31/11