notice of decision: approval -registrationpermits.air.idem.in.gov/35572f.pdf · 2015-04-02 ·...

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT We Protect Hoosiers and Our Environment.

100 N. Senate Avenue • Indianapolis, IN 46204

(800) 451-6027 • (317) 232-8603 • www.idem.IN.gov

Michael R. Pence Thomas W. Easterly Governor Commissioner

To: Interested Parties Date: April 2, 2014 From: Matthew Stuckey, Chief Permits Branch Office of Air Quality Source Name: Nidec Motor Corporation Permit Level: Registration Permit Number: 051-35572-00048 Source Location: 1551 E Broadway Type of Action Taken: Changes that are administrative in nature

Notice of Decision: Approval - Registration

Please be advised that on behalf of the Commissioner of the Department of Environmental Management, I have issued a decision regarding the matter referenced above. The final decision is available on the IDEM website at: http://www.in.gov/apps/idem/caats/ To view the document, select Search option 3, then enter permit 35572. If you would like to request a paper copy of the permit document, please contact IDEM’s central file room:

Indiana Government Center North, Room 1201 100 North Senate Avenue, MC 50-07 Indianapolis, IN 46204 Phone: 1-800-451-6027 (ext. 4-0965) Fax (317) 232-8659

Pursuant to IC 4-21.5-3-4(d) this order is effective when it is served. When served by U.S. mail, the order is effective three (3) calendar days from the mailing of this notice pursuant to IC 4-21.5-3-2(e).

(continues on next page)

An Equal Opportunity Employer

Recycled Paper

If you wish to challenge this decision, IC 4-21.5-3-7 requires that you file a petition for administrative review. This petition may include a request for stay of effectiveness and must be submitted to the Office of Environmental Adjudication, 100 North Senate Avenue, Government Center North, Suite N 501E, Indianapolis, IN 46204, within eighteen (18) calendar days of the mailing of this notice. The filing of a petition for administrative review is complete on the earliest of the following dates that apply to the filing: (1) the date the document is delivered to the Office of Environmental Adjudication (OEA); (2) the date of the postmark on the envelope containing the document, if the document is mailed to

OEA by U.S. mail; or (3) The date on which the document is deposited with a private carrier, as shown by receipt issued

by the carrier, if the document is sent to the OEA by private carrier. The petition must include facts demonstrating that you are either the applicant, a person aggrieved or adversely affected by the decision or otherwise entitled to review by law. Please identify the permit, decision, or other order for which you seek review by permit number, name of the applicant, location, date of this notice and all of the following: (1) the name and address of the person making the request; (2) the interest of the person making the request; (3) identification of any persons represented by the person making the request; (4) the reasons, with particularity, for the request; (5) the issues, with particularity, proposed for considerations at any hearing; and (6) identification of the terms and conditions which, in the judgment of the person making the

request, would be appropriate in the case in question to satisfy the requirements of the law governing documents of the type issued by the Commissioner.

If you have technical questions regarding the enclosed documents, please contact the Office of Air Quality, Permits Branch at (317) 233-0178. Callers from within Indiana may call toll-free at 1-800-451-6027, ext. 3-0178.

Enclosures Decision-Registration 4/8/14

Nidec Motor Corporation Page 2 of 4 Princeton, Indiana Administrative Amendment No. 0051-35572-00048 Permit Reviewer: Brian Wright The PTE of the modification is as follows:

Process/ Emission Unit

PTE of Proposed Modification (tons/year)

PM PM10 PM2.5 SO2 NOx VOC CO Total HAPs

Worst Single HAP

Die Casting Process 2.0E-3 2.0E-3 2.0E-3 0 0 0.0 0 0.0 0.0 (a) The uncontrolled/unlimited potential to emit of the entire source after the addition of this

emission unit will continue to be within the threshold levels specified in 326 IAC 2-5.5-1(b)(1) (Registration). (See Appendix A for the calculations).

(b) No new state rules are applicable to this source due to the addition of the emission unit. (c) There are no New Source Performance Standards (NSPS) (326 IAC 12 and 40 CFR Part

60) or National Emission standards for Hazardous Air Pollutants (NESHAPs) (326 IAC 14, 20 and 40 CFR Part 61, 63) included in this administrative amendment.

PTE of the Entire Source After Issuance of the Registration Administrative Amendment

The table below summarizes the potential to emit of the entire source after the issuance of this

administrative amendment, reflecting all limits, of the emission units, using bold and strikeouts to show the changes:


Potential To Emit of the Entire Source with the Revision (tons/year)

PM PM10* PM2.5 SO2 NOx VOC CO Total HAPs

Worst Single HAP

46 Space Heaters 0.03 0.12 0.12 0.01 1.64 0.09 1.38 0.03 0.03 Hexane Modified Paint Booth 100 1.35 1.35 1.35 0 0 6.58 0 1.19 0.80 Toluene

Paint Booth 101 0.52 0.52 0.52 0 0 3.52 0 1.41 0.95 Glycol Ethers

Powder Paint Booth 102 11.0 11.0 11.0 0 0 0 0 0.0 0

Solvent Based Cleaning Unit 103 0 0 0 0 0 3.22 0 0.0 0

Hobbing/Stamping Machine 0 0 0 0 0 2.57 0 0.0 0

Injection Molding 0 0 0 0 0 0.01 0 0.0 0 Die Casting Process 2.0E-3 2.0E-3 2.0E-3 0 0 0.0 0 0.0 0

Die Casting Process 2.0E-3 2.0E-3 2.0E-3 0 0 0.0 0 0.0 0

New Varnishing Line 104 0.0 0.0 0.0 0 0 4.99 0 0.0 0

Total PTE of Entire Source 12.9 12.9 12.9 0.01 1.64 21.0 1.38 2.63 0.95 Glycol

Ethers Exemptions Levels 5 5 5 10 10 10 25 25 10 Registration Levels 25 25 25 25 25 25 100 25 10 *Under the Part 70 Permit program (40 CFR 70), particulate matter with an aerodynamic diameter less than or equal to a nominal 10 micrometers (PM10), not particulate matter (PM), is considered as a "regulated air pollutant". The table below summarizes the potential to emit of the entire source after issuance of this administrative amendment, reflecting all limits, of the emission units. (Note: the table below was generated from the above table, with bold text un-bolded and strikethrough text deleted).

Nidec Motor Corporation Page 3 of 4 Princeton, Indiana Administrative Amendment No. 0051-35572-00048 Permit Reviewer: Brian Wright


Potential To Emit of the Entire Source with the Revision (tons/year)

PM PM10* PM2.5 SO2 NOx VOC CO Total HAPs

Worst Single HAP

46 Space Heaters 0.03 0.12 0.12 0.01 1.64 0.09 1.38 0.03 0.03 Hexane Modified Paint Booth 100 1.35 1.35 1.35 0 0 6.58 0 1.19 0.80 Toluene

Paint Booth 101 0.52 0.52 0.52 0 0 3.52 0 1.41 0.95 Glycol Ethers

Powder Paint Booth 102 11.0 11.0 11.0 0 0 0 0 0.0 0

Solvent Based Cleaning Unit 103 0 0 0 0 0 3.22 0 0.0 0

Hobbing/Stamping Machine 0 0 0 0 0 2.57 0 0.0 0

Injection Molding 0 0 0 0 0 0.01 0 0.0 0 Die Casting Process 2.0E-3 2.0E-3 2.0E-3 0 0 0.0 0 0.0 0

New Varnishing Line 104 0.0 0.0 0.0 0 0 4.99 0 0.0 0

Total PTE of Entire Source 12.9 12.9 12.9 0.01 1.64 21.0 1.38 2.63 0.95 Glycol

Ethers Exemptions Levels 5 5 5 10 10 10 25 25 10 Registration Levels 25 25 25 25 25 25 100 25 10 *Under the Part 70 Permit program (40 CFR 70), particulate matter with an aerodynamic diameter less than or equal to a nominal 10 micrometers (PM10), not particulate matter (PM), is considered as a "regulated air pollutant".

Pursuant to 326 IAC 2-5.5-6, the registration is hereby amended as follows, with deleted language as strikeouts and new language bolded:

1. The emission unit descriptions in Sections A.2 and D.1 have been revised as follows:

(e) One (1) die-cast operations, used for die-casting zinc cap ends for motors, with a

maximum throughput rate of 60 pounds of zinc alloys per hour. This process was installed in 1994.

(e) One (1) die-cast operations, constructed in 2015, used for die-casting zinc cap

ends for motors, with a maximum throughput rate of 60 pounds of zinc alloys per hour.

2. Conditions D.1.5 and D.1.6 have been revised to provide clarification as follows: D.1.5 Volatile Organic Compounds (VOC) [326 IAC 8-1-2] [326 IAC 8-1-4]

Compliance with the VOC content and usage limitations contained in Conditions D.1.1 and D.1.2 shall be determined pursuant to 326 IAC 8-1-4(a)(3)(A) and 326 IAC 8-1-2(a) by preparing or obtaining from the manufacturer the copies of the "as supplied" and "as applied" VOC data sheets. IDEM, OAQ reserves the authority to determine compliance using Method 24 in conjunction with the analytical procedures specified in 326 IAC 8-1-4.

D.1.6 Record Keeping Requirements

(a) To document the compliance status with Condition D.1.1, the Permittee Registrant shall maintain records of the VOC content of each coating material and solvent used, less water.

(b) To document the compliance status with Condition D.1.2, the Permittee Registrant shall

maintain records in accordance with (1) through (3) below. These records shall be complete and sufficient to establish compliance with Condition D.1.2:

http://www.in.gov/ai/appfiles/idem-caats/

http://www.in.gov/idem/5881.htm

http://www.in.gov/idem/6900.htm

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 2 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD SECTION A SOURCE SUMMARY This registration is based on information requested by the Indiana Department of Environmental Management (IDEM), Office of Air Quality (OAQ). The information describing the source contained in conditions A.1 and A.2 is descriptive information and does not constitute enforceable conditions. However, the Registrant should be aware that a physical change or a change in the method of operation that may render this descriptive information obsolete or inaccurate may trigger requirements for the Registrant to obtain additional permits pursuant to 326 IAC 2. A.1 General Information

The Registrant owns and operates a stationary electric motor manufacturing plant.

Source Address: 1551 East Broadway Street, Princeton, Indiana 47670 General Source Phone Number: (812) 385-2564 SIC Code: 3621 County Location: Gibson County Source Location Status: Attainment for all criteria pollutants Source Status: Registration

A.2 Emission Units and Pollution Control Equipment Summary

This stationary source consists of the following emission units and pollution control devices:

(a) One (1) paint booth, identified as PB 101 (previously identified as #73), used for coating metal motor coils, with a maximum usage rate of 0.37 gallons per hour, using air spray guns, with particulate emissions controlled by dry filters, and exhausting at stack #73. This unit was installed in 1994.

(b) One (1) paint booth, identified as PB 100 (previously identified as #74), used for coating

metal motor coils, with a maximum usage rate of 0.51 gallons of coating per hour, using air spray guns, with particulate emissions controlled by dry filters, and exhausting at stack #100. This unit was constructed in 1994.

(c) One (1) powder coating booth, identified as PB 102, with a maximum throughout rate of

60 pounds per day, with particulate emissions controlled by a dust collector and exhausting inside the building. This unit was installed in 1980.

(d) One (1) injection molding unit, with a maximum usage rate of 0.0015 pounds of mold

release agent per hour. This unit was installed in 1960. (e) One (1) die-cast operations, constructed in 2015, used for die-casting zinc cap ends for

motors, with a maximum throughput rate of 60 pounds of zinc alloys per hour. (f) One (1) metal parts hobbing and stamping process, utilizing an oil-based machining fluid

with a maximum usage rate of 1.37 pounds per hour. This process was installed in 1965. (g) Twelve (12) plunger type containers, located throughout the plant, each with a maximum

capacity of one (1) gallon, used to dispense a non-halogenated solvent onto cloths for production cleaning, collectively identified as EU 103, with a maximum throughput rate of 0.92 pounds per hour. This operation was installed in 1980.

(h) One (1) mop water evaporator unit used for processing used oils, with a maximum

process rate of 10 gallons of mop water per hour. Note: The used oils are disposed off-site.

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 3 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD

(i) Thirty-seven (37) natural gas-fired space heaters, with a maximum combined heat input capacity of 3.83 MMBtu per hour. These units were installed in 1994.

(j) One (1) varnishing line, identified as EU 104, with a maximum usage rate of 0.60 gallons per

hour, using trickling method for varnish application and exhausting at stack #81. This unit was constructed in 2006.

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 4 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD SECTION B GENERAL CONDITIONS B.1 Definitions [326 IAC 2-1.1-1]

Terms in this registration shall have the definition assigned to such terms in the referenced regulation. In the absence of definitions in the referenced regulation, the applicable definitions found in the statutes or regulations (IC 13-11, 326 IAC 1-2 and 326 IAC 2-1.1-1) shall prevail.

B.2 Effective Date of Registration [IC 13-15-5-3]

Pursuant to IC 13-15-5-3, this registration is effective immediately, unless a petition for stay of effectiveness is filed and granted according to IC 13-15-6-3, and may be revoked or modified in accordance with the provisions of IC 13-15-7-1.

B.3 Registration Revocation [326 IAC 2-1.1-9] Pursuant to 326 IAC 2-1.1-9 (Revocation), this registration to operate may be revoked for any of the following causes:

(a) Violation of any conditions of this registration.

(b) Failure to disclose all the relevant facts, or misrepresentation in obtaining this

registration.

(c) Changes in regulatory requirements that mandate either a temporary or permanent reduction of discharge of contaminants. However, the amendment of appropriate sections of this registration shall not require revocation of this registration.

(d) For any cause which establishes in the judgment of IDEM, the fact that continuance of

this registration is not consistent with purposes of this article. B.4 Prior Permits Superseded [326 IAC 2-1.1-9.5]

(a) All terms and conditions of permits established prior to Registration No. R051-22457-00048 and issued pursuant to permitting programs approved into the state implementation plan have been either:

(1) incorporated as originally stated,

(2) revised, or

(3) deleted.

(b) All previous registrations and permits are superseded by this registration.

B.5 Annual Notification [326 IAC 2-5.1-2(f)(3)] [326 IAC 2-5.5-4(a)(3)]

Pursuant to 326 IAC 2-5.1-2(f)(3) and 326 IAC 2-5.5-4(a)(3):

(a) An annual notification shall be submitted by an authorized individual to the Office of Air Quality stating whether or not the source is in operation and in compliance with the terms and conditions contained in this registration.

(b) The annual notice shall be submitted in the format attached no later than March 1 of each

year to:

Indiana Department of Environmental Management Compliance and Enforcement Branch, Office of Air Quality 100 North Senate Avenue


MC 61-53 IGCN 1003 Indianapolis, IN 46204-2251

(c) The notification shall be considered timely if the date postmarked on the envelope or

certified mail receipt, or affixed by the shipper on the private shipping receipt, is on or before the date it is due. If the document is submitted by any other means, it shall be considered timely if received by IDEM, OAQ on or before the date it is due.

B.6 Source Modification Requirement [326 IAC 2-5.5-6(a)]

Pursuant to 326 IAC 2-5.5-6(a), an application or notification shall be submitted in accordance with 326 IAC 2 to the Office of Air Quality (OAQ) if the source proposes to construct new emission units, modify existing emission units, or otherwise modify the source.

B.7 Registrations [326 IAC 2-5.1-2(i)]

Pursuant to 326 IAC 2-5.1-2(i), this registration does not limit the source's potential to emit.

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 6 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD SECTION C SOURCE OPERATION CONDITIONS

Entire Source Emission Limitations and Standards [326 IAC 2-5.1-2(g)] [326 IAC 2-5.5-4(b)]

C.1 Opacity [326 IAC 5-1] Pursuant to 326 IAC 5-1-2 (Opacity Limitations), except as provided in 326 IAC 5-1-3 (Temporary Alternative Opacity Limitations), opacity shall meet the following, unless otherwise stated in this registration:

(a) Opacity shall not exceed an average of forty percent (40%) in any one (1) six (6) minute

averaging period as determined in 326 IAC 5-1-4.

(b) Opacity shall not exceed sixty percent (60%) for more than a cumulative total of fifteen (15) minutes (sixty (60) readings as measured according to 40 CFR 60, Appendix A, Method 9 or fifteen (15) one (1) minute nonoverlapping integrated averages for a continuous opacity monitor) in a six (6) hour period.

C.2 Fugitive Dust Emissions [326 IAC 6-4]

The Registrant shall not allow fugitive dust to escape beyond the property line or boundaries of the property, right-of-way, or easement on which the source is located, in a manner that would violate 326 IAC 6-4 (Fugitive Dust Emissions).

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 7 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD SECTION D.1 OPERATION CONDITIONS

Facility Description [326 IAC 2-5.1-2(f)(2)] [326 IAC 2-5.5-4(a)(2)]:

(a) One (1) paint booth, identified as PB 101 (previously identified as #73), used for coating metal motor

coils, with a maximum usage rate of 0.37 gallons per hour, using air spray guns, with particulate emissions controlled by dry filters, and exhausting at stack #73. This unit was installed in 1994.

(b) One (1) paint booth, identified as PB 100 (previously identified as #74), used for coating metal motor

coils, with a maximum usage rate of 0.51 gallons of coating per hour, using air spray guns, with particulate emissions controlled by dry filters, and exhausting at stack #100. This unit was constructed in 1994.

(c) One (1) powder coating booth, identified as PB 102, with a maximum throughout rate of 60 pounds

per day, with particulate emissions controlled by a dust collector and exhausting inside the building. This unit was installed in 1980.

(d) One (1) injection molding unit, with a maximum usage rate of 0.0015 pounds of mold release agent

per hour. This unit was installed in 1960. (e) One (1) die-cast operations, constructed in 2015, used for die-casting zinc cap ends for motors, with

a maximum throughput rate of 60 pounds of zinc alloys per hour. (f) One (1) metal parts hobbing and stamping process, utilizing an oil-based machining fluid with a

maximum usage rate of 1.37 pounds per hour. This process was installed in 1965. (g) Twelve (12) plunger type containers, located throughout the plant, each with a maximum capacity of

one (1) gallon, used to dispense a non-halogenated solvent onto cloths for production cleaning, collectively identified as EU 103, with a maximum throughput rate of 0.92 pounds per hour. This operation was installed in 1980.

(h) One (1) mop water evaporator unit used for processing used oils, with a maximum process rate of 10

gallons of mop water per hour. Note: The used oils are disposed off-site. (i) Thirty-seven (37) natural gas-fired space heaters, with a maximum combined heat input capacity of

3.83 MMBtu per hour. These units were installed in 1994. (j) One (1) varnishing line, identified as EU 104, with a maximum usage rate of 0.60 gallons per hour,

using trickling method for varnish application and exhausting at stack #81. This unit was constructed in 2006.

(The information describing the process contained in this emissions unit description box is descriptive information and does not constitute enforceable conditions.)

Emission Limitations and Standards [326 IAC 2-5.1-2(f)(1)] [326 IAC 2-5.5-4(a)(1)] D.1.1 Volatile Organic Compounds (VOC) [326 IAC 8-2-9]

Pursuant to 326 IAC 8-2-9, the owner or operator shall not allow the discharge into the atmos-phere VOC from the two (2) paint booths (identified as PB 100 and PB 101), in excess of three and five-tenths (3.5) pounds of VOC per gallon of coating, excluding water, delivered to the applicator for forced warm air dried coatings.

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 8 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD D.1.2 Volatile Organic Compounds (VOC) [326 IAC 8-2-9]

To render the requirements of 326 IAC 8-2-9 (Miscellaneous Metal Coating Operations) not applicable to the one (1) varnishing line (identified as EU 104), the VOC usage for the varnishing line shall be less than 15.0 pounds per day.

Compliance with this limit renders the requirements of 326 IAC 8-2-9 (Miscellaneous Metal Coating Operations) not applicable.

D.1.3 Volatile Organic Compound (VOC) Limitations, Clean-up, and Work Practices Requirements

[326 IAC 8-2-9] Pursuant to 326 IAC 8-2-9(f), work practices shall be used to minimize VOC emissions from mixing operations, storage tanks, and other containers, and handling operations for coatings, thinners, cleaning materials, and waste materials. Work practices shall include, but not limited to, the following: (1) Store all VOC containing coatings, thinners, coating related waste, and cleaning

materials in closed containers. (2) Ensure that mixing and storage containers used for VOC containing coatings, thinners,

coating related waste, and cleaning materials are kept closed at all times except when depositing or removing these materials.

(3) Minimize spills of VOC containing coatings, thinners, coating related waste, and cleaning

materials. (4) Convey VOC containing coatings, thinners, coating related waste, and cleaning materials

from one (1) location to another in closed containers or pipes. (5) Minimize VOC emissions from the cleaning application, storage, mixing, and conveying

equipment by ensuring that equipment cleaning is performed without atomizing the cleaning solvent and all spent solvent is captured in closed containers.

D.1.4 Particulate [326 IAC 6-3-2]

Pursuant to 326 IAC 6-3-2 (Particulate Emission Limitations from Manufacturing Processes), the particulate emissions from any process not exempt under 326 IAC 6-3-1(b) or (c) and which has a maximum process weight rate less than 100 pounds per hour and the methods in 326 IAC 6-3-2(b) through (d) do not apply shall not exceed 0.551 pounds per hour. Therefore, the powder paint booth (identified as PB 103) shall not exceed 0.551 pounds per hour. The dust collector shall be in operation at all times when the powder paint booth is in operation to comply with this rule.

Compliance Determination Requirements [326 IAC 2-5.1-2(g)] [326 IAC 2-5.5-4(b)] D.1.5 Volatile Organic Compounds (VOC) [326 IAC 8-1-2] [326 IAC 8-1-4]

Compliance with the VOC content and usage limitations contained in Conditions D.1.1 and D.1.2 shall be determined pursuant to 326 IAC 8-1-4(a)(3)(A) and 326 IAC 8-1-2(a) by preparing or obtaining from the manufacturer the copies of the "as supplied" and "as applied" VOC data sheets. IDEM, OAQ reserves the authority to determine compliance using Method 24 in conjunction with the analytical procedures specified in 326 IAC 8-1-4.

Nidec Motor Corporation Administrative Amendment No. 051-35572-00048 Page 9 of 10 Princeton, Indiana Revised by: Brian Wright Registration No. R051-22457-00048 Permit Reviewer: ERG/SD Record Keeping and Reporting Requirements [326 IAC 2-5.1-2(g)] [326 IAC 2-5.5-4(b)] D.1.6 Record Keeping Requirements

(a) To document the compliance status with Condition D.1.1, the Registrant shall maintain records of the VOC content of each coating material and solvent used, less water.

(b) To document the compliance status with Condition D.1.2, the Registrant shall maintain

records in accordance with (1) through (3) below. These records shall be complete and sufficient to establish compliance with Condition D.1.2:

(1) Records of the amount of coating material and solvent used on a daily basis.

Records shall include purchase orders, invoices, and material safety data sheets (MSDS) necessary to verify the type and amount used, and solvent usage records shall differentiate between those added to coatings and those used as cleanup solvent;

(2) The daily cleanup solvent usage; and

(3) The total VOC usage for each day.


INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT OFFICE OF AIR QUALITY

Compliance and Enforcement Branch

REGISTRATION ANNUAL NOTIFICATION

This form should be used to comply with the notification requirements under 326 IAC 2-5.1-2(f)(3) and 326 IAC 2-5.5-4(a)(3).

Company Name: Nidec Motor Corporation

Address: 1551 East Broadway Street

City: Princeton, Indiana 47670

Phone Number: (812) 385-2564

Registration No.: R051-22457-00048

I hereby certify that Nidec Motor Corporation is : still in operation. no longer in operation. I hereby certify that Nidec Motor Corporation is : in compliance with the requirements

of Registration No. R051-22457-00048. not in compliance with the requirements

of Registration No. R051-22457-00048.

Authorized Individual (typed):

Title:

Signature:

Phone Number:

Date:

If there are any conditions or requirements for which the source is not in compliance, provide a narrative description of how the source did or will achieve compliance and the date compliance was, or will be achieved.

Noncompliance:

Appendix A: Emissions Calculations Page 1 of 10 TSD, Appendix ASummary

Company Name: Hurst ManufacturingAddress: 1551 East Broadway, Princeton, Indiana 47670

Registration: R051-22457-00048Administrative Amendment No.: 051-35572-00048

Reviewer: Brian WrightDate: 27-Mar-15

Emission Unit/Process PM PM10 PM2.5 SO2 NOx VOC CO Total HAPs46 Space Heaters 0.03 0.12 0.12 0.01 1.64 0.09 1.38 0.03 0.03 Hexane

Modified Paint Booth 100 1.35 1.35 1.35 0 0 6.58 0 1.19 0.80 ToluenePaint Booth 101 0.52 0.52 0.52 0 0 3.52 0 1.41 0.95 Glycol Ethers

Powder Paint Booth 102 11.0 11.0 11.0 0 0 0 0 0 0Solvent Based Cleaning Unit 103 0 0 0 0 0 3.22 0 0 0

Hobbing/Stamping Machine 0 0 0 0 0 2.57 0 0 0Injection Molding 0 0 0 0 0 0.01 0 0 0

Die Casting Process 2.0E-03 2.0E-03 2.0E-03 0 0 0 0 0 0New Varnishing Line 104 0 0 0 0 0 4.99 0 0 0

12.9 12.9 12.9 0.01 1.64 21.0 1.38 2.63 0.95 Glycol Ethers

Worst Single HAP

Appendix A: Emissions Calculations Page 2 of 10 TSD App ANatural Gas Combustion Only

MM BTU/HR <100




Heat Input Capacity HHV Potential ThroughputMMBtu/hr mmBtu MMCF/yr

mmscf3.8 1020 32.9

Pollutant PM* PM10* direct PM2.5* SO2 NOx VOC COEmission Factor in lb/MMCF 1.9 7.6 7.6 0.6 100 5.5 84

**see belowPotential Emission in tons/yr 0.03 0.12 0.12 0.01 1.64 0.09 1.38*PM emission factor is filterable PM only. PM10 emission factor is filterable and condensable PM10 combined.PM2.5 emission factor is filterable and condensable PM2.5 combined.**Emission Factors for NOx: Uncontrolled = 100, Low NOx Burner = 50, Low NOx Burners/Flue gas recirculation = 32

MethodologyAll emission factors are based on normal firing.MMBtu = 1,000,000 BtuMMCF = 1,000,000 Cubic Feet of GasEmission Factors are from AP 42, Chapter 1.4, Tables 1.4-1, 1.4-2, 1.4-3, SCC #1-02-006-02, 1-01-006-02, 1-03-006-02, and 1-03-006-03Potential Throughput (MMCF) = Heat Input Capacity (MMBtu/hr) x 8,760 hrs/yr x 1 MMCF/1,020 MMBtuEmission (tons/yr) = Throughput (MMCF/yr) x Emission Factor (lb/MMCF)/2,000 lb/ton

HAPS Calculations

Benzene Dichlorobenzene Formaldehyde Hexane Toluene Total - OrganicsEmission Factor in lb/MMcf 2.1E-03 1.2E-03 7.5E-02 1.8E+00 3.4E-03Potential Emission in tons/yr 3.45E-05 1.97E-05 1.23E-03 2.96E-02 5.59E-05 3.09E-02

Lead Cadmium Chromium Manganese Nickel Total - MetalsEmission Factor in lb/MMcf 5.00E-04 1.10E-03 1.40E-03 3.80E-04 2.10E-03Potential Emission in tons/yr 8.22E-06 1.81E-05 2.30E-05 6.25E-06 3.45E-05 9.01E-05Methodology is the same as above. Total HAPs 3.104E-02The five highest organic and metal HAPs emission factors are provided above. Worst HAP 2.960E-02Additional HAPs emission factors are available in AP-42, Chapter 1.4.

HAPs - Metals

HAPs - Organics

Appendix A: Emissions Calculations Page 3 of 10 TSD, Appendix A




Emission Unit Booth ID Material VOC Content (lb/gal)

Weight % Non-Volatiles (solids)

Max. Usage Rate (gal/hour)

PTE of VOC (lb/hour)

PTE of VOC (tons/year)

PTE of PM/PM10/PM2.5 (ton/year)

* Transfer Efficiency

PB 100 Black Polane T Black Enamel 2.71 63.0% 0.29 0.80 3.49 1.10 50%Two (2) Paint PB 100 Polane Plus Catalyst 2.56 63.0% 0.07 0.18 0.78 0.25 50%

Booths PB 100 Polane T66 Reducer 7.25 0.00% 0.07 0.53 2.30 0.00 50%Subtotal 1.50 6.58 1.35

PB 101 Polane T66 Reducer 7.25 0.00% 0.07 0.53 2.30 0.00 50%PB 101 * Grainger Gray Fast Dry 0.75 43.0% 0.37 0.28 1.22 0.52 50%

Subtotal 0.80 3.52 0.52Total 2.30 10.09 1.87

Actual VOC (lbs/day) for PB 100 = 11.6Actual VOC (lbs/day) for PB 101 = 6.18

* The VOC content for grainger gray fast dry includes both water and solvent.Material is sprayed manually using air spray gunsFor 326 IAC 8-2-9 compliance calculations, see page 13 of 10 TSD, Appendix A.

METHODOLOGYPTE of VOC (lb/hour) = VOC content (lb/gal) * Maximum usage rate (gal/hour)PTE of VOC (tons/year) = VOC content (lb/gal) * Maximum usage rate (gal/hour) * 8760 hours/year * 1 ton/2000 lbsPTE of PM/PM10/PM2.5 (tons/year) = VOC content (lb/gal) * Maximum usage rate (gal/hour) * Weight % non-volatiles (solids) * (1-Transfer efficiency %) * 8760 hours/year * 1 ton/2000 lbsActual VOC Emissions (lbs/day) = PTE of VOC (lbs/hour) * Actual hours of operation (2000 hours/year) * 1year/260 Days of operation





Emission Unit Booth ID Material Density (lb/gal)

Max. Usage Rate

(gal/hour)

Weight % Ethylbenzene

Weight % Toluene

Weight % Xylene

Weight % Glycol Ethers

PTE of Ethylbenzene

(tons/year)

PTE of Toluene

(tons/year)

PTE of Xylene (tons/year)

PTE of Glycol Ethers

(tons/year)

PTE of Total HAPs

(tons/year)

PB 100Black Polane T Black

Enamel 13.1 0.29 0.30% 2.00% 2.00% 0.00% 0.05 0.34 0.34 0.00 0.72

Two (2) Paint PB 100 Polane Plus Catalyst 9.32 0.07 0.00% 0.20% 0.00% 0.00% 0.00 0.01 0.00 0.00 0.01Booths PB 100 Polane T66 Reducer 7.25 0.07 0.00% 20.0% 0.00% 0.00% 0.00 0.46 0.00 0.00 0.46

Subtotal 0.05 0.80 0.34 0.00 1.19PB 101 Polane T66 Reducer 7.25 0.07 0.00% 20.0% 0.00% 0.00% 0.00 0.46 0.00 0.00 0.46PB 101 Grainger Gray Fast Dry 9.44 0.37 0.00% 0.00% 0.00% 6.21% 0.00 0.00 0.00 0.95 0.95

Subtotal 0.00 0.46 0.00 0.95 1.410.10 2.07 0.67 0.95

Highest Single HAP: Toluene (tons/year) = 2.07Combined HAPs (tons/year) = 3.79

METHODOLOGYPTE of HAPs (tons/year) = Density (lb/gal) * Maximum usage rate (gal/hour) * Weight % HAP * 8760 hours/year * 1 ton/2000 lbs





A. Potential to emit in tons per year estimated by using the amount of dust collectedEmission Unit Booth ID ** Dust Collected PTE of PM/PM10/PM2.5 PTE of PM/PM10/PM2.5

Before Control Before Control(lbs/hour) (lbs/hour) (tons/year)

Powder Paint Booth PB 102 2.25 2.50 11.0

Assume all dust collected is equal to PM, and all PM emissions are equal to PM10 emisisons.** The Dust collected data has been provided by the PermitteeControl efficiency (Dust Collector) = 90 percent

METHODOLOGYBefore Control PTE of PM/PM10/PM2.5 (lbs/hour) = Dust collected (lbs/hour) * 1/Control efficiency (%) Before Control PTE of PM/PM10/PM2.5 (tons/year) = Before Control PTE of PM/PM10/PM2.5 (lbs/hour) * 8760 hours/year * 1 ton/2000 lbs





Emission Unit Booth ID Material Actual Usage Rate Density Maximum Usage Rate Weight % VOC PTE of VOC(gal/year) (lb/gal) (lbs/hour) (tons/year)

Isopropyl Alcohol 223 6.55 0.716 100% 3.14Solvent Based EU 103 Acetone 58.0 6.55 0.186 0% 0.00

Cleaning Nitromethane 4.00 9.46 0.019 100% 0.081SUM 3.22

METHODOLOGYMaximum Usage Rate (lbs/hour) = Actual Usage Rate (gal/year) * 1/Actual Operating Hours (2,040 hours/year) * Density (lb/gal)PTE of VOC (tons/year) = Maximum Usage Rate (lbs/hour) * Weight % VOC * 8760 hours/year * 1 ton/2000 lbs.





Emission Material Actual Usage Rate Density Maximum Usage Rate Weight % VOC PTE of VOCUnit (gal/year) (lb/gal) (lbs/hour) (tons/year)

Hobbing/Stamping Dortan 1653 7.25 5.87 10% 2.57SUM 2.57

An oil based machining fluid is constantly flooded in the machines while the metal parts are hobbed and stamped in the production area.

METHODOLOGYMaximum Usage Rate (lbs/hour) = Actual Usage Rate (gal/year) * 1/Actual Operating Hours (2,040 hours/year) * Density (lb/gal)PTE of VOC (tons/year) = Maximum Usage Rate (lbs/hour) * Weight % VOC * 8760 hours/year * 1 ton/2000 lbs.





Process No. of Machines Material Max. Usage Rate Weight % PTE of VOCUsed (lbs/hour) VOC (tons/year)

Injection Molding 1.0 Mold Release 0.0015 98% 0.0064

There are no HAPs contained in the mold release agent used in the one injection molding unit at this plant.

METHODOLOGYPTE of VOC (tons/year) = Maximum usage rate (lbs/hour) * Weight % VOC * 8760 hours/year * 1 ton/2000 lbs.





Max. Throughput Rate Emission Factor PTE of PM/PM10/PM2.5Process Material PM/PM10/PM2.5 (tons/year)

(lbs/hour) (lb/ton)Die Cast Zinc Alloys 60.0 0.015 2.0E-03

Assume all PM emissions are equal to PM10Emission factor is from FIRE, Casting SSC # 3-04-008-73.

METHODOLOGYPTE of PM/PM10/PM2.5 (tons/year) = Maximum throughput rate (lbs/hour) * Emission factor (lb/ton) * 1 ton/2000 lbs * 8760 hours/year * 1 ton/2000 lbs.





Material Max. Throughput Max. Usage VOC Content PTE of VOC PTE of VOCProcess Unit ID (units/hour) (gal/unit) (lb/gal) (tons/year) (lbs/hour)

Varnishing Line EU 104 8183 SW Polyester Resin 60.0 0.01 1.90 4.99 1.144.99 1.14

Acutal Emissions of VOC (lbs/day) = 8.77

Varnish is applied via trickling method. The material used in this line does not contain any HAPs.

METHODOLOGYPTE of VOC (tons/year) = Maximum throughput (units/hour) * Maximum usage rate (gal/unit) * VOC content (lb/gal) * 8760 hours/year * 1 ton/2000 lbs.Actual VOC Emissions (lbs/day) = PTE of VOC (lbs/hour) * Actual hours of operation (2000 hours/year) * 1year/260 Days of operation

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT We Protect Hoosiers and Our Environment.

100 N. Senate Avenue • Indianapolis, IN 46204

(800) 451-6027 • (317) 232-8603 • www.idem.IN.gov

Michael R. Pence Thomas W. Easterly Governor Commissioner

SENT VIA U.S. MAIL: CONFIRMED DELIVERY AND SIGNATURE REQUESTED

TO: Randall R Floyd Nidec Motor Corp

1551 E Broadway Princeton, IN 47670DATE:

April 2, 2015 FROM: Matt Stuckey, Branch Chief Permits Branch Office of Air Quality SUBJECT: Final Decision Registration 051-35572-00048 Enclosed is the final decision and supporting materials for the air permit application referenced above. Please note that this packet contains the original, signed, permit documents. The final decision is being sent to you because our records indicate that you are the contact person for this application. However, if you are not the appropriate person within your company to receive this document, please forward it to the correct person. A copy of the final decision and supporting materials has also been sent via standard mail to: OAQ Permits Branch Interested Parties List If you have technical questions regarding the enclosed documents, please contact the Office of Air Quality, Permits Branch at (317) 233-0178, or toll-free at 1-800-451-6027 (ext. 3-0178), and ask to speak to the permit reviewer who prepared the permit. If you think you have received this document in error, please contact Joanne Smiddie-Brush of my staff at 1-800-451-6027 (ext 3-0185), or via e-mail at [email protected].

Final Applicant Cover letter.dot 6/13/2013

An Equal Opportunity Employer

Recycled Paper

mailto:[email protected]

Mail Code 61-53

IDEM Staff CDENNY 4/2/2015 Nidec Motor Corp 051-35572-00048 (final)

AFFIX STAMP HERE IF USED AS CERTIFICATE OF MAILING

Name and address of Sender ►

Indiana Department of Environmental Management Office of Air Quality – Permits Branch 100 N. Senate Indianapolis, IN 46204

Type of Mail:

CERTIFICATE OF MAILING ONLY

Line Article

Number Name, Address, Street and Post Office Address Postage Handing

Charges Act. Value (If Registered)

Insured Value

Due Send if COD

R.R. Fee

S.D. Fee S.H. Fee

Rest. Del. Fee Remarks

1 Randall R Floyd Nidec Motor Corp 1551 E Broadway Princeton IN 47670 (Source CAATS) 2 Greg David Operations Manager Nidec Motor Corp 1551 E Broadway Princeton IN 47670 (RO CAATS) 3 Princeton City Council and Mayors Office 603 South Main Street Princeton IN 47670 (Local Official) 4 Gibson County Health Department 203 S Prince Street, Suite A Princeton IN 47670 (Health Department) 5 Eric Anderson 25 Atlantic Avenue Erlanger KY 41018 (Affected Party) 6 Gibson County Commissioners 101 N. Main Street Princeton IN 47670 (Local Official) 7 Oakland City Town Council and Mayors Office 301 S Franklin Street Oakland City IN 47660 (Local Official) 8 Mr. Mark Wilson Evansville Courier & Press P.O. Box 268 Evansville IN 47702-0268 (Affected Party) 9 Mr. Bil Musgrove PO Box 520 Chandler IN 47610 (Affected Party) 10 David Boggs 216 Western Hills Dr Mt Vernon IN 47620 (Affected Party) 11 John Blair 800 Adams Ave Evansville IN 47713 (Affected Party) 12 13 14 15 Total number of pieces Listed by Sender

Total number of Pieces Received at Post Office

Postmaster, Per (Name of Receiving employee)

The full declaration of value is required on all domestic and international registered mail. The maximum indemnity payable for the reconstruction of nonnegotiable documents under Express Mail document reconstructing insurance is $50,000 per piece subject to a limit of $50, 000 per occurrence. The maximum indemnity payable on Express mil merchandise insurance is $500. The maximum indemnity payable is $25,000 for registered mail, sent with optional postal insurance. See Domestic Mail Manual R900, S913, and S921 for limitations of coverage on inured and COD mail. See International Mail Manual for limitations o coverage on international mail. Special handling charges apply only to Standard Mail (A) and Standard Mail (B) parcels.

FACSIMILIE OF PS Form 3877

notice of decision: approval -registrationpermits.air.idem.in.gov/35572f.pdf · 2015-04-02 ·...

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