technical support document 1. 1.1 andtechnical support document, permit action number:...

Technical Support Document, Permit Action Number: 05300384‐006 of 11

TECHNICAL SUPPORT DOCUMENT

For DRAFT/PROPOSED AIR EMISSION PERMIT NO. 05300384‐006

This technical support document (TSD) is intended for all parties interested in the draft/proposed permit and to meet the requirements that have been set forth by the federal and state regulations (40 CFR § 70.7(a)(5) and Minn. R. 7007.0850, subp. 1). The purpose of this document is to provide the legal and factual justification for each applicable requirement or policy decision considered in the preliminary determination to issue the draft/proposed permit. 1. General Information 1.1 Applicant and Stationary Source Location

Table 1. Applicant and Source Address

Applicant/Address Stationary Source/Address

(SIC Code: 2752)

Banta Corporation 111 South Wacker Drive Chicago, IL 60606‐4301

RR Donnelley Maple Grove7401 Kilmer Lane Maple Grove Hennepin County, Minnesota 55369

Contact: Mark P. McManusPhone: 763‐315‐8268

1.2 Facility Description RR Donnelley Maple Grove is a commercial printing facility. The Facility consists of heatset web offset lithographic printing presses, dryers, makeup air units, and pollution control equipment. The main sources of emissions are the press operations. VOC and HAP emissions from presses are controlled by thermal oxidizers. The Facility also has several activities that qualify as insignificant activities. 1.3 Description of the Activities Allowed by this Permit Action This permit action is the reissuance of the Part 70 operating permit. 1.4 Description of Notifications and Applications Included in this Action

Table 2. Notifications and Applications Included in this Action Date Received DQ# Application/Notification Type and description

01/25/2013 4277 Part 70 Reissuance Application

02/20/2014 4803 Reopening: Notice of Compliance, Revision of operating limits for thermal oxidizers

01/27/2009 2461 Reopening: Notice of Compliance, Revision of operating limits for thermal oxidizers, Approval of test frequency schedule for thermal oxidizers


1.5 Facility Emissions

Table 3. Total Facility Potential to Emit Summary

PM tpy

PM10 tpy

PM2.5 tpy

SO2 tpy

NOx tpy

CO tpy

CO2e tpy

VOC tpy

SingleHAP tpy

AllHAPs tpy

Total Facility Limited Potential Emissions

4.69 4.69 4.69 0.67 87.12 50.26 45994 229.35 9.0 21.10

Total Facility Actual Emissions (2013)

0.01 0.01 0.004 0.02 3.88 3.26 * 39.83 *

*Not reported in MN emission inventory.

Table 4. Facility Classification Classification Major Synthetic Minor/Area Minor/Area

PSD X

Part 70 Permit Program X

Part 63 NESHAP X

1.6 Changes to Permit The permit does not authorize any specific modifications, however, the MPCA has a combined operating and construction permitting program under Minnesota Rules Chapter 7007, and under Minn. R. 7007.0800, the MPCA has authority to include additional requirements in a permit. Under that authority, the following changes to the permit are also made through this permit action:

The permit has been updated to reflect current MPCA templates and standard citation formatting

Completed requirements and the requirements for equipment that has been removed have been deleted

Data has been updated for changes in operation and new information submitted by the permittee, including removal of press 2 (EU 002, 007) and press 8 (EU 073, 075) and changes in PTE

Some requirements have been reordered to help with clarity. Emissions from the thermal oxidizers were previously listed at the SV level, but were reordered to be listed at the EU level. EU 115, EU 116, and EU 117 correspond to CE 006, CE 007, and CE 008 respectively.

PTE calculations for PM2.5 and CO2 equivalence were added

44 Inkjet printers, classified as insignificant activities, were previously listed as EUs in the permit. These were removed from the permit entirely and noted in the IA emissions calculations. They were not removed from the facility. 21 additional Inkjet printers were added to the IA list with this permit.

Capped VOC limit was lowered as a result of moving inkjets to insignificant activities list

New minimum operating temperatures were set for thermal oxidizers based on performance test results. Accordingly, general control, monitoring, recordkeeping and reporting requirements remain in GP 005; whereas, minimum operating temperature requirements and performance testing requirements specific to each oxidizer are at the CE level.

2. Regulatory and/or Statutory Basis New Source Review The facility has taken limits for VOCs to avoid major source classification under New Source Review.


Part 70 Permit Program The facility is a major source under the Part 70 permit program. National Emission Standards for Hazardous Air Pollutants (NESHAP) The facility has taken limits to avoid major source classification under the NESHAP program (40 CFR § 63). The Permittee is not subject to the printing and publishing NESHAP because they are not a flexographic printer (as defined in 40 CFR § 63.822(a)). Compliance Assurance Monitoring (CAM) The CAM plan for this facility was submitted with permit action 005 and has not changed with this reissuance. The thermal oxidizers are used to comply with the noncombustion VOC caps, and are subject to CAM (40 CFR pt. 64). Press 5, Press 6, and Press 9 have controlled potential emissions greater than 100 tpy VOCs, and therefore are considered “large pollutant‐specific emission units”. All other presses have controlled potential emissions less than 100 tpy, and therefore are categorized as “other pollutant‐specific emission units”. Although CAM applies to emission units, the requirements of CAM are realized at the pollution control level. Press 6 vents to CE004 and CE005. All other presses have the ability to vent to CE006, CE007, and/or CE008. Additionally, the permit gives the facility the flexibility to reconfigure the control equipment. Therefore, the large pollutant specific emission units have the ability to vent to any of the thermal oxidizers. Therefore, all thermal oxidizers are included in a single CAM plan as allowed under 40 CFR § 64.4(g). The table below lists the sources which are subject to CAM, whether the source is a large pollutant specific emission unit (PSEU), and the monitoring for the applicable pollutants.

Table 5. CAM Summary

Unit Control CAM

Applicability Pollutant

EU 001 CE 006/007/008 Other VOC

EU 003 CE 006/007/008 Other VOC

EU 004 CE 006/007/008 Large VOC

EU 005 CE 004/005 Large VOC

EU 072 CE 006/007/008 Other VOC

EU 113 CE 006/007/008 Large VOC

For large pollutant specific emission units, records of the monitored parameter must be made at a minimum of 4 times per hour, or once every 15 minutes. For other PSEUs (not large), records must made at a minimum of once per 24 hours. Recordkeeping and monitoring are outlined in the CAM Plan. Minnesota State Rules Portions of the facility are subject to the following Minnesota Standards of Performance:

Minn. R. 7011.0610 Standards of Performance for Fossil‐Fuel‐Burning Direct Heating Equipment

Minn. R. 7011.0715 Standards of Performance for Post‐1969 Industrial Process Equipment


Table 6. Regulatory Overview of Facility Subject Item* Applicable Regulations Rationale

TF (Total Facility)

40 CFR § 52.21 and 40 CFR § 63.2 Title I limit to avoid PSD and NESHAP

Prevention of Significant Deterioration (PSD) and National Emission Standards for Hazardous Air Pollutants (NESHAPs). The facility cannot make any changes that would make them a major source under PSD or NESHAP until a permit amendment has been issued. PSD. Limits taken to avoid major source classification under PSD for combustion emissions. Changes and additions to combustion equipment at the facility are subject to the fuel capacity limit.

Minn. R. 7011.0715 Standards of Performance for Post 1969 Industrial Process Equipment. This applies to the press operations and is listed here to simplify the permit.

GP 001 (Total Facility VOC Limits)

40 CFR § 52.21 Title I limit to avoid PSD

Limits taken to avoid major source and modification classification under PSD for all noncombustion emissions of VOC. It is a 12‐month rolling limit due to substantial and unpredictable variations in operation. All emissions from press operations must be vented to control equipment meeting the requirements of GP 005 and the appropriate CE (CE 004‐008). Changes and additions to noncombustion VOC equipment at the facility are subject to the limits set by the caps and the requirements of GP 001.

40 CFR § 63.2 NESHAP for Source Categories. Limits taken to avoid major source classification under the NESHAPs for both total and individual HAPs. All emissions from press operations must be vented to control equipment meeting the requirements of GP 005 and the appropriate CE (CE 004‐008). Changes and additions to noncombustion HAP equipment at the facility are subject to the limits set by the caps and the requirements of GP 001.

GP 002 (Direct Heating Equipment)

40 CFR § 52.21 Title I limit to avoid PSD

Limits taken to avoid major source and modification classification under PSD for all combustion emissions. Changes and additions to the equipment are subject to the requirements of this group and requirements at the TF level.

GP 003 (Press Operations)


PSD and NESHAPs. Limits taken to avoid major source and modification classification under PSD and NESHAP program. This includes a requirement to control emissions from press operations.

Minn. R. 7017 Minnesota Performance Testing Rule. Requirements for initial performance tests of new oxidizers for VOC control efficiencies.

GP 005, CE 004‐008 (Thermal Oxidizers


PSD and NESHAPs. Control efficiency and other operating parameter requirements to limit VOC PTE to avoid major source classification under PSD and NESHAP program. Control efficiency for VOCs is assumed to be control efficiency achieved for HAPs. Changes and additions to control equipment are subject to the requirements of this group.


Subject Item* Applicable Regulations Rationale

40 CFR § 64 Compliance Assurance Monitoring (CAM). Compliance with the noncombustion equipment VOC and HAP cap is achieved by using thermal oxidizers. Potential VOC emissions are greater than 100 tpy, so CAM applies.

Minn. R. 7017.0020 Minnesota Performance Testing Rule. Requirements for submitting a testing frequency plan (new oxidizers only). Requirements for conducting reoccurring performance tests (CE 004‐008).

*Location of the requirement in the permit (e.g., EU, SV, GP, etc.). 3. Technical Information 3.1 Precap All additions, replacements, and changes to noncombustion VOC and HAP‐emitting equipment are covered under the VOC and HAP emissions caps. Press emissions are required to be vented to control equipment, and are subject to the requirements of the control equipment. Therefore, such additions and replacements would not require a major amendment solely due to an emissions increase, but they still need to be evaluated for the applicability of other amendments or requirements. Although changes are not preauthorized, the precap language gives the Permittee the flexibility to make changes without automatically triggering a major amendment. 3.2 One‐source / Two‐source Designation RR Donnelley – Maple Grove has been leasing out a portion of their land since 2003 to Wright‐Hennepin Cooperative Electric Association, a power utility. W‐H has five generators located on the leased land. Determination was previously made that these units will be permitted as a separate source from the RR Donnelley facility. W‐H is responsible for ownership of the air quality permit and subsequent compliance for these units, as specified in their easement agreement with RR Donnelley. These generators are covered under Registration Permit # 05301147, “Banta Generation Facility”. 3.3 Performance Testing and Control Efficiency Table 7 shows the performance tests for thermal oxidizer VOC destruction efficiency conducted since the last reissuance of the permit.

Table 7. Performance Tests for Thermal Oxidizers

Control Equipment ID

Required by Permit Action

Date Performed

VOC DestructionEfficiency Required

VOC Destruction Efficiency Achieved

Temperature(°F)

CE004/CE005 05300384‐005 10/01/2008 ≥ 95% 99.8% ≥ 1400

CE 006 05300384‐005 09/29/2008 ≥ 95% 98.4% ≥ 1430

CE 007 05300384‐005 09/29/2008 ≥ 95% 98.5% ≥ 1423

CE 008 05300384‐005 09/29/2008 ≥ 95% 98.8% ≥ 1420

CE004/CE005 05300384‐005 09/04/2014 ≥ 95% 99.9% ≥ 1400

CE 006 05300384‐005 09/05/2014 ≥ 95% 98.8% ≥ 1400

CE 007 05300384‐005 09/05/2014 ≥ 95% 98.8% ≥ 1400

CE 008 05300384‐005 09/05/2014 ≥ 95% 98.9% ≥ 1400

While the thermal oxidizers are required to have a destruction efficiency of ≥ 95% for both VOCs and HAPs, performance testing is used to verify the destruction efficiency for VOCs only, as testing for HAPs is not feasible. More information can be found in section 3.5 of this TSD.


Calculations in Attachment 1 of controlled PTE of all presses reflect the requirement for 95% VOC destruction efficiency. Based on the destruction efficiency for VOCs and the results the performance tests, a test frequency of every 5 years was established for CE 004‐008. The performance tests also establish new minimum operating temperatures for the thermal oxidizers. The new minimum temperatures were set by taking into account how close the Permittee tested to the limits as well as projected fluctuations in temperature readings. 3.4 Calculations of Potential to Emit Attachment 1 to this TSD contains detailed spreadsheets and supporting information. Note that VOC and HAP emissions from the presses and inkjets are based on the current coatings and formulations for this facility. The permittee assumed certain worst‐case material contents and ink usage rates when determining the annual and short term potential to emit of these units. These assumptions are shown in Attachment 1 and are documented in Appendix C of the permit. The permittee can change formulations or solutions, but changing to a material that has a higher content of any of the given pollutants or increasing the ink or solution usage rate is considered a change in method of operation that must be evaluated to determine if a permit amendment or notification is required. 3.5 Permit Calculations Section 3.6 of this TSD explains the monitoring requirements for this permit. For the VOC and HAP limits, monitoring includes calculating actual emissions on a monthly basis using specified formulas from Appendix A of the permit. These formulas are based on MPCA guidance. The calculations assume that 20% of ink VOCs are retained in the printed product and 100% of the VOC not retained is “carried over” to the dryer (i.e., capture efficiency), 70% of fountain solution VOCs are captured, 40% of blanket wash VOCs (with certain vapor pressure restrictions) is captured, and 50% of manual wash solution VOCs are assumed to stay in the waste rags shipped off site (with certain vapor pressure restrictions). These same assumptions are used for the HAP calculations. The vapor pressure restrictions apply to the HAPs as well. While these assumptions might not apply to all 188 listed HAPs, they do apply to the HAPs used at printers – all are similar solvent materials used in the various wash solutions. Due to the types of HAPs used at this facility, the VOC control efficiency was determined to be representative of the HAP efficiency. The Permittee’s justification for this assumption can be found in Attachment 1 to the TSD. Additionally, testing for specific HAP destruction efficiencies is not reasonable since they are small components of the vapor stream (e.g., only used in cleanup and a low percentage of those materials). 3.6 Monitoring In accordance with the Clean Air Act, it is the responsibility of the owner or operator of a facility to have sufficient knowledge of the facility to certify that the facility is in compliance with all applicable requirements. In evaluating the monitoring included in the permit, the MPCA considered the following:

the likelihood of the facility violating the applicable requirements;

whether add‐on controls are necessary to meet the emission limits;

the variability of emissions over time;

the type of monitoring, process, maintenance, or control equipment data already available for the emission unit;


the technical and economic feasibility of possible periodic monitoring methods; and

the kind of monitoring found on similar units elsewhere. Table 8 summarizes the monitoring requirements.

Table 8. Monitoring

EU/ GP/ CE Emission limit

(Basis) Additional Monitoring Discussion

Total Facility

PM/PM10 ≤ X gr/dscf, variable for each unit Opacity: ≤ 20% (Minn. R. 7011.0715)

none This limit applies to the presses. The presses emit VOCs which may also be considered PM/PM10 condensables, but because these process do not otherwise produce PM/PM10, and VOCs leaving the oxidizers are not likely to condense (low molecular weight hydrocarbons) it is unlikely that either of the limits would be violated.

GP 001: VOC Limits

VOC ≤ 234 tons per year, on a 12‐month rolling basis Limit to avoid PSD Individual HAP ≤ 9 tpy on a 12‐month rolling basis Limit to avoid NESHAP Total HAP ≤ 20 tpy on a 12‐month rolling basis Limit to avoid NESHAP

Recordkeeping: material usage; vapor pressure; coating contents; monthly calculations of emissions.

Records of press ink usage should be generated daily, based on log or meter readings. For fountain solution, automatic blanket wash, and manual blanket wash usage, records shall be generated each time the material is dispensed. Records should indicate the material used. The remaining materials are very low volume and will be based on monthly usage records. The vapor pressure of the wash solutions will be documented. Calculate Monthly VOC and HAP emissions using the formulas given in Appendix A of the permit. These calculations can be done using a combination of purchase, returns, and inventory records. Credit can be taken for waste materials collected and shipped off‐site (dispensed ‐ waste = emissions). Since this is done at most monthly, calculating emissions more frequently than monthly would result in large spikes (while waste is accumulating) and dips (when waste is shipped) – resulting in possible paperwork violations and days with negative emissions. For these reasons, 12‐month rolling limits are reasonable for this Facility. All units must be labeled and inventoried (at TF level). If the destruction efficiency variable, DE, from the formulas in Appendix A is not the same for all oxidizers operations in a given month, the daily records must be used for the monthly calculations to allocate ink usage to each oxidizer. An example of this situation would include an oxidizer breakdown.

GP 002: Direct Heating Equipment

Combustion Capacity ≤ 140 MMBtu/hr Limit to avoid NSR

Recordkeeping and notifications (see GP 003): annual reporting of total capacity.

The facility will maintain a list of all fuel burning equipment at the facility, including the fuel burning capacity of each piece of equipment and total facility combustion capacity. The Permittee is required to update the list prior to making any change, replacement, or modification to fuel burning equipment.


EU/ GP/ CE Emission limit

(Basis) Additional Monitoring Discussion

PM: ≤ variable depending on airflow Opacity: ≤ 20% (Minn. R. 7011.0610)

None All units use natural gas or propane; therefore, the likelihood of violating either of the emission limits is very small. The Permittee can demonstrate that these units will continue to operate such that emissions are well below the emission limits by only burning natural gas or propane.

GP 003: Press Operations

Replacement, reconfiguration, and installation of additional controls

Recordkeeping and Notification

7‐day notice prior to making a control equipment change as well as records and annual report of all changes made.

CE 004/CE 005: Thermal Oxidizers

VOC: Control Efficiency of ≥ 95% Limit to avoid NSR + NESHAP Temperature limit ≥ 1400 °F at the combustion chamber

Temperature monitoring, O & M, inspections, performance testing

Monitoring based on Compliance Assurance Monitoring for thermal oxidizers for large pollutant specific emission units is adequate to fulfill the requirements and is similar to the Minnesota Performance Standard for Control Equipment for thermal oxidizers. The Permittee is required to conduct performance test every 5 years.

CE 006, CE 007, & CE 008: Thermal Oxidizers

VOC: Control Efficiency of ≥ 95% Limit to avoid NSR + NESHAP Temperature limit ≥ 1400 °F at the combustion chamber

Temperature monitoring, O & M, inspections, performance testing

Monitoring based on Compliance Assurance Monitoring for thermal oxidizers for large pollutant specific emission units is adequate to fulfill the requirements and is similar to the Minnesota Performance Standard for Control Equipment for thermal oxidizers. The Permittee is required to conduct a performance test every 5 years.

*Location of the requirement in the permit (e.g., EU, SV, GP, etc.). 3.7 Insignificant Activities RR Donnelley Maple Grove has several operations which are classified as insignificant activities under the MPCA’s permitting rules. These are listed in Appendix B to the permit. The permit is required to include periodic monitoring for all emissions units, including insignificant activities, per EPA guidance. The insignificant activities at this Facility are only subject to general applicable requirements. Using the criteria outlined earlier in this TSD, the following table documents the justification why no additional periodic monitoring is necessary for the current insignificant activities. See Attachment 1 of this TSD for PTE information for the insignificant activities.


Table 9. Insignificant Activities

Insignificant Activity General Applicable

Emission limit Discussion

Fuel use: space heaters fueled by, kerosene, natural gas, or propane, less than 420,000 Btu/hr

PM ≤ 0.6 lb/MMBtu,Opacity ≤ 20% with exceptions (Minn. R. 7011.0510)

The facility has seven space heaters with a total capacity of 1.4 MMBtu/hr max input. For these units, based on the fuels used and EPA published emissions factors, it is highly unlikely that they could violate the applicable requirement. In addition, these types of units are typically operated and vented inside a building, so testing for PM or opacity is not feasible.

Brazing, soldering or welding equipment

PM, variable depending on airflow Opacity ≤ 20% (Minn. R. 7011.0715)

For these units, based on EPA published emissions factors, it is highly unlikely that they could violate the applicable requirement. In addition, these units are typically operated and vented inside a building, so testing for PM or opacity is not feasible.

Individual units, each of which have a potential to emit the following pollutants in amounts less than: 1) 4,000 lb/yr CO 2) 2,000 lb/yr of each NOx, SO2, PM, PM10, VOCs (including HAP VOCs), and O3 3) 1,000 tpy of CO2e

PM, variable depending on airflow Opacity ≤ 20% (Minn. R. 7011.0715 and Minn. R. 7011.0610)

The facility has several gluing operations, 65 inkjet printers, and 41 rooftop HVAC units. These units are not reasonably expected to generate particulate matter. Refer to gluing operations and inkjets PTE calculations. It is highly unlikely that they could violate the applicable requirement. In addition, all of these units are operated and vented inside a building, so testing for PM or opacity is not feasible.

Equipment venting PM/PM10 inside a building, provided that emissions from the equipment are: a). filtered through an air cleaning system; and b). vented inside of the building 100% of the time

PM, variable depending on airflow Opacity ≤ 20% (Minn. R. 7011.0715)

The facility has a trim paper collection system that is an insignificant activity under Minn. R. 7008.4110. It is controlled and vented internally. For these units, it is highly unlikely that they could violate the applicable requirement. In addition, these units are vented inside a building, so testing for PM or opacity is not feasible.

3.8 Permit Organization In general, the permit meets the MPCA Delta Guidance for ordering and grouping of requirements. One area where this permit deviates slightly from Delta guidance is in the use of appendices. While appendices are fully enforceable parts of the permit, in general, any requirement that the MPCA thinks should be electronically tracked (e.g., limits, submittals, etc.), should be in Table A or B of the permit. The main reason is that the appendices are word processing sections and are not part of the electronic tracking system. Violation of the appendices can be enforced, but the computer system will not automatically generate the necessary enforcement notices or documents. Staff must generate these. Appendix A contains specific calculation procedures for VOC and HAP emissions. These procedures are too complex to enter into Delta and must go in an appendix.


Appendix B is a listing of the facility’s Insignificant Activities and their applicable requirements. This is a fairly standard way to include these in the permit, since it is highly unlikely that the MPCA would need to have these as trackable items in Delta. Appendix C is a listing of maximum materials content and maximum ink usage rates for the printing presses, fountain solutions, and wash solutions at the time of permit issuance. These tables are too extensive to put into Delta. Appendix D is a printout from Delta of the control equipment and emissions unit description, forms GI‐05A and GI‐05B. This documents the correlation of specific emissions units to specific control equipment. Delta does not show this data as part of the “associated items” in Table A of the permit. Note that in Delta the combustion emissions from the thermal oxidizers (CE 006, CE 007, CE 008) are listed at the emissions unit level (EU 115, EU 116, EU 117), as control equipment cannot be listed on the pollutant form. Emissions listed from the dryers are combustion only with the exception of press dryer 6 (EU 010). Emissions from this unit include combustion emissions from CE 004/CE 005 as well as combustion emissions from the dryer itself. Emissions listed for the presses are from press operations, even though these emissions pass through both the dryers and thermal oxidizers. Combustion emissions from press dryer 6 include combustion emissions from CE004/005 because the thermal oxidizers are integrated into the dryers. The press has two webs with one dryer for each web, so press 6 dryer is physically two dryers. Because the webs run at the same time and vent out the same stack, the two dryers with integrated thermal oxidizers were permitted as one unit. Another area that deviates from the guidance is in the use of groups where the requirements in the group apply to the members of the group individually. This was done in order to shorten the permit and where no testing or tracking specific to a unit is in the permit (thereby reducing the likelihood that there where will be further unit‐specific requirements later). Specifically, all the general control, monitoring, recordkeeping, and reporting requirements associated with the thermal oxidizers are grouped. However, the minimum operating temperatures and performance test requirements are at the control equipment level because they are not the same for all the oxidizers. Additionally, because the permit gives the Permittee the flexibility to replace existing thermal oxidizers or add new thermal oxidizers, GP 005 contains the applicable requirements for any new thermal oxidizer. Any new thermal oxidizer would automatically be subject to the requirements of GP 005. It should also be noted that CE 004 and CE 005 requirements are listed separately at the control equipment level for consistency; however, these two oxidizers operate at the same conditions and are tested as one unit, CE 004/005. 3.9 Comments Received Public Notice Period: <start date> ‐ <end date> EPA 45‐day Review Period: <start date> ‐ <end date> This section will be completed after the referenced review periods.


4. Conclusion Based on the information provided by RR Donnelley, the MPCA has reasonable assurance that the proposed operation of the emission facility, as described in the Air Emission Permit No. 05300384‐006 and this TSD, will not cause or contribute to a violation of applicable federal regulations and Minnesota Rules. Staff Members on Permit Team: Marta Little (permit engineer)

Brent Rohne (enforcement) Curtis Stock (compliance) Bruce Braaten (peer reviewer) Beckie Olson (permit writing assistant) Laurie O’Brien (administrative support)

AQ File No. 2032A; DQ 4277 Attachments: 1. PTE Summary Calculation Spreadsheet 2. Letter from Permittee for Justification of HAPs Destruction

3. Facility Description and CD‐01 Forms 4. Compliance Assurance Monitoring Plan

Attachment 1

PTE Summary Calculation Spreadsheets

RR Donnelley Maple Grove PTE Summary

This includes control and permit limits for VOC as well as HAPs. Permit limits are applied at the "total" cell

Uncontrolled VOC Controlled, Limited VOC Uncontrolled Total HAP Controlled, Limited Total HAP

EU lb/hr tpy lb/hr tpy lb/hr tpy lb/hr tpy lb/hr tpy

001 207 908 12 53 0.98 4.28 0.33 1.43 0 0

003 229 1005 13 57 1.16 5.07 0.39 1.70 0 0

004 496 2174 32 140 3.03 13.26 1.01 4.44 0 0

005 495 2168 31 137 2.69 11.79 0.90 3.95 0 0

006 0.06 0.27 0.06 0.27

008 0.08 0.36 0.08 0.36009 0.14 0.60 0.14 0.60010 0.06 0.28 0.06 0.28

072 255.68 1119.90 15.35 67.23 1.69 7.42 0.57 2.49 0 0074 0.033 0.145 0.033 0.145

108 0.014 0.062 0.014 0.062

109 0.014 0.062 0.014 0.062

113 661.79 2898.629 42.019 184.045 4.24 18.58 1.42 6.22

114 0.572 2.504 0.572 2.504

Total 1684.0 10277.1 146.9 643.5 13.8 60.4 4.6 20.2 0.0 0.0

IAs 1.192 5.223 0.982 4.301

Total 148.1 648.7 5.6 24.5

The dryer emissions are combustion from the dryer and oxidizer combined. All solvent emissions are assigned to the press.

See the combustion spreadsheets for PM/PM10, SO2, NOx, and CO.

HAP emissions for combustion units were not calculated on an emission unit basis, but rather based on cumulative capacity

These emissions are added to total HAP emissions. See combustion spreadsheets for more detail.

Methanol

EU 011-047 removedEU 057-071 removedEU 048-056, 076-107, 110-112 relabeled as IA

RR Donnelley Maple Grove PTE Summary

Emissions Summary for Press HAP Emissions

Uncontrolled Ethylene Glycol Controlled Ethylene Glycol

EU lb/hr tpy lb/hr tpy lb/hr tpy lb/hr tpy001 0.49 2.14 0.16 0.72 0.98 4.28 0.33 1.43003 0.58 2.54 0.19 0.85 1.16 5.07 0.39 1.70004 1.51 6.63 0.51 2.22 3.03 13.26 1.01 4.44005 1.35 5.90 0.45 1.97 2.69 11.79 0.90 3.95072 0.85 3.71 0.28 1.24 1.69 7.42 0.57 2.49113 2.12 9.29 0.71 3.11 4.24 18.58 1.42 6.22

Total 6.9 30.2 2.3 10.1 13.8 60.4 4.6 20.2

Uncontrolled Glycol Ethers (total HAPS)

Controlled Glycol Ethers (total HAPs)

RR Donnelley Maple GrovePTE from Press Operations

Emissions from Press Operations (EUs 001, 003-006, 008-010, 072, 74, 113)

Printing OperationsThe Permittee completed calculations using the MPCA guidance for printers. The basic procedure is a mass balance approach assuming certain percentages ofmaterials are captured by the dryer and vented to the control device. alculations are based on worst-case material contents (e.g., highest VOC, highest HAPs). The controlled VOC emissions are not considered condensable particulate for applicability purposes.

VOC Emissions

Uncontrolled VOC PTE (lb/hr) Uncontrolled Controlled* Controlled

EU Description InksFountain Solution Hand Wash Blanket Wash Total

VOC (tpy) Total

VOC (lb/hr) Total

VOC (tpy) Total

001 Press 1 203 1.81 2.84 0.00 207 908 12 53003 Press 4 225 2.15 2.19 0.00 229 1005 13 57004 Press 5 480 5.61 4.67 6.14 496 2174 32 140005 Press 6 480 4.99 4.56 5.45 495 2168 31 137072 Press 7 249 3.14 3.71 0.00 256 1120 15 67113 Press 9 640 7.86 10.40 3.53 662 2899 42 184

Total 2276 26 28 15 2345 10273 146 639*Control includes: Fountain solution carryover to dryer 70%Automatic blanket wash carryover to dryer 40%Hand wash remaining in rags 50%Control efficiency of oxidizers 95%

Note: To determine maximum potential VOCs, the calculations use the actual usage of fountain and wash solutions, divided by the hours each press operated, multiplied by 8760 hours per year. This only accounts for scaling up annually, and does not account for the possibility of using more on anhourly basis. These numbers are adjusted by 25% here. Even so, this does not really represent the hourly potential. Since for example, all of the wash solution would be used in a short period of time between press runs, so dividing the usage by the hours the press ran underestimates the hourly potential.However, this does give us a reasonable estimate of the annual potential emissions, which is the parameter used by the applicable regulations.CondensablesVOC emissions may also be PM/PM10 condensables – if they would show up in a PM/PM10 test as condensable, they should be counted as such

for the purposes of permitting applicability and determining compliance.

Since these processes don’t otherwise generate particulate matter, stack testing for PM/PM10 is not likely.

In terms of applicability, it was decided that for these processes, the VOC leaving the oxidizers is not likely to condense

(low molecular weight hydrocarbons) and should not be counted as PM/PM10.


PTE from the Inks was calculated using max ink usage and % VOC by weight from the table below. (From permit appendix C)

The table is located in the appendices to the permit. % VOC was obtained from the material safety data sheets (MSDS) for the inks.

PRESS INKS:

Emission Unit

Max

Materials Content

Max Ink Usage

(% VOC by weight) (lb/hr)

1 36.9 563

3 36.9 625

4 36.9 1333

5 36.9 1333

72 36.9 691

113 36.9 1777

FOUNTAIN AND WASH SOLUTIONS:

Solution

Max Materials Content (lbs VOC/gal)

Max Gallons of

Solvent (gal/yr)

Fountain Solution 1.31

204,730 (gal conc.)

Hand Wash 6.5 24614

Auto Wash 6.72 35320


HAP EmissionsThe Permittee submitted HAP PTE calculations. The permit gives the same credit for carryover or control of HAPs as for VOC.The Permittee submitted a technical justification for this. It is attached to these calculations.No HAPs are in the inks, only the fountain solutions, hand wash, and some auto washes. Maximum potential usage was adjusted by 25% (same as for the VOCs, refer to justification for VOCs).

Fountain Sol'n concentrate:8.838 lb/gal used for calculations

Fountain Solution Ethylene Glycol

EU DescriptionMax Usage (gal conc)

Adjusted Max Usage (lb/hr)

Ethylene Glycol (lb/hr)

Ethylene Glycol (tpy)

Ethylene Glycol (lb/hr)

Ethylene Glycol (tpy)

001 Press 1 9676.00 12.20 0.49 2.14 0.16 0.72003 Press 4 11483.00 14.48 0.58 2.54 0.19 0.85004 Press 5 29996.00 37.83 1.51 6.63 0.51 2.22005 Press 6 26681.00 33.65 1.35 5.90 0.45 1.97072 Press 7 16800.00 21.19 0.85 3.71 0.28 1.24113 press 9 42048.00 53.03 2.12 9.29 0.71 3.11

total 136684.00 172.38 6.90 30.20 2.31 10.12

Fountain Solution Glycol Ethers (total HAPs)

EU DescriptionMax Usage (gal conc)

Adjusted Max Usage (lb/hr)

Glycol Ehters (lb/hr)

Glycol Ethers (tpy)

Glycol Ethers (lb/hr)

Glycol Ethers (tpy)

001 Press 1 9676.00 12.20 0.98 4.28 0.33 1.43003 Press 4 11483.00 14.48 1.16 5.07 0.39 1.70004 Press 5 29996.00 37.83 3.03 13.26 1.01 4.44005 Press 6 26681.00 33.65 2.69 11.79 0.90 3.95072 Press 7 16800.00 21.19 1.69 7.42 0.57 2.49113 press 9 42048.00 53.03 4.24 18.58 1.42 6.22

total 136684.00 172.38 13.79 60.40 4.62 20.23

Uncontrolled Controlled

Uncontrolled Controlled

RR Donnelley Maple GrovePTE from Combustion

EUs 006, 008-010, 74, 114 and CEs 006-008Combustion calculations based on equipment capacity and EPA’s published emissions factors for fuels burned. The dryers, oxidizers, and makeup air units only burn natural gas and propane.

The units burn natural gas and propane only. Chose highest PTE for each pollutant (shaded).The total capacity is limited PTE is calculated using EPA published emissions factors and fuel parameters from AP-42.(Supplement E of 5th edition)Dryers Oxidizers Makeup Air Unit

83.386 MMBtu/hr total 9.9 MMBtu/hr total 5.184 MMBtu/hr totalEach EU Each CE Each EU

9.76 MMBtu/hr 006 1.5 MMBtu/hr 006 2.592 MMBtu/hr 1084.2 MMBtu/hr 007 2.592 MMBtu/hr 109

10.92 MMBtu/hr 008 4.2 MMBtu/hr 00820.9 MMBtu/hr 009

11.874 MMBtu/hr 010*6.048 MMBtu/hr 074

23.884 MMBtu/hr 114*includes CEs 004 and 005 Current Capacity: Total Limited Capacity:

98.47 140 MMBtu/hrgas heat value 1050 Btu/scfNatural Gas Natural Gas (<100 MMBtu/hr)

NO2 EFlb/hr tpy lb/hr tpy (lb/MMSCF)

CE 006 0.011 0.048 0.143 0.626 PM 7.6CE 007 0.030 0.133 0.400 1.752 PM10 7.6CE 008 0.030 0.133 0.400 1.752 NO2 100EU 006 0.071 0.309 0.930 4.071 SO2 0.6EU 008 0.079 0.346 1.040 4.555 CO 84EU 009 0.151 0.663 1.990 8.718 VOC 5.5EU 010 0.086 0.376 1.131 4.953EU 074 0.044 0.192 0.576 2.523EU 108 0.019 0.082 0.247 1.081EU 109 0.019 0.082 0.247 1.081EU 114 0.173 0.757 2.275 9.963Unlimited Total 0.713 3.122 9.378 41.076Limited Total 1.013 4.438 13.333 58.400

PM/PM10/PM2.5


Natural Gas Continued VOC

lb/hr tpy

SO2 CO CE 006 0.008 0.034

lb/hr tpy lb/hr tpy CE 007 0.022 0.096

CE 006 0.0009 0.0038 0.120 0.526 CE 008 0.022 0.096

CE 007 0.0024 0.0105 0.336 1.472 EU 006 0.051 0.224

CE 008 0.0024 0.0105 0.336 1.472 EU 008 0.057 0.251

EU 006 0.0056 0.0244 0.781 3.420 EU 009 0.109 0.480

EU 008 0.0062 0.0273 0.874 3.826 EU 010 0.062 0.272

EU 009 0.0119 0.0523 1.672 7.323 EU 074 0.032 0.139

EU 010 0.0068 0.0297 0.950 4.161 EU 108 0.014 0.059

EU 074 0.0035 0.0151 0.484 2.119 EU 109 0.014 0.059

EU 108 0.0015 0.0065 0.207 0.908 EU 114 0.125 0.548

EU 109 0.0015 0.0065 0.207 0.908

Unlimited Total 0.516 2.259

EU 114 0.0136 0.0598 1.911 8.369

Limited Total 0.733 3.212

Unlimited Total 0.056 0.246 7.878 34.504Limited Total 0.0800 0.350 11.200 49.056


EUs 006, 008-010, 74, 114 and CEs 006-008Combustion calculations are based on equipment capacity and EPA’s published emissions factors for the fuels burned. The dryers, oxidizers, and makeup air units only burn natural gas and propane.

The units burn natural gas and propane only. Chose highest PTE for each pollutant (shaded).The total capacity is limited PTE is calculated using EPA published emissions factors and fuel parameters from AP-42.(Supplement E of 5th edition)Dryers Oxidizers Makeup Air Unit

83.386 MMBtu/hr total 9.9 MMBtu/hr total 5.184 MMBtu/hr totalEach EU Each CE Each EU

9.76 MMBtu/hr 006 1.5 MMBtu/hr 006 2.592 MMBtu/hr 10810.92 MMBtu/hr 008 4.2 MMBtu/hr 007 2.592 MMBtu/hr 109

20.9 MMBtu/hr 009 4.2 MMBtu/hr 00811.874 MMBtu/hr 010*

6.048 MMBtu/hr 07423.884 MMBtu/hr 114

*includes CEs 004 and 005 Current Capacity: Total Limited Capacity:98.47 140 MMBtu/hr

Propane propane heat value 91.50 MMBtu/1000galNO2 Propane (<100 MMBtu/hr)

lb/hr tpy lb/hr tpy EFCE 006 0.011 0.050 0.213 0.933 (lb/1000gal)CE 007 0.032 0.141 0.597 2.614 PM 0.7CE 008 0.032 0.141 0.597 2.614 PM10 0.7EU 006 0.075 0.327 1.387 6.074 NO2 13EU 008 0.084 0.366 1.551 6.795 SO2 0.1EU 009 0.160 0.700 2.969 13.006 CO 7.5EU 010 0.091 0.398 1.687 7.389 VOC 0.5EU 074 0.046 0.203 0.859 3.764 revisedEU 108 0.020 0.087 0.368 1.613 AP-42, Table 1.5-1EU 109 0.020 0.087 0.368 1.613 7/22/2014

EU 114 0.183 0.800 3.393 14.863Unlimited Total 0.753 3.300 13.990 61.277Limited Total 1.071 4.691 19.891 87.121

Chose highest PTE between the two fuels for each pollutant (shaded).

PM/PM10/PM2.5


SO2 CO VOC

lb/hr tpy lb/hr tpy lb/hr tpy

CE 006 0.002 0.007 0.123 0.539 CE 006 0.008 0.036

CE 007 0.005 0.020 0.344 1.508 CE 007 0.023 0.101

CE 008 0.005 0.020 0.344 1.508 CE 008 0.023 0.101

EU 006 0.011 0.047 0.800 3.504 EU 006 0.053 0.234

EU 008 0.012 0.052 0.895 3.920 EU 008 0.060 0.261

EU 009 0.023 0.100 1.713 7.503 EU 009 0.114 0.500

EU 010 0.013 0.057 0.973 4.263 EU 010 0.065 0.284

EU 074 0.007 0.029 0.496 2.171 EU 074 0.033 0.145

EU 108 0.003 0.012 0.212 0.931 EU 108 0.014 0.062

EU 109 0.003 0.012 0.212 0.931 EU 109 0.014 0.062

EU 114 0.026 0.114 1.958 8.575 EU 114 0.131 0.572

Unlimited Total 0.108 0.471 8.071 35.352

Unlimited Total 0.538 2.357

Limited Total 0.153 0.670 11.475 50.262

Limited Total 0.765 3.351

Dryers Oxidizers Makeup Air Units83.386 MMBtu/hr total 9.9 MMBtu/hr total 5.184 MMBtu/hr total

Total Limited Capacity: 140 MMBtu/hr

gas heat value 1050 Btu/scf

Total HAP Emissions Factor (sum of all HAP numbers) is: 1.888402 lb/MMcf

Unlimited Limited

(no HAP factors available for propane, so use natural gas) 0.1771 lb/hr 0.2518 lb/hr

0.7757 tpy 1.1028 tpy

Applicable rule limits for the oxidizers and dryers are based on total airflow.

The dryers and oxidizers vent out the same stacks. Combined stack allowable emissions are calculated below.

SVAirflow (acfm) gas temp DSCFM

Table 2* (gr/dscf)

Table 2* (lb/hr) PTE (lb/hr)

009 23251 800 9740 0.0984 8.214 0.086

012 5600 350 3650 0.1000 3.128 0.589

014 42900 450 24885 0.0733 15.630 0.589

015 42900 450 24885 0.0733 15.630 0.589

The potential to emit is never more than 25% of the allowable rate.

* Table 2 from Minn. R. 7011.0735


Total Current Capacity 98.47 million Btu/hrTotal Limited Capacity 140.0 million Btu/hrFuel Type Natural Gas (no HAP factors available for propane, so use natural gas)Heat Value: 1,050 Btu/cf

Calculations Summary: Source of Data - AP-42, table 1.4-3 dated 7/98HAP Name CAS AP-42 Maximum Maximum Limited Limited

Emission Uncontrolled Uncontrolled Emissions EmissionsFactor Emissions Emissions

(lbs/million scf) (lb/hr) (tons/yr) (lb/hr) (tons/yr)POM* NA 8.63E-05 8.09E-06 3.54E-05 1.15E-05 5.04E-05Benzene 71-43-2 2.10E-03 1.97E-04 8.63E-04 2.80E-04 1.23E-03Formaldehyde 50-00-0 7.50E-02 7.03E-03 3.08E-02 1.00E-02 4.38E-02Hexane 110-54-3 1.80E+00 1.69E-01 7.39E-01 2.40E-01 1.05E+00Naphthalene 91-20-3 6.10E-04 5.72E-05 2.51E-04 8.13E-05 3.56E-04Toluene 108-88-3 3.40E-03 3.19E-04 1.40E-03 4.53E-04 1.99E-03Arsenic 7440-38-2 2.00E-04 1.88E-05 8.22E-05 2.67E-05 1.17E-04Beryllium 7440-41-7 1.20E-05 1.13E-06 4.93E-06 1.60E-06 7.01E-06Cadmium 7440-43-9 1.10E-03 1.03E-04 4.52E-04 1.47E-04 6.42E-04Chromium 7440-47-3 1.40E-03 1.31E-04 5.75E-04 1.87E-04 8.18E-04Cobalt 7440-48-4 8.40E-05 7.88E-06 3.45E-05 1.12E-05 4.91E-05Manganese 7439-96-5 3.80E-04 3.56E-05 1.56E-04 5.07E-05 2.22E-04Mercury 7439-97-6 2.60E-04 2.44E-05 1.07E-04 3.47E-05 1.52E-04Nickel 7440-02-0 2.10E-03 1.97E-04 8.63E-04 2.80E-04 1.23E-03Selenium 7782-49-2 2.40E-05 2.25E-06 9.86E-06 3.20E-06 1.40E-05SUM 1.8868 0.1769 0.7750 0.2516 1.1019

max ind. HAP 0.7394 1.05E+00*POM = Sum of pollutants identified as POM in AP-42 Table 1.4-3, dated 3/98:Acenaphthene 1.80E-06 Fluoranthene 3.00E-06Acenaphthylene 1.80E-06 Fluorene 2.80E-06Anthracene 2.40E-06 Indo(1,2,3-ed)pyrene 1.70E-06Benz(a)anthracene 1.80E-06 2-Methylnaphthalene 2.40E-05Benzo(a)pyrene 1.20E-06 3-Methylchloranthrene 1.80E-06Benzo(b,k)fluoranthene 1.80E-06 from MPCA summary Phenanthrene 1.70E-05Benzo(g,h,i)perylene 1.20E-06 Pyrene 5.00E-06Chrysene 1.80E-06 8.63E-05Dibenzo(a,h)anthrancene 1.20E-067,12-Dimethylbenz(a)anthracene 1.60E-05

POM does not include naphthalene

RR Donnelley Maple GroveInsignificant Activities

The Facility has the following insignificant activities under Minn. R. 7007.1300, subp. 3:

Rule Activity Pollutants7007.1300 subp. 3(A) space heaters that burn natural gas combustion pollutants

total of 1.4 MMBtu/hr

7008.4110 controlled particulate sources venting inside 100% PM/PM10

total of 34650 acfm

7007.1300 subp. 3(H) brazing, soldering or welding equipment PM/PM10

7007.1300 subp. 3(I) VOC

Combustion IAsAll of the combustion units burn natural gas. PTE is calculated using EPA published emissions factors from

the most recent version of AP-42. (Supplement E of 5th edition)

Total Capacity of subp. 3(A)

1.400 MMBtu/hr

gas heat value 1050 Btu/scf

Natural Gas (<100 MMBtu/hr)

EF

(lb/MMSCF) lb/hr tpy

PM 7.6 0.0101 0.0444

PM10 7.6 0.0101 0.0444

NO2 100 0.1333 0.5840

SO2 0.6 0.0008 0.0035

CO 84 0.1120 0.4906

VOC 5.5 0.0073 0.0321

From previous

sheet, total HAP

factor: 1.888402 lb/MMcf 0.003 lb/hr 0.01 tpy

Paper HandlingNo PTE calculations available, but total airflow into each filter house can be used to calculate a controlled and uncontrolled PTE.(emissions commonly achievable for baghouses 0.01 gr/dscf)(control efficiency for PM fabic filter (not total inclosure, uncertified hood) from control equipment rule 59 %)

Air Flow CFM lb/hr tpy lb/hr tpy

filter house 1 12977 1.11 4.87 2.71 11.88filter house 2 18019 1.54 6.76 3.77 16.50filter house 3 12662 1.09 4.75 2.65 11.59

filter house 1 draws air from 3 presses and 10 bindery linesfilter house 2 draws air from filter house 1, 2 stitchers, and baler scavenger fansfilter house 3 draws air from press 5 & 6 and 7 bindery lines

PTE thresholds: gluing, 65 water-based inkjet printers,

and 41 HVAC units

Controlled Emissions Precontrolled Emissions


Gluing

The calculations are summarized hereActual Usage in 2012 2503 lb 44.79 lb/yrVOC Content 0.3 %VOC Usage 7.509 lb/yr PTE 0.022 tpy

No HAPs are in these materials.

Inkjet PrintersOld EUs 048-056, 076-107, 110-112, and 21 new unitsPTE calculations are based on a mass balance (e.g., machine capacity x maximum content) and are completed

for each type of inkjet printer.

The calculations are divided by types of unit.

Scitex 5122Old EUs 076-079, 110-112, 2 new, total of 9 units

VOC Methanol

lb/hr tpy lb/hr tpy

Per Unit 0.02 0.09 0.02 0.07

Total 0.18 0.79 0.15 0.65

Scitex 5120Old EUs 048-056 and 080-107, 13 new, total of 50 units

VOC Methanol

lb/hr tpy lb/hr tpy

Per Unit 0.0100 0.04 0.01 0.04

Total 0.50 2.19 0.42 1.82

Videojet 270New: total of 6 units

VOC Methanol

lb/hr tpy lb/hr tpy

Per Unit 0.0100 0.04 0.01 0.04

Total 0.50 2.19 0.42 1.82

Inkjet Totals:VOC Methanol

lb/hr tpy lb/hr tpy

Total: 1.1800 5.1684 0.9794 4.2898

Adjusted by hours and factor of 4


Total Calculated IA PTElb/hr tpy

PM 3.75 16.43

PM10 3.75 16.43

NO2 0.13 0.58

SO2 0.00 0.00

CO 0.11 0.49

VOC 1.19 5.22

HAP 0.982 4.30

RR Donnelley Maple Grove 05300384 McManus 6/27/2014

Plant Space Heaters included in Insignificant activities

Number Brand Model Serial Location/Use

Heating Capacity (Btu/h) Installed Date Removed Date

1 Roberts Gordon ET3‐175 9042‐135‐175‐0005 NW corner 175,000 Feb‐94

2 Gordon Ray RTH150A 109681 North Center 150,000 Feb‐96

3 Gordon Ray RTH150A 98717 NE corner 150,000 Feb‐96

4 Gordon Ray RTH150A 1077 NE corner 150,000 Feb‐96

5 Gordon Ray RTH150A 1078 North Center 0 Feb‐96 retired* 20006 Gordon Ray RTH150A 1081 NE corner 0 Feb‐96 retired* 20007 Gordon Ray RTH150A 72487 NE corner 0 Feb‐96 retired* 20008 Gordon Ray RTH150A 72507 NE corner 0 Feb‐96 retired* 20009 Gordon Ray RTH150A 89105 NE corner 0 Feb‐96 retired* 200010 Gordon Ray RTH150A 72496 NE corner 0 Feb‐96 retired* 200011 Gordon Ray CTH2150 900485040 SE whse 150,000 Jun‐90

12 Gordon Ray CTH2150 900485045 SE whse 150,000 Jun‐90

13 Gordon Ray ER175 94030351750003 SW corner 175,000 Jun‐94

14 Gordon Ray ER175 94030351750004 SW corner 0 Jun‐94 Removed 2004

Total 1,100,000

For Insignificant Activity: Individual limit < 420,000

Total limit <1,400,000

* Retired heaters are out of service and cannot be used, therefore they are not included in the PTE

Emission SourceOperating

HoursDesign Capacity Fuel High heat Value

CO2 emission

factor

N2O emission

factor

CH4 emission

factor

CO2 emissions

(TPY)

N2O

emissions

(TPY)

CH4

emissions

(TPY)

Total GHG

(TPY)CO2e (TPY)

Units MMBTU/hr mmBTU/scf kg CO2/MMBTU kg N2O/MMBTU kg CH4/MMBTU

EU ‐006 (Press 1 Dryer) 8760 9.76 Natural Gas 0.001050 53.02 0.0001 0.001 4533.08 0.009 0.085 4533.18 4558.8

EU‐008 (Press 4 Dryer) 8760 10.92 Natural Gas 0.001050 53.02 0.0001 0.001 5071.85 0.010 0.096 5071.96 5100.6


EU‐010 (Press 6 Dryer & Emissions Control) 8760 11.87 Natural Gas 0.001050 53.02 0.0001 0.001 5514.94 0.010 0.104 5515.06 5546.2



CE‐006 (Oxidizer) 8760 1.50 Natural Gas 0.001050 53.02 0.0001 0.001 696.68 0.001 0.013 696.70 700.6



EU‐108 (Make‐up Air Unit East 17B) 8760 2.59 Natural Gas 0.001050 53.02 0.0001 0.001 1203.87 0.002 0.023 1203.89 1210.7

EU‐109 (Make‐up Air Unit West 22) 8760 2.59 Natural Gas 0.001050 53.02 0.0001 0.001 1203.87 0.002 0.023 1203.89 1210.7

TOTAL 46,663.81 0.09 0.88 45,735.85 45,994.11

Space Heaters (Insignificant Activities) 8760 2.00 Natural Gas 0.001050 53.02 0.0001 0.001 928.91 0.002 0.018 928.93 934.2

GWP Values

Name CAS No.

Chemical

Formula GWP

Carbon Dioxide 124‐38‐9 CO2 1

Methane 74‐82‐8 CH4 25

Nitrous oxide 10024‐97‐2 N2O 298

Emission factors used are from Table C‐1 of 40 CFR Part 98

Tier 1 calculation method from 40 CFR §98.33Eq C-1b:CO2 = 1 x 10^‐3 * Gas * EF

Where

CO2 = Annual Co2 emissions from natual gas combustion (metric tons)

Gas = Annual natural gas usage (mmBtu)

EF = CO2 emission factor for natural gas (kg co2/mmBTU)

1 x 10^‐3 = Conversion factor from kg to metric tons

Facility‐Wide GHG PTE Emissions

Attachment 2

HAPs Destruction Justification

Attachment 3

Facility Description and CD-01 Forms

ST. PAUL, MN 55155-4194

Show: Active and Pending RecordsAction:AQD Facility ID: 05300384Facility Name:

MINNESOTA POLLUTION CONTROL AGENCYAIR QUALITY520 LAFAYETTE ROAD

10 September, 2014 13:26

FACILITY DESCRIPTION: EMISSION UNIT (EU)

MaxFuelInput

(mil Btu)

RR Donnelley Maple Grove

RetiredBy

(Action)

Operator DescriptionID No. EmissionUnit

Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity

SICManufacturer ModelNumber

Max.Design

Capacity

MaximumDesign

Capacity

Materials Units n Units d

1 Web Offset Press 1EU 001 Active PER 004 CE 007CE 008

SV 012SV 014SV 015

Min 2752Harris Graphics M-1000 1800 Ft

2 Web Offset Press 2EU 002 Active PER 004 CE 006CE 007CE 008

SV 012SV 014SV 015


3 Web Offset Press 2EU 002 Removed PER 006 CE 006CE 007CE 008

SV 012SV 014SV 015



SV 012SV 014SV 015

Min 2752Harris Graphics M-1000BE 2200 Ft


SV 012SV 014SV 015


6 Web Offset Press 6EU 005 Active EIS 007 CE 004CE 005

SV 009 (M) Min 2752Harris Graphics M-3000 3000 Ft

9.767 Press 1 DryersEU 006 Active PER 005 CE 006CE 007CE 008

SV 004 (M) Min 2752TEC P-350 3030 Ft3

9.768 Press 1 DryersEU 006 Active PER 006 SV 004 (M) Min 2752TEC P-350 3030 Ft3


SV 005 (M) Min 2752TEC P-350 3030 Ft3

9.7610 Press 2 DryersEU 007 Removed PER 006 CE 006CE 007CE 008

SV 005 (M) Min 2752TEC P-350 3030 Ft3


SV 006 (M) Min 2752TEC P-390 3030 Ft3



SV 007 (M) Min 2752TEC P-581 5400 Ft3


11.87415 Press 6 Dryer and emissionscontrol

EU 010 Active EIS 007 CE 004CE 005

SV 009 (M) Min 2752Stork Contiweb 130-1460 4885 Ft3(s)

11.87416 Press 6 Dryer and emissionscontrol (CE 004/005)

EU 010 Active PER 006 SV 009 (M) Min 2752Stork Contiweb 130-1460 4885 Ft3(s)

Page 1 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat

Firing MethodAddedBy

(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

1 EU 001 PER 004 12/31/198512/31/1985Active

2 EU 002 PER 004 12/31/198512/31/1985Active

3 EU 002 PER 006 05/01/201012/31/198512/31/1985Removed

4 EU 003 PER 004 12/31/199312/31/1993Active

5 EU 004 PER 004 12/31/199412/31/1994Active

6 EU 005 EIS 007 12/31/198612/31/1986Active

7 EU 006 PER 005 12/31/198512/31/1985Active

8 EU 006 PER 006 12/31/198512/31/1985Active

9 EU 007 PER 005 12/31/198512/31/1985Active

10 EU 007 PER 006 05/01/201012/31/198512/31/1985Removed

11 EU 008 PER 005 12/31/199312/31/1993Active

12 EU 008 PER 006 12/31/199312/31/1993Active

13 EU 009 PER 005 12/31/199412/31/1994Active

14 EU 009 PER 006 12/31/199412/31/1994Active

15 EU 010 EIS 007 12/31/199612/31/1996Active

16 EU 010 PER 006 12/31/199612/31/1996Active

Page 1 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity


17 Videojet inkjet printerEU 011 Removed PER 005 Hr 2752Videojet SR50 0.168 Gal









26 Videojet inkjet printerEU 020 Removed PER 005 Hr 2752Videojet 9416 0.168 Gal

















Page 2 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

17 EU 011 PER 005 12/31/200512/31/198612/31/1986Removed

18 EU 012 PER 005 07/31/200712/31/198612/31/1986Removed

19 EU 013 PER 005 12/31/200512/31/198712/31/1987Removed

20 EU 014 PER 005 12/31/200512/31/198812/31/1988Removed

21 EU 015 PER 005 07/31/200712/31/198912/31/1989Removed

22 EU 016 PER 005 12/31/200512/31/199012/31/1990Removed

23 EU 017 PER 005 12/31/200512/31/199112/31/1991Removed

24 EU 018 PER 005 12/31/200512/31/199212/31/1992Removed

25 EU 019 PER 005 12/31/200512/31/199312/31/1993Removed

26 EU 020 PER 005 12/31/200512/31/199312/31/1993Removed

27 EU 021 PER 005 12/31/200512/31/199312/31/1993Removed

28 EU 022 PER 005 12/31/200512/31/199312/31/1993Removed

29 EU 023 PER 005 12/31/200512/31/199312/31/1993Removed

30 EU 024 PER 005 12/31/200512/31/199312/31/1993Removed

31 EU 025 PER 005 12/31/200512/31/199412/31/1994Removed

32 EU 026 PER 005 12/31/200512/31/199612/31/1996Removed

33 EU 027 PER 005 12/31/200512/31/199612/31/1996Removed

34 EU 028 PER 005 12/31/200512/31/199612/31/1996Removed

35 EU 029 PER 005 12/31/200512/31/199612/31/1996Removed

36 EU 030 PER 005 12/31/200512/31/199612/31/1996Removed

37 EU 031 PER 005 12/31/200512/31/199612/31/1996Removed

38 EU 032 PER 005 12/31/200512/31/199612/31/1996Removed

39 EU 033 PER 005 12/31/200512/31/199612/31/1996Removed

40 EU 034 PER 005 12/31/200512/31/199712/31/1997Removed

41 EU 035 PER 005 12/31/200512/31/199612/31/1996Removed

42 EU 036 PER 005 12/31/200512/31/199612/31/1996Removed

Page 2 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity









50 Videojet inkjet printerEU 044 Removed PER 005 Hr 2752Videojet Printpro 0.168 Gal

51 Videojet inkjet printerEU 045 Removed PER 005 Hr 2752Videojet Excell 170 0.040 Gal



54 Inkjet printerEU 048 Active PER 005 SV 008 (O) Hr 2752Scitex 5120 0.168 Gal

55 Inkjet printerEU 048 Removed PER 006 Hr 2752Scitex 5120 0.168 Gal














Page 3 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

43 EU 037 PER 005 12/31/200512/31/199612/31/1996Removed

44 EU 038 PER 005 12/31/200512/31/199612/31/1996Removed

45 EU 039 PER 005 12/31/200512/31/199612/31/1996Removed

46 EU 040 PER 005 12/31/200512/31/199612/31/1996Removed

47 EU 041 PER 005 12/31/200512/31/198612/31/1986Removed

48 EU 042 PER 005 12/31/200512/31/198612/31/1986Removed

49 EU 043 PER 005 12/31/200512/31/199712/31/1997Removed

50 EU 044 PER 005 12/31/200512/31/200012/31/2000Removed

51 EU 045 PER 005 12/31/200512/31/199712/31/1997Removed

52 EU 046 PER 005 12/31/200512/31/199912/31/1999Removed

53 EU 047 PER 005 12/31/200512/31/199912/31/1999Removed

54 EU 048 PER 005 12/31/199712/31/1997Active

55 EU 048 PER 006 12/31/199712/31/1997Removed

56 EU 049 PER 005 12/31/199712/31/1997Active

57 EU 049 PER 006 12/31/199712/31/1997Removed

58 EU 050 PER 005 12/31/199712/31/1997Active

59 EU 050 PER 006 12/31/199712/31/1997Removed

60 EU 051 PER 005 12/31/199712/31/1997Active

61 EU 051 PER 006 12/31/199712/31/1997Removed

62 EU 052 PER 005 12/31/199712/31/1997Active

63 EU 052 PER 006 12/31/199712/31/1997Removed

64 EU 053 PER 005 12/31/199712/31/1997Active

65 EU 053 PER 006 12/31/199712/31/1997Removed

66 EU 054 PER 005 12/31/199712/31/1997Active

67 EU 054 PER 006 12/31/199712/31/1997Removed

68 EU 055 PER 005 12/31/199912/31/1999Active

Page 3 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity





72 Inkjet printerEU 057 Removed PER 005 Hr 2752Videojet SR-50 0.168 Gal
















SV 012SV 014SV 015



SV 012SV 014SV 015


89 Web Offset Press 8EU 073 Removed PER 006 CE 007CE 008

SV 012SV 014SV 015



SV 010 (M) Min 2752Contiweb 130 6400 Ft3(s)

6.0491 Press 7 DryersEU 074 Active PER 006 SV 010 (M) Min 2752Contiweb 130 6400 Ft3(s)

Page 4 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

69 EU 055 PER 006 12/31/199912/31/1999Removed

70 EU 056 PER 005 12/31/200012/31/2000Active

71 EU 056 PER 006 12/31/200012/31/2000Removed

72 EU 057 PER 005 12/31/2005Removed

73 EU 058 PER 005 12/31/2005Removed

74 EU 059 PER 005 12/31/2005Removed

75 EU 060 PER 005 12/31/2005Removed

76 EU 061 PER 005 04/20/2007Removed

77 EU 062 PER 005 04/20/2007Removed

78 EU 063 PER 005 04/20/2007Removed

79 EU 064 PER 005 04/20/2007Removed

80 EU 065 PER 005 12/31/2005Removed

81 EU 066 PER 005 12/31/2005Removed

82 EU 067 PER 005 12/31/2005Removed

83 EU 068 PER 005 12/31/2005Removed

84 EU 069 PER 005 12/31/2005Removed

85 EU 070 PER 005 12/31/2005Removed

86 EU 071 PER 005 12/31/2005Removed

87 EU 072 PER 004Active


89 EU 073 PER 006 06/01/2010Removed



Page 4 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity



SV 011 (M) Min 2752Thermo Electron 2804 5800 Ft3(s)

8.8893 Press 8 DryersEU 075 Removed PER 006 CE 007CE 008

SV 011 (M) Min 2752Thermo Electron 2804 5800 Ft3(s)

94 Inkjet printerEU 076 Active PER 005 SV 008 Min 2752Scitex 5122 1000 Ft

95 Inkjet printerEU 076 Removed PER 006 Min 2752Scitex 5122 1000 Ft






















Page 5 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status


93 EU 075 PER 006 06/01/2010Removed

94 EU 076 PER 005 12/31/200312/31/2003Active

95 EU 076 PER 006 12/31/200312/31/2003Removed

96 EU 077 PER 005 12/31/200312/31/2003Active

97 EU 077 PER 006 12/31/200312/31/2003Removed

98 EU 078 PER 005 12/31/200312/31/2003Active

99 EU 078 PER 006 12/31/200312/31/2003Removed

100 EU 079 PER 005 12/31/200312/31/2003Active

101 EU 079 PER 006 12/31/200312/31/2003Removed

102 EU 080 PER 005 12/31/200312/31/2003Active

103 EU 080 PER 006 12/31/200312/31/2003Removed

104 EU 081 PER 005 12/31/200312/31/2003Active

105 EU 081 PER 006 12/31/200312/31/2003Removed

106 EU 082 PER 005 12/31/200312/31/2003Active

107 EU 082 PER 006 12/31/200312/31/2003Removed

108 EU 083 PER 005 12/31/200312/31/2003Active

109 EU 083 PER 006 12/31/200312/31/2003Removed

110 EU 084 PER 005 12/31/200312/31/2003Active

111 EU 084 PER 006 12/31/200312/31/2003Removed

112 EU 085 PER 005 12/31/200312/31/2003Active

113 EU 085 PER 006 12/31/200312/31/2003Removed

114 EU 086 PER 005 12/31/200312/31/2003Active

115 EU 086 PER 006 12/31/200312/31/2003Removed

116 EU 087 PER 005 12/31/200312/31/2003Active

Page 5 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity




























Page 6 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

117 EU 087 PER 006 12/31/200312/31/2003Removed

118 EU 088 PER 005 12/31/200312/31/2003Active

119 EU 088 PER 006 12/31/200312/31/2003Removed

120 EU 089 PER 005 12/31/200312/31/2003Active

121 EU 089 PER 006 12/31/200312/31/2003Removed

122 EU 090 PER 005 12/31/200312/31/2003Active

123 EU 090 PER 006 12/31/200312/31/2003Removed

124 EU 091 PER 005 12/31/200312/31/2003Active

125 EU 091 PER 006 12/31/200312/31/2003Removed

126 EU 092 PER 005 12/31/200312/31/2003Active

127 EU 092 PER 006 12/31/200312/31/2003Removed

128 EU 093 PER 005 12/31/200312/31/2003Active

129 EU 093 PER 006 12/31/200312/31/2003Removed

130 EU 094 PER 005 12/31/200312/31/2003Active

131 EU 094 PER 006 12/31/200312/31/2003Removed

132 EU 095 PER 005 12/31/200312/31/2003Active

133 EU 095 PER 006 12/31/200312/31/2003Removed

134 EU 096 PER 005 12/31/200312/31/2003Active

135 EU 096 PER 006 12/31/200312/31/2003Removed

136 EU 097 PER 005 12/31/200312/31/2003Active

137 EU 097 PER 006 12/31/200312/31/2003Removed

138 EU 098 PER 005 12/31/200312/31/2003Active

139 EU 098 PER 006 12/31/200312/31/2003Removed

140 EU 099 PER 005 12/31/200312/31/2003Active

141 EU 099 PER 006 12/31/200312/31/2003Removed

142 EU 100 PER 005 12/31/200312/31/2003Active

Page 6 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity

















2.592158 Makeup air unit East 17BEU 108 Active PER 004 SV 008 Min 2752King 6130hrbvav 30000 Ft3

2.592159 Makeup air unit West 22EU 109 Active PER 004 SV 008 Min 2752King 6130hrbvav 30000 Ft3







166 Press 9EU 113 Active PER 004 CE 006CE 007CE 008

SV 012SV 014SV 015

Hr 2752Goss S3000 100000 Each


SV 013 (M) 2752Contiweb Ecocool/W 14.8-2032

Page 7 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

143 EU 100 PER 006 12/31/200312/31/2003Removed

144 EU 101 PER 005 12/31/200312/31/2003Active

145 EU 101 PER 006 12/31/200312/31/2003Removed

146 EU 102 PER 005 12/31/200312/31/2003Active

147 EU 102 PER 006 12/31/200312/31/2003Removed

148 EU 103 PER 005 12/31/200312/31/2003Active

149 EU 103 PER 006 12/31/200312/31/2003Removed

150 EU 104 PER 005 12/31/200312/31/2003Active

151 EU 104 PER 006 12/31/200312/31/2003Removed

152 EU 105 PER 005 12/31/200312/31/2003Active

153 EU 105 PER 006 12/31/200312/31/2003Removed

154 EU 106 PER 005 12/31/200312/31/2003Active

155 EU 106 PER 006 12/31/200312/31/2003Removed

156 EU 107 PER 005 12/31/200312/31/2003Active

157 EU 107 PER 006 12/31/200312/31/2003Removed

158 EU 108 PER 004 12/31/200312/31/2003Active

159 EU 109 PER 004 12/31/200312/31/2003Active

160 EU 110 PER 004 12/31/200312/31/2003Active

161 EU 110 PER 006 12/31/200312/31/2003Removed

162 EU 111 PER 004 12/31/200312/31/2003Active

163 EU 111 PER 006 12/31/200312/31/2003Removed

164 EU 112 PER 004 12/31/200312/31/2003Active

165 EU 112 PER 006 12/31/200312/31/2003Removed

166 EU 113 PER 004 01/01/200811/01/2007Active

167 EU 114 PER 004 01/01/200811/01/2007Active

Page 7 of 8 (b)

ST. PAUL, MN 55155-4194



10 September, 2014 13:26


MaxFuelInput

(mil Btu)


RetiredBy

(Action)


Status

AddedBy

(Action)

ControlEquip.

ID No(s).

Stack/Vent

ID No(s).

OperatorID

for Item

Insignif-icant

Activity


Max.Design

Capacity

MaximumDesign

Capacity


23.844168 Press 9 DryersEU 114 Active PER 006 SV 013 (M) 2752Contiweb Ecocool/W 14.8-2032

1.5169 Reverse Thermal Oxidizer (CE006)

EU 115 Active PER 006 2752LE America RTO12

4.2170 Reverse Thermal Oxidizer (CE007)

EU 116 Active PER 006 2752Tann TR2592C

4.2171 Reverse Thermal oxidizer (CE008)

EU 117 Active PER 006 2752Tan TR2592C

Page 8 of 8 (a)

10 September, 2014 13:26


ID No. ElevatorType

BottleneckPct.Fuel/

SpaceHeat


(Action)

RemovalDate

InitialStartup

Date

Comm-ence

Const.Date

EmissionUnit

Status

168 EU 114 PER 006 01/01/200811/01/2007Active




Page 8 of 8 (b)

MINNESOTA POLLUTION CONTROL AGENCYAIR QUALITY520 LAFAYETTE ROADST. PAUL, MN 55155-4194

Show: Active and Pending RecordsAction: PER 006AQD Facility ID: 05300384Facility Name: RR Donnelley Maple Grove

10 September, 2014 08:22

FACILITY DESCRIPTION: CONTROL EQUIPMENT (CE)

ID No. AddedBy

(Action)

RetiredBy

(Action)

OperatorID

for Item

Control

Equip.Type

Control Equipment Description ModelControlEquip.Status

Manufacturer PollutantsControlled

AfterburnerCombustionParameters

CaptureEfficiency

(%)

Destruction/CollectionEfficiency

(%)

1 CE 001 PER 004 020 Catalytic Afterburner w/Heat Exchanger HXC-12000Removed TEC VOC 650 deg Finlet

100 90


100 90


100 90

4 CE 004 PER 005 022 Direct Flame Afterburner w/Heat Exchanger Ecotherm 130-1460Active Stork Contiweb HAPvolVOC

1200 degF/0.5 sec

100100

9595

5 CE 005 PER 005 022 Direct Flame Afterburner w/Heat Exchanger Ecotherm 130-1460Active Stork Contiweb HAPvolVOC

1200 degF/0.5 sec

100100

9595

6 CE 006 PER 005 RTO #1 022 Direct Flame Afterburner w/Heat Exchanger RTO 12Active LE America HAPvolVOC

1500 degF/0.8 sec

100100

9595

7 CE 007 PER 005 RTO #2 022 Direct Flame Afterburner w/Heat Exchanger TR2592CActive Tann HAPvolVOC

1200 degF/0.8 sec

100100

9595

8 CE 008 PER 005 RTO #3 022 Direct Flame Afterburner w/Heat Exchanger TR2592CActive Tann HAPvolVOC

1200 degF/0.8 sec

100100

9595

Page 1 of 1


Show:Action:AQD Facility ID:Facility Name:

Active and Pending Records

05300384RR Donnelley Maple Grove

FACILITY DESCRIPTION: GROUPS (GP)

10 September, 2014 13:24

ID No. AddedBy

(Action)

RetiredBy

(Action)

Includein EI

OperatorID

for Item

Group Description Group ItemsGroupStatus

1 GP 001 PER 005 Total Facility VOC Limits EU 001, EU 002, EU 003, EU 004, EU 005, EU 006, EU 007, EU 008, EU 009,EU 010, EU 011, EU 012, EU 013, EU 014, EU 015, EU 016, EU 017, EU 018,EU 019, EU 020, EU 021, EU 022, EU 023, EU 024, EU 025, EU 026, EU 027,EU 028, EU 029, EU 030, EU 031, EU 032, EU 033, EU 034, EU 035, EU 036,EU 037, EU 038, EU 039, EU 040, EU 041, EU 042, EU 043, EU 044, EU 045,EU 046, EU 047, EU 057, EU 058, EU 059, EU 060, EU 061, EU 062, EU 063,EU 064, EU 065, EU 066, EU 067, EU 068, EU 069, EU 070, EU 071, EU 072,EU 073, EU 074, EU 075, EU 113, EU 114

Active

2 GP 001 PER 006 Total Facility VOC Limits EU 001, EU 003, EU 004, EU 005, EU 006, EU 008, EU 009, EU 010, EU 072,EU 074, EU 113, EU 114

Active

3 GP 002 PER 005 Direct Heating Equipment CE 004, CE 005, CE 006, CE 007, CE 008, EU 006, EU 007, EU 008, EU 009,EU 010, EU 074, EU 075, EU 108, EU 109, EU 114

Active

4 GP 002 PER 006 Direct Heating Equipment CE 004, CE 005, CE 006, CE 007, CE 008, EU 006, EU 008, EU 009, EU 010,EU 074, EU 108, EU 109, EU 114, EU 115, EU 116, EU 117

Active

5 GP 003 PER 004 Press Operations CE 004, CE 005, CE 006, CE 007, CE 008, EU 001, EU 002, EU 003, EU 004,EU 005, EU 006, EU 007, EU 008, EU 009, EU 010, EU 072, EU 073, EU 074,EU 075, EU 113, EU 114

Active

6 GP 003 PER 006 Press Operations CE 004, CE 005, CE 006, CE 007, CE 008, EU 001, EU 003, EU 004, EU 005,EU 006, EU 007, EU 008, EU 009, EU 010, EU 072, EU 074, EU 075, EU 113,EU 114, EU 115, EU 116, EU 117

Active

7 GP 004 PER 004 Catalytic OxidizersRemoved

8 GP 005 PER 005 Thermal Oxidizers CE 004, CE 005, CE 006, CE 007, CE 008Active

9 GP 005 PER 006 Thermal Oxidizers CE 004, CE 005, CE 006, CE 007, CE 008, EU 115, EU 116, EU 117Active

10 GP 006 PER 006 Presses EU 001, EU 003, EU 004, EU 005, EU 072, EU 113Active

Page 1 of 1


Show: Active and Pending RecordsAction:AQD Facility ID: 05300384Facility Name: RR Donnelley Maple Grove

10 September, 2014 13:25

FACILITY DESCRIPTION: STACK/VENTS (SV)

ID No. Discharge DirectionFlow Rate/Temperature

Information Source

Exit GasTemperature

at Top(ºF)

DesignFlow Rate

at Top(ACFM)

Width(feet)

Diameteror Length

(feet)

Inside DimensionsHeight ofOpening

FromGround(feet)

AddedBy

(Action)

RetiredBy

(Action)

OperatorID

for Item

Operators DescriptionStack/Vent

Status

1 SV 001 Up, No CapManufacturer500217203350PER 004 Heatset web offset presses 1&2Removed

2 SV 002 Up, No CapManufacturer500195622.672.1750PER 004 Heatset web offset press 4Removed

3 SV 003 Up, No CapManufacturer500108603350PER 004 Heatset web offset press 5Removed

4 SV 004 Up, No CapEstimate35056002250PER 001 Purge damper press 1 dryersActive


6 SV 005 Up, No CapEstimate35056002250PER 006 Purge damper press 2 dryersRemoved



9 SV 008 PER 001 General ventilation -- dummy stack -- emissions thru windowsand doors

Active

10 SV 009 Up, No CapManufacturer800232512.6750PER 001 Heatset web offset press 6Active

11 SV 010 Up, No CapManufacturer90012000350PER 005 Purge Damper Press 7 dryersActive

12 SV 011 Up, No CapEstimate3506400250PER 005 Purge Damper Press 8 dryersActive

13 SV 011 Up, No CapEstimate3506400250PER 006 Purge Damper Press 8 dryersRemoved

14 SV 012 Up, No CapEstimate3505600250PER 005 RTO #1 Exhaust StackActive

15 SV 013 Up, No CapManufacturer350229003.1750PER 004 Press 9 Bypass StackActive

16 SV 014 Up, No CapManufacturer45042900450PER 004 RTO #2 Exhaust StackActive

17 SV 015 Up, No CapManufacturer45042900450PER 004 RTO #3 Exhaust StackActive

Page 1 of 1

MINNESOTA POLLUTION CONTROL AGENCYAIR QUALITY520 LAFAYETTE ROADST. PAUL, MN 55155-4194 COMPLIANCE PLAN CD-01

Facility Name: RR Donnelley Maple Grove

Permit Number: 05300384 - 006

10 Sep, 2014 13:27Page 1 of 17

Subject Item: Total Facility

NC/CA

Type Citation Requirement

CD hdr SITE-SPECIFIC REQUIREMENTS1.0

CD Title I Condition: To avoidclassification as major source ormodification under 40 CFRSection 52.21 & Minn. R.7007.3000; To avoid major sourceclassification under 40 CFRSection 63.2

This permit establishes limits on the facility to keep it a minor source under NewSource Review and the NESHAP program. The Permittee cannot make anychange at the source that would make the source a major source under NewSource Review or the NESHAP program until a permit amendment has beenissued. This includes changes that might otherwise qualify as insignificantmodifications and minor or moderate amendments.

2.0

CD Minn. R. 7007.0800, subp. 2 Equipment Labeling and Inventory: The Permittee shall permanently affix a uniquenumber to each emissions unit for tracking purposes. The numbers shall correlatethe unit to the appropriate EU and GP numbers used in this permit. The numbercan be affixed by placard, stencil, or other means. The number shall be maintainedso that it is readable and visible at all times from a safe distance. If equipment isadded, it shall be given a new unique number; numbers from replaced or removedequipment shall not be reused.

The Permittee shall maintain a written list of all emissions units on site. The listshall correlate the units to the numbers used in this permit (EU, GP, and CE) andshall include the data on GI-04, GI-05B, and GI-05C. The date of construction shallbe the date the change was made for replaced, modified, or new equipment. ThePermittee shall update the list to include any changes.

3.0

CD Minn. R. 7007.0800, subp. 4 & 5;7007.1300 subp. 3; Minn. R.7007.4110; Minn. R. 7011.0510;Minn. R. 7011.0715

Permit Appendices: This permit contains appendices as listed in the permit Table ofContents. The Permittee shall comply with all requirements contained in theappendices.

4.0

CD hdr OPERATIONAL REQUIREMENTS5.0

CD Minn. Stat. Section 116.07, subds.4a & 9; Minn. R. 7007.0100, subp.7(A), 7(L), & 7(M); Minn. R.7007.0800, subps. 1, 2 & 4; Minn.R. 7009.0010-7009.0080

The Permittee shall comply with National Primary and Secondary Ambient AirQuality Standards, 40 CFR pt. 50, and the Minnesota Ambient Air QualityStandards, Minn. R. 7009.0010 to 7009.0080. Compliance shall be demonstratedupon written request by the MPCA.

6.0

CD Minn. R. 7011.0020 Circumvention: Do not install or use a device or means that conceals or dilutesemissions, which would otherwise violate a federal or state air pollution control rule,without reducing the total amount of pollutant emitted.

7.0

CD Minn. R. 7007.0800, subp. 2;Minn. R. 7007.0800, subp. 16(J)

Air Pollution Control Equipment: Operate all pollution control equipment wheneverthe corresponding process equipment and emission units are operated.

8.0

CD Minn. R. 7007.0800, subps. 14and 16(J)

Operation and Maintenance Plan: Retain at the stationary source an operation andmaintenance plan for all air pollution control equipment. At a minimum, the O & Mplan shall identify all air pollution control equipment and control practices and shallinclude a preventative maintenance program for the equipment and practices, adescription of (the minimum but not necessarily the only) corrective actions to betaken to restore the equipment and practices to proper operation to meet applicablepermit conditions, a description of the employee training program for properoperation and maintenance of the control equipment and practices, and the recordskept to demonstrate plan implementation.

9.0

CD Minn. R. 7019.1000, subp. 4 Operation Changes: In any shutdown, breakdown, or deviation the Permittee shallimmediately take all practical steps to modify operations to reduce the emission ofany regulated air pollutant. The Commissioner may require feasible and practicalmodifications in the operation to reduce emissions of air pollutants. No emissionsunits that have an unreasonable shutdown or breakdown frequency of process orcontrol equipment shall be permitted to operate.

10.0

CD Minn. R. 7011.0150 Fugitive Emissions: Do not cause or permit the handling, use, transporting, orstorage of any material in a manner which may allow avoidable amounts ofparticulate matter to become airborne. Comply with all other requirements listed inMinn. R. 7011.0150.

11.0

CD Minn. R. 7030.0010 - 7030.0080 Noise: The Permittee shall comply with the noise standards set forth in Minn. R.7030.0010 to 7030.0080 at all times during the operation of any emission units.This is a state only requirement and is not enforceable by the EPA Administrator orcitizens under the Clean Air Act.

12.0




10 Sep, 2014 13:27Page 2 of 17

CD Minn. R. 7007.0800, subp. 9(A) Inspections: The Permittee shall comply with the inspection procedures andrequirements as found in Minn. R. 7007.0800, subp. 9(A).

13.0

CD Minn. R. 7007.0800, subp. 16 The Permittee shall comply with the General Conditions listed in Minn. R.7007.0800, subp. 16.

14.0

CD hdr PERFORMANCE TESTING15.0

CD Minn. R. ch. 7017 Performance Testing: Conduct all performance tests in accordance with Minn. R.ch. 7017 unless otherwise noted in Tables A, B, and/or C.

16.0

CD Minn. R. 7017.2018; Minn. R.7017.2030, subps. 1-4, Minn. R.7017.2035, subps. 1-2

Performance Test Notifications and Submittals:

Performance Tests are due as outlined in Table A of the permit.See Table B for additional testing requirements.

Performance Test Notification (written): due 30 days before each Performance TestPerformance Test Plan: due 30 days before each Performance TestPerformance Test Pre-test Meeting: due 7 days before each Performance TestPerformance Test Report: due 45 days after each Performance TestPerformance Test Report - Microfiche Copy: due 105 days after each PerformanceTest

The Notification, Test Plan, and Test Report may be submitted in an alternativeformat as allowed by Minn. R. 7017.2018.

17.0

CD Minn. R. 7017.2025, subp. 3 Limits set as a result of a performance test (conducted before or after permitissuance) apply until superseded as stated in the MPCA's Notice of Complianceletter granting preliminary approval. Preliminary approval is based on formal reviewof a subsequent performance test on the same unit as specified by Minn. R.7017.2025, subp. 3. The limit is final upon issuance of a permit amendmentincorporating the change.

18.0

CD hdr MONITORING REQUIREMENTS19.0

CD Minn. R. 7007.0800, subp. 4(D) Monitoring Equipment Calibration - The Permittee shall calibrate or replacerequired monitoring equipment every 12 months.

For each monitor, the Permittee shall maintain a record of all calibrations, includingthe date conducted, and any corrective action that resulted. The Permittee shallinclude the calibration frequencies, procedures, and manufacturer's specifications(if applicable) in the Operations and Maintenance Plan. Any requirements applyingto continuous emission monitors are listed separately in this permit.

20.0

CD Minn. R. 7007.0800, subp. 4(D) Operation of Monitoring Equipment: Unless otherwise noted in Tables A, B, and/orC, monitoring a process or control equipment connected to that process is notnecessary during periods when the process is shutdown, or during checks of themonitoring systems, such as calibration checks and zero and span adjustments. Ifmonitoring records are required, they should reflect any such periods of processshutdown or checks of the monitoring system.

21.0

CD hdr RECORDKEEPING22.0

CD Minn. R. 7007.0800, subp. 5(C) Recordkeeping: Retain all records at the stationary source, unless otherwisespecified within this permit, for a period of five (5) years from the date of monitoring,sample, measurement, or report. Records which must be retained at this locationinclude all calibration and maintenance records, all original recordings forcontinuous monitoring instrumentation, and copies of all reports required by thepermit. Records must conform to the requirements listed in Minn. R. 7007.0800,subp. 5(A).

23.0

CD Minn. R. 7007.0800, subp. 5(B) Recordkeeping: Maintain records describing any insignificant modifications (asrequired by Minn. R. 7007.1250, subp. 3) or changes contravening permit terms (asrequired by Minn. R. 7007.1350, subp. 2), including records of the emissionsresulting from those changes.

24.0

CD Minn. R. 7007.1200, subp. 4 If the Permittee determines that no permit amendment or notification is requiredprior to making a change, the Permittee must retain records of all calculationsrequired under Minn. R. 7007.1200. For expiring permits, these records shall bekept for a period of five years from the date the change was made or until permitreissuance, whichever is longer. For nonexpiring permits, these records shall bekept for a period of five years from the date that the change was made. The recordsshall be kept at the stationary source for the current calendar year of operation andmay be kept at the stationary source or office of the stationary source for all otheryears. The records may be maintained in either electronic or paper format.

25.0

CD hdr REPORTING/SUBMITTALS26.0




10 Sep, 2014 13:27Page 3 of 17

CD Minn. R. 7019.1000, subp. 3 Shutdown Notifications: Notify the Commissioner at least 24 hours in advance of aplanned shutdown of any control equipment or process equipment if the shutdownwould cause any increase in the emissions of any regulated air pollutant. If theowner or operator does not have advance knowledge of the shutdown, notificationshall be made to the Commissioner as soon as possible after the shutdown.However, notification is not required in the circumstances outlined in Items A, Band C of Minn. R. 7019.1000, subp. 3.

At the time of notification, the owner or operator shall inform the Commissioner ofthe cause of the shutdown and the estimated duration. The owner or operator shallnotify the Commissioner when the shutdown is over.

27.0

CD Minn. R. 7019.1000, subp. 2 Breakdown Notifications: Notify the Commissioner within 24 hours of a breakdownof more than one hour duration of any control equipment or process equipment ifthe breakdown causes any increase in the emissions of any regulated air pollutant.The 24-hour time period starts when the breakdown was discovered or reasonablyshould have been discovered by the owner or operator. However, notification is notrequired in the circumstances outlined in Items A, B and C of Minn. R. 7019.1000,subp. 2.

At the time of notification or as soon as possible thereafter, the owner or operatorshall inform the Commissioner of the cause of the breakdown and the estimatedduration. The owner or operator shall notify the Commissioner when the breakdownis over.

28.0

CD Minn. R. 7019.1000, subp. 1 Notification of Deviations Endangering Human Health or the Environment: As soonas possible after discovery, notify the Commissioner or the state duty officer, eitherorally or by facsimile, of any deviation from permit conditions which could endangerhuman health or the environment.

29.0

CD Minn. R. 7019.1000, subp. 1 Notification of Deviations Endangering Human Health or the Environment Report:Within 2 working days of discovery, notify the Commissioner in writing of anydeviation from permit conditions which could endanger human health or theenvironment. Include the following information in this written description:1. the cause of the deviation;2. the exact dates of the period of the deviation, if the deviation has been corrected;3. whether or not the deviation has been corrected;4. the anticipated time by which the deviation is expected to be corrected, if not yetcorrected; and5. steps taken or planned to reduce, eliminate, and prevent reoccurrence of thedeviation.

30.0

CD Minn. R. 7007.0800, subp. 6(A)(2) Semiannual Deviations Report: Due 30 days after end of each calendar half yearfollowing Permit Issuance. The first semiannual report submitted by the Permitteeshall cover the calendar half-year in which the permit is issued. The first report ofeach calendar year covers January 1 - June 30. The second report of eachcalendar year covers July 1 - December 31. If no deviations have occurred, thePermittee shall submit the report stating no deviations.

31.0

CD Minn. R. 7007.1150 - 7007.1500 Application for Permit Amendment: If a permit amendment is needed, submit anapplication in accordance with the requirements of Minn. R. 7007.1150 throughMinn. R. 7007.1500. Submittal dates vary, depending on the type of amendmentneeded.

32.0

CD Minn. R. 7007.0400, subp. 2 Application for Permit Reissuance: due 180 days before expiration of existingpermit.

33.0

CD Minn. R. 7007.1400, subp. 1(H) Extension Requests: The Permittee may apply for an Administrative Amendment toextend a deadline in a permit by no more than 120 days, provided the proposeddeadline extension meets the requirements of Minn. R. 7007.1400, subp. 1(H).Performance testing deadlines from the General Provisions of 40 CFR pt. 60 andpt. 63 are examples of deadlines for which the MPCA does not have authority togrant extensions and therefore do not meet the requirements of Minn. R.7007.1400, subp. 1(H).

34.0

CD Minn. R. 7007.0800, subp. 6(C) Compliance Certification: Due 31 days after end of each calendar year followingPermit Issuance (for the previous calendar year). The Permittee shall submit this tothe Commissioner on a form approved by the Commissioner. This report covers alldeviations experienced during the calendar year.

35.0

CD Minn. R. 7019.3000 - 7019.3100 Emission Inventory Report: due on or before April 1 of each calendar year followingpermit issuance, to be submitted on a form approved by the Commissioner.

36.0

CD Minn. R. 7002.0005 - 7002.0095 Emission Fees: due 30 days after receipt of an MPCA bill.37.0




10 Sep, 2014 13:27Page 4 of 17

Subject Item: GP 001 Total Facility VOC Limits

Associated Items: EU 001 Web Offset Press 1

EU 003 Web Offset Press 4



EU 006 Press 1 Dryers



EU 010 Press 6 Dryer and emissions control (CE 004/005)



EU 113 Press 9


NC/CA


CD hdr EMISSIONS AND OPERATING LIMITS1.0

LIMIT Title I Condition: To avoidclassification as major source ormodification under 40 CFRSection 52.21; Minn. R.7007.3000

Volatile Organic Compounds: less than or equal to 226.0 tons/year using 12-monthRolling Sum to be calculated by the 21st day of each month for the previous12-month period as described later in this permit. This includes all non-combustionemissions of VOC other than those listed in Appendix B of this permit.

VOC contents for each VOC-containing material shall be determined as describedunder the Material Content requirement. The calculation of VOCs used may takeinto account recovered/recycled VOCs as described under the Waste Creditrequirement.

2.0

LIMIT Title I Condition: To avoid majorsource or modificationclassification under 40 CFRSection 63.2

HAPs - Total: less than or equal to 20.0 tons/year using 12-month Rolling Sum tobe calculated by the 21st day of each month for the previous 12-month period.This includes all non-combustion emissions of HAP other than those listed inAppendix B of this permit.

All emission units shall be included in this calculation. HAP contents for eachHAP-containing material shall be determined as described under the MaterialContent requirement. The calculation of HAPs used may take into accountrecovered/recycled HAPs as described under the Waste Credit requirement.

3.0

LIMIT Title I Condition: To avoid majorsource or modificationclassification under 40 CFRSection 63.2

HAP-Single: less than or equal to 9.0 tons/year using 12-month Rolling Sum tobe calculated by the 21st day of each month for the previous 12-month period.This includes all non-combustion emissions of HAP other than those listed inAppendix B of this permit.

All emission units shall be included in this calculation. HAP contents for eachHAP-containing material shall be determined as described under the MaterialContent requirement. The calculation of HAP usage may take into accountrecovered/recycled HAPs as described under the Waste Credit requirement.

4.0

CD Title I Condition: To avoid majorsource classification under 40CFR Section 52.21; Minn. R.7007.3000; To avoid major sourceclassification under 40 CFRSection 63.2

All noncombustion VOC or HAP-emitting equipment at the Facility is covered by thelimits above. If the Permittee replaces any existing VOC or HAP-emittingequipment, adds new VOC or HAP-emitting equipment, or modifies the existingequipment, such equipment is subject to these permit limits as well as all of therequirements of GP 001. Prior to making such a change, the Permittee shall applyfor and obtain the appropriate permit amendment, as applicable. The Permittee isnot required to complete VOC or HAP calculations described in Minn. R.7007.1200, subp. 2.A permit amendment will still be needed regardless of the emissions increase if thechange will be subject to a new applicable requirement or requires revisions to thelimits or monitoring and recordkeeping in this permit.

5.0

CD Title I Condition: To avoidclassification as major source andmodification under 40 CFRSection 52.21 & Minn. R.7007.3000

The Permittee shall vent emissions from all press operations (presses and dryers),including existing, modified, or new press operations, to control equipment meetingthe requirements at the applicable group and control equipment level (e.g. GP 005and CE 004 - CE 008)

6.0




10 Sep, 2014 13:27Page 5 of 17


CD Title I Condition: To avoidclassification as major source andmodification under 40 CFR 52.21;Minn. R. 7007.3000; To avoidmajor source classification under40 CFR 63.2; Minn. R. 7007.0800.subps. 4 & 5

Material Usage Recordkeeping.

Ink materials used at the presses: On each day of operation, the Permittee shallrecord and maintain the quantity of each ink material dispensed in the pressoperations. This shall be based on written usage logs and/or meter readings.

Fountain solution, automatic blanket wash, and manual blanket wash: ThePermittee shall record the amount and type of solvent material, whenever thematerial is dispensed.

Other VOC and HAP-containing materials: The Permittee shall calculate, record,and maintain monthly usage records showing the quantity of each material used.This shall be based on either written usage logs, or purchase/delivery records.

8.0

CD Minn. R. 7007.0800, subps. 4 & 5 Composite VOC Vapor Pressure Records: For materials used for either automaticor manual blanket wash, the Permittee shall document if the composite VOC vaporpressure is equal to, less than, or greater than 10 mmHg at 20 degrees centigrade,for each material. If the composite VOC vapor pressure is unknown, the Permitteeshall assume that it is greater than 10 mmHg in the applicable permit calculationsuntil such time that it is determined to be otherwise.

9.0

CD Minn. R. 7007.0800, subps. 4 & 5 Monthly Recordkeeping -- VOC Emissions.By the 21st of the month, the Permittee shall calculate and record the following:

1. The total usage of each VOC-containing material for the previous calendarmonth using the combination of monthly purchases, returns, and inventory recordsand/or the records specified in the Material Usage Recordkeeping requirement asrequired by the Appendix A permit requirement below. This record shall alsoinclude the VOC contents of each material as determined by the Material Contentrequirement of this permit.

2. The VOC emissions for the previous month using the formulas specified inAppendix A of this permit and as described by the Appendix A permit requirementbelow.

3. The 12-month rolling sum VOC emissions for the previous 12-month period bysumming the monthly VOC emissions data for the previous 12 months.

10.0

CD Minn. R. 7007.0800, subps. 4 & 5 Monthly Recordkeeping -- HAP Emissions.By the 21st of the month, the Permittee shall calculate and record the following:

1. The total usage of each HAP-containing material used in the previous calendarmonth using the combination of monthly purchases, returns, and inventory recordsand/or the records specified in the Material Usage Recordkeeping requirement ofthis permit as required by the Appendix A permit requirement below. This recordshall also include the individual and total HAP contents of each HAP-containingmaterial used in the previous month, as determined by the Material Contentrequirement of this permit.

2. The total and individual HAP emissions for the previous month using theformulas specified in Appendix A of this permit and as described by the Appendix Apermit requirement below.

3. The 12-month rolling sum total and individual HAP emissions for the previous12-month period by summing the monthly emissions data for the previous 12months.

11.0

CD Minn. R. 7007.0800, subps. 4 & 5 Appendix A --

If the destruction efficiency variable, DE, in the formulas given in Appendix A areequivalent for all thermal oxidizer operations in a given month, the Permittee mayuse the monthly purchase, returns, and storage records to determine the materialusage to perform for calculations that month for all presses combined.

If the destruction efficiency variable, DE, in the formulas given in Appendix A arenot equivalent for all thermal oxidizer operations in a given month (for example, inthe case of an oxidizer shutdown), for calculations that month the Permittee mustuse the daily records specified in the Material Usage Recordkeeping requirement ofthis permit to allocate the material usage to each press.

12.0




10 Sep, 2014 13:27Page 6 of 17

CD Minn. R. 7007.0800, subps. 4 & 5 Material Content: VOC and HAPs contents in materials shall be determined byeither:1. a Material Safety Data Sheet (MSDS); or2. a Letter of Certification, provided by the supplier for each material used.

If a material content range is given, the highest number in the range shall be usedin all compliance calculations. Other alternative methods approved by the MPCAmay be used to determine the VOC and HAPs contents. The Commissionerreserves the right to require the Permittee to determine the VOC and/or HAPcontents of any material, according to EPA or ASTM reference methods. If anEPA or ASTM reference method is used for material content determination, thedata obtained shall supersede the MSDS.

13.0

CD Minn. R. 7005.0100, subp. 35a Maximum Contents of Materials and Ink Usage Rate: The Permittee assumedcertain materials content and ink usage rates when determining the annual andshort term potential to emit of units in GP001. These assumptions are listed inAppendix C of this permit. Changing to a material that has a higher content of anyof the given pollutants or increasing the ink usage rate is considered a change inmethod of operation that must be evaluated under Minn. R. 7007.1200, subp. 3 todetermine if a permit amendment or notification is required under Minn R.7007.1150.

14.0

CD Minn. R. 7007.0800, subps. 4 & 5 Waste Credit: If the Permittee elects to obtain credit for HAPs and/or VOC shippedin waste materials, the Permittee shall either use item 1 or 2 to determine the VOCand/or total and individual HAP content for each credited shipment.1. The Permittee shall analyze a composite sample of each waste shipment to determine the weight content of VOC, total HAP, and each individual HAP.2. The Permittee may use supplier data for raw materials to determine the VOC and total and individual HAP contents of each waste shipment, using the same content data used to determine the content of raw materials. If the waste contains several materials, the content of mixed waste shall be assumed to be the lowest VOC and total and individual HAP content of any of the materials.

15.0

S/A Minn. R. 7007.0800, subp. 2 Annual Report: due 31 days after end of each calendar year following PermitIssuance. The Permittee shall submit an annual report by January 31st thatdescribes the changes made at the facility during the previous calendar year usingthe latest MPCA application forms. The report shall include the emission unit,stack/vent, group, and control equipment data for any new or replaced units orcontrol devices. The report shall document the VOC 12-month rolling sumcalculations for the previous calendar year. The report shall be submitted with theannual Compliance Certification listed in Table B. As part of the Annual Report, thePermittee shall verify and certify that the facility has maintained minor source statusfor New Source Review.

16.0




10 Sep, 2014 13:27Page 7 of 17

Subject Item: GP 002 Direct Heating Equipment

Associated Items: CE 004 Direct Flame Afterburner w/Heat Exchanger

CE 005 Direct Flame Afterburner w/Heat Exchanger









EU 108 Makeup air unit East 17B

EU 109 Makeup air unit West 22


EU 115 Reverse Thermal Oxidizer (CE 006)


EU 117 Reverse Thermal oxidizer (CE 008)

NC/CA


LIMIT Title I Condition: To avoidclassification as major source ormodification under 40 CFRSection 52.21 & Minn. R.7007.3000

Total Facility Press Dryers and Control Equipment Capacity: less than or equal to140 million Btu/hour

1.0

CD Title I Condition: To avoidclassification as a major source ormodification under 40 CFRSection 52.21 & Minn. R.7007.3000

All combustion equipment at the Facility is subject to this limit. If the Permitteereplaces any existing combustion equipment, adds new combustion equipment, ormodifies the existing equipment, such equipment is subject to this permit limit aswell as the other requirements listed at the Total Facility Level. Prior to makingsuch a change, the Permittee shall apply for and obtain the appropriate permitamendment, as applicable. A permit amendment may be needed if the change willbe subject to a new applicable requirement or requires revisions to limits or themonitoring and recordkeeping in this permit.

2.0

CD Minn. R. 7007.0800, subps. 4 & 5 The Permittee shall maintain a written list of all fuel burning equipment on site. ThePermittee shall update the list to include any replaced, modified, or new equipmentprior to making the change.

The list shall include the capacity of each piece of equipment and the total facilitycapacity.

3.0

CD Minn. R. 7005.0100, subp. 35a Fuel Type: natural gas or propane only, by design.4.0

CD Minn. R. 7007.0800, subp. 5 The Permittee shall keep records of fuel purchases for the Facility on a monthlybasis.

5.0

LIMIT Minn. R. 7011.0610, subp. 1(A)(1) Total Particulate Matter: less than or equal to 0.30 grains/dry standard cubic foot ofexhaust gas unless required to further reduce emissions to comply with the lessstringent limit of either Minn. R. 7011.0730 or Minn. R. 7011. 0735. This appliesseparately to each piece of direct heating equipment.

6.0

LIMIT Minn. R. 7011.0610, subp. 1(A)(2) Opacity: less than or equal to 20 percent opacity except for one six-minute periodper hour of not more than 60 percent opacity. This applies separately to eachpiece of direct heating equipment.

7.0




10 Sep, 2014 13:27Page 8 of 17

Subject Item: GP 003 Press Operations
















EU 113 Press 9





NC/CA


CD Title I Condition: To avoid majorsource or modification under 40CFR Section 52.21 and 40 CFRSection 63.2; Minn. R. 7007.3000

The Permittee shall control the emissions from the Press operations (presses anddryers), including existing, modified, or new Press operations, with control devicesdescribed by GP 005 and CE 004-008 at all times that the given press is operating.The current control equipment configuration is documented in Appendix D of thispermit.

The Permittee may change the equipment configuration (e.g., vent Press 7operations to a control device other than CE 006), may replace the control deviceslisted in Appendix D, or install additional control devices, so long as all pressoperation emissions are controlled, all control devices meet the requirements of theapplicable group or control equipment (e.g. GP 005 and CE 004 - CE 008), and thedryer and control device capacity limit listed in GP 002 of this permit is met.

1.0

CD Minn. R. 7007.0800, subp. 2 Notification of Control Equipment Changes: The Permittee shall submit anotification to the MPCA of any of the control equipment changes authorized underGP 003 of this permit. The notification shall be submitted at least 7 days prior tomaking the change, shall specify the affected emissions unit and control equipmentnumbers used in this permit, and shall include the updated control equipment datalisted on MPCA Form GI-05A and the planned configuration on MPCA FormGI-05B (current data in Appendix D of this permit). The notification shall alsospecify the new total dryer and control equipment capacity in MMBTU/hr.

2.0




10 Sep, 2014 13:27Page 9 of 17

Subject Item: GP 005 Thermal Oxidizers









NC/CA


CD hdr See CE 004-008 for minimum operating temperature and performance testingrequirements specific to each oxidizer

1.0

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000

The requirements for GP 005 apply separately to each control device listed in GP005. This includes each new or replaced thermal oxidizer added as allowed by GP005.

2.0

CD Title I Condition: To avoidclassification as major source andmodification under 40 CFRSection 52.21 & Minn. R.7007.3000

If the Permittee replaces or modifies any existing thermal oxidizer listed in GP 005,or adds a new thermal oxidizer, such equipment is subject to all of the requirementsof GP 005. Prior to making such a change, the Permittee shall apply for andobtain the appropriate permit amendment, as applicable.

3.0

CD hdr CONTROL REQUIREMENTS (See CE 004-008 for minimum temperaturerequirements)

4.0

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000

The Permittee shall operate and maintain each thermal oxidizer any time that anyprocess equipment controlled by the thermal oxidizer is in operation. ThePermittee shall document periods of non-operation of the control equipment.

5.0

LIMIT Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000

The Permittee shall operate and maintain the control equipment such that itachieves a destruction efficiency for Volatile Organic Compounds: greater than orequal to 95 percent control efficiency

6.0

LIMIT Title I Condition: To avoidclassification as a major source ormodification under 40 CFRSection 63.2 and Minn. R.7007.0800

The Permittee shall operate and maintain the control equipment such that itachieves a destruction efficiency for HAPs - Total: greater than or equal to 95percent

7.0

CD 40 CFR Section 64.7(b); Minn. R.7017.0200

The Permittee shall operate and maintain the thermal oxidizer in accordance withthe O&M Plan. The Permittee shall keep copies of the O&M Plan available onsitefor use by staff and MPCA staff.

8.0

CD hdr PERFORMANCE TESTING FOR NEW OXIDIZERS (See CE 004-008 for testingrequirements for each existing oxidizer)

9.0

S/A Minn. R. 7017.2020, subp. 1 Testing Frequency Plan: due 60 days after Initial Performance Test for new oroxidizers for VOC destruction efficiency. The plan shall specify a testing frequencybased on the test data and MPCA guidance. Future performance tests based onone-year (12 month), 36 month, and 60 month intervals, or as applicable, shall berequired upon written approval of the MPCA.

10.0

CD Minn. R. 7017.2020, subp. 1 Initial performance test for VOC destruction efficiency of new or replaced thermaloxidizer: due 180 days after achieving maximum capacity of controlled press.

11.0

CD hdr MONITORING12.0




10 Sep, 2014 13:27Page 10 of 17

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000; 40 CFR Section64.3(b)(4)(ii); Minn. R. 7017.0200

Temperature Monitoring: The Permittee shall maintain and operate a thermocouplemonitoring device that continuously indicates and records the combustion chambertemperature of the thermal oxidizer. The monitoring device shall have a margin oferror less than the greater of +/- 0.75 percent of the temperature being measured or+/- 2.5 degrees Celsius. The recording device shall also calculate the three-hourrolling average combustion chamber temperature. Recorded values outside therange specified in this permit are considered Deviations as defined by Minn. R.7007.0100, subp. 8a.

13.0

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000; 40 CFR Section64.3(b); Minn. R. 7017.0200

Daily Monitoring: The Permittee shall physically verify the operation of thetemperature recording device at least once each operating day to verify that it isworking and recording properly. The Permittee shall maintain a written record of thedaily verifications.

14.0


Monitoring Equipment: The Permittee shall install and maintain thermocouples toconduct temperature monitoring required by this permit. The monitoring equipmentmust be installed, in use, and properly maintained whenever operation of themonitored control equipment is required.

15.0

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000; 40 CFR Section64.9(b); Minn. R. 7017.0200

The Permittee shall maintain a continuous hard copy readout or computer disk fileof the temperature readings and calculated three hour rolling average temperaturesfor the combustion chamber.

16.0

CD 40 CFR Section 64.3; Minn. R.7017.0200

Annual Calibration: The Permittee shall calibrate the temperature monitor at leastevery 12 months and shall maintain a written record of the calibration and anyaction resulting from the calibration.

17.0


Quarterly Inspections: At least once per calendar quarter, the Permittee shallinspect the control equipment external system components, including but notlimited to the refractory, heat exchanger, and electrical systems. The Permitteeshall maintain a written record of the inspection and any corrective actions takenresulting from the inspection.

18.0


Annual Inspection: At least once per calendar year, the Permittee shall conduct aninternal inspection of the control device that includes all operating systems of thecontrol device. The Permittee shall maintain a written record of the inspection andany action resulting from the inspection.

19.0

CD Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000;

For periods when the thermal oxidizer is operated above the minimum operatingtemperature, the Permittee shall use either one of the following when completingcalculations as required elsewhere in this permit:a. The destruction efficiency limit specified in this permit for this equipment (95%); orb. The destruction efficiency determined during the most recent MPCA approved performance test. If the tested efficiency is less than the efficiency limit in this permit, the Permittee must use the tested value in all calculations until the efficiency is demonstrated to be above the permit limit through a new test.

20.0

CD 40 CFR Section 64.7(d); Minn. R.7017.0200

Corrective Actions: If the temperature is below the minimum specified by thispermit or if the thermal oxidizer or any of its components are found during theinspections to need repair, the Permittee shall take corrective action as soon aspossible. Corrective actions shall return the temperature to at least the permittedminimum and/or include completion of necessary repairs identified during theinspection, as applicable. Corrective actions include, but are not limited to, thoseoutlined in the O&M Plan for the thermal oxidizer. The Permittee shall keep arecord of the type and date of any corrective action taken.

21.0

CD 40 CFR Section 64.7(e); Minn. R.7017.0200

Documentation of Need for Improved Monitoring: If the Permittee fails to achievecompliance with an emission limitation or standard for which the monitoring did notprovide an indication of an excursion or exceedance while providing valid data, orthe results of compliance or performance testing document a need to modify theexisting minimum oxidizer operating temperature(s), the Permittee shall promptlynotify the MPCA and, if necessary, submit a permit amendment application toaddress the necessary monitoring changes.

22.0





10 Sep, 2014 13:27Page 11 of 17


The Permittee shall maintain records of monitoring data, monitor performance data,corrective actions taken, and other supporting information required to bemaintained. The Permittee may maintain records on alternative media, such asmicrofilm, computer files, magnetic tape disks, or microfiche, provided that the useof such alternative media allows for expeditious inspection and review, and doesnot conflict with other applicable recordkeeping requirements.

24.0

CD hdr REPORTING/SUBMITTALS25.0

CD 40 CFR Section 64.9(a)(2); Minn.R. 7017.0200

As required by 40 CFR Section 64.9(a)(2), for the Semi-Annual Deviations Reportlisted in Table B of this permit and/or the Notification of Deviations EndangeringHuman Health and the Environment listed earlier in Table A of this permit, asapplicable, the Permittee shall include the following related to the monitoringidentified as required by 40 CFR pt. 64: 1) Summary information on the number,duration, and cause of excursions or exceedances, as applicable, and thecorrective action taken; and 2) Summary information on the number, duration, andcause for monitor downtime incidents.

26.0




10 Sep, 2014 13:27Page 12 of 17

Subject Item: GP 006 Presses






EU 113 Press 9

NC/CA


LIMIT Minn. R. 7011.0715, subp. 1(A) Total Particulate Matter: less than or equal to 0.30 grains/dry standard cubic foot ofexhaust gas unless required to further reduce emissions to comply with the lessstringent limit of either Minn. R. 7011.0730 or Minn. R. 7011.0735. This appliesseparately to each piece of industrial equipment. Specifically, it applies to eachpress.

1.0

LIMIT Minn. R. 7011.0715, subp. 1(B) Opacity: less than or equal to 20 percent opacity . This applies separately to eachpiece of industrial process equipment. Specifically, it applies to each press.

2.0




10 Sep, 2014 13:27Page 13 of 17

Subject Item: CE 004 Direct Flame Afterburner w/Heat Exchanger


GP 002 Direct Heating Equipment

GP 003 Press Operations

GP 005 Thermal Oxidizers

NC/CA


CD hdr See GP 005 for thermal oxidizer control, monitoring, recordkeeping, reporting, andother requirements. CE 004 and CE 005 are integrated thermal oxidizers for Press6. They operate at the same conditions and are tested as one CE (CE 004/005).

1.0

CD hdr CONTROL REQUIREMENTS2.0

LIMIT Title I Condition: To avoidclassification as a major sourceand modification under 40 CFRSection 52.21 and Minn. R.7007.3000; 40 CFR Section 63.2;Minn. R. 7007.0800

Temperature: greater than or equal to 1400 degrees F as a three-hour rollingaverage at the combustion chamber outlet, unless a new limit is required to be setpursuant to Minn. R. 7017.2025, subp. 3. If a new minimum is required to be set itwill be based on the values recorded during the most recent MPCA-approvedperformance test where compliance was demonstrated. The new limit shall beimplemented upon receipt of the Notice of Compliance letter granting preliminaryapproval. The limit is final upon issuance of a permit amendment incorporating thechange. If the 3-hour rolling average temperature is below the minimumtemperature limit, the VOC emitted during that time shall be considereduncontrolled until the average temperature is above the minimum temperature limit.This shall be reported as a deviation. Down time of 15 or more minutes is not to beincluded as operating time.

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S/A Minn. R. 7017.2020, subp. 1 Performance Test: due before end of each calendar 60 months starting 09/04/2013to measure VOC destruction efficiency using EPA test method 25A or other methodapproved by the MPCA in the performance test plan approval, not to exceed 60months between test dates. Testing conducted up to two months prior to theperformance test due date does not reset the test due date of any future testingrequired by this permit, by the most recently approved Performance TestFrequency Plan, or if specified, by a Notice of Compliance letter.

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NC/CA


CD hdr See GP 005 for thermal oxidizer control, monitoring, recordkeeping, reporting, andother requirements. CE 004 and CE 005 are integrated thermal oxidizers for Press6. They operate at the same conditions and are tested as one CE (CE 004/005).

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NC/CA


CD hdr See GP 005 for thermal oxidizer control, monitoring, recordkeeping, reporting, andother requirements

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Attachment 4

Compliance Assurance Monitoring Plan

technical support document 1. 1.1 andtechnical support document, permit action number:...

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