construction permit application
TRANSCRIPT
Abengoa Bioenergy Biomass of Kansas Source 1890231
Project No. 73387
Updated January 2014
Permit Application
prepared for
Hugoton, Kansas
COPYRIGHT © 2014 BURNS & McDONNELL ENGINEERING COMPANY, INC.
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ABBK Energy, Inc. TOC-1 Burns & McDonnell
TABLE OF CONTENTS
Page No.
1.0 EXECUTIVE SUMMARY ................................................................................... 1-1 HAP Emissions .................................................................................................... 1-3 1.1 Project NAAQS Impact Analysis ........................................................................ 1-3 1.2 BACT for Reciprocating Internal Combustion Engines ...................................... 1-4 1.3 BACT Analysis for Other Equipment .................................................................. 1-5 1.4 Additional Impacts Analysis ................................................................................ 1-7 1.5 Modifications to Thermal Oxidizer in Current Permit ........................................ 1-7 1.6 Modifications to Emission Points in Current Permit ........................................... 1-8 1.7 Modifications to Boiler in Current Permit ........................................................... 1-9 1.8
2.0 INTRODUCTION ............................................................................................... 2-1
3.0 PROJECT OVERVIEW AND OBJECTIVES ..................................................... 3-1 ABBK Facility Project ......................................................................................... 3-1 3.1
3.1.1 Emission Unit Descriptions .................................................................. 3-1
4.0 EMISSIONS ESTIMATES ................................................................................. 4-1 Introduction .......................................................................................................... 4-1 4.1 Emission Sources ................................................................................................. 4-1 4.2
4.2.1 Engine Emissions .................................................................................. 4-1 4.2.2 RICE Start-Up Emissions ..................................................................... 4-2 4.2.3 Emergency Diesel-fired Fire Pump Emissions ..................................... 4-2 4.2.4 Biomass Boiler and Reheat Burner ....................................................... 4-3 4.2.5 Methanol Tank Emissions..................................................................... 4-3 4.2.6 Ethanol Load-out Thermal Oxidizer Emissions ................................... 4-3 4.2.7 Material Handling Fugitive Emissions ................................................. 4-3 4.2.8 Biomass Storage Pile Emissions ........................................................... 4-4 4.2.9 Facility Berm Construction Emissions ................................................. 4-4
HAP Emissions .................................................................................................... 4-4 4.3
5.0 REGULATORY REVIEW .................................................................................. 5-1 PSD Regulations .................................................................................................. 5-1 5.1 New Source Performance Standards .................................................................... 5-2 5.2
5.2.1 40 CFR Part 60, Subpart IIII ................................................................. 5-2 5.2.2 40 CFR Part 60, Subpart JJJJ ................................................................ 5-3
National Emission Standards for Hazardous Air Pollutants (NESHAP) and 5.3 Maximum Achievable Control Technology (MACT) ......................................... 5-3 5.3.1 Subpart ZZZZ ....................................................................................... 5-4 5.3.2 Subpart DDDDD ................................................................................... 5-4
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Kansas Air Quality Standards and Regulations ................................................... 5-4 5.4 5.4.1 K.A.R 28-19-300 to 304 Construction Permits and Approvals;
Applicability ......................................................................................... 5-4 5.4.2 K.A.R 28-19-350 Prevention of Significant Deterioration of Air
Quality .................................................................................................. 5-5 5.4.3 K.A.R 28-19-500 to 518 Operating Permit; Applicability ................... 5-5 5.4.4 K.A.R 28-19-645 Opening Burning Prohibited .................................... 5-5 5.4.5 K.A.R 28-19-650 Emissions Opacity Limits ........................................ 5-5
Mandatory Reporting of Greenhouse Gases – 40 CFR Part 98 ........................... 5-5 5.5 NAAQS ................................................................................................................ 5-5 5.6 Other Ambient Air Quality Standards ................................................................. 5-5 5.7 Additional Impact Analysis ................................................................................. 5-6 5.8 Acid Rain (40 CFR Part 75) – New Unit Utility Exemption ............................... 5-6 5.9
6.0 BEST AVAILABLE CONTROL TECHNOLOGY ANALYSIS ............................ 6-1 PSD BACT Process ............................................................................................. 6-3 6.1
6.1.1 The “Top-Down” Process ..................................................................... 6-3 6.1.2 General Principles ................................................................................. 6-4 6.1.3 GHG BACT Process ............................................................................. 6-6
BACT Technology and Emission Limitations for Similar Units ......................... 6-6 6.2 New Source Performance Standards .................................................................... 6-8 6.3
6.3.1 Subpart JJJJ ........................................................................................... 6-8 BACT For Nitrogen Oxides (NOx) – Non-Emergency RICE ............................. 6-9 6.4
6.4.1 Step 1. Identify All Potential Control Technologies ............................. 6-9 6.4.2 Step 2. Identify Technically Feasible Control Technologies ................ 6-9 6.4.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-11 6.4.4 Step 4. Evaluate the Most Effective Controls ..................................... 6-12 6.4.5 Step 5. Select NOx BACT Emission Limitation ................................. 6-13
BACT For Carbon Monoxide (CO) – Non-Emergency RICE .......................... 6-14 6.5 6.5.1 Step 1. Identify Potential Control Strategies ....................................... 6-14 6.5.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-14 6.5.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-15 6.5.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-16 6.5.5 Step 5. Select CO BACT Emission Limitation ................................... 6-17
BACT For Sulfur Dioxide (SO2) – Non-Emergency RICE ............................... 6-17 6.6 6.6.1 Step 1. Identify Potential Control Strategies ....................................... 6-17 6.6.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-18 6.6.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-18 6.6.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-18 6.6.5 Step 5. Select SO2 BACT Emission Limitation .................................. 6-18
BACT for Volatile Organic Compounds (VOC) – Non-Emergency RICE ...... 6-18 6.7 6.7.1 Step 1. Identify Potential Control Strategies ....................................... 6-18 6.7.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-19 6.7.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-20 6.7.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-20 6.7.5 Step 5. Select VOC BACT Emission Limitation ................................ 6-21
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BACT for Particulate Matter (PM/PM10/PM2.5) – Non-Emergency RICE ........ 6-22 6.8 6.8.1 Step 1. Identify Potential Control Strategies ....................................... 6-22 6.8.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-22 6.8.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-22 6.8.4 Step 4 & 5. Evaluate and Select PM/PM10/PM2.5 BACT Emission
Limitation............................................................................................ 6-22 BACT for Greenhouse Gases (GHG) – Non-Emergency RICE ........................ 6-23 6.9
6.9.1 Introduction ......................................................................................... 6-23 6.9.2 Step 1 and Step 2. Identify Potential Control Strategies and
Eliminate Technologically Infeasible Options ................................... 6-23 6.9.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-27 6.9.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-31 6.9.5 Step 5. Select GHG BACT Emission Limitation ................................ 6-31
BACT for Emergency Diesel Fire Pump ........................................................... 6-31 6.10 6.10.1 BACT for Nitrogen Oxides – Emergency Diesel Fire Pump ............. 6-31 6.10.2 BACT for Carbon Monoxide – Emergency Diesel Fire Pump ........... 6-33 6.10.3 BACT for Sulfur Dioxide – Emergency Diesel Fire Pump ................ 6-33 6.10.4 BACT for Volatile Organic Compounds – Emergency Diesel Fire
Pump ................................................................................................... 6-33 6.10.5 BACT for Particulate Matter (PM/PM10/PM2.5)– Emergency Diesel
Fire Pump ............................................................................................ 6-34 6.10.6 BACT for Greenhouse Gases – Emergency Diesel Fire Pump .......... 6-34
BACT for Biomass-Fired Stoker Boiler and Biomass Boiler Reheat Burner ... 6-35 6.11 6.11.1 BACT for Nitrogen Oxides (NOx) – Biomass-Fired Stoker Boiler
and Biomass Boiler Reheat Burner ..................................................... 6-35 6.11.2 BACT for Carbon Monoxide (CO) – Biomass-Fired Stoker Boiler
and Biomass Boiler Reheat Burner ..................................................... 6-38 6.11.3 BACT for Sulfur Oxides (SO2) – Biomass-Fired Stoker Boiler and
Biomass Boiler Reheat Burner ........................................................... 6-40 6.11.4 BACT for Volatile Organic Compounds (VOC) – Biomass-Fired
Stoker Boiler and Biomass Boiler Reheat Burner .............................. 6-43 6.11.5 BACT for Particulate Matter (PM/PM10/PM2.5) – Biomass-Fired
Stoker Boiler and Biomass Boiler Reheat Burner .............................. 6-45 6.11.6 BACT for Greenhouse Gases – Biomass-Fired Stoker Boiler and
Biomass Boiler Reheat Burner ........................................................... 6-48 BACT for Volatile Organic Compounds (VOC) – Methanol Tank .................. 6-51 6.12
6.12.1 Introduction ......................................................................................... 6-51 BACT for Ethanol Load Out Thermal Oxidizer (EP-02100) ............................ 6-52 6.13
6.13.1 Introduction ......................................................................................... 6-52 6.13.2 BACT for Nitrogen Oxides – Thermal Oxidizer ................................ 6-52 6.13.3 BACT for Carbon Monoxide – Thermal Oxidizer ............................. 6-53 6.13.4 BACT for Sulfur Dioxide – Thermal Oxidizer ................................... 6-53 6.13.5 BACT for Volatile Organic Compounds – Thermal Oxidizer ............ 6-53 6.13.6 BACT for Particulate Matter (PM/PM10/PM2.5) – Thermal Oxidizer . 6-54 6.13.7 BACT for Greenhouse Gases (GHG) – Thermal Oxidizer ................. 6-54
BACT for Biogas/NCG Process Vent Thermal Oxidizer (EP-09100) .............. 6-56 6.14
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6.14.1 Introduction ......................................................................................... 6-56 6.14.2 BACT for Volatile Organic Compounds – Thermal Oxidizer ............ 6-56
BACT for Particulate Matter (PM/PM10/PM2.5) – Material Handling 6.15 Fugitives ............................................................................................................. 6-57 6.15.1 Introduction ......................................................................................... 6-57 6.15.2 BACT for Facility Berm ..................................................................... 6-57 6.15.3 BACT for Biomass Storage Piles ....................................................... 6-58 6.15.4 BACT for Material Handling Transfer Points .................................... 6-59
BACT for Particulate Matter (PM/PM10/PM2.5) – Ash Load-Out Points .......... 6-62 6.16 6.16.1 Introduction ......................................................................................... 6-62 6.16.2 Step 1. Identify Potential Control Technologies ................................. 6-62 6.16.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-63 6.16.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-65 6.16.5 Step 4. Evaluate the Technically Feasible Control Technologies ....... 6-65 6.16.6 Step 5. Select Ash Load-Out Points BACT ........................................ 6-66
BACT for Particulate Matter (PM/PM10/PM2.5) – Fly Ash Silo Bin Vent ........ 6-67 6.17 6.17.1 Step 1. Identify Potential Control Technologies ................................. 6-67 6.17.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-68 6.17.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-68 6.17.4 Step 4. Evaluate the Technically Feasible Control Technologies ....... 6-69 6.17.5 Step 5. Select Fly Ash Silo Bin Vent BACT ...................................... 6-69
BACT for Volatile Organic Compounds (VOC) – Storage Tanks .................... 6-70 6.18 6.18.1 Introduction ......................................................................................... 6-70 6.18.2 Step 1 and Step 2. Identify Potential Control Strategies and
Eliminate Technologically Infeasible Options ................................... 6-70 6.18.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-71 6.18.4 Steps 4 and 5. Evaluate the Most Effective Control Technologies
and Proposed BACT for VOC Emissions .......................................... 6-71 BACT for Volatile Organic Compounds (VOC) – Fugitive Leaks and 6.19
Loading Losses .................................................................................................. 6-71 6.19.1 Introduction ......................................................................................... 6-71 6.19.2 Step 1. Identify Potential Control Strategies ....................................... 6-71 6.19.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-72 6.19.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-72 6.19.5 Step 4 & 5. Evaluate and Select Fugitive Leaks and Loading
Losses BACT ...................................................................................... 6-72 BACT for Volatile Organic Compounds (VOC) – Lignin-Rich Stillage 6.20
Storage ............................................................................................................... 6-72 6.20.1 Introduction ......................................................................................... 6-72 6.20.2 Step 1. Identify Potential Control Strategies ....................................... 6-72 6.20.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-72 6.20.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-73 6.20.5 Step 4 & 5. Evaluate and Select Lignin-Rich Stillage Storage
BACT .................................................................................................. 6-73 BACT for Volatile Organic Compounds (VOC) – EH Fermentation Process .. 6-73 6.21
6.21.1 Introduction ......................................................................................... 6-73
ABBK Energy, Inc. TOC-5 Burns & McDonnell
6.21.2 Step 1. Identify Potential Control Strategies ....................................... 6-74 6.21.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-74 6.21.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-74 6.21.5 Step 4 & 5. Evaluate and Select EH Fermentation CO2 Scrubber
BACT .................................................................................................. 6-74
7.0 AIR DISPERSION MODELING ......................................................................... 7-1 Air Dispersion Model .......................................................................................... 7-1 7.1 Model Parameters ................................................................................................ 7-3 7.2
7.2.1 Good Engineering Practice ................................................................... 7-4 7.2.2 Haul Roads ............................................................................................ 7-5 7.2.3 Storage Piles.......................................................................................... 7-5 7.2.4 Flares ..................................................................................................... 7-6 7.2.5 Inventory of Neighboring Sources ........................................................ 7-6
Modeling Methodology and Parameters .............................................................. 7-7 7.3 7.3.1 Receptor Grid ........................................................................................ 7-7 7.3.2 Meteorological Data.............................................................................. 7-8 7.3.3 Model Parameters ................................................................................. 7-8 7.3.4 Significant Impact Area Determination ................................................ 7-8 7.3.5 NAAQS and PSD Class II Increment Consumption Analysis .............. 7-8 7.3.6 Ambient Monitoring ............................................................................. 7-9 7.3.7 NO2 Modeling – Multi-Tiered Screening Approach .......................... 7-10
Significance Model Results ............................................................................... 7-11 7.4 7.4.1 NO2 Results ......................................................................................... 7-12 7.4.2 CO Results .......................................................................................... 7-12 7.4.3 PM2.5/PM10 Results ............................................................................. 7-13 7.4.4 SO2 Results ......................................................................................... 7-13
PSD Class II Increment Modeling ..................................................................... 7-13 7.5 NAAQS Modeling ............................................................................................. 7-14 7.6 PSD Class I Analysis ......................................................................................... 7-16 7.7 Conclusion ......................................................................................................... 7-16 7.8 Analysis of Secondary PM2.5 Formation............................................................ 7-16 7.9
Scheffe Ozone Analysis ..................................................................................... 7-19 7.10 Representative Monitors .................................................................................... 7-20 7.11
7.11.1 Monitor Location ................................................................................ 7-21 7.11.2 Data Quality ........................................................................................ 7-22 7.11.3 Currentness of Data ............................................................................. 7-22 7.11.4 Monitor Recommendations ................................................................. 7-22
8.0 ADDITIONAL IMPACT ANALYSIS ................................................................... 8-1 Construction Impacts ........................................................................................... 8-1 8.1 Vegetation Impacts .............................................................................................. 8-1 8.2
8.2.1 Nitrogen Oxides .................................................................................... 8-2 8.2.2 Synergistic Effects of Pollutants ........................................................... 8-3 8.2.3 Particulate Matter .................................................................................. 8-3
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8.2.4 Carbon Monoxide ................................................................................. 8-3 8.2.5 Carbon Dioxide ..................................................................................... 8-3
Soil Impacts ......................................................................................................... 8-4 8.3 Industrial, Residential, and Commercial Growth Impacts ................................... 8-4 8.4 Visibility and Deposition Analysis ...................................................................... 8-5 8.5
8.5.1 Class I Area Analysis ............................................................................ 8-5 8.5.2 Visual Impairment Screening Assessment ............................................ 8-5
Conclusion ......................................................................................................... 8-15 8.6
9.0 REFERENCES .................................................................................................. 9-1
APPENDIX A - FORMS APPENDIX B - LAYOUTS APPENDIX C - EMISSION CALCULATIONS APPENDIX D - RBLC APPENDIX E - MODELING PROTOCOL APPENDIX F - FIGURES APPENDIX G - MODELING FILES
LIST OF TABLES
Table 1-1: Project Potential Emissions and PSD Significance Levels .................................... 1-3
Table 1-2: Summary of BACT Results: RICE. ....................................................................... 1-5
Table 1-3: Summary of BACT Results: Other Equipment and Emission Points. ................... 1-6
Table 1-4: Additional Emission Points at Enzymatic Hydrolysis Plant .................................. 1-9
Table 2-1. Facility Potential Emissions and PSD Significance Levels ................................... 2-2
Table 4-1: Non-Emergency RICE Maximum Expected Hourly Emission Rates. ................... 4-2
Table 6-1: Summary of BACT Results: Non-Emergency RICE. ............................................ 6-1
Table 6-2: Summary of BACT Results: Auxiliary Equipment. ............................................... 6-2
Table 6-3: Summary of BACT Results: Material Handling Transfer Points........................... 6-3
Table 6-4: Emission Rates for Engines Similar to Project Engines at Full Load (g/bhp-hr). .............................................................................................................. 6-8
Table 6-5: Summary of Technically Feasible NOx Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-11
Table 6-6: Ranking of Technically Feasible NOx Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-12
Table 6-7: Summary of Technically Feasible CO Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-15
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Table 6-8: Ranking of Technically Feasible CO Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-15
Table 6-9: Summary of Technically Feasible VOC Control Technologies for the Non-Emergency RICE. ........................................................................................ 6-20
Table 6-10: Ranking of Technically Feasible VOC Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-20
Table 6-11: Summary of Potential GHG Control Technologies. ............................................ 6-23
Table 6-12: CO2 Emission Factors for Various Fuels ............................................................. 6-25
Table 6-13: Ranking of Potential Generating Technologies by Heat Rate. ............................. 6-28
Table 6-14: Power Plant Heat Rates and GHG Performance. ................................................. 6-28
Table 6-15: Power Supply Sample Scenarios. ......................................................................... 6-30
Table 6-16: GHG Technology Ranking for the Project. .......................................................... 6-30
Table 6-17: Summary of Potential NOx Control Technologies. .............................................. 6-32
Table 6-18: Ranking of SO2 Control Technologies for the Boiler .......................................... 6-42
Table 6-19: Ranking of PM Control Technologies for the Boiler ........................................... 6-47
Table 6-20: Ranking of GHG Control Technologies for the Boiler and Reheat Burner ......... 6-50
Table 6-21: Fly Ash Load-Out Technically Feasible Control Options ................................... 6-65
Table 6-22: Bottoms Ash Load-Out Technically Feasible Control Options ........................... 6-65
Table 6-23: Ash Load-Out Points BACT Emission Rates ...................................................... 6-67
Table 6-24: Grain Handling Technically Feasible Control Options ........................................ 6-68
Table 6-25: Fly Ash Silo Bin Vent BACT Emission Rates ..................................................... 6-69
Table 7-1: Combustion Engine Emissions and Modeling ParametersA ................................... 7-3
Table 7-2. Emergency Fire Pump and Thermal Oxidizer Modeling Parameters .................... 7-4
Table 7-3: Fence Line Coordinates (Zone 14). ........................................................................ 7-8
Table 7-4: Background Level. ................................................................................................. 7-9
Table 7-5: NAAQS, Significance, and Monitoring Levels and PSD Class II Increment (μg/m3). ............................................................................................... 7-10
Table 7-6: In Stack Ratios. .................................................................................................... 7-11
Table 7-7: Maximum Modeled Concentrations. .................................................................... 7-12
Table 7-8: Increment Modeling Results. ............................................................................... 7-14
Table 7-9: NAAQS Modeling Results. .................................................................................. 7-15
Table 7-10: Modeled Highs. .................................................................................................... 7-15
Table 7-11: EPA’s Cross-State Air Pollution Rule Emission Summary for Kansas ............... 7-17
Table 7-12: EPA’s Cross-State Air Pollution Rule Modeling Results & Estimated Project Impact ...................................................................................................... 7-18
Table 7-13: EPA’s Cross-State Air Pollution Rule Annual PM2.5 Modeling Results & Estimated Project Impact ..................................................................................... 7-19
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Table 7-14: Selected Monitors for Background Concentrations ............................................... 7-21
Table 8-1: Location of Class II Sensitive Areas ...................................................................... 8-7
Table 8-2: Distance to Class II Sensitive Areas and Flow Vectors ......................................... 8-8
Table 8-3: Joint Frequency Distribution Analysis Meteorological Conditions ....................... 8-8
Table 8-4: Joint Frequency Distribution Analysis Meteorological Conditions ....................... 8-9
Table 8-5: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Cimarron National Grasslands – WSW Wind Direction Sector Only ........................................................................................................... 8-10
Table 8-6: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Cimarron National Grasslands – W Wind Direction Sector Only ........................................................................................................... 8-11
Table 8-7: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Hugoton Municipal Airport – SSE Wind Direction Sector Only ........................................................................................................... 8-11
Table 8-8: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Hugoton Municipal Airport – S Wind Direction Sector Only ...................................................................................................................... 8-12
Table 8-9: Level 2 VISCREEN Results for Cimarron National Grasslands ......................... 8-13
Table 8-10: Level 2 VISCREEN Results for Hugoton Municipal Airport .............................. 8-13
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LIST OF FIGURES
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Figure 7-29: Counties in Kansas ...................................................................................... Page 7-19 Figure 7-30: Monitor Locations..................................................................................APPENDIX F Figure 7-31: Primary Land Use – ABBK ...................................................................APPENDIX F Figure 7-32: Primary Land Use – Dodge City, KS ....................................................APPENDIX F Figure 7-33: Primary Land Use – Cedar Bluff, KS ....................................................APPENDIX F Figure 7-34: PM10 Sources Surrounding ABBK ........................................................APPENDIX F Figure 7-35: PM10 Sources Surrounding Dodge City Monitor ...................................APPENDIX F Figure 7-36: PM2.5 Sources Surrounding ABBK .......................................................APPENDIX F Figure 7-37: PM2.5 Sources Surrounding Cedar Bluff Monitor..................................APPENDIX F Figure 7-38. State of Kansas Population Density Map and the Location of PM2.5 Monitors
Compared to Project Site. ............................................................................ Page 7-23
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LIST OF ABBREVIATIONS
AERMOD AMS/EPA Regulatory Model
b* saturation
BPIP-PRIME Building Profile Input Program-Plume Rise Model Enhancements
CAA Clean Air Act
CEM Continuous Emission Monitor
CO carbon monoxide
CO2 carbon dioxide
DEM Digital Elevation Model
EGU Electric Generating Unit
°F degrees Fahrenheit
FLAG Federal Land Managers' Air Quality Related Values Work Group
FLM Federal Land Manager
ft/s feet per second
GEP Good Engineering Practice
g/bhp-hr gram per brake horsepower hour
g/hp-hr gram per horsepower hour
H2SO4 sulfuric acid
hp horsepower
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Abbreviation Term/Phrase/Name K.A.R Kansas Administrative Regulations
KDHE Kansas Department of Health and Environment
kPa kilopascals
kW kilowatt
L* brightness
MACT Maximum Achievable Control Technology
CH4 methane
MW megawatt
NAD North American Datum
NED National Elevation Dataset
NSPS New Source Performance Standards
NO nitrogen oxide
NOx nitrogen oxides
NO2 nitrogen dioxide
N2O nitrous oxide
NMHC non-methane hydrocarbons
OLM Ozone Limiting Method
PM2.5 particulate matter of 2.5 microns in diameter or smaller
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Abbreviation Term/Phrase/Name PM10 particulate matter of 10 microns in diameter or smaller
ppm parts per million
PRIME plume rise model enhancements
PSD Prevention of Significant Deterioration
PVMRM Plume Volume Molar Ratio Method
RBLC RACT/BACT/LAER Clearinghouse
RMP risk management plan
ROI radius of impact
SCR selective catalytic reduction
μm micrometer
PSD Air Construction Permit Application Executive Summary
Abengoa Bioenergy Biomass of Kansas, LLC 1-1 Burns & McDonnell
1.0 EXECUTIVE SUMMARY
Pursuant to the requirements specified in the Kansas Administrative Regulations (K.A.R) 28-19-350,
Abengoa Bioenergy Biomass of Kansas, LLC (ABBK) submits this Prevention of Significant
Deterioration (PSD) construction permit application for several changes to the existing facility
(hereinafter referred to as the Project) located in Stevens County, Kansas, approximately 1.5 miles west of
Hugoton, Kansas.
On September 16, 2011, ABBK was issued a PSD permit for construction of this biomass-to-ethanol and
biomass-to-energy production facility. On January 22, 2013, the PSD permit was amended for the
construction of four natural gas-fired spark ignition emergency engines. This application amends the PSD
permit once more to allow the emergency engines to operate in an unrestricted manner and for several
other plant modifications. Even though the emissions increase associated with this application are below
the PSD major project at a major source thresholds, for permitting purposes this project is considered a
continuation of the previous PSD project and as such is subject to PSD review for PM, PM10, PM2.5, NOx,
CO, VOC, SO2, and CO2e.
The requested modifications are as follows:
1. The ability to operate two of the four natural gas-fired emergency generators for 8,760 hours per
year and the ability to sell excess generated electricity to the grid (but at an amount less than that
which would trigger regulation under the Acid Rain regulations of 40 CFR Part 72)
2. Larger size for the emergency fire pump (617 hp instead of 460…
Project No. 73387
Updated January 2014
Permit Application
prepared for
Hugoton, Kansas
COPYRIGHT © 2014 BURNS & McDONNELL ENGINEERING COMPANY, INC.
PSD Air Construction Permit Application Table of Contents
ABBK Energy, Inc. TOC-1 Burns & McDonnell
TABLE OF CONTENTS
Page No.
1.0 EXECUTIVE SUMMARY ................................................................................... 1-1 HAP Emissions .................................................................................................... 1-3 1.1 Project NAAQS Impact Analysis ........................................................................ 1-3 1.2 BACT for Reciprocating Internal Combustion Engines ...................................... 1-4 1.3 BACT Analysis for Other Equipment .................................................................. 1-5 1.4 Additional Impacts Analysis ................................................................................ 1-7 1.5 Modifications to Thermal Oxidizer in Current Permit ........................................ 1-7 1.6 Modifications to Emission Points in Current Permit ........................................... 1-8 1.7 Modifications to Boiler in Current Permit ........................................................... 1-9 1.8
2.0 INTRODUCTION ............................................................................................... 2-1
3.0 PROJECT OVERVIEW AND OBJECTIVES ..................................................... 3-1 ABBK Facility Project ......................................................................................... 3-1 3.1
3.1.1 Emission Unit Descriptions .................................................................. 3-1
4.0 EMISSIONS ESTIMATES ................................................................................. 4-1 Introduction .......................................................................................................... 4-1 4.1 Emission Sources ................................................................................................. 4-1 4.2
4.2.1 Engine Emissions .................................................................................. 4-1 4.2.2 RICE Start-Up Emissions ..................................................................... 4-2 4.2.3 Emergency Diesel-fired Fire Pump Emissions ..................................... 4-2 4.2.4 Biomass Boiler and Reheat Burner ....................................................... 4-3 4.2.5 Methanol Tank Emissions..................................................................... 4-3 4.2.6 Ethanol Load-out Thermal Oxidizer Emissions ................................... 4-3 4.2.7 Material Handling Fugitive Emissions ................................................. 4-3 4.2.8 Biomass Storage Pile Emissions ........................................................... 4-4 4.2.9 Facility Berm Construction Emissions ................................................. 4-4
HAP Emissions .................................................................................................... 4-4 4.3
5.0 REGULATORY REVIEW .................................................................................. 5-1 PSD Regulations .................................................................................................. 5-1 5.1 New Source Performance Standards .................................................................... 5-2 5.2
5.2.1 40 CFR Part 60, Subpart IIII ................................................................. 5-2 5.2.2 40 CFR Part 60, Subpart JJJJ ................................................................ 5-3
National Emission Standards for Hazardous Air Pollutants (NESHAP) and 5.3 Maximum Achievable Control Technology (MACT) ......................................... 5-3 5.3.1 Subpart ZZZZ ....................................................................................... 5-4 5.3.2 Subpart DDDDD ................................................................................... 5-4
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Kansas Air Quality Standards and Regulations ................................................... 5-4 5.4 5.4.1 K.A.R 28-19-300 to 304 Construction Permits and Approvals;
Applicability ......................................................................................... 5-4 5.4.2 K.A.R 28-19-350 Prevention of Significant Deterioration of Air
Quality .................................................................................................. 5-5 5.4.3 K.A.R 28-19-500 to 518 Operating Permit; Applicability ................... 5-5 5.4.4 K.A.R 28-19-645 Opening Burning Prohibited .................................... 5-5 5.4.5 K.A.R 28-19-650 Emissions Opacity Limits ........................................ 5-5
Mandatory Reporting of Greenhouse Gases – 40 CFR Part 98 ........................... 5-5 5.5 NAAQS ................................................................................................................ 5-5 5.6 Other Ambient Air Quality Standards ................................................................. 5-5 5.7 Additional Impact Analysis ................................................................................. 5-6 5.8 Acid Rain (40 CFR Part 75) – New Unit Utility Exemption ............................... 5-6 5.9
6.0 BEST AVAILABLE CONTROL TECHNOLOGY ANALYSIS ............................ 6-1 PSD BACT Process ............................................................................................. 6-3 6.1
6.1.1 The “Top-Down” Process ..................................................................... 6-3 6.1.2 General Principles ................................................................................. 6-4 6.1.3 GHG BACT Process ............................................................................. 6-6
BACT Technology and Emission Limitations for Similar Units ......................... 6-6 6.2 New Source Performance Standards .................................................................... 6-8 6.3
6.3.1 Subpart JJJJ ........................................................................................... 6-8 BACT For Nitrogen Oxides (NOx) – Non-Emergency RICE ............................. 6-9 6.4
6.4.1 Step 1. Identify All Potential Control Technologies ............................. 6-9 6.4.2 Step 2. Identify Technically Feasible Control Technologies ................ 6-9 6.4.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-11 6.4.4 Step 4. Evaluate the Most Effective Controls ..................................... 6-12 6.4.5 Step 5. Select NOx BACT Emission Limitation ................................. 6-13
BACT For Carbon Monoxide (CO) – Non-Emergency RICE .......................... 6-14 6.5 6.5.1 Step 1. Identify Potential Control Strategies ....................................... 6-14 6.5.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-14 6.5.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-15 6.5.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-16 6.5.5 Step 5. Select CO BACT Emission Limitation ................................... 6-17
BACT For Sulfur Dioxide (SO2) – Non-Emergency RICE ............................... 6-17 6.6 6.6.1 Step 1. Identify Potential Control Strategies ....................................... 6-17 6.6.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-18 6.6.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-18 6.6.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-18 6.6.5 Step 5. Select SO2 BACT Emission Limitation .................................. 6-18
BACT for Volatile Organic Compounds (VOC) – Non-Emergency RICE ...... 6-18 6.7 6.7.1 Step 1. Identify Potential Control Strategies ....................................... 6-18 6.7.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-19 6.7.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-20 6.7.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-20 6.7.5 Step 5. Select VOC BACT Emission Limitation ................................ 6-21
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BACT for Particulate Matter (PM/PM10/PM2.5) – Non-Emergency RICE ........ 6-22 6.8 6.8.1 Step 1. Identify Potential Control Strategies ....................................... 6-22 6.8.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-22 6.8.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-22 6.8.4 Step 4 & 5. Evaluate and Select PM/PM10/PM2.5 BACT Emission
Limitation............................................................................................ 6-22 BACT for Greenhouse Gases (GHG) – Non-Emergency RICE ........................ 6-23 6.9
6.9.1 Introduction ......................................................................................... 6-23 6.9.2 Step 1 and Step 2. Identify Potential Control Strategies and
Eliminate Technologically Infeasible Options ................................... 6-23 6.9.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-27 6.9.4 Step 4. Evaluate the Most Effective Control Technologies ................ 6-31 6.9.5 Step 5. Select GHG BACT Emission Limitation ................................ 6-31
BACT for Emergency Diesel Fire Pump ........................................................... 6-31 6.10 6.10.1 BACT for Nitrogen Oxides – Emergency Diesel Fire Pump ............. 6-31 6.10.2 BACT for Carbon Monoxide – Emergency Diesel Fire Pump ........... 6-33 6.10.3 BACT for Sulfur Dioxide – Emergency Diesel Fire Pump ................ 6-33 6.10.4 BACT for Volatile Organic Compounds – Emergency Diesel Fire
Pump ................................................................................................... 6-33 6.10.5 BACT for Particulate Matter (PM/PM10/PM2.5)– Emergency Diesel
Fire Pump ............................................................................................ 6-34 6.10.6 BACT for Greenhouse Gases – Emergency Diesel Fire Pump .......... 6-34
BACT for Biomass-Fired Stoker Boiler and Biomass Boiler Reheat Burner ... 6-35 6.11 6.11.1 BACT for Nitrogen Oxides (NOx) – Biomass-Fired Stoker Boiler
and Biomass Boiler Reheat Burner ..................................................... 6-35 6.11.2 BACT for Carbon Monoxide (CO) – Biomass-Fired Stoker Boiler
and Biomass Boiler Reheat Burner ..................................................... 6-38 6.11.3 BACT for Sulfur Oxides (SO2) – Biomass-Fired Stoker Boiler and
Biomass Boiler Reheat Burner ........................................................... 6-40 6.11.4 BACT for Volatile Organic Compounds (VOC) – Biomass-Fired
Stoker Boiler and Biomass Boiler Reheat Burner .............................. 6-43 6.11.5 BACT for Particulate Matter (PM/PM10/PM2.5) – Biomass-Fired
Stoker Boiler and Biomass Boiler Reheat Burner .............................. 6-45 6.11.6 BACT for Greenhouse Gases – Biomass-Fired Stoker Boiler and
Biomass Boiler Reheat Burner ........................................................... 6-48 BACT for Volatile Organic Compounds (VOC) – Methanol Tank .................. 6-51 6.12
6.12.1 Introduction ......................................................................................... 6-51 BACT for Ethanol Load Out Thermal Oxidizer (EP-02100) ............................ 6-52 6.13
6.13.1 Introduction ......................................................................................... 6-52 6.13.2 BACT for Nitrogen Oxides – Thermal Oxidizer ................................ 6-52 6.13.3 BACT for Carbon Monoxide – Thermal Oxidizer ............................. 6-53 6.13.4 BACT for Sulfur Dioxide – Thermal Oxidizer ................................... 6-53 6.13.5 BACT for Volatile Organic Compounds – Thermal Oxidizer ............ 6-53 6.13.6 BACT for Particulate Matter (PM/PM10/PM2.5) – Thermal Oxidizer . 6-54 6.13.7 BACT for Greenhouse Gases (GHG) – Thermal Oxidizer ................. 6-54
BACT for Biogas/NCG Process Vent Thermal Oxidizer (EP-09100) .............. 6-56 6.14
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6.14.1 Introduction ......................................................................................... 6-56 6.14.2 BACT for Volatile Organic Compounds – Thermal Oxidizer ............ 6-56
BACT for Particulate Matter (PM/PM10/PM2.5) – Material Handling 6.15 Fugitives ............................................................................................................. 6-57 6.15.1 Introduction ......................................................................................... 6-57 6.15.2 BACT for Facility Berm ..................................................................... 6-57 6.15.3 BACT for Biomass Storage Piles ....................................................... 6-58 6.15.4 BACT for Material Handling Transfer Points .................................... 6-59
BACT for Particulate Matter (PM/PM10/PM2.5) – Ash Load-Out Points .......... 6-62 6.16 6.16.1 Introduction ......................................................................................... 6-62 6.16.2 Step 1. Identify Potential Control Technologies ................................. 6-62 6.16.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-63 6.16.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-65 6.16.5 Step 4. Evaluate the Technically Feasible Control Technologies ....... 6-65 6.16.6 Step 5. Select Ash Load-Out Points BACT ........................................ 6-66
BACT for Particulate Matter (PM/PM10/PM2.5) – Fly Ash Silo Bin Vent ........ 6-67 6.17 6.17.1 Step 1. Identify Potential Control Technologies ................................. 6-67 6.17.2 Step 2. Identify Technically Feasible Control Technologies .............. 6-68 6.17.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-68 6.17.4 Step 4. Evaluate the Technically Feasible Control Technologies ....... 6-69 6.17.5 Step 5. Select Fly Ash Silo Bin Vent BACT ...................................... 6-69
BACT for Volatile Organic Compounds (VOC) – Storage Tanks .................... 6-70 6.18 6.18.1 Introduction ......................................................................................... 6-70 6.18.2 Step 1 and Step 2. Identify Potential Control Strategies and
Eliminate Technologically Infeasible Options ................................... 6-70 6.18.3 Step 3. Rank the Technically Feasible Control Technologies ............ 6-71 6.18.4 Steps 4 and 5. Evaluate the Most Effective Control Technologies
and Proposed BACT for VOC Emissions .......................................... 6-71 BACT for Volatile Organic Compounds (VOC) – Fugitive Leaks and 6.19
Loading Losses .................................................................................................. 6-71 6.19.1 Introduction ......................................................................................... 6-71 6.19.2 Step 1. Identify Potential Control Strategies ....................................... 6-71 6.19.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-72 6.19.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-72 6.19.5 Step 4 & 5. Evaluate and Select Fugitive Leaks and Loading
Losses BACT ...................................................................................... 6-72 BACT for Volatile Organic Compounds (VOC) – Lignin-Rich Stillage 6.20
Storage ............................................................................................................... 6-72 6.20.1 Introduction ......................................................................................... 6-72 6.20.2 Step 1. Identify Potential Control Strategies ....................................... 6-72 6.20.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-72 6.20.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-73 6.20.5 Step 4 & 5. Evaluate and Select Lignin-Rich Stillage Storage
BACT .................................................................................................. 6-73 BACT for Volatile Organic Compounds (VOC) – EH Fermentation Process .. 6-73 6.21
6.21.1 Introduction ......................................................................................... 6-73
ABBK Energy, Inc. TOC-5 Burns & McDonnell
6.21.2 Step 1. Identify Potential Control Strategies ....................................... 6-74 6.21.3 Step 2. Identify Technically Feasible Control Technologies .............. 6-74 6.21.4 Step 3. Rank the Technically Feasible Control Technologies ............ 6-74 6.21.5 Step 4 & 5. Evaluate and Select EH Fermentation CO2 Scrubber
BACT .................................................................................................. 6-74
7.0 AIR DISPERSION MODELING ......................................................................... 7-1 Air Dispersion Model .......................................................................................... 7-1 7.1 Model Parameters ................................................................................................ 7-3 7.2
7.2.1 Good Engineering Practice ................................................................... 7-4 7.2.2 Haul Roads ............................................................................................ 7-5 7.2.3 Storage Piles.......................................................................................... 7-5 7.2.4 Flares ..................................................................................................... 7-6 7.2.5 Inventory of Neighboring Sources ........................................................ 7-6
Modeling Methodology and Parameters .............................................................. 7-7 7.3 7.3.1 Receptor Grid ........................................................................................ 7-7 7.3.2 Meteorological Data.............................................................................. 7-8 7.3.3 Model Parameters ................................................................................. 7-8 7.3.4 Significant Impact Area Determination ................................................ 7-8 7.3.5 NAAQS and PSD Class II Increment Consumption Analysis .............. 7-8 7.3.6 Ambient Monitoring ............................................................................. 7-9 7.3.7 NO2 Modeling – Multi-Tiered Screening Approach .......................... 7-10
Significance Model Results ............................................................................... 7-11 7.4 7.4.1 NO2 Results ......................................................................................... 7-12 7.4.2 CO Results .......................................................................................... 7-12 7.4.3 PM2.5/PM10 Results ............................................................................. 7-13 7.4.4 SO2 Results ......................................................................................... 7-13
PSD Class II Increment Modeling ..................................................................... 7-13 7.5 NAAQS Modeling ............................................................................................. 7-14 7.6 PSD Class I Analysis ......................................................................................... 7-16 7.7 Conclusion ......................................................................................................... 7-16 7.8 Analysis of Secondary PM2.5 Formation............................................................ 7-16 7.9
Scheffe Ozone Analysis ..................................................................................... 7-19 7.10 Representative Monitors .................................................................................... 7-20 7.11
7.11.1 Monitor Location ................................................................................ 7-21 7.11.2 Data Quality ........................................................................................ 7-22 7.11.3 Currentness of Data ............................................................................. 7-22 7.11.4 Monitor Recommendations ................................................................. 7-22
8.0 ADDITIONAL IMPACT ANALYSIS ................................................................... 8-1 Construction Impacts ........................................................................................... 8-1 8.1 Vegetation Impacts .............................................................................................. 8-1 8.2
8.2.1 Nitrogen Oxides .................................................................................... 8-2 8.2.2 Synergistic Effects of Pollutants ........................................................... 8-3 8.2.3 Particulate Matter .................................................................................. 8-3
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8.2.4 Carbon Monoxide ................................................................................. 8-3 8.2.5 Carbon Dioxide ..................................................................................... 8-3
Soil Impacts ......................................................................................................... 8-4 8.3 Industrial, Residential, and Commercial Growth Impacts ................................... 8-4 8.4 Visibility and Deposition Analysis ...................................................................... 8-5 8.5
8.5.1 Class I Area Analysis ............................................................................ 8-5 8.5.2 Visual Impairment Screening Assessment ............................................ 8-5
Conclusion ......................................................................................................... 8-15 8.6
9.0 REFERENCES .................................................................................................. 9-1
APPENDIX A - FORMS APPENDIX B - LAYOUTS APPENDIX C - EMISSION CALCULATIONS APPENDIX D - RBLC APPENDIX E - MODELING PROTOCOL APPENDIX F - FIGURES APPENDIX G - MODELING FILES
LIST OF TABLES
Table 1-1: Project Potential Emissions and PSD Significance Levels .................................... 1-3
Table 1-2: Summary of BACT Results: RICE. ....................................................................... 1-5
Table 1-3: Summary of BACT Results: Other Equipment and Emission Points. ................... 1-6
Table 1-4: Additional Emission Points at Enzymatic Hydrolysis Plant .................................. 1-9
Table 2-1. Facility Potential Emissions and PSD Significance Levels ................................... 2-2
Table 4-1: Non-Emergency RICE Maximum Expected Hourly Emission Rates. ................... 4-2
Table 6-1: Summary of BACT Results: Non-Emergency RICE. ............................................ 6-1
Table 6-2: Summary of BACT Results: Auxiliary Equipment. ............................................... 6-2
Table 6-3: Summary of BACT Results: Material Handling Transfer Points........................... 6-3
Table 6-4: Emission Rates for Engines Similar to Project Engines at Full Load (g/bhp-hr). .............................................................................................................. 6-8
Table 6-5: Summary of Technically Feasible NOx Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-11
Table 6-6: Ranking of Technically Feasible NOx Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-12
Table 6-7: Summary of Technically Feasible CO Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-15
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Table 6-8: Ranking of Technically Feasible CO Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-15
Table 6-9: Summary of Technically Feasible VOC Control Technologies for the Non-Emergency RICE. ........................................................................................ 6-20
Table 6-10: Ranking of Technically Feasible VOC Control Technologies for the Non- Emergency RICE. ................................................................................................. 6-20
Table 6-11: Summary of Potential GHG Control Technologies. ............................................ 6-23
Table 6-12: CO2 Emission Factors for Various Fuels ............................................................. 6-25
Table 6-13: Ranking of Potential Generating Technologies by Heat Rate. ............................. 6-28
Table 6-14: Power Plant Heat Rates and GHG Performance. ................................................. 6-28
Table 6-15: Power Supply Sample Scenarios. ......................................................................... 6-30
Table 6-16: GHG Technology Ranking for the Project. .......................................................... 6-30
Table 6-17: Summary of Potential NOx Control Technologies. .............................................. 6-32
Table 6-18: Ranking of SO2 Control Technologies for the Boiler .......................................... 6-42
Table 6-19: Ranking of PM Control Technologies for the Boiler ........................................... 6-47
Table 6-20: Ranking of GHG Control Technologies for the Boiler and Reheat Burner ......... 6-50
Table 6-21: Fly Ash Load-Out Technically Feasible Control Options ................................... 6-65
Table 6-22: Bottoms Ash Load-Out Technically Feasible Control Options ........................... 6-65
Table 6-23: Ash Load-Out Points BACT Emission Rates ...................................................... 6-67
Table 6-24: Grain Handling Technically Feasible Control Options ........................................ 6-68
Table 6-25: Fly Ash Silo Bin Vent BACT Emission Rates ..................................................... 6-69
Table 7-1: Combustion Engine Emissions and Modeling ParametersA ................................... 7-3
Table 7-2. Emergency Fire Pump and Thermal Oxidizer Modeling Parameters .................... 7-4
Table 7-3: Fence Line Coordinates (Zone 14). ........................................................................ 7-8
Table 7-4: Background Level. ................................................................................................. 7-9
Table 7-5: NAAQS, Significance, and Monitoring Levels and PSD Class II Increment (μg/m3). ............................................................................................... 7-10
Table 7-6: In Stack Ratios. .................................................................................................... 7-11
Table 7-7: Maximum Modeled Concentrations. .................................................................... 7-12
Table 7-8: Increment Modeling Results. ............................................................................... 7-14
Table 7-9: NAAQS Modeling Results. .................................................................................. 7-15
Table 7-10: Modeled Highs. .................................................................................................... 7-15
Table 7-11: EPA’s Cross-State Air Pollution Rule Emission Summary for Kansas ............... 7-17
Table 7-12: EPA’s Cross-State Air Pollution Rule Modeling Results & Estimated Project Impact ...................................................................................................... 7-18
Table 7-13: EPA’s Cross-State Air Pollution Rule Annual PM2.5 Modeling Results & Estimated Project Impact ..................................................................................... 7-19
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Table 7-14: Selected Monitors for Background Concentrations ............................................... 7-21
Table 8-1: Location of Class II Sensitive Areas ...................................................................... 8-7
Table 8-2: Distance to Class II Sensitive Areas and Flow Vectors ......................................... 8-8
Table 8-3: Joint Frequency Distribution Analysis Meteorological Conditions ....................... 8-8
Table 8-4: Joint Frequency Distribution Analysis Meteorological Conditions ....................... 8-9
Table 8-5: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Cimarron National Grasslands – WSW Wind Direction Sector Only ........................................................................................................... 8-10
Table 8-6: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Cimarron National Grasslands – W Wind Direction Sector Only ........................................................................................................... 8-11
Table 8-7: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Hugoton Municipal Airport – SSE Wind Direction Sector Only ........................................................................................................... 8-11
Table 8-8: Worst-Case Meteorological Conditions for Plume Visual Impact Calculations at the Hugoton Municipal Airport – S Wind Direction Sector Only ...................................................................................................................... 8-12
Table 8-9: Level 2 VISCREEN Results for Cimarron National Grasslands ......................... 8-13
Table 8-10: Level 2 VISCREEN Results for Hugoton Municipal Airport .............................. 8-13
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LIST OF FIGURES
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Figure 7-29: Counties in Kansas ...................................................................................... Page 7-19 Figure 7-30: Monitor Locations..................................................................................APPENDIX F Figure 7-31: Primary Land Use – ABBK ...................................................................APPENDIX F Figure 7-32: Primary Land Use – Dodge City, KS ....................................................APPENDIX F Figure 7-33: Primary Land Use – Cedar Bluff, KS ....................................................APPENDIX F Figure 7-34: PM10 Sources Surrounding ABBK ........................................................APPENDIX F Figure 7-35: PM10 Sources Surrounding Dodge City Monitor ...................................APPENDIX F Figure 7-36: PM2.5 Sources Surrounding ABBK .......................................................APPENDIX F Figure 7-37: PM2.5 Sources Surrounding Cedar Bluff Monitor..................................APPENDIX F Figure 7-38. State of Kansas Population Density Map and the Location of PM2.5 Monitors
Compared to Project Site. ............................................................................ Page 7-23
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LIST OF ABBREVIATIONS
AERMOD AMS/EPA Regulatory Model
b* saturation
BPIP-PRIME Building Profile Input Program-Plume Rise Model Enhancements
CAA Clean Air Act
CEM Continuous Emission Monitor
CO carbon monoxide
CO2 carbon dioxide
DEM Digital Elevation Model
EGU Electric Generating Unit
°F degrees Fahrenheit
FLAG Federal Land Managers' Air Quality Related Values Work Group
FLM Federal Land Manager
ft/s feet per second
GEP Good Engineering Practice
g/bhp-hr gram per brake horsepower hour
g/hp-hr gram per horsepower hour
H2SO4 sulfuric acid
hp horsepower
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Abbreviation Term/Phrase/Name K.A.R Kansas Administrative Regulations
KDHE Kansas Department of Health and Environment
kPa kilopascals
kW kilowatt
L* brightness
MACT Maximum Achievable Control Technology
CH4 methane
MW megawatt
NAD North American Datum
NED National Elevation Dataset
NSPS New Source Performance Standards
NO nitrogen oxide
NOx nitrogen oxides
NO2 nitrogen dioxide
N2O nitrous oxide
NMHC non-methane hydrocarbons
OLM Ozone Limiting Method
PM2.5 particulate matter of 2.5 microns in diameter or smaller
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Abbreviation Term/Phrase/Name PM10 particulate matter of 10 microns in diameter or smaller
ppm parts per million
PRIME plume rise model enhancements
PSD Prevention of Significant Deterioration
PVMRM Plume Volume Molar Ratio Method
RBLC RACT/BACT/LAER Clearinghouse
RMP risk management plan
ROI radius of impact
SCR selective catalytic reduction
μm micrometer
PSD Air Construction Permit Application Executive Summary
Abengoa Bioenergy Biomass of Kansas, LLC 1-1 Burns & McDonnell
1.0 EXECUTIVE SUMMARY
Pursuant to the requirements specified in the Kansas Administrative Regulations (K.A.R) 28-19-350,
Abengoa Bioenergy Biomass of Kansas, LLC (ABBK) submits this Prevention of Significant
Deterioration (PSD) construction permit application for several changes to the existing facility
(hereinafter referred to as the Project) located in Stevens County, Kansas, approximately 1.5 miles west of
Hugoton, Kansas.
On September 16, 2011, ABBK was issued a PSD permit for construction of this biomass-to-ethanol and
biomass-to-energy production facility. On January 22, 2013, the PSD permit was amended for the
construction of four natural gas-fired spark ignition emergency engines. This application amends the PSD
permit once more to allow the emergency engines to operate in an unrestricted manner and for several
other plant modifications. Even though the emissions increase associated with this application are below
the PSD major project at a major source thresholds, for permitting purposes this project is considered a
continuation of the previous PSD project and as such is subject to PSD review for PM, PM10, PM2.5, NOx,
CO, VOC, SO2, and CO2e.
The requested modifications are as follows:
1. The ability to operate two of the four natural gas-fired emergency generators for 8,760 hours per
year and the ability to sell excess generated electricity to the grid (but at an amount less than that
which would trigger regulation under the Acid Rain regulations of 40 CFR Part 72)
2. Larger size for the emergency fire pump (617 hp instead of 460…