INDIANA DEPARTMENT OF ENVIRONMENTAL ANAGEMENT We Protect ...

I NDIANA D EPARTMENT OF E NVIRONMENTAL M ANAGEMENT

We Protect Hoosiers and Our Environment.

100 North Senate Avenue

Indianapolis, Indiana 46204

(317) 232-8603

Toll Free (800) 451-6027

idem.

Mitchell E. Daniels Jr.

Governor

Thomas W. Easterly

Commissioner

TO:

Interested Parties / Applicant

DATE:

July 20, 2012

RE:

Metal Technologies Auburn, LLC/033-31731-00042

FROM:

Matthew Stuckey, Branch Chief

Permits Branch

Office of Air Quality

Notice of Decision: Approval - Effective Immediately

Please be advised that on behalf of the Commissioner of the Department of Environmental Management,

I have issued a decision regarding the enclosed matter. Pursuant to IC 13-15-5-3, this permit is effective

immediately, unless a petition for stay of effectiveness is filed and granted according to IC 13-15-6-3, and

may be revoked or modified in accordance with the provisions of IC 13-15-7-1.

If you wish to challenge this decision, IC 4-21.5-3 and IC 13-15-6-1 require that you file a petition for

administrative review. This petition may include a request for stay of effectiveness and must be submitted

to the Office of Environmental Adjudication, 100 North Senate Avenue, Government Center North, Suite

N 501E, Indianapolis, IN 46204, within eighteen (18) calendar days of the mailing of this notice. The

filing of a petition for administrative review is complete on the earliest of the following dates that apply to

the filing:

(1)

the date the document is delivered to the Office of Environmental Adjudication (OEA);

(2)

the date of the postmark on the envelope containing the document, if the document is mailed to

OEA by U.S. mail; or

(3)

The date on which the document is deposited with a private carrier, as shown by receipt issued

by the carrier, if the document is sent to the OEA by private carrier.

The petition must include facts demonstrating that you are either the applicant, a person aggrieved or

adversely affected by the decision or otherwise entitled to review by law. Please identify the permit,

decision, or other order for which you seek review by permit number, name of the applicant, location, date

of this notice and all of the following:

(1)

the name and address of the person making the request;

(2)

the interest of the person making the request;

(3)

identification of any persons represented by the person making the request;

(4)

the reasons, with particularity, for the request;

(5)

the issues, with particularity, proposed for considerations at any hearing; and

(6)

identification of the terms and conditions which, in the judgment of the person making the

request, would be appropriate in the case in question to satisfy the requirements of the law

governing documents of the type issued by the Commissioner.

If you have technical questions regarding the enclosed documents, please contact the Office of Air

Quality, Permits Branch at (317) 233-0178. Callers from within Indiana may call toll-free at 1-800-4516027, ext. 3-0178.

Enclosures

FNPER.dot12/03/07

Recycled Paper

An Equal Opportunity Employer

Please Recycle

Metal Tech. Auburn, LLC

Auburn, IN

Page 2 of 5

Source Modification No. 033-31731-00042

of 9 11 tons of metal and 55 tons of sand per hour; a maximum capacity of 11.25 15 tons

of metal and 62.5 75 tons of sand per hour; particulate emissions controlled by baghouse

DC-8; emissions exhaust to stack S-8. EU- 3a3 is considered part of the affected source

under 40 CFR Part 63, Subpart EEEEE.

(e)

One (1) Line 4 pouring and casting operation; identified as EU-3a4; constructed in 1995

and approved for modification in 2012; a nominal capacity of 9 11 tons of metal and 55

tons of sand per hour; a maximum capacity of 11.25 15 tons of metal and 62.5 75 tons of

sand per hour; particulate emissions controlled by baghouse DC-8; emissions exhaust to

stack S-8. EU-3a4 is considered part of the affected source under 40 CFR Part 63,

Subpart EEEEE.

(f)

One (1) Line 1 casting mold cooling operation; identified as EU-3b1; constructed in

1995; a nominal capacity of 10 tons of metal and 55 tons of sand per hour; a maximum

capacity of 11.25 15 tons of metal and 62.5 75 tons of sand per hour; emissions exhaust

to stack S-3b.

(g)

One (1) Line 2 casting mold cooling operation; identified as EU-3b2; constructed in

1995; a nominal capacity of 9 10 tons of metal and 55 tons of sand per hour; a maximum

capacity of 11.25 15 tons of metal and 62.5 75 tons of sand per hour; emissions exhaust

to stack S-3b.

(h)

One (1) Line 3 casting mold cooling operation; identified as EU-3b3; constructed in 1995

and approved for modification in 2012; a nominal capacity of 9 11 tons of metal and 55

tons of sand per hour; a maximum capacity of 11.25 15 tons of metal and 62.5 75 tons of

sand per hour; emissions exhaust to stack S-3d.

(i)

One (1) Line 4 casting mold cooling operation; identified as EU-3b4; constructed in 1995

and approved for modification in 2012; a nominal capacity of 9 11 tons of metal and 55

tons of sand per hour; a maximum capacity of 11.25 15 tons of metal and 62.5 75 tons of

sand per hour; emissions exhaust to stack S-3d.

(j)

One (1) Line 3 and Line 4 shakeout/casting cooling operation; identified as EU-4;

constructed in 1995 and approved for modification in 2012; consisting of the

following equipment/operations: a nominal capacity of 18 tons of metal and 110 tons

of sand per hour; a maximum capacity of 22.5 tons of metal and 125 tons of sand per

hour; particulate emissions controlled by baghouses DC-4 and DC-8; emissions exhaust

to stacks S-4 and S-8.

(k)

(1)

Line 3 shakeout/ casting cooling operation identified as EU-4a with a

nominal capacity of 11 tons of metal and 55 tons of sand per hour; a

maximum capacity of 15 tons of metal and 75 tons of sand per hour,

particulate emissions controlled by baghouse DC-3 and exhausting to

stacks S-15.

(2)

Line 4 shakeout/ casting cooling operation identified as EU-4b with a

nominal capacity of 11 tons of metal and 55 tons of sand per hour; a

maximum capacity of 15 tons of metal and 75 tons of sand per hour,

particulate emissions controlled by baghouse DC-4, emissions exhausting

to stack S-4.

One (1) shot reblast unit; identified as EU-6; constructed in 1997; a nominal capacity of

1.12 tons of iron castings per hour; a maximum capacity of 5 tons of iron castings per

hour; emissions controlled by baghouse DC-8, which exhausts to stack S-8.

Metal Tech. Auburn, LLC

Auburn, IN

Page 3 of 5

Source Modification No. 033-31731-00042

(l)

One (1) shot blast system; consisting of four (4) shot blast units; identified as EU-16

through EU-19; constructed in 1999 and approved for modification in 2012; a total

nominal capacity of 27 tons of iron castings per hour; a total maximum capacity of 32 tons

of iron castings per hour; with emissions controlled by baghouse DC-73, which exhausts

to stack S-8 15.

(m)

One (1) ductile iron conversion process: one identified as EU-20; constructed in 2009,

with a nominal capacity of 36 30 tons of metal per hour, and a maximum capacity of 45 35

tons of metal per hour; 58% of particulate emissions controlled by baghouse System 20 to

stack S-20; Production limited to 95,000 tons per rolling 12-months period.

(n)

One (1) Phenolic Urethane Cold Box (PUCB) core production process with a

nominal capacity of 2.9 tons of cores per hour, approved for construction in 2012,

consisting of the following units:

1. Two (2) 65 ton core sand silos identified as EU-30a and EU-30b each controlled

by a bin vent filter exhausting inside the building.

2. One (1) Core sand mixer and sand transport system, identified as EU-30b, with

a nominal capcity of 2.9 tons per hour, with emissions vented back to the core

sand silo.

3. One (1) PUCB core machine, identified as EU30c with a nominal capacity of 2.9

tons of cores/hour, each using a tertiary amine catalyst gas controlled by an

acid scrubber, identified as SC-1 venting to stack SC-1.

4. One (1) water based core wash; and

5.

(o)

One (1) 1.5 MMBtu per hr natural gas fired drying oven.

One (1) Warm Box Core production process with a nominal capacity of 2.9 tons

cores per hour, approved for construction in 2012, consisting of the following

units;

(1)

One (1) 65 ton core sand silo, identified as EU-31a controlled by a bin vent

filter exhausting inside the building; and

(2)

One (1) warm box core machine, identified as EU31b with a nominal

capacity of 2.9 tons of cores/hour and 0.6 MMBtu per hr of natural gas.

Insignificant Activities

(a)

Grinding and machining operations controlled with fabric filters, scrubbers, mist collectors,

wet collectors and electrostatic precipitators with a design grain loading of less than or

equal to 0.03 grains per actual cubic foot and a gas flow rate less than or equal to 4000

actual cubic feet per minute, including the following: deburring, buffing, polishing, abrasive

blasting, pneumatic conveying, and woodworking operations, which include the following:

Two (2) enclosed grinding units controlled by fabric filters and exhausting inside the

building; and One (1) test sample blast machine; identified as EU-1b; constructed in

1995 controlled by fabric filters and exhausting inside the building. [326 IAC 6-3-2]

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