Exhibit 10.1
UNITED STATES DISTRICT COURT
CENTRAL DISTRICT OF ILLINOIS
UNITED STATES OF AMERICA, |
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Plaintiff, and |
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STATE OF ILLINOIS, |
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Plaintiff-Intervenor, |
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Civil Action Number: 05-1395 |
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MGP INGREDIENTS OF ILLINOIS, INC., |
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Defendant. |
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CONSENT DECREE
TABLE OF CONTENTS
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CONSENT DECREE
WHEREAS, Plaintiff, the United States of America (hereinafter Plaintiff or the United States), on behalf of the United States Environmental Protection Agency (herein, U.S. EPA), has, simultaneously with lodging of this Consent Decree, filed a Complaint alleging that Defendant, MGP Ingredients of Illinois, Inc. (MGP or Defendant) commenced construction of major modifications to a major emitting facility in violation of the Prevention of Significant Deterioration (PSD) requirements at Part C of the Clean Air Act (the Act), 42 U.S.C. §§ 7470-7492, and the regulations promulgated thereunder at 40 C.F.R. § 52.21 (the PSD Rules);
WHEREAS, Plaintiff further alleged that Defendant commenced construction of major modifications to a major emitting facility and thereafter operated the facility without first obtaining the appropriate preconstruction permits and installing the appropriate air pollution control equipment required by 40 C.F.R. § 52.21 and the Illinois State Implementation Plan (SIP) approved pursuant to 42 U.S.C. § 7410;
WHEREAS, Plaintiff further alleged that potential air emissions from the Defendants facility were underestimated by MGP for purposes of determining the applicable permit requirements;
WHEREAS, the State of Illinois, (Plaintiff-Intervenor or Illinois), has, simultaneously with lodging of this Consent Decree, filed a Complaint in Intervention, alleging that MGP was and is in violation of PSD requirements and the Illinois SIP, by failing to obtain the appropriate pre-construction permits and state permits, and by failing to install appropriate pollution control technology, in violation of applicable federal and state laws, including Sections 9(b) and 9.1 of the Illinois Environmental Protection Act;
WHEREAS, MGP has operated a grain processing facility in Pekin, Illinois (the Facility) since at least 1980;
WHEREAS, MGP has made various modifications to its grain processing facility, including changes in 1988 and 1993, pursuant to permits 88010011 and 93080045, respectively, issued by the Illinois Environmental Protection Agency (IEPA), which resulted in significant increases in its production capacity;
WHEREAS, on June 3, 2002, the U.S. EPA met with representatives of the ethanol plants in Illinois, including MGP, to discuss VOC testing and test results, VOC emissions, and related compliance issues;
WHEREAS, on April 2, 2003, MGP met with U.S. EPA and IEPA and agreed to negotiate with U.S. EPA and Illinois for the installation of controls on the Facility to address the alleged violations of the PSD requirements;
WHEREAS, MGP has worked cooperatively with U.S. EPA and IEPA regarding the alleged violations;
WHEREAS, the Defendant does not admit the facts or violations alleged in the Complaints;
WHEREAS, the United States and Plaintiff-Intervenor (collectively Plaintiffs) and the Defendant have agreed that settlement of this action is in the best interest of the parties and in the public interest, and that entry of this Consent Decree without further litigation is the most appropriate means of resolving this matter; and
WHEREAS, Plaintiffs and the Defendant consent to entry of this Consent Decree without trial of any issues;
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NOW, THEREFORE, without any admission of fact or law, and without any admission of the violations alleged in the Complaints, it is hereby ORDERED AND DECREED as follows:
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(b). MGP owns and operates a grain processing facility in Pekin, Illinois (the Facility), for the manufacture of various products from flour and grain, including fuel and beverage ethanol. The Plaintiffs allege that in the course of MGPs manufacturing activities significant quantities of particulate matter (PM), particulate matter at or below 10 microns (PM10), carbon monoxide (CO), volatile organic compounds (VOCs), nitrogen oxides (NOx) and other pollutants are generated, including hazardous air pollutants (HAPs) listed under Section 112(b)(1), 42 U.S.C. § 7412(b)(1) of the Act. The primary sources of these emissions are the feed dryers, fermentation tanks, distillation units, and load-out of ethanol into trucks.
(c). Plaintiffs allege that the Facility is a major emitting facility, as defined by Section 169(1) of the Act, 42 U.S.C. § 7479(1), and the federal and state regulations promulgated pursuant to the Act.
(d). Unless otherwise defined herein, terms used in this Consent Decree shall have the meaning given to those terms in the Act, and the federal and state regulations promulgated pursuant to the Act.
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I certify under penalty of law that I have personally examined the information submitted herein and that I have made a diligent inquiry of those individuals immediately responsible for obtaining the information and that to the best of my knowledge and belief, the information submitted herewith is true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fine and imprisonment.
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Illinois Environmental Protection Agency
Fiscal Services Section
1021 North Grand Avenue East
P.O. Box 19276
Springfield, IL 62794-9276
Defendants Federal Employers Identification Number (FEIN) is 48-0911013 and shall be set forth on each certified check or certified fund transfer.
(a). for each day of failure to meet a deadline, including any modified deadline agreed to in writing by the Plaintiffs, for installation of control technology set
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forth in the Control Technology Plan or applying for a revised operating permit under Paragraph 13:
1st through 30th day after deadline |
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$ |
800 |
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31st through 60th day after deadline |
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1,200 |
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Beyond 60th day |
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2,000 |
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(b). for failure to conduct a compliance test as required by Paragraph 19, per unit per day:
1st through 30th day after deadline |
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$ |
250 |
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31st through 60th day after deadline |
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500 |
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Beyond 60th day |
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1,000 |
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(c). for failure to demonstrate compliance with emission limits set forth in the approved Control Technology Plan or emission limits set pursuant to Part V Section C (Emission Limits): $500 per day per test for each pollutant.
(d). for each failure to submit reports as required by Part V Section E (Recordkeeping and Reporting Requirements) of this Consent Decree, per day per report or notice:
1st through 30th day after deadline |
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$ |
250 |
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31st through 60th day after deadline |
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500 |
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Beyond 60th day |
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1,000 |
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(e). for failure to pay or escrow stipulated penalties, as specified in Paragraphs 32 and 33 of this section, $500 per day per penalty demand.
(f). for failure to notify the Plaintiffs pursuant to Paragraph 2 of MGPs sale or transfer of the Facility, $250 per day.
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(a). submitting a timely and complete permit application;
(b). responding to requests for additional information by the permitting authority in a timely fashion; and
(c). prosecuting appeals of any disputed terms and conditions imposed by the permitting authority in an expeditious fashion.
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As to the United States:
Chief
Environmental Enforcement Section
Environment and Natural Resources Division
U.S. Department of Justice
P.O. Box 7611, Ben Franklin Station
Washington, DC 20044-7611
As to the U.S. EPA:
Director, Air Enforcement Division
U.S. Environmental Protection Agency
Ariel Rios Building
1200 Pennsylvania Avenue, N.W.
Mail Code 2242-A
Washington, DC 20004
Region 5:
Compliance Tracker
Air Enforcement Branch, AE-17J
U.S. EPA, Region 5
77 W. Jackson Blvd.
Chicago, IL 60604
As to MGP Ingredients of Illinois, Inc.:
Robert Taphorn
MGP Ingredients of Illinois, Inc.
1301 S. Front Street
Pekin, IL 61555
and
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(Counsel for MGP)
Amy L. Wachs
Husch & Eppenberger, L.L.C.
190 Carondelet Plaza
Suite 600
St. Louis, MO 63105
As to Plaintiff-Intervenor the State of Illinois:
Julie K. Armitage
Illinois Environmental Protection Agency
Compliance and Enforcement Section, Manager
1021 North Grand Avenue East
Springfield, Illinois 62794
and
(Illinois Attorney Generals Office)
Jane McBride
Assistant Attorney General
Office of the Attorney General
500 South Second Street
Springfield, IL 62706
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So ordered in accordance with the foregoing this 19th day of April, 200[6].
/s/ Michael M. Mihm |
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United States District Court Judge |
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Central District of Illinois |
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U.S. and the State of Illinois v. MGP, Ingredients of Illinois, Inc.
FOR PLAINTIFF, UNITED STATES OF AMERICA:
s/: Sue Ellen Wooldridge |
Date December 5, 2005 |
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s/: William D. Brighton |
Date December 14, 2005 |
U.S. and the State of Illinois v. MGP, Ingredients of Illinois, Inc.
RODGER A. HEATON |
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s/: GERARD A. BROST |
Date December 21, 2005 |
U.S. and the State of Illinois v. MGP, Ingredients of Illinois, Inc.
FOR U.S. ENVIRONMENTAL PROTECTION AGENCY:
s/: Granta Y. Nakayama |
Date December 14, 2005 |
U.S. and the State of Illinois v. MGP, Ingredients of Illinois, Inc.
FOR THE PLAINTIFF-INTERVENOR, THE STATE OF ILLINOIS
s/: Thomas Davis |
Date September 27, 2005 |
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s/: William Ingersoll |
Date October 19, 2005 |
U.S. and the State of Illinois v. MGP, Ingredients of Illinois, Inc.
FOR DEFENDANT, MGP INGREDIENTS OF ILLINOIS, INC.:
s/: David L. Wilbur |
Date September 22, 2005 |
CONTROL TECHNOLOGY PLAN
June 30, 2005
TABLE OF CONTENTS
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4-1 |
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5-1 |
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PROPOSED MONITORING PARAMETERS FOR POLLUTION CONTROL DEVICES |
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POLLUTION CONTROL DEVICE PERFORMANCE TEST SCHEDULE AND TEST METHODS USED |
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9.0 |
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PAVED ROADWAY SITE PLAN |
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MGP Ingredients of Illinois, Inc. has entered into a consent decree with the United States and the State of Illinois that requires MGP Ingredients of Illinois, Inc. to implement a program of compliance at the corn dry mill ethanol plant it operates in Pekin, Illinois. MGP Ingredients of Illinois, Inc. prepared and submitted this Control Technology Plan (CTP) as an integral part of the consent decree. This CTP fulfills the requirements of the consent decree and has been reviewed and approved by the US Environmental Protection Agency (USEPA) and the Illinois Environmental Protection Agency (IEPA) as part of the consent decree.
The CTP includes the following items:
· Identification of all units to be controlled;
· Engineering design criteria for all the controls capable of meeting the emission levels required by Part V of the Consent Decree;
· Emission limits and controlled outlet concentrations for each pollutant as appropriate;
· A schedule for expedited installation with specific milestones applicable on a unit-by-unit basis;
· Monitoring parameters for all control equipment and parameter ranges;
· Identification of all units to be emission tested under Paragraph 11 of the Consent Decree and schedule for initial tests and retest;
· The test methods that will be used to demonstrate compliance with the emissions levels set forth by the Consent Decree;
· Program for minimization of fugitive dust emissions from facility operations.
1-1
2.0 EMISSION UNITS REQUIRING POLLUTION CONTROL EQUIPMENT
The following emission units, fugitive sources, and control equipment have been designated as affected units in the consent decree and have emission limits requiring pollution control technology.
Unit Description |
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Control Equipment Description |
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Prefermentation Tank #400 |
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Fermentation Scrubber #405 |
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Fermentation Tank #410 |
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Fermentation Tank #420 |
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Fermentation Tank #430 |
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Fermentation Tank #415 |
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Fermentation Scrubber #451 |
Fermentation Tank #425 |
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Fermentation Tank #435 |
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Fermentation Tank #440 |
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Beerwell Tank #445 |
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Distillation |
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Distillation Scrubber #501 |
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De-Gasser |
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Degasser Scrubber #561 |
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DDGS Dryer #6000 |
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Internal Thermal Oxidizer |
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DDGS Dryers #660 |
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Thermal Oxidizer/Replace dryer(s) with add-on thermal |
DDGS Dryers #650 |
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oxidizer or with dryer equipped with an internal thermal oxidizer such as the Swiss Control Eco-Dry System |
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Ethanol Truck Loadout |
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Vapor Combustion Unit |
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Rail & Barge Loadout |
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Dedicated Fleet |
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Valve, Flange, and Seal Fugitive Emissions |
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LDAR Program under 40 CFR 60 Subpart VV |
2-1
3.0 ENGINEERING DESIGN CRITERIA FOR POLLUTION CONTROL EQUIPMENT
After identifying the affected units that require installation of air pollution control technology, MGP Ingredients conducted a design and engineering review of each unit to select the pollution control technology that would achieve the emission level reductions identified in the consent decree.
Process Description |
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Control Device |
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Operating |
Prefermentation |
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Packed Bed Scrubber Scrubber #405 (existing) |
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Water flow rate > 30 GPM |
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Fermentation |
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Packed Bed Scrubber Scrubber #451 (existing) |
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Water flow rate > 45 GPM |
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Distillation |
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Packed Bed Scrubber Scrubber #501 (existing) |
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Water flow rate > 3 GPM |
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Degasser |
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Packed Bed Scrubber Scrubber #561 (existing) |
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Water flow rate > 17 GPM |
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DDGS Dryer #6000 |
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Internal Thermal Oxidizer (existing) |
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> 1500°F |
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DDGS Dryers #650 & #660 |
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Thermal Oxidizer(s) or New dryer(s) with thermal oxidizer(s) or internal thermal oxidizer (proposed) |
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> 1500°F |
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Dedicated Fleet |
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Submerged Loading (existing) |
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Not Applicable |
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Ethanol Truck Loadout |
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Vapor Combustion Unit (existing) |
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Presence of Pilot Flame |
3-1
The following flow diagram presents the affected units and associated control technology as determined by the results of engineering design criteria.
3-2
4.0 PROPOSED EMISSION LIMITS FROM POLLUTION CONTROL EQUIPMENT
The consent decree specifies the emission reductions or emission limits allowable for each affected unit. After evaluating the pollution control technology engineering and design, MGP Ingredients of Illinois, Inc. agrees to meet the following emission limits.
Unless otherwise stated, all controlled emission limitations apply at all times except during periods when the process equipment is not operating or if the construction or operating permit contains alternative limits for startup, shutdowns or malfunction, at which point the permit provisions shall prevail.
Any deviations from the requirements of section 4.0, 4.1 and/or 4.2 shall be reported in quarterly reports and as required by state or federal regulations.
4-1
Process Description |
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Control Device |
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Pollutant |
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Emission Rate |
Prefermentation |
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Packed Bed Scrubber #405 |
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VOC |
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95% reduction or not to exceed 20 ppm if inlet concentration is less than 200 ppm |
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Fermentation |
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Packed Bed Scrubber #451 |
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VOC |
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97.5% reduction |
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Distillation |
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Packed Bed Scrubber #501 |
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VOC |
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95% reduction or not to exceed |
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20 ppm if inlet concentration |
Degasser |
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Packed Bed Scrubber #561 |
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VOC |
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is less than 200 ppm |
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DDGS Dryer #6000 |
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Internal Thermal Oxidizer / |
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CO |
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90% reduction or emissions no higher than |
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Replacement Dryer(s) with |
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100 PPM |
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Internal Thermal Oxidizer |
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DDGS Dryers #650 & #660 |
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or Thermal Oxidizer* |
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PM |
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0.01 gr/dscf |
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VOC |
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95% reduction of VOC or emissions no higher |
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than 10 ppm |
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NOx |
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0.15lb/mmbtu* |
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Ethanol Truck Loadout |
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Vapor Combustion Unit |
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VOC |
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95% reduction of VOC |
*The NOx limit of 0.15 lb/mmbtu applies to a feed dryer with an internal thermal oxidizer, as present in the DDGS Dryer #6000 and proposed by MGP to replace existing DDGS. Dryers #650 and #660. If MGP decides to replace DDGS Dryer #650 and #660 with new dryer(s) equipped with add-on thermal oxidation (or retrofit add-on thermal oxidizers to the existing dryers), the NOx limit for the dryer burner is 0.04 lb/mmbtu. For this purpose, compliance may be determined for the dryer without the oxidizer, i.e., NOx emissions in the ductwork prior to the oxidizer and only the heat input to the dryer burner, or at MGPs option, for the dryer as a whole, i.e., NOx at the stack and the actual heat input to the burners in the dryer and the thermal oxidizer.
4-2
4.1 Alternate Operating Scenarios
The facility may continue to operate and produce wet cake during periods of dryer control device downtime.
If thermal oxidizer for existing dryers DDGS Dryer 660 and DDGS Dryer 650 is installed there will be no more than 50 hours per year for bake-out of the Regenerative Thermal Oxidizer (RTO) with each individual bake-out lasting no longer than 12 hours while the dryers are in operation. Off-line RTO regeneration while the associated dryers are shutdown is not included in these operating limitations. MGP may petition USEPA and IEPA to adjust these operating limitations for a specific RTO based on operating experience with the RTO and the dryers on which the RTO is installed. Changes to these regeneration hour limitations shall be considered non-material modifications under paragraph 57 of the Consent Decree, provided MGP obtains written approval of the change(s) from USEPA and IEPA.
4-3
4.2 Interim Operating Scenario
If MGP continues to pursue installation of a replacement dryer, Dryers 650 and D660 will continue to operate during construction of the new dryer. Once the new dryer is installed Dryers D650 and D660 will continue to operate as standby dryers for a period of one (1) year from the official start up date of the new dryer. At this time, MGP will physically disable D650 and D660 by removing the fuel and preventing wet feed supply to the dryers.
MGP will operate Dryers D650 and D660 in their present configuration to minimize PM emissions to the greatest extent reasonably possible.
MGP will not operate D650 and D660 in conjunction with the new dryer and the existing Swiss-combi dryer to facilitate increased feed production by the plant beyond 851 tons per day. Total feed production by the plant during the day when existing feed dryers D650 and D660 operate shall not exceed 851 tons per day. MGP will maintain daily records documenting compliance with the above mentioned limit.
4-4
5.0 POLLUTION CONTROL EQUIPMENT INSTALLATION SCHEDULE
The following table presents the schedule for procurement, installation and startup of new control equipment specified by this plan for DDGS Dryers D650 and D660. MGPs preferred approach for these dryers, which it is currently pursuing, is installation of a replacement feed dryer with an internal thermal oxidizer. The schedule also addresses other approaches to the dryers, i.e., replacement of dryers with new dryers equipped with add-on thermal oxidizers or retrofit of thermal oxidizers to the existing dryers.
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Replacement Dryer |
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Apply for Construction Permit |
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June 1st 2004 |
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Construction Permit Issuance |
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Actual Date (a) |
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Order Equipment |
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Permit Date plus 90 days (b) |
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Commence On-Site Construction |
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Permit Date plus 12 months (b) |
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Startup |
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Permit Date plus 23 months (b) |
a). Actual date of issuance of the Construction Permit, or the date the permit becomes effective, if the permit is not effective when issued. MGP shall take reasonable efforts to support the expeditious issuance of the Construction Permit by the Illinois EPA. The expected date for this to occur is July 15, 2005.
b). Specific dates will be set based on actual date a construction permit is issued or becomes effective, if the permit is not effective when issued. The project is expected to be complete by December 31, 2007, or later, depending on the issuance date of the construction permit.
5-1
6.0 PROPOSED MONITORING PARAMETERS FOR POLLUTION CONTROL DEVICES
Unit/Control |
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Operating Range |
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Monitoring |
Prefermentation/ Scrubber #405 |
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Water flow rate |
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> 30 GPM |
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Daily when operating |
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Fermentation/ Scrubber #451 |
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Water flow rate |
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> 45 GPM |
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Daily when operating |
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Distillation/ Scrubber #501 |
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Water flow rate |
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> 3 GPM |
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Daily when operating |
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Degasser/ Scrubber #561 |
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Water flow rate |
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> 17 GPM |
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Daily when operating |
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DDGS Dryer #6000/ Internal Thermal Oxidizer |
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Temperature Combustion Chamber |
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> 1500°F |
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Daily when operating |
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DDGS Dryer #650 & #660/Thermal Oxidizer or Eco-Dry System with Internal Thermal Oxidizer |
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Temperature Combustion Chamber |
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> 1500°F |
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Daily when operating |
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Ethanol Truck Loadout/Vapor Combustion Unit |
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Flame Present |
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Per 40 CFR 60.18(f)(2) |
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Daily when operating |
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Valve, Flange, and Seal Fugitive Emissions |
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As described in 40 CFR 60 Subpart VV: Standards of Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals Manufacturing industry |
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A described in 40 CFR 60 Subpart VV: Standards of Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals Manufacturing industry |
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As described in 40 CFR 60 Subpart VV: Standards of Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals Manufacturing industry |
6-1
7.0 POLLUTION CONTROL DEVICE PERFORMANCE TEST SCHEDULE AND TEST METHODS USED
The following schedule and methods will be used to demonstrate initial compliance with the emission limits contained in Section 4.0 of this Control Technology Plan.
Process |
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Unit/Control |
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Proposed |
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Pollutants |
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Proposed |
Replacement Dryer with Internal Thermal Oxidizer or DDGS Dryers #650 & #660 |
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Internal Thermal Oxidizer or Thermal Oxidizer |
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Performance tests 60 days after full production or no later than 180 days after initial start-up of thermal oxidizer or replacement dryer with internal thermal oxidizer |
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Total VOC |
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Methods 1, 2, 3A, 4, 18, 25, or 25A if less than 50 ppm |
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PM/PM10 |
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Methods 1, 2, 3A, 4 5 |
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CO |
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Methods 1, 2, 3A or 3B, 4, 10 |
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HAPS |
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Methods 1, 2, 3A, 4, 18, for specified HAPS |
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NOx |
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Methods 1, 2, 3A or 3B, 4, 7E |
7-1
All testing for the Prefermentation, Fermentation, Distillation and Vapor Combustion processes are complete. No testing is required for the Degasser at this time. In the event at some future date testing is required for one of these units, the parties agree that the following methods shall be used for that future testing.
Process |
|
Unit/Control |
|
Pollutant |
|
Proposed |
Prefermentation |
|
Scrubber #405 |
|
Total VOC |
|
Method 1, 2, 3A, 4, 18, 25, or 25A if less than 50 ppm |
|
|
|
|
|
|
|
Fermentation |
|
Scrubber #451 |
|
Total VOC |
|
Method 1, 2, 3A, 4, 18, 25, or 25A if less than 50 ppm |
|
|
|
|
|
|
|
Distillation |
|
Scrubber #501 |
|
Total VOC |
|
Method 1, 2, 3A, 4, 18, 25, or 25A if less than 50 ppm |
|
|
|
|
|
|
|
Degasser |
|
Scrubber #561 |
|
Total VOC |
|
Method 1, 2, 3A, 4, 18, 25, or 25A if less than 50 ppm |
|
|
|
|
|
|
|
Vapor Combustion Unit |
|
Flare |
|
Total VOC |
|
Proper Operation Per 40 CFR 60.18 as applicable |
7-2
8.0 FUGITIVE DUST EMISSION CONTROL PROGRAM
Asphalt paving on specified unpaved roadways as shown on attached site plan will be completed by December 15, 2005. Paved and unpaved roadways are to be inspected on a weekly basis and observations conducted for emissions of fugitive dust and inspections recorded. Paved roads are to be swept, flushed or otherwise treated to minimize fugitive dust as needed based on inspections. Water and/or dust suppressant agent is to be applied to unpaved roadways to minimize fugitive dust as needed based on inspections.
8-1