PERMIT MEMORANDUM 99-103-TV DRAFT 23
OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY
AIR QUALITY DIVISION
MEMORANDUM August 11, 2006
TO: Dawson Lasseter, P.E., Chief Engineer
THROUGH: Kendal Stegmann, Supervising Attorney, Air Quality Division
THROUGH: Rick Groshong, Environmental Program Manager, Enforcement Section
THROUGH: David Schutz, P.E., New Source Permits Section
THROUGH: Grover Campbell, P.E., Existing Source Permits Section
THROUGH: Peer Review
FROM: Phillip Martin, P.E., New Source Permits Section
SUBJECT: Evaluation of Permit Application No. 99-103-TV
Goodyear Tire & Rubber Company
#1 Goodyear Boulevard, Sec 36, T2N, R13W
Lawton, Comanche County, OK 73505
Latitude 34.5989° Longitude -98.5104°
SECTION I. INTRODUCTION
The Goodyear Tire & Rubber Company operates a tire manufacturing plant (SIC 3011) in Lawton, Oklahoma (Goodyear Lawton). An initial construction permit was issued to Goodyear Lawton in May 1977 (Permit # 77-021), and the first tire was produced in February 1979. Since that time, several changes and permit actions have occurred:
· Permit Number 85-015-O issued March 15, 1985, for four additional White Sidewall Grinders.
· Permit Number 85-039-O issued June 17, 1986, for an additional Banbury Mixer.
· Permit Number 88-023-C issued May 12, 1988, for the addition of twelve Force Variation Machine Grinders, seven White Sidewall Grinders, and a blend/bagging station.
· Permit Number 87-016-O issued July 20, 1992, for the relocation of two Force Variation Machine Grinders and addition of a dust collector.
· Permit Number 89-037-O issued October 8, 1992, for the addition of a Banbury Mixer.
· Permit Number 94-383-O issued on June 10, 1997, for the ventilation system for the Green Tire Stripping Process.
· Applicability Determination Number 77-021-AD issued July 24, 1997, for operation of the facility’s three boilers in “standby status”.
· Applicability Determination Number 97-374-AD issued November 19, 1997, for the Tire Bladder Manufacturing Operation.
· Applicability Determination Number 97-387-AD issued December 9, 1997, for the Extruder Line #1 Cushion Mill Addition.
· Applicability Determination Number 97-388-AD issued December 22, 1997, for the White Sidewall Banbury Mill Addition.
· Permit Number 97-302-O issued January 5, 1998, for the Non-powered Transportation Equipment (NPTE) paint spray booth.
· Permit Number 77-021-C (M-1) issued April 23, 1998, for the addition of three Force Variation Machine Grinders.
· Permit Number 97-301-O issued on June 26, 1998, for the addition of an additional Banbury Mixing line.
· Permit Number 99-103-C (PSD) issued December 11, 2000, for the introduction of silica compounds as tire ingredients.
· Applicability Determination Number 99-103-AD (M-1), issued December 21, 2001 for a new warehouse (no permit action required).
· Permit Number 2002-077-C, issued May 1, 2002, for the Hot Former project. Construction on the project began in June 2002.
· Permit application submitted on June 28, 2002, for Green Tire Spray project. DEQ letter was sent to company stating that no construction permit would be issued for this minor modification, but conditions as appropriate to address the modification will be incorporated into your final Part 70 permit, when issued.
· MACT Hammer Part 1 Application Number 2002-328-MT was received by DEQ in May, 2002. EPA promulgated 40 CFR Part 63, Subpart XXXX on July 9, 2002. Therefore, DEQ has withdrawn the AD and will incorporate any applicable requirements of 40 CFR Part 63, Subpart XXXX into Goodyear’s Title V permit.
· Permit Number 99-103-TV, for a facility-wide operating permit, has been applied for.
· Permit Number 2002-414-C (PSD) issued December 11, 2002, for a facility modernization project. The equipment for this project includes a Banbury, a Hot Former, a Quad Extruder, a curing press trench, and other supporting equipment. The Banbury No.8 was never constructed.
· Permit Number 89-037-O (M-1) issued June 2, 2004, changed the method of showing compliance with the PM limitations of Banbury No. 6.
· Permit Number 94-383-O (M-1) issued September 8, 2004, increased the amount of solvent that can be used in the Green Tire Stripping Process.
· Permit Number 2005-057-C issued July 21, 2005, authorized the construction of a new Tandem 3-Roll Fabric Calender (FC2) and the replacement of 17 existing 42-inch Curing Presses with 17 new 52-inch Curing Presses.
· Permit Number 89-037-C M-2 issued January 20, 2006, authorized the replacement of a Four-Wing Rotor with a Six-Wing Rotor on Banbury No. 6 (BB06).
Goodyear Lawton is a Title V source and is an existing major source for Prevention of Significant Deterioration (PSD) with potential-to-emit (PTE) greater than 250 tons per year (TPY) of Nitrogen Oxides (NOx), Volatile Organic Compounds (VOC), PM10, and SO2.
All previous permits will be incorporated into this Part 70 operating permit.
SECTION II. PROCESS DESCRIPTION
Manufacturing tires requires the use of various types and formulations of rubber compounds. The formulation of ingredients depends on a number of factors including the desired rubber properties and performance characteristics. Formulation differences and changes are driven by the specific function of the compound being utilized within the tire (tread, belt, ply, sidewall, bead, inner liner, etc.). Production of a tire is a dynamic trade-off between formulation issues and construction techniques. These items impact desired properties such as tire wear, cornering traction, heat build up, rolling resistance, fuel economy, stopping distance, and wet traction. The production of a tire involves the following basic steps:
· A compounder determines desired rubber formulations for various tire components based on customer requirements.
· Various raw materials needed to produce the required compounds are combined in a process known as “Banbury mixing.”
· The mixed rubber is then extruded or calendered into components, which will be used to build a “green,” or uncured, tire. Tread striping and end cementing can occur at the Extruder Line.
· Uncured rubber components are assembled at a tire building machine.
· Uncured or “green” tires are transported to the curing area, where the inside of the “green” tire is sprayed with a release compound in the Green Tire Spray Booth (GTSB) and then cured in a curing press under heat and pressure.
· Grinding for uniformity by Force Variation Machines (FVMs) and Radial Run-out Grinders. White sidewall grinding may also occur.
· Final inspection of the cured tire prior to customer release.
SECTION III. EQUIPMENT
The Emission units (EUs) have been arranged into the following Emission Unit Groups (EUGs). Certain EUGs were modified from the permit application.
EUG / POINT / EU Name / Model / Construction /Modification Date
EUG-BSWBB / * / Black Sidewall Banburys / *
EUG-WSWBB / * / White Sidewall Banbury / *
EUG-EXT / * / Extruders,2, 3, 5, and 6 / *
EUG-EXTNSPS / * / Extruders 1, 4, and 7 / *
EUG-GC / * / Gum Calender 2 and 3 / *
EUG-FWC / * / Fabric & Wire Calenders / *
EUG-GTS / * / Non-NSPS Green Tire Spray Booths / *
EUG-GTSNSPS / * / NSPS Green Tire Spray Booths / *
EUG-HF / * / Hot Former / *
EUG-STRIPP / * / Green Tire Stripping / *
EUG-CP / * / Curing Presses / *
EUG-GRFVM / * / Force Variation Machines & Radial Run-out Grinders / *
EUG-GRWSW / * / White Sidewall Grinders / *
EUG-BLUE / * / White Sidewall Machines / *
EUG-RECYCLE / * / Recycling Mills / *
EUG-B&W / * / Babcock and Wilcox Boilers / *
EUG-KEEL / * / Keeler Boiler / *
EUG-COOL / * / Cooling Towers / *
EUG-TANK / * / Gasoline/2FO Split Tank / *
* See individual EUG for Point ID#'s and Construction/Modification Date.
EUG “BSWBB”: Black Sidewall Banburys
EU / POINT / EU Name / Model / Constr./Mod. DateBB01 / 12U / Banbury # 1 mixer (routed to dust collector) / 1985
BB01M1 / 12U / Banbury # 1 100” mill (routed to scrubber) / 1985
BB01M2 / 12U / Banbury # 1 84" mill (routed to scrubber) / 1985
BB01 SDT / 14U / Banbury # 1 Scrubber discharge tank / 1985
BB01SU / 13U / Banbury # 1 slurry unit / 1985
BB01SC / 15U / Banbury # 1 slab cooling / 1985
BB02 / 12W / Banbury #2 mixer (routed to dust collector) / 1979
BB02M1 / 112W / Banbury #2 100” mill (routed to scrubber) / 1979
BB02M2 / 12W / Banbury # 2 84” mill (routed to scrubber) / 1979
BB02SDT / 14W / Banbury # 2 Scrubber discharge tank / 1979
BB02SU / 17W / Banbury # 2 slurry unit / 1979
BB02SC / 17W-21WZ / Banbury # 2 slab cooling / 1979
BB03 / 12BN / Banbury #3 mixer (routed to dust collector) / 1979
BB03EXT / 12BN / Banbury #3 extruder and takeaway (routed to scrubber) / 1979
BB03M1 / 12BN / Banbury # 3 100" mill (routed to scrubber) / 1979
BB03M2 / 13BN / Banbury # 3 84" mill (routed to scrubber) / 1979
BB03SDT / 15BN / Banbury # 3 scrubber discharge tank / 1979
BB03SU / 19BN / Banbury # 3 slurry unit / 1979
BB03SC / 20BN / Banbury # 3 slab cooling / 1979
BB04 / 11CN / Banbury # 4 mixer (routed to dust collector) / 1979
BB04EXT / 11CN / Banbury # 4 extruder and takeaway (routed to scrubber) / 1979
BB04M1 / 12CN / Banbury # 4 100" mill (routed to scrubber) / 1979
BB04M2 / 13CN / Banbury # 4 84" mill (routed to scrubber) / 1979
BB04SC1 / 15CN / Banbury # 4 scrubber discharge tank / 1979
BB04SC2 / 16CN / Banbury # 4 slurry unit / 1979
BB04SC3 / 19CN / Banbury # 4 slab cooling / 1979
BB05 / 11EN / Banbury # 5 mixer (routed to dust collector) / 1979
BB05EXT / 12EN / Banbury # 5 extruder and takeaway (routed to scrubber) / 1979
BB05Ml / 12EN / Banbury # 5 100" mill (routed to scrubber / 1979
BB05M2 / 13EN / Banbury # 5 84" mill (routed to scrubber / 1979
BB05SDT / 14FN / Banbury # 5 scrubber discharge tank / 1979
BB05SU / 17EN / Banbury # 5 slurry unit / 1979
BB05SC / 21EN / Banbury # 5 slab cooling / 1979
BB06 / 12GN / Banbury # 6 Mixer (routed to dust collector & RTO) / 1992
BB06EXTRD / 12zFx/N / Banbury # 6 roller die extruder (routed to scrubber) / 1992
BB06SDT / 13GN / Banbury # 6 Scrubber discharge tank / 1992
BB06SU / 13FXN / Banbury # 6 slurry unit / 1992
BB06SC / 15-21GN / Banbury # 6 slab cooling / 1992
BB07 / 12ZHN / Banbury # 7 mixer (routed to dust collector & RTO) / 1995
BB07EXTRD / 12HN / Banbury # 7 roller die extruder (routed to scrubber) / 1995
BB07SDT / 13JN / Banbury # 7 Scrubber discharge tank / 1995
BB07SU / 13HN / BB #7 slurry unit / 1995
BB07SC / 13-21HN / BB #7 slab cooling / 1995
EUG “WSWBB”: White Sidewall Banbury
EU / POINT / EU Name / Model / Constr./Mod. DateBBWSW / 11Sx / WSW Banbury mixer (routed to dust collector) / 1979
BBWSWM1 / 11Sx / WSW Banbury 84" Mill / 1979
BBWSWM2 / 12Sx / WSW Banbury 84" Mill / 1979
BBWSWSU / 13Sx / WSW Banbury slurry unit / 1979
BBWSWSC / 13-15Sx / WSW Banbury Slab cooling / 1979
EUG “HF”: Hot Former
EU / POINT / EU Name / Model / Constr./Mod. DateHF01 / 50-62VWx / Hot Former #1 / 2002
EUG “EXT”: Extruders 2, 3, 5, & 6
EU / POINT / EU Name / Model / Constr./Mod. DateCU02 / 37M / Duplex extruder #2 / 1979
CU02A / 38L / 3.5" extruder (not in use) / 1979
CU02B / 39L / 4.5” extruder / 2006
CU02M1 / 38N / 84" mill # 1 / 1979
CU02M2 / 39M / 84" mill #2 / 1979
CU02M3 / 40L / 36" cushion mill / 1979
CU02SC / 42-44L / Cooling line / 1979
CU03 / 40L / Single 8" extruder #3 / 1979
CU03SC / 42-45L / Cooling line / 1979
CU05 / 38J / Duplex extruder #5 / 1979
CU05M1 / 38L / Mill #1 / 1979
CU05M2 / 39L / Mill #2 / 1979
CU05SC / 39-45J / Slab cooling / 1979
CU06 / 38G / Triplex extruder #6 / 1979
CU06A / 41G / 3.5" Extruder / 1979
CU06M1 / 41G / 36” Cushion mill / 1979
CU06SC / 42G / Cooling line / 1979
TLM01 / 32L / Tread line #1 marking / striping / 1992
TLM04 / 32J / Tread line #4 marking / striping / 1992
TU01 / 31L / Tread line #1 quad extruder (6", 12", 4.5", 8") / 1979
TU01-CE / 54L / Tread line #l end cement application / 1985
TU01M1 / 31N / Tread line #184" single mill #1 / 1979
TU01SC / 34L / Tread line # 1 cooling line / 1979
TU04 / 30K / 4.5", 6", & 10" Triplex Extruder #4 / 1979
TU04-CE / 54J / Tread line #4 end cement application / 1985
TU04M1 / 32N / Tread line #4 batchoff mill #1 / 1979
TU04SC / 35-49J / Tread line #4 cooling line / 1979
EUG “EXTNSPS”: Extruders 1, 4, & 7
EU / POINT / EU Name / Model / Constr./Mod. DateTLM07 / 35H / Tread line #7 marking / striping / 1993
TU07 / 35J / Tread line #7 quad extruder #7 (4.5", 8", 10",6") / 1993
TU07-CE / 53J / Tread line #7 end cement application / 1994
TU07M1 / 34H / Tread line #7 36" mill / 1993
TU07SC1 / 37J / Tread line #7 cooling #1 / 1993
EUG “GC”: Gum Calenders
EU / POINT / EU Name / Model / Constr./Mod. DateGC2 / 38Q / Gum calender #2 / 1979
GC2M1 / 37N / Gum calender #2 mill #1 / 1979
GC2M2 / 37Q / Gum calender #2 mill #2 / 1979
GC2SC1 / 39-40Q / Gum calender #2 covered cooling area / 1979
GC3 / 44N / Gum calender #3 / 1979
GC3M1 / 44N / Gum calender #3 mill #1 / 1979
GC3SC1 / 39-43N / Gum calender #3 covered cooling area / 1979
EUG “FWC”: Fabric & Wire Calenders