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New Source Review (NSR) Permitting

IronUnits LLC - Permitting Information

1. Facility Information

IronUnits LLC

2. Location

2768 Front Street
Toledo, Ohio
Lucas County
 

3. Distance from US/Canada Border

Approximately 40 km

4. Facility Type and Size

320 tons/hr hot briquetted iron (HBI) production facility. This permit is for an Administrative Modification to PTI P0123395 issued February 9, 2018.

5. Sources of Emissions

1,687 mmBtu/hr natural gas & process gas (spent reducing gas) fired reformer; roadways & parking areas; storage piles; direct reduced iron (DRI) reactor; iron briquetting machine; iron briquette cooling system; process water degasser; cooling tower; pressure relief vent flare; natural gas fugitive equipment leaks; iron oxide material handling; and hot briquetted iron material handling

6. Type of Fuel

Natural gas and spent reducing gas from the DRI reactor is used to fuel the reformer.

7. Type and Quantity of Emissions

Pollutant Tons/Yr

CO

11,671.32  (+11,094.31)

NOx

478.70       (+0.33)

PM10

136.16       (-2.48)

PM2.5

133.68       (-2.85)

SO2

25.20         (+3.55)

VOC

16.40         (+2.63) 

GHG

1,649,721  (+22,843)

8. Emission Control Technology

Reformer: low NOx burners

Roadways and Parking Areas: water or chemical dust suppressant

Storage Piles: Use of water or chemical dust suppressant, minimize drop height

DRI Reactor: Venturi scrubber

Iron Briquetting Unit: Venturi Scrubber

HBI Cooling System: Venturi Scrubber

Process Water Degasser: No control

Cooling tower: Mist eliminator, total dissolved solids restriction

Pressure Relief Vent Flare: Designed to meet flare requirements under 40 CFR 60.18.

Natural gas equipment leaks: No control

Iron Oxide Material Handling: Enclosures, minimize drop height, some enclosures vented to baghouses

HBI Material Handling: Enclosures, minimize drop height, some enclosures vented to venturi scrubber or baghouses, truck loading inside full enclosure with doors closed and vented to baghouse, HBI rail loading inside shed open on each end with strip curtains on each end and use of telescoping chute with water or chemical spray.

9. Date Permit Application Received

The initial administrative modification application was submitted on July 30, 2019 and a revised application was submitted on September 13, 2019.

10. Stack Height and Diameter

Reformer
            stack height: 197 ft
            inside diameter: 14.1 ft
 
Cooling Tower (4-cell)
            stack height: 62 ft (each)
            inside diameter: 25 ft (each)
 
DRI Reactor (includes charge hopper and bottom seal gas vent)
            Charge Hopper Scrubber
        stack height: 433 ft
                                    inside diameter: 0.9 ft
 
            Bottom Seal Gas Scrubber
                        stack height: 450 ft
                        inside diameter: 4.6 ft
 
            Iron Briquetting Unit
                        stack height: 450 ft
                        inside diameter: 5.6 ft
 
            Iron Briquette Cooling System
                        stack height: 447 ft
                        inside diameter: 4.7 ft
 
            Process Water Degasser
                        stack height: 74 ft
                        inside diameter: 2.3 ft
 
            Pressure Relief Vent Flare
                        stack height: 131.2 ft
                        inside diameter: 7.2 ft
 
            Iron Oxide Material Handling
                        MTR-5 hopper to conveyor baghouse exhaust
                                    stack height: 29 ft
                                    inside diameter: 2 ft
 
                        SR-1 oxide screen transfer baghouse
                                    stack height: 90 ft
                                    inside diameter: 3 ft
 
                        TR-1 oxide transfer
                                    stack height: 61 ft
                                    inside diameter: 2 ft
           
                        TR-6 Transfer tower II baghouse exhaust
                                    stack height: 39 ft
                                    inside diameter: 2 ft
 
                        TR-7 Transfer tower III baghouse exhaust
                                    stack height: 75 ft
                                    inside diameter: 2 ft
 
                        TR-10 oxide day bins transfer exhaust
                                    stack height: 105 ft
                                    inside diameter: 2 ft
 
                        TR-13a oxide transfer to bucket elevator baghouse exhaust
                                    stack height: 185 ft
                                    inside diameter: 2 ft
 
                        TR-13b conveyors for fines transfer baghouse exhaust
                                    stack height: 75 ft
                                    inside diameter: 1 ft
 
                        TR-14 baghouse for coating storage/transfer and fines transfer
                                    stack height: 75 ft
                                    inside diameter: 2 ft
 
                        TR-28a oxide transfer to furnace feed conveyor baghouse exhaust
                                    stack height: 87.9 ft
                                    inside diameter: 1 ft
 
            HBI Material Handling
                        TR-17 HBI conveyor transfer scrubber
                                    stack height: 60 ft
                                    inside diameter: 2 ft
 
                        TR-18 HBI conveyor transfer baghouse
                                    stack height: 60 ft
                                    inside diameter: 2 ft
 
                        TR-23 HBI conveyor transfer baghouse
                                    stack height: 55 ft
                                    inside diameter: 2 ft
 
                        TR-24 HBI conveyor transfer baghouse
                                    stack height: 125 ft
                                    inside diameter: 2 ft
 
                        TR-25 HBI truck loadout baghouse
                                    stack height: 125 ft
                                    inside diameter: 2 ft   
 

11. Permit Agency Contact

Mike Hopkins, P.E.
Assistant Chief, Permitting Section, DAPC
Ohio Environmental Protection Agency
Lazarus Government Center
50 West Town Street, Suite 700
P.O. Box 1049
Columbus, OH 43216-1049
(614) 644-3611