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ENB Region 6 Completed Applications 08/01/2012

St Lawrence County

Applicant:

Alcoa Inc
201 Isabella St
Pittsburgh, PA 15212 -5858

Facility:

Alcoa Massena Operations (West Plant)
Park Ave E
Massena, NY 13662

Application ID:

6-4058-00003/00380

Permit(s) Applied for:

Article 19 Air State Facility

Project is Located:

St Lawrence County

Project Description:

This Department has received a request to issue a permit to operate air pollution emission sources and has drafted pursuant to Article 19 (Air Pollution Control) of the Environmental Conservation Law, a State Facility Permit, for the facility located at Alcoa Massena Operations (West Plant), Town of Massena, St. Lawrence County, New York. Alcoa Inc. owns and operates a primary aluminum producing and fabricating facility in Massena, NY (Massena Operations). Massena Operations is comprised of three production areas: Smelting Plant (Area III), Ingot-Extrusion (Area II), and Fabricating Plant (Area I). Products include aluminum metal, ingot, wire, rod and bar. The facility also produces steam in an on-site boilerhouse. The Standard Industrial Classifications representative of this facility are 3334, Primary Aluminum; and 3354, Aluminum Extruded Products.

This project involves a rebuild of #14 furnace (Emission Unit M-00001; Emission Source M003A) that will result in a larger combustion train as well as a larger physical holding capacity for the furnace. The furnace currently has a 27,900,000 Btu/hr rating with an uncontrolled, two burner configuration (south side and north side). The new burner system will be comprised of a 45,000,000 Btu/hr, four low-NOx burner configuration (north side, south side & two east side) with an expected reduction in NOx of 40% over uncontrolled burners of the same size. The furnace today has a physical holding capacity of 140,000 lbs. The new design will increase capacity to 180,000 lbs (40,000 lb increase). The project will also include the installation of five 2.5 MMBtu/hr space heaters (exempt emission sources) throughout the areas of the Casthouse (Bldg. 220 and a portion of Bldg. 221). These heaters would replace the heating load that the central boilerhouse currently provides.

The following regulations have been reviewed for applicability to the proposed project:

National Emission Standards for Hazardous Air Pollutants (NESHAP) at Secondary Aluminum Production - This furnace project will be considered a reconstruction activity under 40 CFR 63.1503 Subpart RRR and thus will be a new source. #14 furnace will be removed from the existing Secondary Aluminum Processing Unit (SAPU) at Massena West Plant and an initial performance test will be conducted within 90 days of start-up.

Reasonably Available Control Technology (RACT) For Major Facilities of Oxides Of Nitrogen (NOx) - Low NOx burners are being installed with this project. Low NOx burners have been considered RACT, under 6 NYCRR Part 227-2, for the furnace burners. A NOx RACT study has been conducted at the request of the Department.

Modifications to Existing Major Facilities in Nonattainment Areas and Attainment Areas of the State within the Ozone Transport Region (NSR) & Modifications to Existing Major Facilities in Attainment Areas (Prevention of Significant Deterioration (PSD)) - The potential increases in emissions resulting from this project do not exceed significant project thresholds, contained in 6 NYCRR Part 231-6 & 231-8, and therefore PSD and Non-attainment NSR requirements are not applicable to this project.

The draft permit with conditions is available for review in the Region 6 NYSDEC office in Watertown, NY.

Availability of Application Documents:

Filed application documents, and Department draft permits where applicable, are available for inspection during normal business hours at the address of the contact person. To ensure timely service at the time of inspection, it is recommended that an appointment be made with the contact person.

State Environmental Quality Review (SEQR) Determination:

Project is an Unlisted Action and will not have a significant impact on the environment. A Negative Declaration is on file. A coordinated review was not performed.

SEQR Lead Agency: None Designated

State Historic Preservation Act (SHPA) Determination:

The proposed activity is not subject to review in accordance with SHPA. The permit type is exempt or the activity is being reviewed in accordance with federal historic preservation regulations.

Coastal Management:

This project is not located in a Coastal Management area and is not subject to the Waterfront Revitalization and Coastal Resources Act.

Opportunity for Public Comment:

Comments on this project must be submitted in writing to the Contact Person no later than Aug 31, 2012.

Contact:

Lawrence R Ambeau
NYSDEC Region 6 Headquarters
State Office Building - 317 Washington St
Watertown, NY 13601
(315)785-2245
dep.r6@dec.ny.gov


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