OPERATING AIR PERMIT Pursuant to the Regulations of the Arkansas Operating Air Permit Program, Regulation #26: Permit 385-AOP-R2 #: IS ISSUED TO: Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging 1701 Jefferson Parkway Pine Bluff, AR 71602 Jefferson County CSN: 35-0017 THIS PERMIT AUTHORIZES THE ABOVE REFERENCED PERMITTEE TO INSTALL, OPERATE, AND MAINTAIN THE EQUIPMENT AND EMISSION UNITS DESCRIBED IN THE PERMIT APPLICATION AND ON THE FOLLOWING PAGES. THIS PERMIT IS VALID BETWEEN: July 13, 1998 and July 12, 2003 AND IS SUBJECT TO ALL LIMITS AND CONDITIONS CONTAINED HEREIN. Signed: Keith A. Michaels Modified Date SECTION I: FACILITY INFORMATION PERMITTEE: Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging CSN: 35-0017 PERMIT NUMBER: 385-AOP-R2 FACILITY ADDRESS: 1701 Jefferson Parkway Pine Bluff, Arkansas 71602 COUNTY: Jefferson CONTACT PERSON: Alban Bush, Director of Technical Services TELEPHONE NUMBER: (870) 541-5049 REVIEWING ENGINEER: Kimberly Lindsey UTM North-South (X): 3792.0 UTM East-West (Y): 589.6 2 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 SECTION II: INTRODUCTION Gaylord Container Corporation (Gaylord) operates a kraft pulp and paper mill in Pine Bluff, Arkansas. Mid-America Packaging (Mid-America), a subsidiary of Gaylord, manufactures multi- wall bags from the paper produced by Gaylord. The modification to this permit is to clarify the wording of three specific conditions (SC # 28, # 44, #60) which require monitoring of specified parameters associated with scrubber pressure. There are no emission limit increases associated with this modification. Gaylord and Mid-America are subject to regulation under Regulation #18 (Air Code), Regulation #19 (SIP) and Regulation #26. Gaylord is also subject to NESHAP Subpart S - National Emission Standard for Hazardous Air Pollutants from the Pulp and Paper Industry. Mid-America is also subject to NESHAP Subpart KK – National Emission Standards for the Printing and Publishing Industry. Pine Bluff Mill Chips are brought in as raw material at Gaylord’s Pine Bluff Mill. Chips are unloaded into hoppers and conveyed to the screening system which separates acceptable from unacceptable material. A fan is used to separate knots and rocks from the chips and a cyclone is used to collect the chips. Unacceptable material is sent to the hogged fuel storage piles. Acceptable chips are stored in chip piles or in the chip silo. Chips are conveyed from the chip silo to the digesters (SN-13 and SN-17). A mixture of white liquor and spent caustic from the white liquor measuring tank and black liquor from the washers is charged along with the chips. A batch is cooked by recirculating liquor through a steam supplied heat exchanger. During digester cooks, the capping valve at the top of the digester is closed. Gases generated during the cooking cycle are extracted from the digester and flow to the turpentine system where the gases are condensed. The resulting turpentine is stored until being loaded into railcars. Non-condensible gases (NCGs) generated are collected and burned in the lime kiln. Between and during chip fills, the capping valve is open and any remaining gases are released to the atmosphere. Upon completion of the cook, the contents of the digesters are blown to the blow tank. Gases from the blow tank are condensed in the primary and secondary condensers. Water and condensed gases fall into the accumulator while the remaining NCGs are collected and burned in the lime kiln (SN-01). Hot water overflow from the top of the accumulator is sent to the ground level sewer drain where it flashes upon contact. A vent hood located over the sewer drain opening collects the vapors 3 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 and an exhaust fan connected to the vent hood draws vapors from the hood and discharges them to the atmosphere. Gaylord is currently considering source reduction alternatives to control the emissions from this vent. From the blow tank, the pulp is sent to the washers (SN-08A and SN-08B) to remove black liquor which flows to the foam tank (SN-11). The black liquor is de-foamed before it is pumped to weak black liquor storage. Washed pulp is sent from the washers to the high density tanks for storage. Recycled paper (secondary fiber) is used as supplemental feed stock. Secondary fiber is reduced to a pulp form in the pulper tub and sent to high density storage. Pulp from the high density storage tanks (SN-36 and SN-37) is pumped to the decker where the consistency is adjusted to the desired level before being sent to the paper machine. Blowers (SN- 16A thru SN-16C) and vacuum pumps (SN-18 and SN-19A thru SN-19D) pull a vacuum on the wet end of the paper machine to aid in drying the paper sheet. The paper sheet then passes to the dry end (SN-15A thru SN-15J) where it is further dried over steam heated dryer cans. Air heated by natural gas fired burners is blown into the dryer section to aid in the drying process. Emissions from the dry end of the paper machine are captured by an exhaust hood and discharged to the atmosphere. As the sheet exits the dry end it is wound onto rolls in preparation for shipping. Weak black liquor from the weak black liquor storage tanks (SN-33 and SN-34) is pumped to the black liquor evaporators where the solids content of the black liquor is increased due to evaporation of water. Pure steam is used as the heat source for the first evaporator while a mixture of steam and vapor is used as the heat source for subsequent evaporators. Vapor from the evaporators is collected and condensed, and the remaining non-condensible gases (NCGs) are burned in the lime kiln. Black liquor is pumped from the evaporators to the soap collection system where the soap is skimmed and stored in preparation for railcar loading. Heavy black liquor from the final evaporator is pumped to the heavy black liquor storage. Black liquor from the heavy black liquor storage is pumped to the black liquor oxidation tank (SN-12) where air is blown into the oxidizer tank, contacting the black liquor and raising the solids content. The liquor is then pumped to the recovery boiler (SN-02) where it is burned, creating the heat necessary to produce steam for use throughout the mill. Natural gas is used for startup of the recovery boiler. Boiler flue gases are blown through the electrostatic precipitator and sent to the total reduced sulfur (TRS) scrubber where the gases are cleaned and discharged. The recovery operations recover spent cooking chemicals for reuse in the digesters. Smelt resulting from the combustion process flows to the smelt dissolving tank (SN-04) where it is dissolved to form 4 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 green liquor which is sent to the caustic area. Gases emitted during the dissolving process are cleaned in a scrubber and discharged. Green liquor passes through a clarifier (SN-31 and SN-35) which removes dregs before it is sent to storage (SN-20 and SN-21). Clarified green liquor is then sent to the slaker (SN-03) where fresh lime and reburned lime are added to form sodium hydroxide and calcium carbonate. The dregs are washed with water and discarded to the sewer (SN-23 and SN-24). This white slurry then passes through the causticizers before entering a clarifier. Here lime mud is separated from the white liquor. The white liquor is sent to storage to be used in the pulping process. Dilute lime mud is then washed with water, the cake is collected in a filter (SN-14), and the cake is fed to the lime kiln (SN-01). The reburned lime is sent to storage. Gaylord purchases fresh lime to be used as make up for the reburned lime. The fresh lime is delivered and unloaded by a pneumatic truck. Air is blown into the storage compartment of the truck to force the lime from the storage compartment into the lime silo (SN-10). Heat is provided to the lime kiln by burning natural gas along with non-condensible gas (NCG) collected from the mill. Flue gases from the lime kiln pass through two scrubbers in series to remove dust before being discharged to the atmosphere. A hog fuel boiler (SN-05) and a power boiler (SN-06) are operated to meet the steam demands of the mill. Hog fuel (bark, fines, knots) is burned in the hog fuel boiler to generate steam for the mill. Flue gas from the boiler passes through a cyclone and a scrubber to remove particulate before being discharged to the atmosphere. Natural gas is used for startup of the boiler and as an auxiliary fuel. Natural gas is the only fuel used in the power boiler which converts water to steam for the mill. Mid-America Packaging Mid-America is a manufacturer of multi-wall bags. Paper printed with graphics specified by the customer is used as the outer layer of the bags. The plates used in the printing process are made on- site at Mid-America. Several layers of paper are pasted together and the paper is folded and pasted into tubes. The tubes are bottomed to form the bags, and the bags are shipped to the customer. Mid-America has four printing presses, No. 1 through No. 4, which are capable of printing different colors on a single roll of paper. Presses No. 3 and No. 4 also have the capability to apply a water- based lacquer coating to the paper. Various additives are mixed with the ink to maintain appropriate application conditions. 5 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 Press No. 3 is equipped with two drying chambers heated by natural gas. After ink has been applied to the paper, the sheet passes through the Tunnel Dryer (SN-102). Water-based lacquer is then applied to the paper sheet and the sheet passes through another heated chamber connected to the Lacquer Dryer (SN-103). Press No. 4 is equipped with three natural gas heated drying chambers and one chamber consisting of a blower only (no combustion unit). Ink is dried as the paper sheet passes through chambers connected to the Between Decks Dryer (SN-104) and the Tunnel Dryer (SN-105). The paper then enters another chamber into which unheated air is blown by the Auxiliary Blower (SN-106). Water- based lacquer is then applied to the paper sheet and the sheet passes through another heated chamber connected to the Lacquer Dryer (SN-107). The printed paper sheet then enters the rewind unit where it is wound onto a reel. Bags are assembled using the printed paper rolls as the outer wall of the bags. Layers of paper are pasted together, the paper is folded and pasted into tubes, and the bottoms of the tubes are pasted or sewn shut. The bags are then prepared for shipping. Bottom and seam paste are made on site at Mid-America. Starch and water are combined and cooked to make the paste. During the addition of the starch to the cooker, an exhaust hood fan (SN-101) pulls particulate matter from the work area and exhausts it to the atmosphere. After the batch is cooked, resin and other ingredients are added to the paste. A natural gas fired boiler (SN-100) produces the steam necessary to cook the paste. 6 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 EMISSION SUMMARY Source Description Pollutant Emission Rates Cross No. Reference lb/hr ton/yr Page Total Allowable Emissions PM 154.3 429.5 N/A (Pine Bluff Mill and Mid-America Packaging Combined) PM10 154.3 429.5 SO 30.3 110.4 2 VOC 573.7 2,216.5 CO 7,907.6 22,310.5 NO 70.5 295.8 X Pb 0.008 0.031 TRS 33.8 373.7 Pine Bluff Mill 01 Lime Kiln PM 5.7 24.7 53 PM 5.7 24.7 10 SO 6.3 9.2 2 VOC 3.4 12.5 CO 2.1 8.2 NO 12.5 48.8 X Pb 0.003 0.011 TRS 2.9 12.8 02 Recovery Boiler PM 27.9 122.0 38 PM 27.9 122.0 10 SO 21.2 92.7 2 VOC 374.2 1638.9 CO 7703.6 21,420.0 NO 15.5 67.9 X TRS 26.2 114.8 03 Lime Slaker PM 3.0 13.1 47 PM 3.0 13.1 10 VOC 0.7 2.7 TRS 0.1 0.1 7 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 EMISSION SUMMARY Source Description Pollutant Emission Rates Cross No. Reference lb/hr ton/yr Page 04 Smelt Dissolving Tank PM 4.2 16.3 44 PM 4.2 16.3 10 SO 0.4 1.4 2 VOC 3.8 16.3 NO 6.6 28.7 X TRS 0.7 3.0 05 Hog Fuel Boiler PM 53.6 234.7 64 PM 53.6 234.7 10 SO 1.1 4.2 2 VOC 7.1 31.1 CO 197.6 865.2 NO 20.3 82.2 X Pb 0.005 0.02 06 Power Boiler PM 1.1 4.9 68 PM 1.1 4.9 10 SO 0.1 0.5 2 VOC 0.3 1.4 CO 2.7 11.9 NO 10.7 46.9 X 08A Washer Hood Exhaust Fan A These sources are routed to the Lime Kiln 28 08B Washer Hood Exhaust (SN-01) as required by NESHAP Subpart S Fan B 11 Foam Tank Stack 10 Fresh Lime Storage PM 55.0 5.0 47 PM 55.0 5.0 10 12 Black Liquor Oxidation SO 0.5 1.7 35 2 Tank Stack VOC 8.2 35.9 TRS 0.8 3.6 14 Lime Mud Filter VOC 0.3 1.0 47 Vacuum Pump TRS 0.1 0.1 13 Digester Building Vent VOC 5.4 26 (No. 1 and No. 2) TRS 0.2 15.01 0.51 8 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 EMISSION SUMMARY Source Description Pollutant Emission Rates Cross No. Reference lb/hr ton/yr Page 17 Digester Building Vent VOC 2.7 26 No. 3 TRS 0.1 15 Paper Machine PM 0.4 1.8 29 (A thru J) Dry End Fans PM 0.4 1.8 10 (1, 1A, 1B, 2, 2A, SO 0.1 0.1 2 3, 3A, 4, 5 and 6) VOC 8.82 31.12 CO 1.0 4.4 NO 3.9 17.1 X TRS 0.3 0.8 16A Fourdrinier Blower A VOC 6.92 24.52 29 16B Fourdrinier Blower B VOC 5.82 20.62 29 16C Fourdrinier Blower C VOC 6.92 24.52 29 18 Paper Machine VOC 11.82 41.62 29 Vacuum Pumps (1 thru 3) 19A Paper Machine VOC 7.42 26.12 29 Vacuum Pump 4 19B Paper Machine VOC 7.42 26.12 29 Vacuum Pump 5 19C Paper Machine VOC 7.42 26.12 29 Vacuum Pump 6 19D Paper Machine VOC 9.62 33.82 29 Vacuum Pump 7 20 Green Liquor Storage VOC 0.9 3.2 50 Tank North TRS 0.1 0.1 21 Green Liquor Storage VOC 0.9 3.2 50 Tank South TRS 0.1 0.1 22 Multi Purpose Tank VOC 0.9 3.2 50 TRS 0.1 0.1 23 Dregs Mixer VOC 0.9 3.2 47 TRS 0.1 0.1 9 Gaylord Container Corporation Pine Bluff Mill / Mid-America Packaging Permit #: 385-AOP-R2 CSN: 35-0017 EMISSION SUMMARY Source Description Pollutant Emission Rates Cross No. Reference lb/hr ton/yr Page 24 Dregs Washer VOC 0.9 3.2 47 TRS 0.1 0.1 27 White Liquor Clarifier VOC 0.2 0.5 47 No. 2 28 East White Liquor VOC 0.2 0.5 50 Storage Tank 29 West White Liquor VOC 0.2 0.5 50 Storage Tank 30 White Liquor VOC 0.2 0.5 50 Measuring Tank 31 Green Liquor Clarifier VOC 0.9 3.2 47 No.2 TRS 0.1 0.1 32 Weak Wash Storage VOC 0.9 3.2 50 Tank TRS 0.1 0.1 33 North Weak Black VOC 0.9 4.0 35 Liquor Tank TRS 0.1 0.3 34 South Weak Black VOC 0.9 4.0 35 Liquor Tank TRS 0.1 0.3 35 Green Liquor Clarifier VOC 0.9 3.2 47 No.1 TRS 0.1 0.1 36 High Density Storage VOC 0.1 0.4 33 Tank No.2 TRS 0.1 0.3 37 High Density Storage VOC 0.1 0.4 33 Tank No.3 TRS 0.1 0.3 38 Heavy Black Liquor VOC 0.2 0.8 35 Storage Tank No.2 TRS 0.3 1.0 39 Black Liquor Spill Tank VOC 0.2 0.8 35 TRS 0.3 1.0 40 Paper Machine General VOC -- 36.02 29 Building Ventilation TRS -- 1.3 10