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Certainteed Gypsum Buchanan LLC, Buchanan NY 

New York State Department of Environmental Conservation
Notice of Complete Application

Date: 10/25/2024

Applicant: CERTAINTEED GYPSUM BUCHANAN, LLC, 350 BROADWAY, BUCHANAN, NY 10511

Facility: CERTAINTEED GYPSUM BUCHANAN LLC, 350 BROADWAY, BUCHANAN, NY 10511

Application ID: 3-5522-00087/00019

Permits(s) Applied for: 1 - Article 19 Air Title V Facility

Project is located: in CORTLANDT in WESTCHESTER COUNTY

Project Description:
The Department has prepared a draft permit and has made a tentative determination, subject to public comment or other information, to approve a Title V permit modification that involves the installation of a RotoChopper which is used to reclaim and grind boards, thereby increasing the reclaim board processing capacity. The RotoChopper will be installed within an existing on-site building.

This addition of a RotoChopper would support the existing activities at CertainTeed at Buchanan which entails producing bulk gypsum and wallboard. Gypsum rock is delivered to the facility by water borne vessel. Raw, reclaimed gypsum material, and synthetic gypsum material can be stockpiled or sent directly to processing.

The first step in the process is the crushing of the raw, reclaimed gypsum material and synthetic gypsum to reduce the maximum rock size. The material then proceeds to the calcining mill, where the free and chemically bound water is removed.

The product of the calcining mill, called stucco, is then pneumatically conveyed to the wallboard plant where the stucco is conveyed to the pin mixer. Depending upon the type of wallboard being produced, appropriate additives, including water, are mixed with the stucco in the pin mixer to produce a slurry. The slurry is placed between two sheets of paper on the forming line. While traveling down the length of the forming line, the slurry hardens into wet wallboard. At the end of the forming, the wet wallboard is cut into varying lengths and is inverted to protect the face of the board during drying.

Finally, the boards are conveyed through the board dryer to drive off moisture and induce chemical bonding of the wallboard ingredients. The wallboard is finished with end saws and the exposed ends are sealed with tape. The wallboard is then stored until shipment off site.

The installation of a RotoChopper which is used to reclaim and grind boards, would increase the reclaim board processing capacity. The reclaim grinder will be equipped with an electric motor to power the shredding rotor that will break apart the scrap board down to the desired size.

Pursuant to the requirements of Sections 7(2) and 7(3) of the Climate Leadership and Community Protection Act (CLCPA), the Department has requested and received information regarding the project’s consistency with the CLCPA.

Regulatory requirements pertaining to this modification include 200, 201-6, 211, 40 CFR 60 Subpart OOO.

In accordance with 6NYCRR Parts 621.7(d)(9) and 201-6.3(c), the Administrator of the United States Environmental Protection Agency (USEPA) has the authority to bar issuance of any Title V Facility Permit if it is determined not to be in compliance with applicable requirements of the Clean Air Act or 6NYCRR Part 201.

Persons wishing to inspect the subject Title V files, including the application with all relevant supporting materials, the draft permit, and all other materials available to the DEC (the "permitting authority") that are relevant to this permitting decision should contact the DEC representative listed below. The Draft Permit and Permit Review Report may be viewed and printed from the Department web site at: https://dec.ny.gov/environmental-protection/air-quality/controlling-pollution-from-facilities/permitsregistrations-fees.

DEC will evaluate the application and the comments received on it to determine whether to hold a public hearing. Comments and requests for a public hearing should be in writing and addressed to the Department representative listed below. A copy of the Department's permit hearing procedures is available upon request or on the Department web site at: https://dec.ny.gov/regulatory/permits-licenses/environmental-permits/guide-topermit-hearings.

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
Cultural resource lists and maps have been checked. The proposed activity is not in an area of identified archaeological sensitivity and no known registered, eligible or inventoried archaeological sites or historic structures were identified or documented for the project location. No further review in accordance with SHPA is required.

Coastal Management
This project is located in a Coastal Management area and is subject to the Waterfront Revitalization and Coastal Resources Act.

DEC Commissioner Policy 29, Environmental Justice and Permitting (CP-29)
The proposed action is subject to CP-29.

Availability For Public Comment 
Comments on this project must be submitted in writing to the Contact Person no later than 11/29/2024 or 30 days after the publication date of this notice, whichever is later. 

Contact Person
ELLEN M HART
NYSDEC
21 S Putt Corners Rd
New Paltz, NY 12561
(845) 256-3051

Draft permit