Chapter NR 439

NR 439.096(8)(a) (a) An engineering study to identify the optimized combustion profile or equipment modifications needed to optimize combustion. The study shall address, but is not limited to, the modification of the following systems: fuel delivery, burner, primary and secondary combustion monitoring, combustion air delivery and burner management.

NR 439.096(8)(b) (b) The combustion optimization shall be based on burner tune-up procedures which result in maximum combustion efficiency and a low NOx operating curve. This curve shall determine the operating range of combustion variables such as CO and O2 at set points within the following ranges: 20-30% load, 45-55% load, 70-80% load and 95-100% load, for those set points that represent at least 10% of boiler operating hours in a typical year.

NR 439.096(8)(c) (c) A continuous combustion analyzer shall be used to monitor the operation of the combustion unit in accordance with the combustion efficiency and low NOx operating curve required under this section. The analyzer shall monitor the combustion parameters CO and O2 or monitor NOx directly. The fuel flow rate shall be monitored.

NR 439.096(9) (9) Combustion optimization reporting requirements. The owner or operator of a source that conducts a combustion optimization shall submit a copy of the report of the combustion optimization to the department within 60 days after its completion. If requested, the department may grant an extension of up to 30 days for combustion optimization report submittal. The failure to include the following information in a combustion optimization report may result in rejection of the combustion optimization. The combustion optimization report shall include, but need not be limited to, the following information:

NR 439.096(9)(a) (a) A detailed description of the process optimized and the procedures employed.

NR 439.096(9)(b) (b) A log of the operating conditions of the process optimized and of any associated air pollution control device.

NR 439.096(9)(c) (c) A summary of results, expressed in terms of the concentrations of NOx, O2 and CO, prior to and following the combustion optimization.

NR 439.096(9)(d) (d) Sample calculations employing all the formulas used to calculate the results.

NR 439.096(9)(e) (e) The field and laboratory data for the optimization.

NR 439.096(9)(f) (f) The engineering study and combustion efficiency and low NOx operating curve required under sub. (8) (a) and (b).

NR 439.096(9)(g) (g) The report of any visible emission evaluations performed during the combustion optimization.

NR 439.096(9)(h) (h) A copy of any steam, opacity or airflow charts made during the optimization.

NR 439.096(9)(i) (i) The report of any fuel analysis performed on the fuel burned during the optimization.

NR 439.096(9)(j) (j) Documentation of any process upset occurring during the optimization.

NR 439.096(9)(k) (k) If the combustion optimization being conducted is one required under sub. (10), the changes made to the process or control device since the last test.

NR 439.096(10) (10) Additional combustion optimizations.

NR 439.096(10)(a) (a) The department may require an NOx emissions source to conduct an additional combustion optimization if the department determines that a source has not satisfied the requirements of sub. (8) or (9).

NR 439.096(10)(b) (b) Combustion units that are modified sources with respect to NOx due to a change in the method of operation shall perform a new combustion optimization including the determination of a new combustion efficiency and low NOx operating curve.

NR 439.096 History History: Cr. Register, January, 2001, No. 541, eff. 2-1-01.

NR 439.098 NR 439.098 Methods and procedures for parametric testing of NOx emissions pursuant to an acid rain program alternative NOx emission limitation.

NR 439.098(1) (1) The owner or operator of an affected unit subject to the requirements of s. NR 409.065 may use the following tests as a basis for the report required by s. NR 409.065 (6) (e) 7.

NR 439.098(1)(a) (a) An ultimate analysis of coal conducted according to ASTM D 3176-89, incorporated by reference in s. NR 484.10 (44).

NR 439.098(1)(b) (b) A proximate analysis of coal conducted according to ASTM D 3172-89, incorporated by reference in s. NR 484.10 (41m).

NR 439.098(1)(c) (c) A measurement of the coal mass flow rate to each individual burner using ASME Performance Test Code 4.2-1969 (1997) or ISO 9931 (1991), incorporated by reference in s. NR 484.11 (6) and (8).

NR 439.098(2) (2) The owner or operator of an affected unit subject to the requirements of s. NR 409.065 may measure and record the actual NOx emission rate in accordance with the requirements of s. NR 409.065 while varying the following parameters where possible to determine their effects on the emissions of NOx from the affected boiler:

NR 439.098(2)(a) (a) Excess air levels.

NR 439.098(2)(b) (b) Settings of burners or coal and air nozzles, including tilt and yaw, or swirl.

NR 439.098(2)(c) (c) For tangentially fired boilers, distribution of combustion air within the NOx emission control system.

NR 439.098(2)(d) (d) Coal mass flow rates to each individual burner.

NR 439.098(2)(e) (e) Coal-to-primary air ratio (based on pound per hour) for each burner, the average coal-to-primary air ratio for all burners, and the deviations of individual burners’ coal-to-primary air ratios from the average value.

NR 439.098(2)(f) (f) If the boiler uses varying types of coal, the type of coal; in this case the owner or operator shall provide the results of proximate and ultimate analyses of each type of as-fired coal.

NR 439.098(3) (3) In performing the tests specified in sub. (1), the owner or operator shall begin the tests using the equipment settings for which the NOx emission control system was designed to meet the NOx emission rate guaranteed by the primary NOx emission control system vendor. These results constitute the baseline controlled condition.

NR 439.098(4) (4) After establishing the baseline controlled condition under sub. (3), the owner or operator may do any of the following:

NR 439.098(4)(a) (a) Change excess air levels ±5% from the baseline controlled condition to determine the effects on emissions of NOx, by providing a minimum of 3 readings.

NR 439.098 Note Note: For example, with a baseline reading of 20% excess air, excess air levels will be changed to 19% and 21%.

NR 439.098(4)(b) (b) For tangentially fired boilers, change the distribution of combustion air within the NOx emission control system to determine the effects on NOx emissions by providing a minimum of 3 readings, one with the minimum, one with the baseline, and one with the maximum amounts of staged combustion air.

NR 439.098(4)(c) (c) Show that the combustion process within the boiler is optimized.

NR 439.098 Note Note: For example, boiler optimization can mean that the burners are balanced.

NR 439.098 History History: Cr. Register, November, 1999, No. 527, eff. 12-1-99; correction in (1) (c) made under s. 13.93 (2m) (b) 7., Stats., Register August 2001 No. 548.

NR 439.10 NR 439.10 Circumvention. No person may cause, allow or permit the installation or use of any article, machine, equipment, process or method which conceals an emission which would otherwise constitute a violation of an applicable rule. Concealment includes, but is not limited to, the use of gaseous diluents to achieve compliance and the unnecessary separation of an operation into parts to avoid coverage by a rule that applies only to operations larger than a specified size.

NR 439.10 History History: Renum. from NR 154.06 (8), Register, September, 1986, No. 369, eff.10-1-86; renum. from NR 439.08 and am. Register, September, 1987, No. 381, eff. 10-1-87; CR 02-146: am. Register October 2003 No. 574, eff. 11-1-03.

NR 439.11 NR 439.11 Malfunction prevention and abatement plans.

NR 439.11(1) (1) The owner or operator of any direct or portable source which may emit hazardous substances or emits more than 15 pounds in any day or 3 pounds in any hour of any air contaminant for which emission limits have been adopted shall prepare a malfunction prevention and abatement plan to prevent, detect and correct malfunctions or equipment failures which may cause any applicable emission limitation to be violated or which may cause air pollution. The plan shall be in writing and updated at least every 5 years, and shall include:

NR 439.11(1)(a) (a) Identification of the individual responsible for inspecting, maintaining and repairing the air pollution control equipment.

NR 439.11(1)(b) (b) The maximum intervals for inspection and routine maintenance of the air pollution control equipment. The maximum interval for routine inspection and maintenance may not exceed that recommended by the manufacturer unless otherwise specified in a plan prepared under this section.

NR 439.11(1)(c) (c) A description of the items or conditions that will be checked.

NR 439.11(1)(d) (d) A listing of materials and spare parts that will be maintained in inventory.

NR 439.11(1)(e) (e) A description of the corrective procedures that will be taken in the event of a malfunction or failure which results in the exceedance of the applicable emission limitation. These corrective procedures shall achieve and maintain compliance with the applicable emission limitations as expeditiously as possible but not longer than the time necessary to discontinue operation of the source consistent with safe operating procedures.

NR 439.11(1)(f) (f) A description of the activities and maximum intervals for routine maintenance and inspection of instrumentation installed and operated to monitor the operation of air pollution control equipment as required under s. NR 439.055 (1). The maximum interval for inspection and routine maintenance may not exceed that recommended by the manufacturer of the instrumentation unless otherwise specified in a plan prepared under this section.

NR 439.11(1)(g) (g) The calibration schedule for any device which monitors either a source or air pollution control equipment operational variables. The time between calibrations may not exceed one year or as specified in a plan prepared under this section, whichever is shorter.

NR 439.11(1)(h) (h) Such other information as the department may deem pertinent.

NR 439.11(2) (2) The department may order any owner or operator to submit the plan required by sub. (1) for review and approval. The department may amend the plan if deemed necessary for malfunction prevention or the reduction of excess emissions during malfunctions.

NR 439.11(3) (3) No owner or operator may fail to carry out a plan required under sub. (1) or as amended under sub. (2).

NR 439.11(4) (4) All air pollution control equipment shall be operated and maintained in conformance with good engineering practices to minimize the possibility for the exceedance of any emission limitations.

NR 439.11 History History: Renum. from NR 154.06 (9) and am. Register, September, 1986, No. 369, eff. 10-1-86; renum. from NR 439.09 and am. Register, September, 1987, No. 381, eff. 10-1-87; am. (1) (g), Register, May, 1992, No. 437, eff. 6-1-92; am. (1) (intro.) and (b), r. and recr. (1) (e) to (g), Register, December, 1993, No. 456, eff. 1-1-94.