Chapter NR 440

NR 440.30(4)(b) (b) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows:

NR 440.30(4)(b)1. 1. Method 5 shall be used to determine the particulate matter concentration during representative periods of charging and refining, but not during the pouring part of the production cycle. The sampling time and sample volume for each run shall be at least 120 minutes and 1.80 dscm (63.6 dscf).

NR 440.30(4)(b)2. 2. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity.

NR 440.30 History History: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (1) (a), (4) (a) 3. and 4., cr. (4) (a) 5., Register, September, 1986, No. 369, eff. 10-1-86; am. (2) (intro)., Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (4), Register, July, 1993, No. 451, eff. 8-1-93; CR 06-109: am. (4) (b) 1. Register May 2008 No. 629, eff. 6-1-08.

NR 440.31 NR 440.31 Primary emissions from basic oxygen process furnaces for which construction is commenced after June 11, 1973.

NR 440.31(1) (1) Applicability and designation of affected facility.

NR 440.31(1)(a) (a) The affected facility to which the provisions of this section apply is each basic oxygen process furnace.

NR 440.31(1)(b) (b) Any facility under par. (a) that commences construction or modification after June 11, 1973, is subject to the requirements of this section.

NR 440.31(2) (2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02.

NR 440.31(2)(a) (a) “Basic oxygen process furnace” or “BOPF” means any furnace with a refractory lining in which molten steel is produced by charging scrap metal, molten iron, and flux materials or alloy additions into a vessel and introducing a high volume of an oxygen-rich gas. Open hearth, blast and reverberatory furnaces are not included in this definition.

NR 440.31(2)(b) (b) “Primary emissions” means particulate matter emissions from the BOPF generated during the steel production cycle and captured by the BOPF primary control system.

NR 440.31(2)(c) (c) “Primary oxygen blow” means the period in the steel production cycle of a BOPF during which a high volume of oxygen-rich gas is introduced to the bath of molten iron by means of a lance inserted from the top of the vessel or through tuyeres in the bottom or through the bottom and sides of the vessel. This definition does not include any additional or secondary oxygen blows made after the primary blow or the introduction of nitrogen or other inert gas through tuyeres in the bottom or bottom and sides of the vessel.

NR 440.31(2)(d) (d) “Steel production cycle” means the operations conducted within the BOPF steelmaking facility that are required to produce each batch of steel and includes the following operations: scrap charging, preheating (when used), hot metal charging, primary oxygen blowing, sampling (vessel turndown and turnup), additional oxygen blowing (when used), tapping, and deslagging. This definition applies to an affected facility constructed, modified, or reconstructed after January 20, 1983. For an affected facility constructed, modified, or reconstructed after June 11, 1973, but on or before January 20, 1983, “steel production cycle” means the operations conducted within the BOPF steelmaking facility that are required to produce each batch of steel and includes the following operations: scrap charging, preheating (when used), hot metal charging, primary oxygen blowing, sampling (vessel turndown and turnup), additional oxygen blowing (when used) and tapping.

NR 440.31(3) (3) Standard for particulate matter.

NR 440.31(3)(a) (a) Except as provided under par. (b), on and after the date on which the performance test required to be conducted by s. NR 440.08 is completed, no owner or operator subject to the provisions of this section may discharge or cause the discharge into the atmosphere from any affected facility any gases which:

NR 440.31(3)(a)1. 1. Contain particulate matter in excess of 50 mg/dscm (0.022 gr/dscf).

NR 440.31(3)(a)2. 2. Exit from a control device and exhibit 10% opacity or greater, except that an opacity of greater than 10% but less than 20% may occur once per steel production cycle.

NR 440.31(3)(b) (b) For affected facilities constructed, modified, or reconstructed after January 20, 1983, the following limits shall apply:

NR 440.31(3)(b)1. 1. On or after the date on which the performance test under s. NR 440.08 is required to be completed, no owner or operator of an affected facility for which open hooding is the method for controlling primary emissions may cause to be discharged to the atmosphere any gases that:

NR 440.31(3)(b)1.a. a. Contain particulate matter in excess of 50 mg/dscm (0.022 gr/dscf), as measured for the primary oxygen blow.

NR 440.31(3)(b)1.b. b. Exit from a control device not used solely for the collection of secondary emissions, as defined in s. NR 440.315 (2), and exhibit 10% opacity or greater, except that an opacity greater than 10% but less than 20% may occur once per steel production cycle.

NR 440.31(3)(b)2. 2. On or after the date on which the performance test required by s. NR 440.08 is completed, no owner or operator of an affected facility for which closed hooding is the method for controlling primary emissions may cause to be discharged into the atmosphere any gases that:

NR 440.31(3)(b)2.a. a. Contain particulate matter in excess of 68 mg/dscm (0.030 gr/dscf), as measured for the primary oxygen blow.

NR 440.31(3)(b)2.b. b. Exit from a control device not used solely for the collection of secondary emissions, as defined in s. NR 440.315 (2), and exhibit 10% opacity or greater, except that an opacity greater than 10% but less than 20% may occur once per steel production cycle.

NR 440.31(3)(c) (c) On and after the date on which the performance test required by s. NR 440.08 is completed, each owner or operator of an affected facility subject to par. (b) shall operate the primary gas cleaning system during any reblow in a manner identical to operation during the primary oxygen blow.

NR 440.31(4) (4) Monitoring of operations.

NR 440.31(4)(a) (a) The owner or operator of an affected facility shall maintain a single time-measuring instrument which shall be used in recording daily the time and duration of each steel production cycle, and the time and duration of any diversion of exhaust gases from the main stack servicing the BOPF.

NR 440.31(4)(b) (b) The owner or operator of any affected facility that uses venturi scrubber emission control equipment shall install, calibrate, maintain, and continuously operate monitoring devices as follows:

NR 440.31(4)(b)1. 1. A monitoring device for the continuous measurement of the pressure loss through the venturi constriction of the control equipment. The monitoring device shall be certified by the manufacturer to be accurate within ± 250 Pa (± 1 inch water).

NR 440.31(4)(b)2. 2. A monitoring device for the continuous measurement of the water supply pressure to the control equipment. The monitoring device shall be certified by the manufacturer to be accurate within ± 5% of the design water supply pressure. The monitoring device’s pressure sensor or pressure tap shall be located close to the water discharge point. The department shall be consulted for approval in advance of selecting alternative locations for the pressure sensor or tap.

NR 440.31(4)(b)3. 3. All monitoring devices shall be synchronized each day with the time-measuring instrument used under par. (a). The chart recorder error directly after synchronization may not exceed 0.08 cm (1/32 inch).

NR 440.31(4)(b)4. 4. All monitoring devices shall use chart recorders which are operated at a minimum chart speed of 3.8 cm/hr (1.5 in/hr).

NR 440.31(4)(b)5. 5. All monitoring devices shall be recalibrated annually, and at other times as the department may require, in accordance with the procedures under s. NR 440.13 (2).

NR 440.31(4)(c) (c) Any owner or operator subject to requirements under par. (b) shall report to the department, on a semiannual basis, all measurements over any 3-hour period that average more than 10% below the average levels maintained during the most recent performance test conducted under s. NR 440.08 in which the affected facility demonstrated compliance with the mass standards under sub. (3) (a) 1., (b) 1. a. or 2. a. The accuracy of the respective measurements, not to exceed the values specified in par. (b) 1. and 2., may be taken into consideration when determining the measurement results that must be reported.

NR 440.31(5) (5) Test methods and procedures.

NR 440.31(5)(a) (a) In conducting the performance tests required in s. NR 440.08, the owner or operator shall use as reference methods and procedures the test methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, or other methods and procedures as specified in this subsection, except as provided in s. NR 440.08 (2).

NR 440.31(5)(b) (b) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows:

NR 440.31(5)(b)1. 1. The time-measuring instrument of sub. (4) shall be used to document the time and duration of each steel production cycle and each diversion period during each run.

NR 440.31(5)(b)2. 2. Method 5 shall be used to determine the particulate matter concentration. The sampling time and sample volume for each run shall be at least 60 minutes and 1.50 dscm (53 dscf). Sampling shall be discontinued during periods of diversions.

NR 440.31(5)(b)2.a. a. For affected facilities that commenced construction, modification or reconstruction on or before January 20, 1983, the sampling for each run shall continue for an integral number of steel production cycles. A cycle shall start at the beginning of either the scrap preheat or the oxygen blow and shall terminate immediately before tapping.

NR 440.31(5)(b)2.b. b. For affected facilities that commenced construction, modification or reconstruction after January 20, 1983, the sampling for each run shall continue for an integral number of primary oxygen blows.

NR 440.31(5)(b)3. 3. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity. Observations taken during a diversion period may not be used in determining compliance with the opacity standard. Opacity observations taken at 15-second intervals immediately before and after a diversion of exhaust gases from the stack may be considered to be consecutive for the purpose of computing an average opacity for a 6-minute period.

NR 440.31(5)(c) (c) The owner or operator shall use the monitoring devices of sub. (4) (b) 1. and 2. for the duration of the particulate matter runs. The arithmetic average of all measurements taken during these runs shall be used to determine compliance with sub. (4) (c).

NR 440.31 History History: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), and (a), (3) (a) (intro.), (4) (b) 2. and (c), (5) (b), r. and recr. (2) (b), renum. (2) (c) to be (2) (d) and am., cr. (2) (c), (3) (b) and (c), Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (b) 5., r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; am. (4) (b) 1., 4., Register, December, 1995, No. 480, eff. 1-1-96; CR 06-109: am. (5) (c) Register May 2008 No. 629, eff. 6-1-08.

NR 440.315 NR 440.315 Basic oxygen process steelmaking facilities for which construction is commenced after January 20, 1983.

NR 440.315(1) (1) Applicability and designation of affected facilities.

NR 440.315(1)(a) (a) The provisions of this section apply to the following affected facilities in an iron and steel plant: top-blown BOPFs and hot metal transfer stations and skimming stations used with bottom-blown or top-blown BOPFs.

NR 440.315(1)(b) (b) This section applies to any facility identified in par. (a) that commences construction, modification or reconstruction after January 20, 1983.

NR 440.315(1)(c) (c) Any BOPF subject to the provisions of this section is subject to those provisions of s. NR 440.31 applicable to affected facilities commencing construction, modification or reconstruction after January 20, 1983.

NR 440.315(2) (2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02.

NR 440.315(2)(a) (a) “Basic oxygen process furnace” or “BOPF” means any furnace with a refractory lining in which molten steel is produced by charging scrap metal, molten iron, and flux materials or alloy additions into a vessel and by introducing a high volume of oxygen-rich gas. Open hearth, blast and reverberatory furnaces are not included in this definition.

NR 440.315(2)(b) (b) “Bottom-blown furnace” means any BOPF in which oxygen and other combustion gases are introduced to the bath of molten iron through tuyeres in the bottom of the vessel or through tuyeres in the bottom and sides of the vessel.

NR 440.315(2)(c) (c) “Fume suppression system” means the equipment comprising any system used to inhibit the generation of emissions from steelmaking facilities with an inert gas, flame or steam blanket applied to the surface of molten iron or steel.

NR 440.315(2)(d) (d) “Hot metal transfer station” means the facility where molten iron is emptied from the railroad torpedo car or hot metal car to the shop ladle. This includes the transfer of molten iron from the torpedo car or hot metal car to a mixer (or other intermediate vessel) and from a mixer (or other intermediate vessel) to the ladle. This facility is also known as the reladling station or ladle transfer station.

NR 440.315(2)(e) (e) “Primary emission control system” means the combination of equipment used for the capture and collection of primary emissions, e.g., an open hood capture system used in conjunction with a particular cleaning device such as an electrostatic precipitator or a closed hood capture system used in conjunction with a particulate matter cleaning device such as a scrubber.

NR 440.315(2)(f) (f) “Primary emissions” means particulate matter emissions from the BOPF generated during the steel production cycle which are captured by, and do not thereafter escape from the BOPF primary control system.

NR 440.315(2)(g) (g) “Primary oxygen blow” means the period in the steel production cycle of a BOPF during which a high volume of oxygen-rich gas is introduced to the bath of molten iron by means of a lance inserted from the top of the vessel. This definition does not include any additional, or secondary, oxygen blows made after the primary blow.

NR 440.315(2)(h) (h) “Secondary emission control system” means the combination of equipment used for the capture and collection of secondary emissions, e.g.:

NR 440.315(2)(h)1. 1. An open hood system for the capture and collection of primary and secondary emissions from the BOPF, with local hooding ducted to a secondary emission collection device such as a baghouse for the capture and collection of emissions from the hot metal transfer and skimming station; or

NR 440.315(2)(h)2. 2. An open hood system for the capture and collection of primary and secondary emissions from the furnace, plus a furnace enclosure with local hooding ducted to a secondary emission collection device, such as a baghouse, for additional capture and collection of secondary emissions from the furnace, with local hooding ducted to a secondary emission collection device, such as a baghouse for the capture and collection of emissions from hot metal transfer and skimming stations; or

NR 440.315(2)(h)3. 3. A furnace enclosure with local hooding ducted to a secondary emission collection device such as a baghouse for the capture and collection of secondary emissions from a BOPF controlled by a closed hood primary emission control system, with local hooding ducted to a secondary emission collection device, such as baghouse, for the capture and collection of emissions from hot metal transfer and skimming stations.

NR 440.315(2)(i) (i) “Secondary emissions” means particulate matter emissions that are not captured by the BOPF primary control system, including emissions from hot metal transfer and skimming stations. This definition also includes particulate matter emissions that escape from openings in the primary emission control system, such as from lance hole openings, gaps or tears in the ductwork of the primary emission control system, or leaks in hoods.

NR 440.315(2)(j) (j) “Skimming station” means the facility where slag is mechanically raked from the top of the molten iron.

NR 440.315(2)(k) (k) “Steel production cycle” means the operations conducted within the BOPF steelmaking facility that are required to produce each batch of steel, including the following operations: scrap charging, preheating (when used), hot metal charging primary oxygen blowing, sampling (vessel turndown and turnup), additional oxygen blowing (when used), tapping and deslagging. Hot metal transfer and skimming operations from the next steel production cycle are also included when the hot metal transfer station or skimming station is an affected facility.

NR 440.315(2)(L) (L) “Top-blown furnace” means any BOPF in which oxygen is introduced to the bath of molten iron by means of an oxygen lance inserted from the top of the vessel.

NR 440.315(3) (3) Standards for particulate matter.

NR 440.315(3)(a) (a) Except as provided under pars. (b) and (c), on and after the date on which the performance test under s. NR 440.08 is required to be completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any affected facility any secondary emissions that:

NR 440.315(3)(a)1. 1. Exit from the BOPF shop roof monitor (or other building openings) and exhibit greater than 10% opacity during the steel production cycle of any top-blown BOPF or during hot metal transfer or skimming operations for any bottom-blown BOPF, except that an opacity greater than 10% but less than 20% may occur once per steel production cycle.

NR 440.315(3)(a)2. 2. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming operations for a top-blown BOPF and contain particulate matter in excess of 23 mg/dscm (0.010 gr/dscf).

NR 440.315(3)(a)3. 3. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming operations for a top-blown or a bottom-blown BOPF and exhibit more than 5% opacity.

NR 440.315(3)(b) (b) A fume suppression system used to control secondary emissions from an affected facility is not subject to par. (a) 2. and 3.

NR 440.315(3)(c) (c) A control device used to collect both primary and secondary emissions from a BOPF is not subject to par. (a) 2. and 3.

NR 440.315(4) (4) Monitoring of operations.

NR 440.315(4)(a) (a) Each owner or operator of an affected facility shall install, calibrate, operate, and maintain a monitoring device that continually measures and records for each steel production cycle the various rates or levels of exhaust ventilation at each phase of the cycle through each duct of the secondary emission capture system. The monitoring device or devices are to be placed at locations near each capture point of the secondary emission capture system to monitor the exhaust ventilation rates or levels adequately, or in alternative locations approved in advance by the department.

NR 440.315(4)(b) (b) If a chart recorder is used, the owner or operator shall use chart recorders that are operated at minimum chart speed of 3.8 cm/hr (1.5 in/hr).

NR 440.315(4)(c) (c) All monitoring devices required by par. (a) shall be certified by the manufacturer to be accurate to within ± 10% compared to Method 2 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1). The owner or operator shall recalibrate and check the devices annually and at other times as the department may require, in accordance with the written instructions of the manufacturer and by comparing the device against Method 2.

NR 440.315(4)(d) (d) Each owner or operator subject to the requirements of par. (a) shall report on a semiannual basis all measurements of exhaust ventilation rates or levels over any 3-hour period that average more than 10% below the average rates or levels of exhaust ventilation maintained during the most recent performance test conducted under s. NR 440.08 in which the affected facility demonstrated compliance with the standard under sub. (3) (a) 2. The accuracy of the respective measurements, not to exceed the values specified in par. (c), may be considered when determining the measurement results that are to be reported.

NR 440.315(4)(e) (e) If a scrubber primary emission control device is used to collect secondary emissions, the owner or operator shall report on a semiannual basis all measurements of exhaust ventilation rate over any 3-hour period that average more than 10% below the average levels maintained during the most recent performance text conducted under s. NR 440.08 in which the affected facility demonstrated compliance with the standard under sub. (3) (a) 1.

NR 440.315(5) (5) Test methods and procedures.

NR 440.315(5)(a) (a) In conducting the performance tests required in s. NR 440.08, the owner or operator shall use as reference methods and procedures the test methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, or other methods and procedures as specified in this subsection, except as provided in s. NR 440.08 (2).

NR 440.315(5)(b) (b) The owner or operator shall determine compliance with the particulate matter standard in sub. (3) as follows:

NR 440.315(5)(b)1. 1. Start and end times of each steel production cycle during each run shall be recorded.

NR 440.315 Note Note: See sub. (6) (c) and (d) for the definitions of start and end times of a cycle.

NR 440.315(5)(b)2. 2. Method 5 shall be used to determine the particulate matter concentration. Sampling shall be conducted only during the steel production cycle and for a sufficient number of steel production cycles to obtain a total sample volume of at least 5.67 dscm (200 dscf) for each run.

NR 440.315(5)(b)3. 3. Method 9 and the procedures of s. NR 440.11 shall be used to determine opacity, except sections 2.4 and 2.5 of Method 9 shall be replaced with the following instructions for recording observations and reducing data:

NR 440.315(5)(b)3.a. a. Section 2.4. Opacity observations shall be recorded to the nearest 5% at 15-second intervals. During the initial performance test conducted pursuant to s. NR 440.08, observations shall be made and recorded in this manner for a minimum of 3 steel production cycles. During any subsequent compliance test, observations may be made for any number of steel production cycles, although, where conditions permit, observations will generally be made for a minimum of 3 steel production cycles.

NR 440.315(5)(b)3.b. b. Section 2.5. Opacity shall be determined as an average of 12 consecutive observations recorded at 15-second intervals. For each steel production cycle, divide the observations recorded into sets of 12 consecutive observations. Sets need not be consecutive in time, and in no case may 2 sets overlap. For each set of 12 observations, calculate the average by summing the opacity of 12 consecutive observations and dividing this sum by 12.

NR 440.315(5)(c) (c) In complying with the requirements of sub. (4) (c), the owner or operator shall conduct an initial test as follows:

NR 440.315(5)(c)1. 1. For devices that monitor and record the exhaust ventilation rate, compare velocity readings recorded by the monitoring device against the velocity readings obtained by Method 2. Take Method 2 readings at a point or points that would properly characterize the monitoring device’s performance and that would adequately reflect the various rates of exhaust ventilation. Obtain readings at sufficient intervals to obtain 12 pairs of readings for each duct of the secondary emission capture system. Compare the averages of the 2 sets to determine whether the monitoring device velocity is within ± 10% of the Method 2 average.