NR 440.32(5)(b)2.2. Method 5 shall be used to determine the particulate matter concentration (cs) and the volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.90 dscm (31.8 dscf). NR 440.32(5)(b)3.3. The dry sludge charging rate (S) for each run shall be computed using either of the following equations: where:
S is the charging rate of dry sludge, kg/hr (ton/hr)
Sm is the total mass of sludge charge, kg (ton)
Rdm is the average mass of dry sludge per unit mass of sludge charged, kg/kg (ton/ton)
is the duration of run, hr Sv is the total volume of sludge charged, m3 (gal)
Rdv is the average mass of dry sludge per unit volume of sludge charged, kg/m3 (lb/gal)
Kv is the conversion factor, 1 g/g (2000 lb/ton)
NR 440.32(5)(b)4.4. The flow measuring device described in sub. (4) (a) 1. shall be used to determine the total mass (Sm) or volume (Sv) of sludge charged to the incinerator during each run. If the flow measuring device is on a time rate basis, readings shall be taken and recorded at 5-minute intervals during the run and the total charge of sludge shall be computed using the following equations, as applicable: where:
Sm is the total mass of sludge charged to the incinerator during the test run
Sv is the total volume of sludge charged to the incinerator during the test run
Qmi is the average mass flow rate calculated by averaging the flow rates at the beginning and end of each interval “i”, kg/hr (ton/hr)
Qvi is the average volume flow rate calculated by averaging the flow rates at the beginning and end of each interval “i”, m3/hr (gal/hr)
i is the duration of interval “i”, hr NR 440.32(5)(b)5.5. Samples of the sludge charged to the incinerator shall be collected in nonporous jars at the beginning of each run and at approximately 1-hour intervals thereafter until the test ends, and Method 2540 G., “Total, Fixed, and Volatile Solids in Solid and Semisolid Samples”, in Standard Methods for the Examination of Water and Wastewater, 20th edition, 1998, incorporated by reference in s. NR 440.17 (2) (e) 2., shall be used to determine dry sludge content of each sample (total solids residue), except that: NR 440.32(5)(b)5.a.a. Evaporating dishes shall be ignited to at least 103°C rather than the 550°C specified in step 3.a.1). NR 440.32(5)(b)5.c.c. The quantity of dry sludge per unit sludge charged shall be determined in terms of kg/m3 (lb/gal) or kg/kg (ton/ton). NR 440.32(5)(b)5.d.d. The average dry sludge content shall be the arithmetic average of all the samples taken during the run. NR 440.32(5)(d)(d) The owner or operator of any sludge incinerator subject to the provisions of this section shall conduct a performance test during which the monitoring and recording devices required under sub. (4) (a) 1. and (b) 1. to 4., are installed and operating and for which the sampling and analysis procedures required under sub. (4) (b) 5. are performed. The owner or operator shall provide the department at least 30 days prior notice of the performance test to afford the department the opportunity to have an observer present. NR 440.32(5)(d)1.1. For incinerators that commenced construction or modification on or before April 18, 1986, the performance test shall be conducted by October 1, 1989 unless the monitoring and recording devices required under sub. (4) (a) 1. and (b) 1. to 4. were installed and operating and the sampling and analysis procedures required under sub. (4) (b) 5. were performed during the most recent performance test and a record of the measurements taken during the performance test is available. NR 440.32(5)(d)2.2. For incinerators that commence construction or modification after April 18, 1986, the date of the performance test shall be determined by the requirements in s. NR 440.08. NR 440.32(6)(a)(a) The owner or operator of any multiple hearth, fluidized bed or electric sludge incinerator subject to the provisions of this section shall submit to the department semiannually a report in writing which contains the following: NR 440.32(6)(a)1.1. A record of average scrubber pressure drop measurements for each period of 15 minute duration or more during which the pressure drop of the scrubber was less than, by a percentage specified in subd. 1. a. or b., as applicable, the average scrubber pressure drop measured during the most recent performance test. The percent reduction in scrubber pressure drop for which a report is required shall be determined as follows: NR 440.32(6)(a)1.a.a. For incinerators that achieved an average particulate matter emission rate of 0.38 kg/Mg (0.75 lb/ton) dry sludge input or less during the most recent performance test, a scrubber pressure drop reduction of more than 30% from the average scrubber pressure drop recorded during the most recent performance test shall be reported. NR 440.32(6)(a)1.b.b. For incinerators that achieved an average particulate matter emission rate of greater than 0.38 kg/Mg (0.75 lb/ton) dry sludge input during the most recent performance test, a percent reduction in pressure drop greater than that calculated according to the following equation shall be reported: P = - 111E + 72.15
where:
P is the percent reduction in pressure drop, and
E is the average particulate matter emissions (kg/megagram)
NR 440.32(6)(a)2.2. A record of average oxygen content in the incinerator exhaust gas for each period of 1-hour duration or more that the oxygen content of the incinerator exhaust gas exceeds the average oxygen content measured during the most recent performance test by more than 3%. NR 440.32(6)(b)(b) The owner or operator of any multiple hearth, fluidized bed or electric sludge incinerator from which the average particulate matter emission rate measured during the performance test required under sub. (5) (d) exceeds 0.38 g/kg of dry sludge input (0.75 lb/ton of dry sludge input) shall include in the report for each calendar day that a decrease in scrubber pressure drop or increase in oxygen content of exhaust gas is reported a record of the following: NR 440.32(6)(b)1.1. Scrubber pressure drop averaged over each 1-hour incinerator operating period. NR 440.32(6)(b)2.2. Oxygen content in the incinerator exhaust averaged over each 1-hour incinerator operating period. NR 440.32(6)(b)3.3. Temperatures of every hearth in multiple hearth incinerators; of the bed and outlet of fluidized bed incinerators; and of the drying, combustion and cooling zones of electric incinerators averaged over each 1-hour incinerator operating period. NR 440.32(6)(b)4.4. Rate of sludge charged to the incinerator averaged over each 1-hour incinerator operating period. NR 440.32(6)(b)5.5. Incinerator fuel use averaged over each 8-hour incinerator operating period. NR 440.32(6)(b)6.6. Moisture and volatile solids content of the daily grab sample of sludge charged to the incinerator. NR 440.32(6)(c)(c) The owner or operator of any sludge incinerator other than a multiple hearth, fluidized bed or electric incinerator or any sludge incinerator equipped with a control device other than a wet scrubber shall include in the semiannual report a record of control device operation measurements, as specified in the plan approved under sub. (4) (e). NR 440.32 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (a) 1., cr. (4) (b) to (e) and (6), r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; am. (5) (d) 2., r. (5) (d) 3. to 5., Register, December, 1995, No. 480, eff. 1-1-96; CR 06-109: am. (4) (b) 3., (5) (b) 4. and 5. (intro.) and c., r. and recr. (5) (b) 1. and 3. Register May 2008 No. 629, eff. 6-1-08. NR 440.33(1)(1) Applicability and designation of affected facility. NR 440.33(1)(a)(a) The provisions of this section are applicable to the following affected facilities in primary copper smelters: dryer, roaster, smelting furnace, and copper converter. NR 440.33(1)(b)(b) Any facility under par. (a) that commences construction or modifications after October 16, 1974, is subject to the requirements of this section. NR 440.33(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.33(2)(a)(a) “Calcine” means the solid materials produced by a roaster. NR 440.33(2)(b)(b) “Copper converter” means any vessel to which copper matte is charged and oxidized to copper. NR 440.33(2)(c)(c) “Dryer” means any facility in which a copper sulfide ore concentrate charge is heated in the presence of air to eliminate a portion of the moisture from the charge, provided less than 5% of the sulfur contained in the charge is eliminated in the facility. NR 440.33(2)(d)(d) “Fossil fuel” means natural gas, petroleum, coal and any form of solid, liquid or gaseous fuel derived from such materials for the purpose of creating useful heat. NR 440.33(2)(e)(e) “High level of volatile impurities” means a total smelter charge containing more than 0.2 weight percent arsenic, 0.1 weight percent antimony, 4.5 weight percent lead or 5.5 weight percent zinc, on a dry basis. NR 440.33(2)(f)(f) “Primary copper smelter” means any installation or any intermediate process engaged in the production of copper from copper sulfide ore concentrates through the use of pyrometallurgical techniques. NR 440.33(2)(g)(g) “Reverberatory smelting furnace” means any vessel in which the smelting of copper sulfide ore concentrates or calcines is performed and in which the heat necessary for smelting is provided primarily by combustion of fossil fuel. NR 440.33(2)(h)(h) “Roaster” means any facility in which a copper sulfide ore concentrate charge is heated in the presence of air to eliminate a significant portion (5% or more) of the sulfur contained in the charge. NR 440.33(2)(i)(i) “Smelting” means processing techniques for the melting of a copper sulfide ore concentrate or calcine charge leading to the formation of separate layers of molten slag, molten copper, or copper matte, or all 3. NR 440.33(2)(j)(j) “Smelting furnace” means any vessel in which the smelting of copper sulfide ore concentrate or calcines is performed and in which the heat necessary for smelting is provided by an electric current, rapid oxidation of a portion of the sulfur contained in the concentrate as it passes through an oxidizing atmosphere, or the combustion of a fossil fuel. NR 440.33(2)(k)(k) “Sulfuric acid plant” means any facility producing sulfuric acid by the contact process. NR 440.33(2)(L)(L) “Total smelter charge” means the weight (dry basis) of all copper sulfide ore concentrates processed at a primary copper smelter, plus the weight of all other solid materials introduced into the roasters and smelting furnaces at a primary copper smelter, except calcine, over a one-month period. NR 440.33(3)(a)(a) 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 cause to be discharged into the atmosphere from any dryer any gases which contain particulate matter in excess of 50 mg/dscm (0.022 gr/dscf). NR 440.33(4)(a)(a) 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 cause to be discharged into the atmosphere from any roaster, smelting furnace or copper converter any gases which contain sulfur dioxide in excess of 0.065% by volume, except as provided in pars. (b) and (c). NR 440.33(4)(b)(b) Reverberatory smelting furnaces are exempt from par. (a) during periods when the total smelter charge at the primary copper smelter contains a high level of volatile impurities. NR 440.33(4)(c)(c) A change in the fuel combusted in a reverberatory smelting furnace may not be considered a modification under this chapter. NR 440.33(5)(a)(a) 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 cause to be discharged into the atmosphere from any dryer any visible emissions which exhibit greater than 20% opacity. NR 440.33(5)(b)(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 cause to be discharged into the atmosphere from any affected facility that uses a sulfuric acid plant to comply with the standard set forth in sub. (4), any visible emissions which exhibit greater than 20% opacity. NR 440.33(6)(a)(a) The owner or operator of any primary copper smelter subject to sub. (4) (b) shall keep a monthly record of the total smelter charge and the weight percent (dry basis) of arsenic, antimony, lead and zinc contained in this charge. The analytical methods and procedures employed to determine the weight of the total smelter charge and the weight percent of arsenic, antimony, lead and zinc shall be approved by the department and shall be accurate to within ± 10%. NR 440.33(6)(b)(b) The owner or operator of any primary copper smelter subject to the provisions of this section shall install and operate: NR 440.33(6)(b)1.1. A continuous monitoring system to monitor and record the opacity of gases discharged into the atmosphere from any dryer. The span of this system shall be set at 80 to 100% opacity. NR 440.33(6)(b)2.2. A continuous monitoring system to monitor and record sulfur dioxide emissions discharged into the atmosphere from any roaster, smelting furnace or copper converter subject to sub. (4) (a). The span of this system shall be set at a sulfur dioxide concentration of 0.20% by volume. NR 440.33(6)(b)2.b.b. For the purpose of the continuous monitoring system performance evaluation required under s. NR 440.13 (3), the reference method referred to under the Relative Accuracy Test Procedure in Performance Specification 2 of 40 CFR part 60, Appendix B, incorporated by reference in s. NR 440.17, shall be Method 6 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17. For the performance evaluation, each concentration measurement shall be of one hour duration. The pollutant gas used to prepare the calibration gas mixtures required under Performance Specification 2 of Appendix B and for calibration checks under s. NR 440.13 (4) shall be sulfur dioxide. NR 440.33(6)(c)(c) Six-hour average sulfur dioxide concentrations shall be calculated and recorded daily for the 4 consecutive 6-hour periods of each operating day. Each 6-hour average shall be determined as the arithmetic mean of the appropriate 6 contiguous one-hour average sulfur dioxide concentrations provided by the continuous monitoring system installed under par. (b). NR 440.33(6)(d)(d) For the purpose of reports required under s. NR 440.07 (3), periods of excess emissions that shall be reported are defined as follows: NR 440.33(6)(d)1.1. Opacity. Any 6-minute period during which the average opacity, as measured by the continuous monitoring system installed under par. (b), exceeds the standard under sub. (5) (a). NR 440.33(6)(d)2.2. Sulfur dioxide. All 6-hour periods during which the average emissions of sulfur dioxide, as measured by the continuous monitoring system installed under par. (b), exceed the level of the standard. The department may not consider emissions in excess of the level of the standard for less than or equal to 1.5% of the 6-hour periods during the quarter as indicative of a potential violation of s. NR 440.11 (4), provided the affected facility, including air pollution control equipment, is maintained and operated in a manner consistent with good air pollution control practice for minimizing emissions during these periods. Emissions in excess of the level of the standard during periods of startup, shutdown and malfunction may not be included within the 1.5%. NR 440.33(7)(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 440.33(7)(b)(b) The owner or operator shall determine compliance with the particulate matter, sulfur dioxide (SO2) and visible emission standards in subs. (3) to (5) as follows: NR 440.33(7)(b)1.1. 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 0.85 dscm (30 dscf). NR 440.33(7)(b)2.2. The continuous monitoring system of sub. (6) (b) 2. shall be used to determine the SO2 concentrations on a dry basis. The sampling time for each run shall be 6 hours, and the average SO2 concentration shall be computed for the 6-hour period as in sub. (6) (c). The monitoring system drift during the run may not exceed 2% of the span value.
