NR 440.34(7)(b)
(b) The owner or operator shall determine compliance with the particulate matter, sulfur dioxide (SO
2) and visible emission standards in
subs. (3) to
(5) as follows:
NR 440.34(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 440.34(7)(b)2.
2. The continuous monitoring system of
sub. (6) (a) 2. shall be used to determine the SO
2 concentrations on a dry basis. The sampling time for each run shall be 2 hours, and the average SO
2 concentration for the 2-hour period shall be computed as in
sub. (6) (b). The monitoring system drift during the run may not exceed 2% of the span value.
NR 440.34 History
History: Cr.
Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.),
Register, September, 1990, No. 417, eff. 10-1-90; am. (6) (a) 2. a. and b., r. and recr. (7),
Register, July, 1993, No. 451, eff. 8-1-93; am. (6) (a) 2. b.,
Register, December, 1995, No. 480, eff. 1-1-96.
NR 440.35(1)
(1)
Applicability and designation of affected facility. NR 440.35(1)(a)(a) The provisions of this section are applicable to the following affected facilities in primary lead smelters: sintering machine, sintering machine discharge end, blast furnace, dross reverberatory furnace, electric smelting furnace and converter.
NR 440.35(1)(b)
(b) Any facility under
par. (a) that commences construction or modification after October 16, 1974, is subject to the requirements of this section.
NR 440.35(2)
(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in
s. NR 440.02.
NR 440.35(2)(a)
(a) “Blast furnace" means any reduction furnace to which sinter is charged and which forms separate layers of molten slag and lead bullion.
NR 440.35(2)(b)
(b) “Converter" means any vessel which lead concentrate or bullion is charged and refined.
NR 440.35(2)(c)
(c) “Dross reverberatory furnace" means any furnace used for the removal or refining of impurities from lead bullion.
NR 440.35(2)(d)
(d) “Electric smelting furnace" means any furnace in which the heat necessary for smelting of the lead sulfide ore concentrate charge is generated by passing an electric current through a portion of the molten mass in the furnace.
NR 440.35(2)(e)
(e) “Primary lead smelter" means any installation or any intermediate process engaged in the production of lead from lead sulfide ore concentrates through the use of pyrometallurgical techniques.
NR 440.35(2)(f)
(f) “Sinter bed" means the lead sulfide ore concentrate charge within a sintering machine.
NR 440.35(2)(g)
(g) “Sintering machine" means any furnace in which a lead sulfide ore concentrate charge is heated in the presence of air to eliminate sulfur contained in the charge and to agglomerate the charge into a hard porous mass called “sinter."
NR 440.35(2)(h)
(h) “Sintering machine discharge end" means any apparatus which receives sinter as it is discharged from the conveying grate of a sintering machine.
NR 440.35(2)(i)
(i) “Sulfuric acid plant" means any facility producing sulfuric acid by the contact process.
NR 440.35(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 blast furnace, dross reverberatory furnace or sintering machine discharge end any gases which contain particulate matter in excess of 50 mg/dscm (0.022 gr/dscf).
NR 440.35(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 sintering machine, electric smelting furnace, or converter gases which contain sulfur dioxide in excess of 0.065% by volume.
NR 440.35(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 blast furnace, dross reverberatory furnace, or sintering machine discharge end any visible emissions which exhibit greater than 20% opacity.
NR 440.35(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 440.35(6)(a)(a) The owner or operator of any primary lead smelter subject to the provisions of this section shall install and operate:
NR 440.35(6)(a)1.
1. A continuous monitoring system to monitor and record the opacity of gases discharged into the atmosphere from any blast furnace, dross reverberatory furnace, or sintering machine discharge end. The span of this system shall be set at 80 to 100% opacity.
NR 440.35(6)(a)2.
2. A continuous monitoring system to monitor and record sulfur dioxide emissions discharged into the atmosphere from any sintering machine, electric furnace or converter subject to
sub. (4). The span of this system shall be set at a sulfur dioxide concentration of 0.20% by volume.
NR 440.35(6)(a)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 440.35(6)(b)
(b) Two-hour average sulfur dioxide concentrations shall be calculated and recorded daily for the 12 consecutive 2-hour periods of each operating day. Each 2-hour average shall be determined as the arithmetic mean of the appropriate 2 contiguous one-hour average sulfur dioxide concentrations provided by the continuous monitoring system installed under
par. (a).
NR 440.35(6)(c)
(c) 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 440.35(6)(c)1.
1. Opacity. Any 6-minute period during which the average opacity, as measured by the continuous monitoring system installed under
par. (a), exceeds the standard under
sub. (5) (a).
NR 440.35(6)(c)2.
2. Sulfur dioxide. Any 2-hour period, as described in
par. (b), during which the average emissions of sulfur dioxide, as measured by the continuous monitoring system installed under
par. (a), exceeds the standard under
sub. (4).
NR 440.35(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 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
s. NR 440.08 (2).
NR 440.35(7)(b)
(b) The owner or operator shall determine compliance with the particulate matter, sulfur dioxide (SO
2) and visible emission standards in
subs. (3) to
(5) as follows:
NR 440.35(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 440.35(7)(b)2.
2. The continuous monitoring system of
sub. (6) (a) 2. shall be used to determine the SO
2 concentrations on a dry basis. The sampling time for each run shall be 2 hours, and the average SO
2 concentration for the 2-hour period shall be computed as in
sub. (6) (b). The monitoring system drift during the run may not exceed 2% of the span value.
NR 440.35 History
History: Cr.
Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.),
Register, September, 1990, No. 417, eff. 10-1-90; am. (6) (a) 2. a. and b., r. and recr. (7),
Register, July, 1993, No. 451, eff. 8-1-9
3; am. (6) (a) 2. b.,
Register, December, 1995, No. 480, eff. 1-1-96.
NR 440.36
NR 440.36 Primary aluminum reduction plants. NR 440.36(1)(1)
Applicability and designation of affected facility. NR 440.36(1)(a)(a) The affected facilities in primary aluminum reduction plants to which this section applies are potroom groups and anode bake plants.
NR 440.36(1)(b)
(b) Except as provided in
par. (c), any affected facility under
par. (a) that commences construction or modification after October 23, 1974, is subject to the requirements of this section.
NR 440.36(1)(c)
(c) An owner or operator of an affected facility under
par. (a) may elect to comply with the requirements of this section or the requirements of
40 CFR part 63.
NR 440.36(2)
(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in
s. NR 440.02.
NR 440.36(2)(a)
(a) “Aluminum equivalent" means an amount of aluminum which can be produced from a Mg of anodes produced by an anode bake plant as determined by
sub. (6) (b) 4. b.
NR 440.36(2)(b)
(b) “Anode bake plant" means a facility which produces carbon anodes for use in a primary aluminum reduction plant.
NR 440.36(2)(c)
(c) “Potroom" means a building unit which houses a group of electrolytic cells in which aluminum is produced.
NR 440.36(2)(d)
(d) “Potroom group" means an uncontrolled potroom, a potroom which is controlled individually, or a group of potrooms or potroom segments ducted to a common control system.
NR 440.36(2)(e)
(e) “Primary aluminum reduction plant" means any facility manufacturing aluminum by electrolytic reduction.
NR 440.36(2)(f)
(f) “Primary control system" means an air pollution control system designed to remove gaseous and particulate fluorides from exhaust gases which are captured at the cell.
NR 440.36(2)(g)
(g) “Roof monitor" means that portion of the roof of a potroom where gases not captured at the cell exit from the potroom.
NR 440.36(2)(h)
(h) “Total fluorides" means elemental fluorine and all fluoride compounds as measured by reference methods specified in
sub. (6) or by equivalent or alternative methods.
NR 440.36(3)(a)(a) On and after the date on which the initial 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 any gases containing total fluorides, as measured according to
sub. (6), in excess of:
NR 440.36(3)(a)1.
1. 1.0 kg/Mg (2.0 lb/ton) of aluminum produced for potroom groups at Soderberg plants, except that emissions between 1.0 kg/Mg and 1.3 kg/Mg (2.6 lb/ton) shall be considered in compliance if the owner or operator demonstrates that exemplary operation and maintenance procedures were used with respect to the emission control system and that proper control equipment was operating at the affected facility during the performance tests;
NR 440.36(3)(a)2.
2. 0.95 kg/Mg (1.9 lb/ton) of aluminum produced for potroom groups at prebake plants, except that emissions between 0.95 kg/Mg and 1.25 kg/Mg (2.5 lb/ton) shall be considered in compliance if the owner or operator demonstrates that exemplary operation and maintenance procedures were used with respect to the emission control system and that proper control equipment was operating at the affected facility during the performance test; and
NR 440.36(3)(a)3.
3. 0.050 kg/Mg (0.10 lb/ton) of aluminum equivalent for anode bake plants.
NR 440.36(3)(b)
(b) Within 30 days of any performance test which reveals emissions which fall between the 1.0 kg/Mg and 1.3 kg/Mg levels in
par. (a) 1. or between to 0.95 kg/Mg and 1.25 kg/Mg levels in
par. (a) 2., the owner or operator shall submit a report to the department indicating whether all necessary control devices were on-line and operating properly during the performance test, describing the operating and maintenance procedures followed, and setting forth any explanation for the excess emissions.
NR 440.36(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:
NR 440.36(4)(a)1.
1. From any potroom group any gases which exhibit 10% opacity or greater, or
NR 440.36(4)(a)2.
2. From any anode bake plant any gases which exhibit 20% opacity or greater.
NR 440.36(5)(a)(a) The owner or operator of any affected facility subject to the provisions of this section shall install, calibrate, maintain and operate monitoring devices which can be used to determine daily the weight of aluminum and anode produced. The weighing devices shall have an accuracy of
" 5% over their operating range.
NR 440.36(5)(b)
(b) The owner or operator of any affected facility shall maintain a record of daily production rates of aluminum and anodes, raw material feed rates, and cell or potline voltages.
NR 440.36(5)(c)
(c) Following the initial performance test as required under
s. NR 440.08 (1), an owner or operator shall conduct a performance test at least once each month during the life of the affected facility, except when malfunctions prevent representative sampling, as provided under
s. NR 440.08 (3). The owner or operator shall give the department at least 15 days advance notice of each test. The department may require additional testing under
ch. NR 439.
NR 440.36 Note
Note:
Under
40 CFR 60.195 (b), an owner or operator may petition the administrator to establish an alternate testing requirement that requires testing less frequently than once each month for a primary control system or an anode bake plant if it can be shown that their emissions have low variability during day-to-day operations. The alternative testing requirement must be published in the federal register and include a testing schedule and, in the case of a primary control system, the method to be used to determine primary control system emissions for the purpose of performance tests.
NR 440.36(6)(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 440.36(6)(b)
(b) The owner or operator shall determine compliance with the total fluorides and visible emission standards in
subs. (3) and
(4) as follows:
NR 440.36(6)(b)1.
1. The emission rate (E
p) of total fluorides from potroom groups shall be computed for each run using the following equation:
Ep = [(Cs Qsd)1 + (Cs Qsd)2]/(PK)
where:
Ep is the emission rate of total fluorides from a potroom group, kg/Mg (lb/ton)
Cs is the concentration of total fluorides, mg/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the aluminum production rate, Mg/hr (ton/hr)
K is the conversion factor, 106 mg/kg (7000 gr/lb)
1 is the subscript for primary control system effluent gas
2 is the subscript for secondary control system or roof monitor effluent gas
NR 440.36(6)(b)2.
2. The emission rate (E
b) of total fluorides from anode bake plants shall be computed for each run using the following equation:
Eb = (Cs Qsd)/(PeK)
where:
Eb is the emission rate of total fluorides, kg/Mg (lb/ton) of aluminum equivalent
