NR 440.51(2)(b)
(b) “Lime product" means the product of the calcination process including, but not limited to, calcitic lime, dolomitic lime and dead-burned dolomite.
NR 440.51(2)(c)
(c) “Positive-pressure fabric filter" means a fabric filter with the fans on the upstream side of the filter bags.
NR 440.51(2)(d)
(d) “Rotary lime kiln" means a unit with an inclined rotating drum which is used to produce a lime product from limestone by calcination.
NR 440.51(2)(e)
(e) “Stone feed" means limestone feedstock and millscale or other iron oxide additives that become part of the product.
NR 440.51(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 rotary lime kiln any gases which:
NR 440.51(3)(a)1.
1. Contain particulate matter in excess of 0.30 kilogram per megagram of stone feed (0.60 lb/ton).
NR 440.51(3)(a)2.
2. Exhibit greater than 15% opacity when exiting from a dry emission control device.
NR 440.51(4)(a)(a) The owner or operator subject to the provisions of this section shall install, calibrate, maintain and operate a continuous monitoring system, except as provided in
pars. (b) and
(c), to monitor and record the opacity of a representative portion of the gases discharged into the atmosphere from any rotary lime kiln. The span of this system shall be set at 40% opacity.
NR 440.51(4)(b)
(b) The owner or operator of any rotary lime kiln having a control device with a multiple stack exhaust or a roof monitor may, in lieu of the continuous opacity monitoring requirements of
par. (a), monitor visible emissions at least once per day of operation by using a certified visible emissions observer who, for each site where visible emissions are observed, will perform 3 Reference Method 9 tests and record the results. (Reference Method 9 of
40 CFR part 60, Appendix A, is incorporated by reference in
s. NR 440.17). Visible emission observation shall occur during normal operation of the rotary lime kiln at least once per day. For at least 3 6-minute periods, the opacity shall be recorded for any points where visible emissions are observed, and the corresponding feed rate of the kiln shall also be recorded. Records shall be maintained of any 6-minute average that is in excess of the emissions specified in
sub. (3) (a).
NR 440.51(4)(c)
(c) The owner or operator of any rotary lime kiln using a wet scrubbing emission control device subject to the provisions of this section may not be required to monitor the opacity of the gases discharged as required in
par. (a), but shall install, calibrate, maintain and operate the following continuous monitoring devices:
NR 440.51(4)(c)1.
1. A monitoring device for the continuous measurement of the pressure loss of the gas stream through the scrubber. The monitoring device shall be accurate within
" 250 pascals (one inch of water).
NR 440.51(4)(c)2.
2. A monitoring device for continuous measurement of the scrubbing liquid supply pressure to the control device. The monitoring device shall be accurate within
" 5% of the design scrubbing liquid supply pressure.
NR 440.51(4)(d)
(d) For the purpose of conducting a performance test under
s. NR 440.08 the owner or operator of any lime manufacturing plant subject to the provisions of this section shall install, calibrate, maintain and operate a device for measuring the mass rate of stone feed to any affected rotary lime kiln. The measuring device used shall be accurate within
" 5% of the mass rate over its operating range.
NR 440.51(4)(e)
(e) For the purpose of reports required under
s. NR 440.07 (3) periods of excess emissions that shall be reported are defined as all 6-minute periods during which the average opacity of the plume from any lime kiln subject to
par. (a) is greater than 15% or, in the case of wet scrubbers, any period in which the scrubber pressure drop is greater than 30% below the rate established during the performance test. If visible emission observations are made according to
par. (b), reports of excess emissions shall be submitted semiannually.
NR 440.51(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 440.51(5)(b)
(b) The owner or operator shall determine compliance with the particulate matter standards in
sub. (3) (a) as follows:
NR 440.51(5)(b)1.
1. The emission rate (E) of particulate matter shall be computed for each run using the following equation:
E = (cs Qsd)/PK)
where:
E is the emission rate of particulate matter, kg/Mg (lb/ton) of stone feed
cs is the concentration of particulate matter, g/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the stone feed rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 g/kg (7000 gr/lb)
NR 440.51(5)(b)2.
2. Method 5 shall be used at negative-pressure fabric filters and other types of control devices and Method 5D shall be used at positive-pressure fabric filters to determine the particulate matter concentration (c
s) and the volumetric flow rate (Q
sd) 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 440.51(5)(b)3.
3. The monitoring device of
sub. (4) (d) shall be used to determine the stone feed rate (P) for each run.
NR 440.51(5)(c)
(c) During the particulate matter run, the owner or operator shall use the monitoring devices in
sub. (4) (c) 1. and
2. to determine the average pressure loss of the gas stream through the scrubber and the average scrubbing liquid supply pressure.
NR 440.51 History
History: Cr.
Register, January, 1984, No. 337, eff. 2-1-84; am. (1) (a), (2), (3) (a), (4) and (5),
Register, September, 1986, No. 369, eff. 10-1-86; am. (2) (intro.), (4) (b) and (5) (c),
Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (e), r. and recr. (5),
Register, June, 1993, No. 450, eff. 8-1-93;
CR 06-109: r. and recr. (5) (b) 1., am. (5) (b) 2. Register May 2008 No. 629, eff. 6-1-08. NR 440.52
NR 440.52 Lead-acid battery manufacturing plants. NR 440.52(1)(1)
Applicability and designation of affected facility. NR 440.52(1)(a)(a) The provisions of this section are applicable to the affected facilities listed in
par. (b) at any lead-acid battery manufacturing plant that produces or has the design capacity to produce in one day (24 hours) batteries containing an amount of lead equal to or greater than 5.9 Mg (6.5 tons).
NR 440.52(1)(b)
(b) The provisions of this section are applicable to the following affected facilities used in the manufacture of lead-acid storage batteries:
NR 440.52(1)(c)
(c) Any facility under
par. (b) that commences construction or modification after January 14, 1980, is subject to the requirements of this section.
NR 440.52(2)
(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in
s. NR 440.02.
NR 440.52(2)(a)
(a) “Grid casting facility" means the facility which includes all lead melting pots and machines used for casting the grid used in battery manufacturing.
NR 440.52(2)(b)
(b) “Lead-acid battery manufacturing plant" means any plant that produces a storage battery using lead and lead compounds for the plates and sulfuric acid for the electrolyte.
NR 440.52(2)(c)
(c) “Lead oxide manufacturing facility" means a facility that produces lead oxide from lead, including product recovery.
NR 440.52(2)(d)
(d) “Lead reclamation facility" means the facility that remelts lead scrap and casts it into lead ingots for use in the battery manufacturing process, and which is not a furnace affected under
s. NR 440.29.
NR 440.52(2)(e)
(e) “Other lead-emitting operation" means any lead-acid battery manufacturing plant operation from which lead emissions are collected and ducted to the atmosphere and which is not part of a grid casting, lead oxide manufacturing, lead reclamation, paste mixing, 3-process operation facility or a furnace affected under
s. NR 440.29.
NR 440.52(2)(f)
(f) “Paste mixing facility" means the facility including lead oxide storage, conveying, weighing, metering and charging operations; paste blending, handling and cooling operations; and plate pasting, takeoff, cooling and drying operations.
NR 440.52(2)(g)
(g) “Three-process operation facility" means the facility including those processes involved with plate stacking, burning or strap casting, and assembly of elements into the battery case.
NR 440.52(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:
NR 440.52(3)(a)1.
1. From any grid casting facility any gases that contain lead in excess of 0.40 milligram of lead per dry standard cubic meter of exhaust (0.000175 gr/dscf).
NR 440.52(3)(a)2.
2. From any paste mixing facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf).
NR 440.52(3)(a)3.
3. From any 3-process operation facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf).
NR 440.52(3)(a)4.
4. From any lead oxide manufacturing facility any gases that contain in excess of 5.0 milligrams of lead per kilogram of lead feed (0.010 lb/ton).
NR 440.52(3)(a)5.
5. From any lead reclamation facility any gases that contain in excess of 4.50 milligrams of lead per dry standard cubic meter of exhaust (0.00197 gr/dscf).
NR 440.52(3)(a)6.
6. From any other lead-emitting operation any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf).
NR 440.52(3)(a)7.
7. From any affected facility other than a lead reclamation facility any gases with greater than zero percent opacity measured according to Method 9 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17, and rounded to the nearest whole percentage.
NR 440.52(3)(a)8.
8. From any lead reclamation facility any gases with greater than 5% opacity, measured according to Method 9 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17, and rounded to the nearest whole percentage.
NR 440.52(3)(b)
(b) When 2 or more facilities at the same plant (except the lead oxide manufacturing facility) are ducted to a common control device, an equivalent standard for the total exhaust from the commonly controlled facilities shall be determined as follows: -
See PDF for diagram 
where:
Se is the equivalent standard for the total exhaust stream
Sa is the actual standard for each exhaust stream ducted to the control device
N is the total number of exhaust streams ducted to the control device
-
See PDF for diagram is the dry standard volumetric flow rate of the effluent gas stream from each facility ducted to the control device
-
See PDF for diagram is the total dry standard volumetric flow rate of all effluent gas streams ducted to the control device
NR 440.52(4)
(4) Monitoring of emissions and operations. The owner or operator of any lead-acid battery manufacturing facility subject to the provisions of this section and controlled by scrubbing systems shall install, calibrate, maintain and operate a monitoring device or devices that measure and record the pressure drop across the scrubbing systems at least once every 15 minutes. The monitoring device shall have an accuracy of
" 5% over its operating range.
NR 440.52(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 440.52(5)(b)
(b) The owner or operator shall determine compliance with the lead standards in
sub. (3), except
sub. (3) (a) 4., as follows:
NR 440.52(5)(b)1.
1. Method 12 shall be used to determine the lead concentration and, if applicable, the volumetric flow rate (Q
sda) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30 dscf).
NR 440.52(5)(b)2.
2. When different operations in a 3-process operation facility are ducted to separate control devices, the lead emission concentration (C) from the facility shall be determined as follows: -
See PDF for diagram
where:
C is the concentration of lead emissions for the entire facility, mg/dscm (gr/dscf)
Ca is the concentration of lead emissions from facility “a", mg/dscm (gr/dscf)
Qsda is the volumetric flow rate of effluent gas from facility “a", dscm/hr (dscf/hr)
N is the total number of control devices to which separate operations in the facility are ducted
NR 440.52(5)(b)3.
3. Method 9 and the procedures in
s. NR 440.11 shall be used to determine opacity. The opacity numbers shall be rounded off to the nearest whole percentage.
where:
E is the emission rate of lead, mg/kg (lb/ton) of lead charged
CPbi is the concentration of lead from emission point “i", mg/dscm (gr/dscf)
Qsdi is the volumetric flow rate of effluent gas from emission point “i", dscm/hr (dscf/hr)
M is the number of emission points in the affected facility
P is the lead feed rate to the facility, kg/hr (ton/hr)
K is the conversion factor, 1.0 mg/mg (7000 gr/lb)
