NR 440.647(6)(f)
(f) The owner or operator shall determine compliance with the net heating value provisions in
s. NR 440.18 as referenced by
sub. (3) (a) 1. a. 3). The net heating value of the process vent stream being combusted in a flare shall be computed as follows:
where:
HT is the vent stream net heating value, MJ/scm (Btu/scf), where the net enthalpy per mole of offgas is based on combustion at 25°C and 760 mm Hg (77°F and 30 in Hg), but the standard temperature for determining the volume corresponding to one mole is 20°C (68°F)
K3 is 1.74 x 10-7 (l/ppm)(g-mole/scm)(MJ/kcal) for metric units where standard temperature for (g-mole/scm) is 20°C and 4.67 x 10-6 (1/ppm)(lb-mole/scf)(Btu/kcal) for English units where standard temperature for (lb-mole/scf) is 68°F
Cj is the concentration on a wet basis of compound j in ppm
Hj is the net heat of combustion of compound j, kcal/g-mole (kcal/lb-mole), based on combustion at 25°C and 760 mm Hg (77°F and 30 in Hg)
NR 440.647(6)(f)1.
1. Method 18 shall be used to determine the concentration of each individual organic component (C
j) in the gas stream. Method 1 or 1A, as appropriate, shall be used to determine the sampling site to the inlet of the flare. Using this same sample, ASTM D1946-90 (reapproved 1994), incorporated by reference in
s. NR 440.17 (2) (a) 24., shall be used to determine the hydrogen and carbon monoxide content.
NR 440.647(6)(f)2.
2. The sampling time for each run shall be 1 hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at 15 minute intervals.
NR 440.647(6)(f)3.
3. Published or calculated values shall be used for the net heats of combustion of the sample components. If values are not published or cannot be calculated, ASTM D2382-88 or D4809-95, incorporated by reference in
s. NR 440.17 (2) (a) 30. and
61., may be used to determine the net heat of combustion of component “j".
NR 440.647(6)(g)1.
1. If applicable, the net heating value (H
T) of the process vent shall be determined according to the procedures in
par. (f) to determine the applicable velocity requirements.
NR 440.647(6)(g)2.
2. If applicable, the maximum permitted velocity (V
max) for steam-assisted and nonassisted flares shall be computed using the following equation:
where:
Vmax is the maximum permitted velocity, m/sec (ft/sec)
K4 is 28.8 for metric units and 1212 for English units
K5 is 31.7 for metric units and 850.8 for English units
HT is the net heating value as determined in par. (f), MJ/scm (Btu/scf)
NR 440.647(6)(g)3.
3. The maximum permitted velocity, V
max, for air-assisted flares shall be determined by the following equation:
where:
Vmax is the maximum permitted velocity, m/sec (ft/sec)
K6 is 8.706 m/sec for metric units and 28.56 ft/sec for English units
K7 is 0.7084 [(m/sec)/(MJ/scm)] for metric units and 0.00245 [(ft/sec)/(Btu/scf)] for English units
HT is the net heating value as determined in par. (f), MJ/scm (Btu/scf)
NR 440.647(6)(g)4.
4. The actual exit velocity of a flare shall be determined by dividing the volumetric flow rate (in units of standard temperature and pressure), as determined by Method 2, 2A, 2C or 2D as appropriate, by the unobstructed (free) cross sectional area of the flare tip.
NR 440.647(6)(h)1.
1. The emission rate of TOC shall be computed using the following equation:
where:
ERTOC is the emission rate of total organic compounds, minus methane and ethane, kg TOC/Mg product (lb TOC/ton)
ETOC is the emission rate of total organic compounds, minus methane and ethane, in the sample, kg/hr (lb/hr)
Pp is the rate of polymer production, kg/hr (lb/hr)
K5 is 1,000 kg/Mg for metric units and 2,000 lb/ton for English units
NR 440.647(6)(h)2.
2. The mass rate of TOC, E
TOC, shall be determined according to the procedures, as appropriate, in
par. (c) 2. The sampling site for determining compliance with
sub. (1) (d) and
(e) shall be before any add-on control devices and after all product recovery devices. Otherwise, the sampling site shall be at the outlet of the control device.
NR 440.647(6)(h)3.
3. The rate of polymer production, P
p, shall be determined by dividing the weight of polymer pulled (in kg (lb)) from the process line during the performance test by the number of hours taken to perform the performance test. The weight of polymer pulled shall be determined by direct measurement or, subject to prior approval by the department, computed from materials balance by good engineering practice.
NR 440.647(6)(i)
(i) The owner or operator shall determine continuous compliance with the temperature requirements in
sub. (3) (b) 1. b. and
1. a. 2) by using the temperature monitoring equipment described in
sub. (5) (a) 1. An average temperature shall be determined from measurements taken at least every 15 minutes every 3 hours while the vent stream is normally routed and constituted. Each 3-hour period constitutes a performance test.
NR 440.647(6)(j)
(j) For purposes of determining compliance with
sub. (3) (c) 1. b. 2), 3), 2. b.
2) or 3), the ethylene glycol concentration in either the cooling tower or the liquid effluent from steam-jet ejectors used to produce a vacuum in the polymerization reactors, whichever is applicable, shall be determined:
NR 440.647(6)(j)1.
1. Using procedures that conform to the methods described in ASTM D2908-91, Standard Practice for Measuring Volatile Organic Matter in Water by Aqueous-Injection Gas Chromatography, incorporated by reference in
s. NR 440.17 (2) (a) 37., except as provided in
subd. 2.:
NR 440.647(6)(j)1.a.
a. At least one sample per operating day shall be collected using the grab sampling procedures of ASTM D3370-95a, Standard Practices for Sampling Water, incorporated by reference in
s. NR 440.17 (2) (a) 47. An average ethylene glycol concentration by weight shall be calculated on a daily basis over a rolling 14-day period of operating days, except as provided in
subd. 1. b. and
c. Each daily average ethylene glycol concentration so calculated constitutes a performance test. Exceedance of the standard during the reduced testing program specified in
subd. 1. b. and
c. is a violation of these standards.
NR 440.647(6)(j)1.b.
b. For those determining compliance with
sub. (3) (c) 1. b. 2) or 2. b. 2), the owner or operator may elect to reduce the sampling program to any 14 consecutive day period once every 2 calendar months, if at least 17 consecutive 14-day rolling average concentrations immediately preceding the reduced sampling program are each less than 0.10 weight percent ethylene glycol. If the average concentration obtained over the 14 day sampling during the reduced testing period exceeds the upper 95% confidence interval calculated from the most recent test results in which no one 14-day average exceeded 0.10 weight percent ethylene glycol, then the owner or operator shall reinstitute a daily sampling program. A reduced sampling program can be reinstituted if the requirements specified in this paragraph are met.
NR 440.647(6)(j)1.c.
c. For those determining compliance with
sub. (3) (c) 1. b. 3) or 2. b. 3) the owner or operator may elect to reduce the sampling program to any 14 consecutive day period once every 2 calendar months, if at least 17 consecutive 14-day rolling average concentrations immediately preceding the reduced sampling program are each less than 1.8 weight percent ethylene glycol. If the average concentration obtained over the 14 day sampling during the reduced test period exceeds the upper 95% confidence interval calculated from the most recent test results in which no one 14-day average exceeded 1.8 weight percent ethylene glycol, then the owner or operator shall reinstitute a daily sampling program. A reduced program can be reinstituted if the requirements specified in this paragraph are met.
NR 440.647(6)(j)1.d.
d. The upper 95% confidence interval shall be calculated using the following equation:
where:
Xi is the daily ethylene glycol concentration for each day used to calculate the 14-day rolling average used in test results to justify implementing the reduced testing program
n is the number of ethylene glycol concentrations
NR 440.647(6)(j)2.
2. Measuring an alternative parameter, such as carbon oxygen demand or biological oxygen demand, that is demonstrated to be directly proportional to the ethylene glycol concentration. The parameter shall be measured during the initial 14-day performance test during which the facility is shown to be in compliance with the ethylene glycol concentration standard whereby the ethylene glycol concentration is determined using the procedures described in
subd. 1. The alternative parameter shall be measured on a daily basis and the average value of the alternative parameter shall be calculated on a daily basis over a rolling 14-day period of operating days. Each daily average value of the alternative parameter constitutes a performance test.
NR 440.647(7)(a)(a) Each owner or operator subject to the provisions of this section shall keep an up-to-date, readily-accessible record of the following information measured during each performance test and shall include the following information in the report of the initial performance test in addition to the written results of such performance tests as required under
s. NR 440.08. Where a control device is used to comply with
sub. (3) (a) 1. a. 4) only, a report containing performance test data need not be submitted, but a report containing the information in
subd. 11. is required. Where a boiler or process heater with a design heat input capacity of 150 million Btu/hr or greater is used to comply with
sub. (3) (a) a report containing performance test data need not be submitted, but a report containing the information in
subd. 2. a. is required. The same information specified in this subsection shall be submitted in the reports of all subsequently required performance tests where either the emission control efficiency of a combustion device or the outlet concentration of TOC, minus methane and ethane, is determined.
NR 440.647(7)(a)1.a.
a. The average firebox temperature of the incinerator (or the average temperature upstream and downstream of the catalyst bed), measured at least every 15 minutes and averaged over the performance test period, and
NR 440.647(7)(a)1.b.
b. The percent reduction of TOC (minus methane and ethane) achieved by the incinerator, the concentration of TOC (minus methane and ethane) (ppmv, by compound) at the outlet of the control device on a dry basis or the emission rate in terms of kg TOC (minus methane and ethane) per Mg of product (lb TOC/ton) at the outlet of the control device, whichever is appropriate. If supplemental combustion air is used, the TOC concentration corrected to 3% oxygen shall be recorded and reported.
NR 440.647(7)(a)2.a.
a. A description of the location at which the vent stream is introduced into the boiler or process heater, and
NR 440.647(7)(a)2.b.
b. For boilers or process heaters with a design heat input capacity of less than 150 million Btu/hr, all 3-hour periods of operation during which the average combustion temperature was more than 28
°C (50
°F) below the average combustion temperature during the most recent performance test at which compliance was determined.
NR 440.647(7)(a)3.a.
a. All visible emission readings, heat content determinations, flow rate measurements and exit velocity determinations made during the performance test,
NR 440.647(7)(a)3.c.
c. Records of all periods of operations during which the pilot flame is absent.
NR 440.647(7)(a)4.
4. When an incinerator, boiler or process heater is used to demonstrate compliance with
sub. (3) (a) 2., a description of the location at which the vent stream is introduced into the incinerator, boiler or process heater.
NR 440.647(7)(a)6.
6. When an absorber is the final unit in a system to demonstrate compliance with
sub. (3) except
sub. (3) (a) 2., the specific gravity, or alternative parameter that is a measure of the degree of absorbing liquid saturation, if approved by the department, and average temperature, measured at least every 15 minutes and averaged over the performance test period, of the absorbing liquid, both measured while the vent stream is normally routed and constituted.
NR 440.647(7)(a)7.
7. When a condenser is the final unit in a system to demonstrate compliance with
sub. (3) except
sub. (3) (a) 2. the average exit (product side) temperature, measured at least every 15 minutes and averaged over the performance test period while the vent stream is normally routed and constituted.
NR 440.647(7)(a)8.
8. Daily measurement and daily average 14-day rolling average of the ethylene glycol concentration in the liquid effluent exiting the vacuum system servicing the polymerization reaction section, if an owner or operator is subject to
sub. (3) (c) 1. b. 2) or 2. b. 2) or of the ethylene glycol concentration in the cooling water in the cooling tower, if subject to
sub. (3) (c) 2. b. 3) or c. 3).
NR 440.647(7)(a)9.
9. When a carbon adsorber is the final unit in a system to demonstrate compliance with
sub. (3) except
sub. (3) (a) 2., the concentration level or reading indicated by the organics monitoring device at the outlet of the adsorber, measured at least every 15 minutes and averaged over the performance test period while the vent stream is normally routed and constituted.
NR 440.647(7)(a)10.
10. When an owner or operator seeks to comply with the requirements of this section by complying with the uncontrolled threshold emission rate cutoff provision in
sub. (1) (d) and
(e) or with the individual stream exemptions in
sub. (1) (g), each process operation variable, for example, pressure, temperature, type of catalyst, that may result in an increase in the uncontrolled emission rate, if
sub. (1) (d) or
(e) is applicable or in an increase in the uncontrolled annual emissions or the VOC weight percent, as appropriate, if
sub. (1) (g) is applicable, should such operating variable be changed.
NR 440.647(7)(a)11.
11. When an owner or operator uses a control device to comply with
sub. (3) (a) 1. a. 4) alone: all periods when the control device is not operating.
NR 440.647(7)(b)1.1. Each owner or operator subject to the provisions of this section shall submit with the initial performance test or, if complying with
sub. (3) (a) 1. a. 4) as a separate report, an engineering report describing in detail the vent system used to vent each affected vent stream to a control device. This report shall include all valves and vent pipes that could vent the stream to the atmosphere, thereby bypassing the control device and identify which valves are car-sealed opened and which valves are car-sealed closed.
NR 440.647(7)(b)2.
2. If a vent system containing valves that could divert the emission stream away from the control device is used, each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:
NR 440.647(7)(b)2.b.
b. All times when maintenance is performed on car-sealed valves, when the car seal is broken and when the valve position is changed, that is, from open to closed for valves in the vent piping to the control device and from closed to open for valves that vent the stream directly or indirectly to the atmosphere bypassing the control device.
NR 440.647(7)(c)
(c) Where an incinerator is used to comply with
sub. (3), except
sub. (3) (a) 1. a. 4) and 2., each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:
NR 440.647(7)(c)2.
2. Records of periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. Periods of operation during which the parameter boundaries established during the most recent performance test are exceeded are defined as follows:
NR 440.647(7)(c)2.a.
a. For noncatalytic incinerators, all 3-hour periods of operation during which the average combustion temperature was more than 28
°C (50
°F) below the average combustion temperature during the most recent performance test at which compliance was demonstrated.
NR 440.647(7)(c)2.b.
b. For catalytic incinerators, all 3-hour periods of operation during which the average temperature of the vent stream immediately before the catalyst bed is more than 28
°C (50
°F) below the average temperature of the vent stream during the most recent performance test at which compliance was demonstrated. The owner or operator also shall record all 3-hour periods of operation during which the average temperature difference across the catalyst bed is less than 80% of the average temperature difference across the catalyst bed during the most recent performance test at which compliance was demonstrated.
NR 440.647(7)(d)
(d) Where a boiler or process heater is used to comply with
sub. (3) except
sub. (3) (a) 1. a. 4) and (a) 2., each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:
NR 440.647(7)(d)1.
1. Where a boiler or process heater with a heat input design capacity of 150 million Btu/hr or greater is used, all periods of operation of the boiler or process heater,
NR 440.647 Note
Note:
Examples of such records could include records of steam use, fuel use or monitoring data collected pursuant to other state or federal regulatory requirements.
NR 440.647(7)(d)2.
2. Where a boiler or process heater with a heat input design capacity of less than 150 million Btu/hr is used, all periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. Periods of operation during which the parameter boundaries established during the most recent performance test are exceeded are defined as all 3-hour periods of operation during which the average combustion temperature was more than 28
°C (50
°F) below the average combustion temperature during the most recent performance test at which compliance was demonstrated.
NR 440.647(7)(e)
(e) Where a flare is used to comply with
sub. (3) except
sub. (3) (a) 1. a. 4), each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:
