NR 440.67(4)(b)
(b) Each owner or operator of an affected facility shall determine compliance with the applicable standard in
sub. (3) by determining and recording monthly the VOC emissions per unit mass solvent feed from each affected facility for the current and preceding 5 consecutive calendar months and using these values to calculate the 6-month average emissions. Each calculation is considered a performance test. The owner or operator of an affected facility shall use the following procedure to determine VOC emissions for each calendar month:
NR 440.67(4)(b)1.
1. Install, calibrate, maintain, and operate monitoring devices that continuously measure and permanently record for each calendar month the amount of makeup solvent and solvent feed. These values shall be used in calculating VOC emissions according to
subd. 2. All monitoring devices, meters and peripheral equipment shall be calibrated and any error recorded. Total compounded error of the flow measuring and recording devices may not exceed 1% accuracy over the operating range. As an alternative to measuring solvent feed the owner or operator may:
NR 440.67(4)(b)1.a.
a. Measure the amount of recovered solvent returned to the solvent feed storage tanks and use the following equation to determine the amount of solvent feed:
Solvent Feed = Makeup Solvent + Recovered Solvent + Change in the Amount of Solvent Contained in the Solvent Feed Holding Tank.
NR 440.67(4)(b)1.b.
b. Measure and record the amount of polymer introduced into the affected facility and the solvent-to-polymer ratio of the spinning solutions and use the following equation to determine the amount of solvent feed: -
See PDF for diagram 
where subscript “i" denotes each particular spinning solution used during the test period; values of “i" vary from one to the total number of spinning solutions, “n," used during the calendar month.
NR 440.67(4)(b)2.
2. VOC emissions shall be determined each calendar month by use of the following equations:
where all values are for the calendar month only and where:
E is the VOC emissions in kg/Mg (lb/ton) solvent
SV is the measured or calculated volume of solvent feed in liters (gallons)
SW is the weight of solvent feed in Mg (ton)
MV is the measured volume of makeup solvent in liters (gallons)
MW is the weight of makeup in kg (lb)
N is the allowance for nongaseous losses, 13 kg/Mg (26 lb/ton) solvent feed to the spinning solution preparation system and precipitation bath. This value shall be used in all cases unless an owner or operator demonstrates to the satisfaction of the department that greater nongaseous losses occur at the affected facility. In this case, the greater value may be substituted in the equation.
SP is the fraction of measured volume that is actual solvent (excludes water)
D is the density of the solvent in kg/liter (lb/gallon)
K is a conversion factor, 1000 kg/Mg (2,000 lb/ton)
I is the allowance for solvent inventory variation or changes in the amount of solvent contained in the affected facility, kg/Mg (lb/ton) solvent feed (may be positive or negative)
IS is the amount of solvent contained in the affected facility at the beginning of test period, as determined by the owner or operator, in kg (lb)
IE is the amount of solvent contained in the affected facility at the close of the test period, as determined by the owner or operator, in kg (lb)
NR 440.67(5)(a)(a) The owner or operator of an affected facility shall submit a written report to the department of the following:
NR 440.67(5)(a)2.
2. The results of subsequent performance tests that indicate that VOC emissions exceed the standards in
sub. (3). These reports shall be submitted quarterly at 3-month intervals after the initial performance test. If no exceedances occur during a particular quarter, a report stating this shall be submitted to the department semiannually.
NR 440.67(5)(b)
(b) Solvent-spun synthetic fiber producing facilities exempted from these standards in
sub. (1) (a) (those producing less than 500 Mg (551 tons) annually) shall report to the department within 30 days whenever extruded fiber for the preceding 12 calendar months exceeds 500 Mg (551 tons).
NR 440.67 History
History: Cr.
Register, September, 1986, No. 369, eff. 10-1-86; renum. (2) (a) (intro.) and 1. to 18. to be (2) (intro.) and (a) to (r) and am. (2) (intro.), am. (3) (a), r. (5) (c),
Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (b) 2. and (5) (a) 2.,
Register, July, 1993, No. 451, eff. 8-1-93;
CR 06-109: am. (1) (a), (4) (b) (intro.) and (5) (b), renum. (3) (a) to be (3) and am., r. and recr. (4) (b) 2. Register May 2008 No. 629, eff. 6-1-08. NR 440.675
NR 440.675 Volatile organic compound (VOC) emissions from the synthetic organic chemical manufacturing industry (SOCMI) air oxidation unit processes. NR 440.675(1)(1)
Applicability and designation of affected facility. NR 440.675(1)(a)(a) The provisions of this section apply to each affected facility designated in
par. (b) that produces any of the chemicals listed in
sub. (8) as a product, co-product, by-product or intermediate, except as provided in
par. (c).
NR 440.675(1)(b)
(b) The affected facility is any of the following for which construction, modification or reconstruction commenced after October 21, 1983:
NR 440.675(1)(b)1.
1. Each air oxidation reactor not discharging its vent stream into a recovery system.
NR 440.675(1)(b)2.
2. Each combination of an air oxidation reactor and the recovery system into which its vent stream is discharged.
NR 440.675(1)(b)3.
3. Each combination of 2 or more air oxidation reactors and the common recovery system into which their vent streams are discharged.
NR 440.675(1)(c)
(c) Each affected facility that has a total resource effectiveness (TRE) index value greater than 4.0 is exempt from all provisions of this section except for
subs. (3),
(5) (f),
(6) (h) and
(L).
NR 440.675 Note
Note:
The intent of these standards is to minimize the emissions of VOC through the application of best demonstrated technology (BDT). The numerical emission limits in these standards are expressed in terms of total organic compounds (TOC), measured as TOC minus methane and ethane. This emission limit reflects the performance of BDT.
NR 440.675(1)(d)1.1. Owners or operators of process vents that are subject to this section may choose to comply with the provisions of
40 CFR part 65, subpart D, as in effect on December 14, 2000, to satisfy the requirements of
subs. (3) to
(6). The provisions of
40 CFR part 65, subpart D, as in effect on December 14, 2000, also satisfy the criteria of
par. (c). Other provisions applying to an owner or operator who chooses to comply with
40 CFR part 65, subpart D, as in effect on December 14, 2000, are provided in
40 CFR 65.1.
NR 440.675(1)(d)2.
2. Owners or operators who choose to comply with
40 CFR part 65, subpart D, as in effect on December 14, 2000, shall also comply with
ss. NR 440.01,
440.02,
440.05,
440.06,
440.07 (1) (a) and
(d),
440.14 and
440.15 for those process vents. All sections or subsections from
ss. NR 440.01 to
440.19 not specified in this subdivision do not apply to owners or operators of process vents complying with
40 CFR part 65, subpart D, as in effect on December 14, 2000, except that provisions required to be met prior to implementing
40 CFR part 65 still apply. Owners or operators who choose to comply with
40 CFR part 65, subpart D, as in effect on December 14, 2000, shall comply with
40 CFR part 65, subpart A.
NR 440.675(1)(d)3.
3. Owners or operators who choose to comply with
40 CFR part 65, subpart D, as in effect on December 14, 2000, at initial startup shall comply with
subds. 1. and
2. for each vent stream on and after the date on which the initial performance test is completed, but not later than 60 days after achieving the maximum production rate at which the affected facility will be operated, or 180 days after the initial startup, whichever date comes first.
NR 440.675(1)(d)4.
4. Each owner or operator subject to the provisions of this section that chooses to comply with
40 CFR part 65, subpart D, as in effect on December 14, 2000, at initial startup shall notify the administrator of the specific provisions of
40 CFR 65.63 (a) (1), (2) or (3) with which the owner or operator has elected to comply. Notification shall be submitted with the notification of initial startup required by
40 CFR 65.5 (b).
NR 440.675(2)
(2) Definitions. As used in this section, all terms not defined here shall have the meanings given them in
s. NR 440.02 and the following terms shall have the specific meanings given them.
NR 440.675(2)(a)
(a) “Air oxidation reactor" means any device or process vessel in which one or more organic reactants are combined with air or a combination of air and oxygen, to produce one or more organic compounds. Ammoxidation and oxychlorination reactions are included in this definition.
NR 440.675(2)(b)
(b) “Air oxidation reactor recovery train" means an individual recovery system receiving the vent stream from at least one air oxidation reactor, along with all air oxidation reactors feeding vent streams into this system.
NR 440.675(2)(c)
(c) “Air oxidation unit process" means a unit process, including ammoxidation and oxychlorination unit process, that uses air or a combination of air and oxygen, as an oxygen source in combination with one or more organic reactants to produce one or more organic compounds.
NR 440.675(2)(d)
(d) “Boilers" means any enclosed combustion device that extracts useful energy in the form of steam.
NR 440.675(2)(e)
(e) “By compound" means by individual stream components, not carbon equivalents.
NR 440.675(2)(f)
(f) “Continuous recorder" means a data recording device recording an instantaneous data value at least once every 15 minutes.
NR 440.675(2)(g)
(g) “Flame zone" means the portion of the combustion chamber in a boiler occupied by the flame envelope.
NR 440.675(2)(h)
(h) “Flow indicator" means a device which indicates whether gas flow is present in a vent stream.
NR 440.675(2)(i)
(i) “Halogenated vent stream" means any vent stream determined to have a total concentration, by volume, of compounds containing halogens of 20 ppmv by compound or greater.
NR 440.675(2)(j)
(j) “Incinerator" means any enclosed combustion device that is used for destroying organic compounds and does not extract energy in the form of steam or process heat.
NR 440.675(2)(k)
(k) “Process heater" means a device that transfers heat liberated by burning fuel to fluids contained in tubes, including all fluids except water that is heated to produce steam.
NR 440.675(2)(L)
(L) “Process unit" means equipment assembled and connected by pipes or ducts to produce, as intermediate or final products, one or more of the chemicals in
sub. (8). A process unit can operate independently if supplied with sufficient fuel or raw materials and sufficient product storage facilities.
NR 440.675(2)(m)
(m) “Product" means any compound or chemical listed in
sub. (8) that is produced for sale as a final product as that chemical or is produced for use in a process that needs that chemical for the production of other chemicals in another facility. By-products, co-products and intermediates are considered to be products.
NR 440.675(2)(n)
(n) “Recovery device" means an individual unit of equipment, such as an absorber, condenser and carbon adsorber, capable of and used to recover chemicals for use, reuse or sale.
NR 440.675(2)(o)
(o) “Recovery system" means an individual recovery device or series of such devices applied to the same process stream.
NR 440.675(2)(p)
(p) “Total organic compounds" or “TOC" means those compounds measured according to the procedures in
sub. (5) (b) 4. For the purposes of measuring molar composition as required in
sub. (5) (e) 3. a., hourly emissions rate as required in
sub. (5) (e) 6. and
(f), and TOC concentration as required in
sub. (6) (b) 4. and
(g) 4., those compounds which the department has determined do not contribute appreciably to the formation of ozone are to be excluded. The compounds to be excluded are identified in
s. NR 400.02 (162).
NR 440.675(2)(q)
(q) “Total resource effectiveness (TRE) index value" means a measure of the supplemental total resource requirement per unit reduction of TOC associated with an individual air oxidation vent stream, based on vent stream flow rate, emission rate of TOC, net heating value and corrosion properties, whether or not the vent stream is halogenated, as quantified by the equation given under
sub. (5) (e).
NR 440.675(2)(r)
(r) “Vent stream" means any gas stream, containing nitrogen which was introduced as air to the air oxidation reactor, released to the atmosphere directly from any air oxidation reactor recovery train or indirectly, after diversion through other process equipment. The vent stream excludes equipment leaks and relief valve discharges including, but not limited to, pumps, compressors and valves.
NR 440.675(3)
(3) Standards. Each owner or operator of any affected facility shall comply with
par. (a),
(b) or
(c) for each vent stream on and after the date on which the initial performance test required by
s. NR 440.08 and
sub. (5) is completed, but not later than 60 days after achieving the maximum production rate at which the affected facility will be operated or 180 days after the initial startup, whichever date comes first. Each owner or operator shall either:
NR 440.675(3)(a)
(a) Reduce emissions of TOC (minus methane and ethane) by 98 weight- percent or to a TOC (minus methane and ethane) concentration of 20 ppmv on a dry basis corrected to 3% oxygen, whichever is less stringent. If a boiler or process heater is used to comply with this paragraph, then the vent stream shall be introduced into the flame zone of the boiler or process heater; or
NR 440.675(3)(c)
(c) Maintain a TRE index value greater than 1.0 without use of VOC emission control devices.
NR 440.675(4)(a)(a) The owner or operator of an affected facility that uses an incinerator to seek to comply with the TOC emission limit specified under
sub. (3) (a) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment:
NR 440.675(4)(a)1.
1. A temperature monitoring device equipped with a continuous recorder and having an accuracy of
± 1% of the temperature being monitored expressed in degrees Celsius or
±
0.5
°C, whichever is greater.
NR 440.675(4)(a)1.a.
a. Where an incinerator other than a catalytic incinerator is used, a temperature monitoring device shall be installed in the firebox.
NR 440.675(4)(a)1.b.
b. Where a catalytic incinerator is used, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalyst bed.
NR 440.675(4)(a)2.
2. A flow indicator that provides a record of vent stream flow to the incinerator at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each affected facility at a point closest to the inlet of each incinerator and before being joined with any other vent stream.
NR 440.675(4)(b)
(b) The owner or operator of an affected facility that uses a flare to seek to comply with
sub. (3) (b) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment:
NR 440.675(4)(b)1.
1. A heat sensing device, such as an ultra-violet sensor or thermocouple, at the pilot light to indicate the continuous presence of a flame.
NR 440.675(4)(b)2.
2. A flow indicator that provides a record of vent stream flow to the flare at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each affected facility at a point closest to the flare and before being joined with any other vent stream.
NR 440.675(4)(c)
(c) The owner or operator of an affected facility that uses a boiler or process heater to seek to comply with
sub. (3) (a) shall install, calibrate, maintain and operate according to the manufacturer's specifications the following equipment:
NR 440.675(4)(c)1.
1. A flow indicator that provides a record of vent stream flow to the boiler or process heater at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each air oxidation reactor within an affected facility at a point closest to the inlet of each boiler or process heater and before being joined with any other vent stream.
NR 440.675(4)(c)2.
2. A temperature monitoring device in the firebox equipped with a continuous recorder and having an accuracy of
" 1% of the temperature being measured expressed in degrees Celsius or
" 0.5
°C, whichever is greater, for boilers or process heaters of less than 44 MW (150 million Btu/hr) heat input design capacity.
NR 440.675(4)(d)
(d) The owner or operator of an affected facility that uses a boiler or process heater to comply with
sub. (3) (a) shall monitor and record the periods of operation of the boiler or process heater if the design input capacity of the boiler is 44 MW (150 million Btu/hr) or greater. The records shall be readily available for inspection.
NR 440.675(4)(e)
(e) The owner or operator of an affected facility that seeks to demonstrate compliance with the TRE index value limit specified under
sub. (3) (c) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment, unless alternative monitoring procedures or requirements are approved for that facility by the department:
NR 440.675(4)(e)1.
1. Where an absorber is the final recovery device in a recovery system:
NR 440.675(4)(e)1.a.
a. A scrubbing liquid temperature monitoring device having an accuracy of
" 1% of the temperature being monitored expressed in degrees Celsius or
" 0.5
°C, whichever is greater, and a specific gravity monitoring device having an accuracy of
" 0.02 specific gravity units, each equipped with a continuous recorder;
NR 440.675(4)(e)1.b.
b. An organic monitoring device used to indicate the concentration level of organic compounds exiting the recovery device based on a detection principle such as infra-red, photoionization or thermal conductivity, each equipped with a continuous recorder.
NR 440.675(4)(e)2.
2. Where a condenser is the final recovery device in a recovery system:
NR 440.675(4)(e)2.a.
a. A condenser exit or product side temperature monitoring device equipped with a continuous recorder and having an accuracy of
" 1% of the temperature being monitoring expressed in degrees Celsius or
"0.5
°C, whichever is greater;
NR 440.675(4)(e)2.b.
b. An organic monitoring device used to indicate the concentration level of organic compounds exiting the recovery device based on a detection principle such as infra-red, photoionization or thermal conductivity, each equipped with a continuous recorder.
NR 440.675(4)(e)3.
3. Where a carbon adsorber is the final recovery device in a recovery system:
NR 440.675(4)(e)3.a.
a. An integrating steam flow monitoring device having an accuracy of
" 10% and a carbon bed temperature monitoring device having an accuracy of
" 1% of the temperature being monitored expressed in degrees Celsius or
" 0.5
°C, whichever is greater, both equipped with a continuous recorder;
