NR 440.705(2)(2) Definitions. All terms not defined in this section have the meanings given in s. NR 440.02. In this section: NR 440.705(2)(a)(a) “Batch operation” means any noncontinuous reactor process that is not characterized by steady state conditions and in which reactants are not added and products are not removed simultaneously. NR 440.705(2)(b)(b) “Boiler” means any enclosed combustion device that extracts useful energy in the form of steam and is not an incinerator. NR 440.705(2)(c)(c) “By compound” means by individual stream components, not carbon equivalents. NR 440.705(2)(d)(d) “Car-seal” means a seal that is placed on a device that is used to change the position of a valve, for example, from opened to closed, in such a way that the position of the valve cannot be changed without breaking the seal. NR 440.705(2)(e)(e) “Combustion device” means an individual unit of equipment, such as an incinerator, flare, boiler or process heater, used for combustion of a vent stream discharged from the process vent. NR 440.705(2)(f)(f) “Continuous recorder” means a data recording device recording an instantaneous data value at least once every 15 minutes. NR 440.705(2)(g)(g) “Flame zone” means the portion of the combustion chamber in a boiler occupied by the flame envelope. NR 440.705(2)(h)(h) “Flow indicator” means a device which indicates whether gas flow is present in a line. NR 440.705(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 440.705(2)(j)(j) “Incinerator” means an enclosed combustion device that is used for destroying organic compounds. If there is energy recovery, the energy recovery section and the combustion chambers are not of integral design. That is, the energy recovery section and the combustion section are not physically formed into one manufactured or assembled unit but are joined by ducts or connections carrying flue gas. NR 440.705(2)(k)(k) “Primary fuel” means the fuel fired through a burner or a number of similar burners. The primary fuel provides the principal heat input to the device and the amount of fuel is sufficient to sustain operation without the addition of other fuels. NR 440.705(2)(L)(L) “Process heater” means a device that transfers heat liberated by burning fuel directly to process streams or to heat transfer liquids other than water. NR 440.705(2)(m)(m) “Process unit” means equipment assembled and connected by pipes or ducts to produce as intermediates or final products one or more of the chemicals in sub. (8). A process unit can operate independently if supplied with sufficient feed or raw materials and sufficient product storage facilities. NR 440.705(2)(n)(n) “Product” means any compound or chemical listed in sub. (8) which is produced for sale as a final product as that chemical or for use in the production of other chemicals or compounds. By-products, co-products and intermediates are considered to be products. NR 440.705(2)(o)(o) “Reactor processes” means unit operations in which one or more chemicals or reactants, other than air, are combined or decomposed in such a way that their molecular structures are altered and one or more new organic compounds are formed. NR 440.705(2)(p)(p) “Recovery device” means an individual unit of equipment, such as an absorber, carbon adsorber or condenser, capable of and used for the purpose of recovering chemicals for use, reuse or sale. NR 440.705(2)(q)(q) “Recovery system” means an individual recovery device or series of recovery devices applied to the same vent stream. NR 440.705(2)(r)(r) “Relief valve” means a valve used only to release an unplanned, nonroutine discharge. A relief valve discharge results from an operator error, a malfunction such as a power failure or equipment failure or other unexpected cause that requires immediate venting of gas from process equipment in order to avoid safety hazards or equipment damage. NR 440.705(2)(s)(s) “Secondary fuel” means a fuel fired through a burner other than a primary fuel burner. The secondary fuel may provide supplementary heat in addition to the heat provided by the primary fuel. NR 440.705(2)(t)(t) “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) (d) 2. a. and b., hourly emission rate as required in sub. (5) (d) 5. and (e) and TOC concentration as required in sub. (6) (b) 4. and (f) 4., those compounds which the department has determined do not contribute appreciably to the formation of ozone are to be excluded. NR 440.705(2)(u)(u) “Total resource effectiveness” or “TRE index value” means a measure of the supplemental total resource requirement per unit reduction of TOC associated with a vent stream from an affected reactor process facility based on vent stream flow rate, emission rate of TOC, net heating value and corrosion properties, whether or not the vent stream contains halogenated compounds as quantified by the equation given under sub. (5) (e). NR 440.705(2)(v)(v) “Vent stream” means any gas stream discharged directly from a reactor process to the atmosphere or indirectly to the atmosphere after diversion through other process equipment. The vent stream excludes relief valve discharges and equipment leaks. NR 440.705(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 440.705(3)(a)(a) Reduce emissions of TOC, less methane and ethane, by 98 weight percent or to a TOC, less 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 440.705(3)(c)(c) Maintain a TRE index value greater than 1.0 without use of a VOC emission control device. NR 440.705(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 440.705(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 440.705(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 or in the ductwork immediately downstream of the firebox in a position before any substantial heat exchange is encountered. NR 440.705(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 440.705(4)(a)2.2. A flow indicator that provides a record of vent stream flow diverted from being routed to the incinerator at least once every 15 minutes for each affected facility, except as provided in subd. 2. b. NR 440.705(4)(a)2.a.a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the incinerator, resulting in its emission to the atmosphere. NR 440.705(4)(a)2.b.b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line. NR 440.705(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 440.705(4)(b)1.1. A heat sensing device, such as an ultraviolet beam sensor or thermocouple at the pilot light to indicate the continuous presence of a flame. NR 440.705(4)(b)2.2. A flow indicator that provides a record of vent stream flow diverted from being routed to the flare at least once every 15 minutes for each affected facility, except as provided in subd. 2. b. NR 440.705(4)(b)2.a.a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the flare, resulting in its emission to the atmosphere. NR 440.705(4)(b)2.b.b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line. NR 440.705(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 440.705(4)(c)1.1. A flow indicator that provides a record of vent stream flow diverted from being routed to the boiler or process heater at least once every 15 minutes for each affected facility, except as provided in subd. 1. b. NR 440.705(4)(c)1.a.a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the boiler or process heater, resulting in its emission to the atmosphere. NR 440.705(4)(c)1.b.b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line. NR 440.705(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 monitored 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) design heat input capacity. Any vent stream introduced with primary fuel into a boiler or process heater is exempt from this requirement. NR 440.705(4)(d)(d) 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 440.705(4)(d)1.1. Where an absorber is the final recovery device in the recovery system: NR 440.705(4)(d)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; or NR 440.705(4)(d)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 infrared, photoionization or thermal conductivity, each equipped with a continuous recorder. NR 440.705(4)(d)2.2. Where a condenser is the final recovery device in the recovery system: NR 440.705(4)(d)2.a.a. A product side condenser exit 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; or NR 440.705(4)(d)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 infrared, photoionization or thermal conductivity, each equipped with a continuous recorder. NR 440.705(4)(d)3.3. Where a carbon adsorber is the final recovery device unit in the recovery system: NR 440.705(4)(d)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; or NR 440.705(4)(d)3.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 infrared, photoionization or thermal conductivity, each equipped with a continuous recorder. NR 440.705(4)(e)(e) An owner or operator of an affected facility seeking to demonstrate compliance with the standards specified under sub. (3) with a control device other than an incinerator, boiler, process heater or flare, or a recovery device other than an absorber, condenser or carbon adsorber, shall provide to the administrator information describing the operation of the control device or recovery device and the process parameters which would indicate proper operation and maintenance of the device. The administrator may request further information and will specify appropriate monitoring procedures or requirements. NR 440.705(5)(a)(a) For the purpose of demonstrating compliance with sub. (3), all affected facilities shall be run at full operating conditions and flow rates during any performance test. NR 440.705(5)(b)(b) The following methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, except as provided under s. NR 440.08 (2), shall be used as reference methods to determine compliance with the emission limit or percent reduction efficiency specified under sub. (3) (a): NR 440.705(5)(b)1.1. Method 1 or 1A, as appropriate, for selection of the sampling sites. The control device inlet sampling site for determination of vent stream molar composition or TOC, less methane and ethane, reduction efficiency shall be prior to the inlet of the control device and after the recovery system. NR 440.705(5)(b)2.2. Method 2, 2A, 2C or 2D, as appropriate, for determination of the gas volumetric flow rates. NR 440.705(5)(b)3.3. The emission rate correction factor, integrated sampling and analysis procedure of Method 3B shall be used to determine the oxygen concentration (%O2d) for the purposes of determining compliance with the 20 ppmv limit. The sampling site shall be the same as that of the TOC samples, and the samples shall be taken during the same time that the TOC samples are taken. The TOC concentration corrected to 3% O2 (Cc) shall be computed using the following equation: where:
Cc is the concentration of TOC corrected to 3% O2, dry basis ppm by volume
CTOC is the concentration of TOC minus methane and ethane, dry basis ppm by volume
%O2d is the concentration of O2, dry basis percent by volume
NR 440.705(5)(b)4.4. Method 18 to determine the concentration of TOC in the control device outlet and the concentration of TOC in the inlet when the reduction efficiency of the control device is to be determined. NR 440.705(5)(b)4.a.a. The minimum sampling time for each run shall be one 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 approximately 15-minute intervals. NR 440.705(5)(b)4.b.b. The emission reduction (R) of TOC, minus methane and ethane, shall be determined using the following equation:
where: R is the emission reduction, percent by weight
Ei is the mass rate of TOC entering the control device, kg TOC/hr
Eo is the mass rate of TOC discharged to the atmosphere, kg TOC/hr
NR 440.705(5)(b)4.c.c. The mass rates of TOC (Ei, Eo) shall be computed using the following equations: where:
Cij, Coj is the concentration of sample component “j” of the gas stream at the inlet and outlet of the control device, respectively, dry basis ppm by volume
Mij, Moj is the molecular weight of sample component “j” of the gas stream at the inlet and outlet of the control device, respectively, g/g-mole (lb/lb-mole)
Qi, Qo is the flow rate of gas stream at the inlet and outlet of the control device respectively, dscm/min (dscf/hr)
K2 is a constant, 2.494 × 10-6 (l/ppm) (g-mole/scm) (kg/g) (min/hr), where standard temperature for g-mole/scm is 20°C
NR 440.705(5)(b)4.d.d. The TOC concentration (CTOC) is the sum of the individual components and shall be computed for each run using the following equation: where:
CTOC is the concentration of TOC, minus methane and ethane, dry basis ppm by volume
Cj is the concentration of sample components “j“, dry basis ppm by volume
n is the number of components in the sample
NR 440.705(5)(b)5.a.a. When a boiler or process heater with a design heat input capacity of 44 MW (150 million Btu/hour) or greater is used to seek compliance with sub. (3) (a). NR 440.705(5)(b)5.b.b. When a vent stream is introduced into a boiler or process heater with the primary fuel. NR 440.705(5)(b)5.c.c. The department reserves the option to require testing at such other times as may be required. NR 440.705(5)(b)6.6. For purposes of complying with the 98 weight percent reduction in sub. (3) (a), if the vent stream entering a boiler or process heater with a design capacity less than 44 MW (150 million Btu/hour) is introduced with the combustion air or as secondary fuel, the weight percent reduction of TOC, minus methane and ethane, across the combustion device shall be determined by comparing the TOC, minus methane and ethane, in all combusted vent streams, primary fuels and secondary fuels with the TOC, minus methane and ethane, exiting the combustion device.
