NR 440.22(3)(b)1.1. Contain particulate matter in excess of 0.050 kg per metric ton of feed (dry basis) to the kiln (0.10 lb. per ton). NR 440.22(3)(c)(c) 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 other than the kiln and clinker cooler any gases which exhibit 10% opacity, or greater. NR 440.22(4)(a)(a) The owner or operator of any portland cement plant subject to the provisions of this section shall record the daily production rates and kiln feed rates. NR 440.22(4)(b)(b) Except as provided for in par. (c), each owner or operator of a kiln or clinker cooler that is subject to the provisions of this section shall install, calibrate, maintain and operate in accordance with s. NR 440.13 a continuous opacity monitoring system to measure the opacity of the emissions discharged into the atmosphere from any kiln or clinker cooler. Except as provided for in par. (c), a continuous opacity monitoring system shall be installed on each stack of any multiple stack device controlling emissions from any kiln or clinker cooler. If there is a separate bypass installed, each owner or operator of a kiln or clinker cooler shall also install, calibrate, maintain and operate a continuous opacity monitoring system on each bypass stack in addition to the main control device stack. Each owner or operator of an affected kiln or clinker cooler for which the performance test required under s. NR 440.08 has been completed prior to December 14, 1988, shall install the continuous opacity monitoring system within 180 days after December 14, 1988. NR 440.22(4)(c)(c) Each owner or operator of a kiln or clinker cooler subject to the provisions of this section using a positive-pressure fabric filter with multiple stacks, or an electrostatic precipitator with multiple stacks may, in lieu of installing the continuous opacity monitoring system required by par. (b), monitor visible emissions at least once per day by using a certified visible emissions observer. If the control device exhausts gases through a monovent, visible emissions observations in lieu of a continuous opacity monitoring system are required. These observations shall be taken in accordance with Method 9 of 40 CFR part 60 Appendix A, incorporated by reference in s. NR 440.17. Visible emissions shall be observed during conditions representative of normal operation. Observations shall be recorded for at least 3 6-minute periods each day. In the event that visible emissions are observed for a number of emission sites from the control device with multiple stacks, Method 9 observations shall be recorded for the emission site with the highest opacity. All records of visible emissions shall be maintained for a period of 2 years. NR 440.22(4)(d)(d) For the purpose of reports under sub. (6), periods of excess emissions that shall be reported are defined as all 6-minute periods during which the average opacity exceeds that allowed by sub. (3) (a) 2. or (b) 2. NR 440.22(4)(e)(e) The provisions of pars. (a), (b) and (c) apply to kilns and clinker coolers for which construction, modification or reconstruction commenced after August 17, 1971. NR 440.22(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 440.22(5)(b)(b) The owner or operator shall determine compliance with the particulate matter standard in sub. (3) as follows: NR 440.22(5)(b)1.1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: where:
E is the emission rate of particulate matter, kg/metric ton (lb/ton) of kiln 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 total kiln feed (dry basis) rate, metric ton/hr (ton/hr)
K is the conversion factor, 1000 g/kg (7000 gr/lb)
NR 440.22(5)(b)2.2. Method 5 shall be used to determine the particulate matter concentration (cs) and the volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30.0 dscf) for the kiln and at least 60 minutes and 1.15 dscm (40.6 dscf) for the clinker cooler. NR 440.22(5)(b)3.3. Suitable methods shall be used to determine the kiln feed rate (P), except fuels, for each run. Material balance over the production system shall be used to confirm the feed rate. NR 440.22(6)(a)(a) Each owner or operator required to install a continuous opacity monitoring system under sub. (4) (b) shall submit reports of excess emissions as defined in sub. (4) (d). The content of these reports shall comply with the requirements in s. NR 440.07 (3). Notwithstanding the provisions of s. NR 440.07 (3), reports shall be submitted semiannually. NR 440.22(6)(b)(b) Each owner or operator monitoring visible emissions under sub. (4) (c) shall submit semiannual reports of observed excess emissions as defined in sub. (4) (d). NR 440.22(6)(c)(c) Each owner or operator subject to the provisions of sub. (4) (c) shall submit semiannual reports of the malfunction information required to be recorded by s. NR 440.07 (2). These reports shall include the frequency, duration and cause of any incident resulting in deenergization of any device controlling kiln emissions or in the venting of emissions directly to the atmosphere. NR 440.22 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), Register, September, 1990, No. 417, eff. 10-1-90; cr. (2) (b) to (d), (4) (b) to (e) and (6), r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; CR 06-109: am. (5) (b) 1. Register May 2008 No. 629, eff. 6-1-08. NR 440.23(1)(1) Applicability and designation of affected facility. NR 440.23(1)(a)(a) The provisions of this section are applicable to each nitric acid production unit, which is the affected facility. NR 440.23(1)(b)(b) Any facility under par. (a) that commences construction or modification after August 17, 1971, is subject to the requirements of this section. NR 440.23(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.23(2)(a)(a) “Nitric acid production unit” means any facility producing weak nitric acid by either the pressure or atmospheric pressure process. NR 440.23(2)(b)(b) “Weak nitric acid” means acid which is 30 to 70% in strength. NR 440.23(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 affected facility any gases which: NR 440.23(3)(a)1.1. Contain nitrogen oxides, expressed as NO2, in excess of 1.5 kg per metric ton of acid produced (3.0 lb per ton), the production being expressed as 100% nitric acid. NR 440.23(4)(a)(a) The source owner or operator shall install, calibrate, maintain and operate a continuous monitoring system for measuring nitrogen oxides (NOx). The pollutant gas mixtures under Performance Specification 2 of Appendix B of 40 CFR part 60, incorporated by reference in s. NR 440.17, and for calibration checks under s. NR 440.13 (4) shall be nitrogen dioxide (NO2). The span value shall be 500 ppm of NO2. Method 7 shall be used for the performance evaluation under s. NR 440.13 (3). Acceptable alternative methods to Method 7 are given in sub. (5) (c). NR 440.23(4)(b)(b) The owner or operator shall establish a conversion factor for the purpose of converting monitoring data into units of the applicable standard (kg/metric ton, lb/ton). The conversion factor shall be established by measuring emissions with the continuous monitoring system concurrent with measuring emissions with the applicable reference method tests. Using only that portion of the continuous monitoring emission data that represents emission measurements concurrent with the reference method test periods, the conversion factor shall be determined by dividing the reference method test data averages by the monitoring data averages to obtain a ratio expressed in units of the applicable standard to units of the monitoring data, i.e., kg/metric ton per ppm (lb/ton per ppm). The conversion factor shall be reestablished during any performance test under s. NR 440.08 or any continuous monitoring system performance evaluation under s. NR 440.13 (3). NR 440.23(4)(c)(c) The owner or operator shall record the daily production rate and hours of operation. NR 440.23(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 any 3-hour period during which the average nitrogen oxides emissions (arithmetic average of 3 contiguous one-hour periods) as measured by a continuous monitoring system exceed the standard under sub. (3) (a). NR 440.23(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). Acceptable alternative methods and procedures are given in par. (c). NR 440.23(5)(b)(b) The owner or operator shall determine compliance with the NOx standard in sub. (3) as follows: NR 440.23(5)(b)1.1. The emission rate (E) of NOx shall be computed for each run using the following equation: E = (Cs Qsd)/(PK)
where:
E is the emission rate of NOx as NO2, kg/metric ton (lb/ton) of 100% nitric acid
Cs is the concentration of NOx as NO2, g/dscm (lb/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the acid production rate, metric ton/hr (ton/hr) or 100% nitric acid
K is the conversion factor, 1000 g/kg (1.0 lb/lb)
NR 440.23(5)(b)2.2. Method 7 shall be used to determine the NOx concentration of each grab sample. Method 1 shall be used to select the sampling site and the sampling point shall be the centroid of the stack or duct or at a point no closer to the walls than 1 m (3.28 ft). Four grab samples shall be taken at approximately 15-minute intervals. The arithmetic mean of the 4 sample concentrations shall constitute the run value (Cs). NR 440.23(5)(b)3.3. Method 2 shall be used to determine the volumetric flow rate (Qsd) of the effluent gas. The measurement site shall be the same as for the NOx sample. A velocity traverse shall be made once per run within the hour that the NOx samples are taken. NR 440.23(5)(b)4.4. The methods of sub. (4) (c) shall be used to determine the production rate (P) of 100% nitric acid for each run. Material balance over the production system shall be used to confirm the production rate. NR 440.23(5)(c)(c) The owner or operator may use the following as alternatives to the methods and procedures specified in this subsection: NR 440.23(5)(c)1.1. For Method 7, Method 7A, 7B, 7C or 7D may be used. If Method 7C or 7D is used, the sampling time shall be at least 1 hour. NR 440.23(5)(d)(d) The owner or operator shall use the procedure in sub. (4) (b) to determine the conversion factor for converting the monitoring data to the units of the standard. NR 440.23 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (4) (a), (5) (a) 1., and (b), Register, September, 1986, No. 369, eff. 10-1-86; am. (2) (intro.), (4) (e) and (5) (b), Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (4) (a) and (5), am. (4) (b), Register, June, 1993, No. 450, eff. 8-1-93. NR 440.24(1)(1) Applicability and designation of affected facility. NR 440.24(1)(a)(a) The provisions of this section are applicable to each sulfuric acid production unit, which is the affected facility. NR 440.24(1)(b)(b) Any facility under par. (a) that commences construction or modification after August 17, 1971, is subject to the requirements of this section. NR 440.24(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.24(2)(a)(a) “Acid mist” means sulfuric acid mist, as measured by Method 8 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, or an equivalent or alternative method. NR 440.24(2)(b)(b) “Sulfuric acid production unit” means any facility producing sulfuric acid by the contact process by burning elemental sulfur, alkylation acid, hydrogen sulfide, organic sulfides and mercaptans or acid sludge, but does not include facilities where conversion to sulfuric acid is utilized primarily as a means of preventing emissions to the atmosphere of sulfur dioxide or other sulfur compounds. NR 440.24(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 affected facility any gases which contain sulfur dioxide in excess of 2.0 kg per metric ton of acid produced (4.0 lb per ton), the production being expressed as 100% H2SO4. NR 440.24(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 affected facility any gases which: NR 440.24(4)(a)1.1. Contain acid mist, expressed as H2SO4, in excess of 0.075 kg per metric ton of acid produced (0.15 lb per ton), the production being expressed as 100% H2SO4. NR 440.24(5)(a)(a) A continuous monitoring system for the measurement of sulfur dioxide shall be installed, calibrated, maintained and operated by the owner or operator. The pollutant gas used to prepare calibration gas mixtures under Performance Specification 2 of 40 CFR part 60, Appendix B, incorporated by reference in s. NR 440.17, and for calibration checks under s. NR 440.13 (4) shall be sulfur dioxide (SO2). Method 8 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, shall be used for conducting monitoring system performance evaluations under s. NR 440.13 (3), except that only the sulfur dioxide portion of the Method 8 results shall be used. The span value shall be set at 1000 ppm of sulfur dioxide. NR 440.24(5)(b)(b) The owner or operator shall establish a conversion factor for the purpose of converting monitoring data into units of the applicable standard (kg/metric ton, lb/ton). The conversion factor shall be determined, at a minimum, 3 times daily by measuring the concentration of sulfur dioxide entering the converter using suitable methods (e.g., the Reich test, National Air Pollution Control Administration Publication No. 999-AP-13) and calculating the appropriate conversion factor for each 8-hour period as follows: where:
CF is the conversion factor (kg/metric ton per ppm, lb/ton per ppm)
k is the constant derived from material balance. For determining CF in metric units, k = 0.0653. For determining CF in English units, k = 0.1306.
r is the percentage of sulfur dioxide by volume entering the gas converter. Appropriate corrections must be made for air injection plants subject to the department’s approval.
s is the percentage of sulfur dioxide by volume in the emissions to the atmosphere determined by the continuous monitoring system required under par. (a).
NR 440.24(5)(c)(c) The owner or operator shall record all conversion factors and values under par. (b) from which they were computed (i.e., CF, r, and s). NR 440.24(5)(d)(d) Alternatively, a source that processes elemental sulfur or an area that contains elemental sulfur and uses air to supply oxygen may use the following continuous emission monitoring approach and calculation procedures in determining SO2 emission rates in terms of the standard. This procedure is not required but is an alternative that would alleviate problems encountered in the measurement of gas velocities or production rate. Continuous emission monitoring systems for measuring SO2, O2 and CO2, if required, shall be installed, calibrated, maintained and operated by the owner or operator and subjected to the certification procedures in Performance Specifications 2 and 3 in Appendix B, 40 CFR part 60, incorporated by reference in s. NR 440.17 (1). The calibration procedure and span value for the SO2 monitor shall be as specified in par. (b). The span value for CO2, if required, shall be 10% and for O2 shall be 20.9% (air). A conversion factor based on process rate data is not necessary. Calculate the SO2 emission rate as follows: where:
Es is the SO2 emission rate in kg/metric ton (lb/ton) of 100% of H2SO4 produced
Cs is the concentration of SO2, kg/dscm (lb/dscf) (see the table in the note following this paragraph)
S is the acid production rate factor, 368 dscm/metric ton (11,800 dscf/ton) of 100% H2SO4 produced
%O2 is the oxygen concentration, percent dry basis
