Chapter NR 440

NR 440.315(2)(h)2. 2. An open hood system for the capture and collection of primary and secondary emissions from the furnace, plus a furnace enclosure with local hooding ducted to a secondary emission collection device, such as a baghouse, for additional capture and collection of secondary emissions from the furnace, with local hooding ducted to a secondary emission collection device, such as a baghouse for the capture and collection of emissions from hot metal transfer and skimming stations; or

NR 440.315(2)(h)3. 3. A furnace enclosure with local hooding ducted to a secondary emission collection device such as a baghouse for the capture and collection of secondary emissions from a BOPF controlled by a closed hood primary emission control system, with local hooding ducted to a secondary emission collection device, such as baghouse, for the capture and collection of emissions from hot metal transfer and skimming stations.

NR 440.315(2)(i) (i) “Secondary emissions” means particulate matter emissions that are not captured by the BOPF primary control system, including emissions from hot metal transfer and skimming stations. This definition also includes particulate matter emissions that escape from openings in the primary emission control system, such as from lance hole openings, gaps or tears in the ductwork of the primary emission control system, or leaks in hoods.

NR 440.315(2)(j) (j) “Skimming station” means the facility where slag is mechanically raked from the top of the molten iron.

NR 440.315(2)(k) (k) “Steel production cycle” means the operations conducted within the BOPF steelmaking facility that are required to produce each batch of steel, including the following operations: scrap charging, preheating (when used), hot metal charging primary oxygen blowing, sampling (vessel turndown and turnup), additional oxygen blowing (when used), tapping and deslagging. Hot metal transfer and skimming operations from the next steel production cycle are also included when the hot metal transfer station or skimming station is an affected facility.

NR 440.315(2)(L) (L) “Top-blown furnace” means any BOPF in which oxygen is introduced to the bath of molten iron by means of an oxygen lance inserted from the top of the vessel.

NR 440.315(3) (3) Standards for particulate matter.

NR 440.315(3)(a) (a) Except as provided under pars. (b) and (c), on and after the date on which the performance test under s. NR 440.08 is required to be 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 secondary emissions that:

NR 440.315(3)(a)1. 1. Exit from the BOPF shop roof monitor (or other building openings) and exhibit greater than 10% opacity during the steel production cycle of any top-blown BOPF or during hot metal transfer or skimming operations for any bottom-blown BOPF, except that an opacity greater than 10% but less than 20% may occur once per steel production cycle.

NR 440.315(3)(a)2. 2. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming operations for a top-blown BOPF and contain particulate matter in excess of 23 mg/dscm (0.010 gr/dscf).

NR 440.315(3)(a)3. 3. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming operations for a top-blown or a bottom-blown BOPF and exhibit more than 5% opacity.

NR 440.315(3)(b) (b) A fume suppression system used to control secondary emissions from an affected facility is not subject to par. (a) 2. and 3.

NR 440.315(3)(c) (c) A control device used to collect both primary and secondary emissions from a BOPF is not subject to par. (a) 2. and 3.

NR 440.315(4) (4) Monitoring of operations.

NR 440.315(4)(a) (a) Each owner or operator of an affected facility shall install, calibrate, operate, and maintain a monitoring device that continually measures and records for each steel production cycle the various rates or levels of exhaust ventilation at each phase of the cycle through each duct of the secondary emission capture system. The monitoring device or devices are to be placed at locations near each capture point of the secondary emission capture system to monitor the exhaust ventilation rates or levels adequately, or in alternative locations approved in advance by the department.

NR 440.315(4)(b) (b) If a chart recorder is used, the owner or operator shall use chart recorders that are operated at minimum chart speed of 3.8 cm/hr (1.5 in/hr).

NR 440.315(4)(c) (c) All monitoring devices required by par. (a) shall be certified by the manufacturer to be accurate to within ± 10% compared to Method 2 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1). The owner or operator shall recalibrate and check the devices annually and at other times as the department may require, in accordance with the written instructions of the manufacturer and by comparing the device against Method 2.

NR 440.315(4)(d) (d) Each owner or operator subject to the requirements of par. (a) shall report on a semiannual basis all measurements of exhaust ventilation rates or levels over any 3-hour period that average more than 10% below the average rates or levels of exhaust ventilation maintained during the most recent performance test conducted under s. NR 440.08 in which the affected facility demonstrated compliance with the standard under sub. (3) (a) 2. The accuracy of the respective measurements, not to exceed the values specified in par. (c), may be considered when determining the measurement results that are to be reported.

NR 440.315(4)(e) (e) If a scrubber primary emission control device is used to collect secondary emissions, the owner or operator shall report on a semiannual basis all measurements of exhaust ventilation rate over any 3-hour period that average more than 10% below the average levels maintained during the most recent performance text conducted under s. NR 440.08 in which the affected facility demonstrated compliance with the standard under sub. (3) (a) 1.

NR 440.315(5) (5) Test methods and procedures.

NR 440.315(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 440.315(5)(b) (b) The owner or operator shall determine compliance with the particulate matter standard in sub. (3) as follows:

NR 440.315(5)(b)1. 1. Start and end times of each steel production cycle during each run shall be recorded.

NR 440.315 Note Note: See sub. (6) (c) and (d) for the definitions of start and end times of a cycle.

NR 440.315(5)(b)2. 2. Method 5 shall be used to determine the particulate matter concentration. Sampling shall be conducted only during the steel production cycle and for a sufficient number of steel production cycles to obtain a total sample volume of at least 5.67 dscm (200 dscf) for each run.

NR 440.315(5)(b)3. 3. Method 9 and the procedures of s. NR 440.11 shall be used to determine opacity, except sections 2.4 and 2.5 of Method 9 shall be replaced with the following instructions for recording observations and reducing data:

NR 440.315(5)(b)3.a. a. Section 2.4. Opacity observations shall be recorded to the nearest 5% at 15-second intervals. During the initial performance test conducted pursuant to s. NR 440.08, observations shall be made and recorded in this manner for a minimum of 3 steel production cycles. During any subsequent compliance test, observations may be made for any number of steel production cycles, although, where conditions permit, observations will generally be made for a minimum of 3 steel production cycles.

NR 440.315(5)(b)3.b. b. Section 2.5. Opacity shall be determined as an average of 12 consecutive observations recorded at 15-second intervals. For each steel production cycle, divide the observations recorded into sets of 12 consecutive observations. Sets need not be consecutive in time, and in no case may 2 sets overlap. For each set of 12 observations, calculate the average by summing the opacity of 12 consecutive observations and dividing this sum by 12.

NR 440.315(5)(c) (c) In complying with the requirements of sub. (4) (c), the owner or operator shall conduct an initial test as follows:

NR 440.315(5)(c)1. 1. For devices that monitor and record the exhaust ventilation rate, compare velocity readings recorded by the monitoring device against the velocity readings obtained by Method 2. Take Method 2 readings at a point or points that would properly characterize the monitoring device’s performance and that would adequately reflect the various rates of exhaust ventilation. Obtain readings at sufficient intervals to obtain 12 pairs of readings for each duct of the secondary emission capture system. Compare the averages of the 2 sets to determine whether the monitoring device velocity is within ± 10% of the Method 2 average.

NR 440.315(5)(c)2. 2. For devices that monitor the level of exhaust ventilation and record only step changes when a set point rate is reached, compare step changes recorded by the monitoring device against the velocity readings obtained by Method 2. Take Method 2 readings at a point or points that would properly characterize the performance of the monitoring device and that would adequately reflect the various rates of exhaust ventilation. Obtain readings at sufficient intervals to obtain 12 pairs of readings for each duct of the secondary emission capture system. Compare the averages of the 2 sets to determine whether the monitoring device step change is within ± 10% of the setpoint rate.

NR 440.315(5)(d) (d) To comply with sub. (4) (d) or (e), the owner or operator shall use the monitoring device of sub. (4) (a) to determine the exhaust ventilation rates or levels during the particulate matter runs. Each owner or operator shall then use these rates or levels to determine the 3-hour averages required by sub. (4) (d) and (e).

NR 440.315(6) (6) Compliance provisions.

NR 440.315(6)(a) (a) When determining compliance with mass and visible emission limits specified in sub. (3) (a) 2. and 3., the owner or operator of a BOPF shop that normally operates 2 furnaces with overlapping cycles may elect to operate only one furnace. If an owner or operator chooses to shut down one furnace, he or she shall be allowed a reasonable time period to adjust the production schedule before the compliance tests are conducted. The owner or operator of an affected facility may also elect to suspend shop operations not subject to this section during compliance testing.

NR 440.315(6)(b) (b) During compliance testing for mass and visible emission standards, if an owner or operator elects to shut down one furnace in a shop that normally operates 2 furnaces with overlapping cycles, the owner or operator shall operate the secondary emission control system for the furnace being tested at exhaust ventilation rates or levels for each duct of the secondary emission control system that are appropriate for single-furnace operating. Following the compliance test, the owner or operator shall operate the secondary emission control system at exhaust ventilation rates or levels for each duct of the system that are no lower than 90% of the exhaust ventilation values established during the most recent compliance test.

NR 440.315(6)(c) (c) For the purpose of determining compliance with visible and mass emission standards, a steel production cycle begins when the scrap or hot metal is charged to the vessel (whichever operation occurs first) and terminates 3 minutes after slag is emptied from the vessel into the slag pot. Consecutive steel production cycles are not required for the purpose of determining compliance. Where a hot metal transfer or skimming station is an affected facility, the steel production cycle also includes the hot metal transfer or skimming operation for the next steel production cycle for the affected vessel. Visible emission observations for both hot metal transfer and skimming operations begin with the start of the operation and terminate 3

NR 440.315(6)(d) (d) For the purpose of determining compliance with visible emission standards specified in sub. (3) (a) 1. and 3., the starting and stopping times of regulated process operations shall be determined and the starting and stopping times of visible emissions data sets shall be determined accordingly.

NR 440.315(6)(e) (e) To determine compliance with sub. (3) (a) 1., the owner or operator shall select the data sets yielding the highest and second highest 3-minute average opacities for each steel production cycle. Compliance is achieved if the highest 3-minute average for each cycle observed is less than 20% and the second highest 3-minute average is 10% or less.

NR 440.315(6)(f) (f) To determine compliance with sub. (3) (a) 2., the owner or operator shall determine the concentration of particulate matter in exhaust gases exiting the secondary emission collection device with Method 5 of Appendix A, 40 CFR part 60, incorporated by reference in s. NR 440.17 (1). Compliance is achieved if the concentration of particulate matter does not exceed 23 mg/dscm (0.010 gr/dscf).

NR 440.315(6)(g) (g) To determine compliance with sub. (3) (a) 3., the owner or operator shall construct consecutive 3-minute averages for each steel production cycle. Compliance is achieved if no 3-minute average is more than 5%.

NR 440.315 History History: Cr. Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; am. (5) (c) 1., 2., Register, December, 1995, No. 480, eff. 1-1-96; correction in (2) made under s. 13.93 (2m) (b) 1., Stats., Register, November, 1999, No. 527; CR 06-109: am. (4) (c), (5) (d) and (6) (e) to (g) Register May 2008 No. 629, eff. 6-1-08.

NR 440.32 NR 440.32 Sewage treatment plants.

NR 440.32(1) (1) Applicability and designation of affected facility.

NR 440.32(1)(a) (a) The affected facility is each incinerator that combusts wastes containing more than 10% sewage sludge (dry basis) produced by municipal sewage treatment plants, or each incinerator that charges more than 1000 kg (2205 lb) per day municipal sewage sludge (dry basis).

NR 440.32(1)(b) (b) Any facility under par. (a) that commences construction or modification after June 11, 1973, is subject to the requirements of this section.

NR 440.32(2) (2) Definitions. As used in this section, terms have the meanings given in s. NR 440.02.

NR 440.32(3) (3) Standard for particulate matter.

NR 440.32(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 of any sewage sludge incinerator subject to the provisions of this section may discharge or cause the discharge into the atmosphere of:

NR 440.32(3)(a)1. 1. Particulate matter at a rate in excess of 0.65 g/kg dry sludge input (1.30 lb/ton dry sludge input).

NR 440.32(3)(a)2. 2. Any gases which exhibit 20% opacity or greater.

NR 440.32(4) (4) Monitoring of operations.

NR 440.32(4)(a) (a) The owner or operator of any sludge incinerator subject to the provisions of this section shall:

NR 440.32(4)(a)1. 1. Install, calibrate, maintain, and operate a flow measuring device which can be used to determine either the mass or volume of sludge charged to the incinerator. The flow measuring device shall be certified by the manufacturer to have an accuracy of ± 5% over its operating range. Except as provided in par. (d), the flow measuring device shall be operated continuously and data recorded during all periods of operation of the incinerator.

NR 440.32(4)(a)2. 2. Provide access to the sludge charged so that a well-mixed representative grab sample of the sludge can be obtained.

NR 440.32(4)(a)3. 3. Install, calibrate, maintain and operate a weighing device for determining the mass of any municipal solid waste charged to the incinerator when sewage sludge and municipal solid waste are incinerated together. The weighing device shall have an accuracy of ± 5% over its operating range.

NR 440.32(4)(b) (b) The owner or operator of any multiple hearth, fluidized bed or electric sludge incinerator subject to the provisions of this section shall comply with the requirements of par. (a) and:

NR 440.32(4)(b)1. 1. For incinerators equipped with a wet scrubbing device, install calibrate, maintain and operate a monitoring device that continuously measures and records the pressure drop of the gas flow through the wet scrubbing device. Where a combination of wet scrubbers is used in series, the pressure drop of the gas flow through the combined system shall be continuously monitored. The device used to monitor scrubber pressure drop shall be certified by the manufacturer to be accurate within ±250 pascal (±1 inch water gauge) and shall be calibrated on an annual basis in accordance with the manufacturer’s instructions.

NR 440.32(4)(b)2. 2. Install, calibrate, maintain and operate a monitoring device that continuously measures and records the oxygen content of the incinerator exhaust gas. The oxygen monitoring shall be located upstream of any rabble shaft cooling air inlet into the incinerator exhaust gas stream, fan, ambient air recirculation damper, or any other source of dilution air. The oxygen monitoring device shall be certified by the manufacturer to have a relative accuracy of ±5% over its operating range and shall be calibrated according to method or methods prescribed by the manufacturer at least once each 24-hour operating period.

NR 440.32(4)(b)3. 3. Install, calibrate, maintain and operate temperature measuring devices at every hearth in multiple hearth furnaces; in the bed and outlet of fluidized bed incinerators; and in the drying, combustion and cooling zones of electric incinerators. For multiple hearth furnaces, a minimum of one temperature measuring device shall be installed in each hearth in the cooling and drying zones, and a minimum of 2 temperature measuring devices shall be installed in each hearth in the combustion zone. For electric incinerators, a minimum of one temperature measuring device shall be installed in the drying zone and one in the cooling zone, and a minimum of 2 temperature measuring devices shall be installed in the combustion zone. Each temperature measuring device shall be certified by the manufacturer to have an accuracy of + 5% over its operating range. Except as provided in par. (d), the temperature monitoring devices shall be operated continuously and data recorded during all periods of operation of the incinerator.

NR 440.32(4)(b)4. 4. Install, calibrate, maintain and operate a device for measuring the fuel flow to the incinerator. The flow measuring device shall be certified by the manufacturer to have an accuracy of ±5% over its operating range. Except as provided in par. (d), the fuel flow measuring device shall be operated continuously and data recorded during all periods of operation of the incinerator.

NR 440.32(4)(b)5. 5. Except as provided in par. (d), collect and analyze a grab sample of the sludge fed to the incinerator once per day. The dry sludge content and the volatile solids content of the sample shall be determined in accordance with the method specified under sub. (5) (b) 5., except that the determination of volatile solids, step 3.b. of the method, may not be deleted.

NR 440.32(4)(c) (c) The owner or operator of any multiple hearth, fluidized bed or electric sludge incinerator subject to the provisions of this section shall retain the following information and make it available for inspection by the department for a minimum of 2 years:

NR 440.32(4)(c)1. 1. For incinerators equipped with a wet scrubbing device, a record of the measured pressure drop of the gas flow through the wet scrubbing device, as required by par. (b) 1.

NR 440.32(4)(c)2. 2. A record of the measured oxygen content of the incinerator exhaust gas, as required by par. (b) 2.

NR 440.32(4)(c)3. 3. A record of the rate of sludge charged to the incinerator, the measured temperatures of the incinerator, the fuel flow to the incinerator, and the total solids and volatile solids content of the sludge charged to the incinerator, as required by pars. (a) 1. and (b) 3., 4. and 5.

NR 440.32(4)(d) (d) The owner or operator of any multiple hearth, fluidized bed, or electric sludge incinerator subject to the provisions of this section from which the particulate matter emission rate measured during the performance test required under sub. (5) (d) is less than or equal to 0.38 g/kg of dry sludge input (0.75 lb/ton) shall be required to comply with the requirements in pars. (a) to (c) during all periods of operation of this incinerator following the performance test except that:

NR 440.32(4)(d)1. 1. Continuous operation of the monitoring devices and data recorders in pars. (a) 1. and (b) 3. and 4. is not required.

NR 440.32(4)(d)2. 2. Daily sampling and analysis of sludge feed in par. (b) 5. is not required.

NR 440.32(4)(d)3. 3. Recordkeeping specified in par. (c) 3. is not required.

NR 440.32(4)(e) (e) The owner or operator of any sludge incinerator other than a multiple hearth, fluidized bed or electric incinerator or any sludge incinerator equipped with a control device other than a wet scrubber shall submit to the administrator for approval a plan for monitoring and recording incinerator and control device operation parameters. The plan shall be submitted to the administrator:

NR 440.32(4)(e)1. 1. No later than 90 days after October 6, 1988, for sources which have provided notification of commencement of construction prior to October 6, 1988.

NR 440.32(4)(e)2. 2. No later than 90 days after the notification of commencement of construction, for sources which provide notification of commencement of construction on or after October 6, 1988.

NR 440.32(4)(e)3. 3. At least 90 days prior to the date on which the new control device becomes operative, for sources switching to a control device other than a wet scrubber.

NR 440.32(5) (5) Test methods and procedures.

NR 440.32(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 and Appendix B of 40 CFR part 61, 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 440.32(5)(b) (b) The owner or operator shall determine compliance with the particulate matter emission standards in sub. (3) as follows:

NR 440.32(5)(b)1. 1. The emission rate (E) of particulate matter for each run shall be computed using the following equation:

=

where:

E is the emission rate of particulate matter, g/kg (lb/ton) of dry sludge input

cs is the concentration of particulate matter, g/dscm (gr/dscf)

Qsd is the volumetric flow rate of exhaust gas, dscm/hr (dscf/hr)

S is the charging rate of dry sludge during the run, kg/hr (ton/hr)

K is the conversion factor, 1.0 g/g (7000 gr/lb)

NR 440.32(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 0.90 dscm (31.8 dscf).

NR 440.32(5)(b)3. 3. The dry sludge charging rate (S) for each run shall be computed using either of the following equations:

where: