NR 440.36 NoteNote: Under 40 CFR 60.195 (b), an owner or operator may petition the administrator to establish an alternate testing requirement that requires testing less frequently than once each month for a primary control system or an anode bake plant if it can be shown that their emissions have low variability during day-to-day operations. The alternative testing requirement must be published in the federal register and include a testing schedule and, in the case of a primary control system, the method to be used to determine primary control system emissions for the purpose of performance tests. NR 440.36(6)(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 440.36(6)(b)(b) The owner or operator shall determine compliance with the total fluorides and visible emission standards in subs. (3) and (4) as follows: NR 440.36(6)(b)1.1. The emission rate (Ep) of total fluorides from potroom groups shall be computed for each run using the following equation: Ep = [(Cs Qsd)1 + (Cs Qsd)2]/(PK)
where:
Ep is the emission rate of total fluorides from a potroom group, kg/Mg (lb/ton)
Cs is the concentration of total fluorides, mg/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the aluminum production rate, Mg/hr (ton/hr)
K is the conversion factor, 106 mg/kg (7000 gr/lb)
1 is the subscript for primary control system effluent gas
2 is the subscript for secondary control system or roof monitor effluent gas
NR 440.36(6)(b)2.2. The emission rate (Eb) of total fluorides from anode bake plants shall be computed for each run using the following equation: Eb = (Cs Qsd)/(PeK)
where:
Eb is the emission rate of total fluorides, kg/Mg (lb/ton) of aluminum equivalent
Cs is the concentration of total fluorides, mg/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
Pe is the aluminum equivalent for anode production rate, Mg/hr (ton/hr)
K is the conversion factor, 106 mg/kg (7000 gr/lb)
NR 440.36(6)(b)3.3. Method 13A or 13B shall be used for ducts or stacks and Method 14 for roof monitors not employing stacks or pollutant collection systems, to determine the total fluorides concentration (Cs) and volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 8 hours and 6.80 dscm (240 dscf) for potroom groups and at least 4 hours and 3.40 dscm (120 dscf) for anode bake plants. NR 440.36(6)(b)4.4. The monitoring devices of sub. (5) (a) shall be used to determine the daily weight of aluminum and anode produced. NR 440.36(6)(b)4.a.a. The aluminum production rate (P) shall be determined by dividing 720 hours into the weight of aluminum tapped from the affected facility during a period of 30 days before and including the final run of a performance test. NR 440.36(6)(b)4.b.b. The aluminum equivalent production rate (Pe) for anodes shall be determined as 2 times the average weight of anode produced during a representative oven cycle divided by the cycle time. An owner or operator may establish a multiplication factor other than 2 by submitting production records of the amount of aluminum produced and the concurrent weight of anodes consumed by the potrooms. NR 440.36 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (6) (a), Register, September, 1986, No. 369, eff. 10-1-86; am. (2) (intro.), (3) (a) 3., (6) (a), r. (6) (b), Register, September, 1990, No. 417, eff. 10-1-90; renum. (6) (a)to be (5) (c), cr. (6) (a) and (b), r. (6) (c) to (i), Register, July, 1993, No. 451, eff. 8-1-93; correction in (2) (a) made under s. 13.93 (2m) (b) 7., Stats., Register, November, 1999, No. 527; CR 06-109: am. (1) (b), (3) (a) (intro.) and (6) (b) 1. and 2., cr. (1) (c) Register May 2008 No. 629, eff. 6-1-08. NR 440.37NR 440.37 Phosphate fertilizer industry: wet-process phosphoric acid plants. NR 440.37(1)(1) Applicability and designation of affected facility. NR 440.37(1)(a)(a) The affected facility to which the provisions of this section apply is each wet-process phosphoric acid plant having a design capacity of more than 15 tons of equivalent P2O5 feed per calendar day. For the purpose of this section, the affected facility includes any combination of: reactors, filters, evaporators and hotwells. NR 440.37(1)(b)(b) Any facility under par. (a) that commences construction or modification after October 22, 1974, is subject to the requirements of this section. NR 440.37(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.37(2)(a)(a) “Equivalent P2O5 feed” means the quantity of phosphorus, expressed as phosphorus pentoxide, fed to the process. NR 440.37(2)(b)(b) “Total fluorides” means elemental fluorine and all fluoride compounds as measured by reference methods specified in sub. (5), or equivalent or alternative methods. NR 440.37(2)(c)(c) ‘‘Wet-process phosphoric acid plant” means any facility manufacturing phosphoric acid by reacting phosphate rock and acid. NR 440.37(3)(3) Standard for fluorides. 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 to which contain total fluorides in excess of 10.0 g/Mg of equivalent P2O5 feed (0.020 lb/ton). NR 440.37(4)(a)(a) The owner or operator of any wet-process phosphoric acid plant subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device which can be used to determine the mass flow of phosphorous-bearing feed material to the process. The monitoring device shall have an accuracy of ±5% over its operating range. NR 440.37(4)(b)(b) The owner or operator of any wet-process phosphoric acid plant shall maintain a daily record of equivalent P2O5 feed by first determining the total mass rate in Mg/hr of phosphorus bearing feed using a monitoring device for measuring mass flow rate which meets the requirements of par. (a) and then by proceeding according to sub. (5) (b) 3. NR 440.37(4)(c)(c) The owner or operator of any wet-process phosphoric acid plant subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device which continuously measures and permanently records the total pressure drop across the process scrubbing system. The monitoring device shall have an accuracy of ± 5% over its operating range. NR 440.37(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 440.37(5)(b)(b) The owner or operator shall determine compliance with the total fluorides standard in sub. (3) as follows: NR 440.37(5)(b)1.1. The emission rate (E) of total fluorides shall be computed for each run using the following equation: where:
E is the emission rate of total fluorides, g/Mg (lb/ton) of equivalent P2O5 feed
Csi is the concentration of total fluorides from emission point “i”, mg/dscm (gr/dscf)
Qsdi is the volumetric flow rate of effluent gas from emission point “i”, dscm/hr (dscf/hr)
N is the number of emission points associated with the affected facility
P is the equivalent P2O5 feed rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 mg/g (7000 gr/lb)
NR 440.37(5)(b)2.2. Method 13A or 13B shall be used to determine the total fluorides concentration (Csi) and volumetric flow rate (Qsdi ) of the effluent gas from each of the emission points. The sampling shall be at least 60 minutes and 0.85 dscm (30 dscf). NR 440.37(5)(b)3.3. The equivalent P2O5 feed rate (P) shall be computed for each run using the following equation: P = Mp Rp
where:
Mp is the total mass flow rate of phosphorus-bearing feed, Mg/hr (ton/hr)
Rp is the P2O5 content, decimal fraction
NR 440.37(5)(b)3.a.a. The accountability system of sub. (4) (a) shall be used to determine the mass flow rate (Mp) of the phosphorus-bearing feed. NR 440.37(5)(b)3.b.b. The Association of Official Analytical Chemists (AOAC) Method 9, incorporated by reference in s. NR 440.17, shall be used to determine the P2O5 content (Rp) of the feed. NR 440.37 HistoryHistory: Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (b), r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; CR 06-109: renum. (3) (a) to be (3) and am., am. (4) (b) and (5) (b) 1. and 3. (intro.) Register May 2008 No. 629, eff. 6-1-08. NR 440.38NR 440.38 Phosphate fertilizer industry: superphosphoric acid plants. NR 440.38(1)(1) Applicability and designation of affected facility. NR 440.38(1)(a)(a) The affected facility to which the provisions of this section apply is each superphosphoric acid plant having a design capacity of more than 15 tons of equivalent P2O5 feed per calendar day. For the purpose of this section, the affected facility includes any combination of: evaporators, hotwells, acid sumps and cooling tanks. NR 440.38(1)(b)(b) Any facility under par. (a) that commences construction or modification after October 22, 1974, is subject to the requirements of this section. NR 440.38(2)(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. NR 440.38(2)(a)(a) “Equivalent P2O5 feed” means the quantity of phosphorus, expressed as phosphorus pentoxide, fed to the process. NR 440.38(2)(b)(b) “Superphosphoric acid plant’’ means any facility which concentrates wet-process phosphoric acid to 66% or greater P2O5 content by weight for eventual consumption as a fertilizer. NR 440.38(2)(c)(c) “Total fluorides” means elemental fluorine and all fluoride compounds as measured by reference methods specified in sub. (5), or equivalent or alternative methods. NR 440.38(3)(3) Standard for fluorides. 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 total fluorides in excess of 5.0 Mg/ton of equivalent P2O5 feed (0.010 lb/ton). NR 440.38(4)(a)(a) The owner or operator of any superphosphoric acid plant subject to the provisions of this section shall install, calibrate, maintain and operate a flow monitoring device which can be used to determine the mass flow of phosphorus-bearing feed material to the process. The flow monitoring device shall have an accuracy of ± 5% over its operating range. NR 440.38(4)(b)(b) The owner or operator of any superphosphoric acid plant shall maintain a daily record of equivalent P2O5 feed by first determining the total mass rate in Mg/hr of phosphorus-bearing feed using a flow monitoring device meeting the requirements of par. (a) and then proceeding according to sub. (5) (b) 3. NR 440.38(4)(c)(c) The owner or operator of any superphosphoric acid plant subject to the provisions of this section shall install, calibrate, maintain and operate a monitoring device which continuously measures and permanently records the total pressure drop across the process scrubbing system. The monitoring device shall have an accuracy of ±5% over its operating range. NR 440.38(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 440.38(5)(b)(b) The owner or operator shall determine compliance with the total fluorides standard in sub. (3) as follows: NR 440.38(5)(b)1.1. The emission rate (E) of total fluorides shall be computed for each run using the following equation: where:
E is the emission rate of total fluorides, g/Mg (lb/ton) of equivalent P2O5 feed
Csi is the concentration of total fluorides from emission point “i”, mg/dscm (gr/dscf)
Qsdi is the volumetric flow rate of effluent gas from emission point “i”, dscm/hr (dscf/hr)
N is the number of emission points associated with the affected facility
P is the equivalent P2O5 feed rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 mg/g (7000 gr/lb)
NR 440.38(5)(b)2.2. Method 13A or 13B shall be used to determine the total fluorides concentration (Csi) and volumetric flow rate (Qsdi) of the effluent gas from each of the emission points. The sampling shall be at least 60 minutes and 0.85 dscm (30 dscf). NR 440.38(5)(b)3.3. The equivalent P2O5 feed rate (P) shall be computed for each run using the following equation: where:
Mp is the total mass flow rate of phosphorus-bearing feed, Mg/hr (ton/hr)
