where:
Decision Making Process for Uncontrolled Continuous Emissions from Polypropylene and Polyethylene Affected Facilities
NR 440.647(3)(a)1.c.c. Controlled continuous emissions. For each vent stream that emits continuous emissions from an affected facility as defined in sub. (1) (a) 1. and that is controlled in an existing control device, each owner or operator shall determine whether the emissions entering the control device are greater than or equal to the calculated threshold emissions (CTE) level, which is to be calculated using the TOC concentration of the inlet vent stream and the equations in footnote b of Table 3. If the inlet stream’s TOC concentration is equal to or greater than 20 weight percent, the calculated threshold emissions level is 18.2 Mg/yr (20.1 ton/yr). If multiple emission streams are vented to the control device, the individual streams are not to be separated into individual weight percent ranges for calculation purposes as would be done for uncontrolled emission streams. Emissions vented to an existing control device are required to be controlled as described in subd. 1. c. 1) and 2). Figure 2 illustrates the control determination procedure for controlled continuous emissions. NO FURTHER
CONTROL IS
REQUIRED.
ARE EMISSIONS NOW EQUAL TO OR
GREATER THAN THE CALCULATED THRESHOLD EMISSIONS?
Figure 2.
Decision Making Process for Continuous Emissions
Already Controlled at Polypropylene and Polyethylene Affected Facilities.
1) If the annual emissions of the stream entering the control device are equal to or greater than the CTE levels, then compliance with one of the requirements identified in subd. 1. a. 1), 2) or 3) is required when the control device is reconstructed or replaced or has its operating conditions modified as a result of state or local regulations, including changes in the operating permit, including those instances where the control device is reconstructed, replaced or modified in its operation at the same time the existing process section is modified or reconstructed and becomes an affected facility. If the existing control device already complies with one of the requirements identified in subd. 1. a. 1), 2) or 3) no further control is required.
2) If the annual emissions of the stream entering the control device are less than the CTE level, then the requirements of subd. 1. a. 1), 2) or 3) are not applicable at that time. However, if the control device is replaced, reconstructed or modified at a later date, each owner or operator shall reevaluate the applicability of these standards. This is done by combining with the vent stream entering the control device any uncontrolled vent streams in the same weight percent range as the controlled vent stream and determining whether the annual emissions of the stream entering the control device plus the applicable uncontrolled vent streams are greater than or equal to the CTE level, which is based on the weighted TOC concentration of the controlled vent stream and the uncontrolled vent streams. If the annual emissions entering the control device, including the applicable uncontrolled vent streams, are greater than or equal to the CTE level, then compliance with one of the requirements identified in subd. 1. a. 1), 2) or 3) is required at that time for both the controlled and uncontrolled vent streams. If the annual emissions are less than the CTE level, compliance with these standards is again not required at such time. However, if the control device is again replaced, reconstructed or modified, each owner or operator shall repeat this determination procedure.
NR 440.647(3)(a)2.2. ’Intermittent emissions.’ The owner or operator shall control each vent stream that emits intermittent emissions from an affected facility as defined in sub. (1) (a) 1. by meeting one of the control requirements specified in subd. 2. a. and b. If a vent stream that emits intermittent emissions is controlled in an existing flare, incinerator, boiler or process heater, the requirements of this paragraph are waived until such time the control device is reconstructed or replaced or is modified in its operating conditions as a result of state or local regulation, including changes in the operating permit. This paragraph does not apply to emergency vent streams exempted by sub. (1) (h) and as defined in sub. (2). 1) Designed for and operated with no visible emissions, except for periods not to exceed a total of 5 minutes during any 2 consecutive hours,
2) Operated with a flame present at all times, and
3) Designed to maintain a stable flame.
NR 440.647(3)(a)2.b.b. Combust the emissions in an incinerator, boiler or process heater. The emissions shall be introduced into the flame zone of a boiler or process heater. NR 440.647(3)(b)(b) Each owner or operator of a polystyrene process line containing process sections subject to the provisions of this section shall comply with the provisions in this subsection on and after the date on which the initial performance test required by s. NR 440.08 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 initial startup, whichever comes first. Each owner or operator of a polystyrene process line using a continuous process shall: NR 440.647(3)(b)1.1. Limit the continuous TOC emissions from the material recovery section by complying with one of the following: NR 440.647(3)(b)1.a.a. Not allow continuous TOC emissions to be greater than 0.0036 kg TOC/Mg (0.0072 lb TOC/ton) product. NR 440.647(3)(b)1.b.b. Not allow the outlet gas stream temperature from each final condenser in the material recovery section to exceed -25°C (-13°F). For purposes of this standard, temperature excursions above this limit may not be considered a violation when the excursions occur during periods of startup, shutdown or malfunction. NR 440.647(3)(b)2.2. If continuous TOC emissions from the material recovery section are routed through an existing emergency vapor recovery system, then compliance with these standards is required when the emergency vapor recovery system undergoes modification, reconstruction or replacement. In such instances, compliance with these standards shall be achieved no later than 180 days after completion of the modification, reconstruction or replacement. NR 440.647(3)(c)(c) Each owner or operator of a poly(ethylene terephthalate) process line containing process sections subject to the provisions of this section shall comply with the provisions in this subsection on and after the date on which the initial performance test required by s. NR 440.08 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 initial startup, whichever comes first. NR 440.647(3)(c)1.1. Each owner or operator of a PET process line using a dimethyl terephthalate process shall: NR 440.647(3)(c)1.a.a. Limit the continuous TOC emissions from the material recovery section, that is, methanol recovery, by complying with one of the following: 1) Not allow the continuous TOC emissions to be greater than 0.018 kg TOC/Mg (0.040 lb TOC/ton) product.
2) Not allow the outlet gas stream temperature from each final condenser in the material recovery section, that is, methanol recovery, to exceed + 3°C (+ 37°F). For purposes of this standard, temperature excursions above this limit will not be considered a violation when the excursions occur during periods of startup, shutdown or malfunction.
NR 440.647(3)(c)1.b.b. Limit the continuous TOC emissions and, if steam-jet ejectors are used to provide vacuum to the polymerization reactors, the ethylene glycol concentration from the polymerization reaction section by complying with the following appropriate standard. The ethylene glycol concentration limits specified in subd. 1. b. 2) and 3) shall be determined by the procedures specified in sub. (6) (j). 1) Not allow continuous TOC emissions from the polymerization reaction section, including emissions from any equipment used to further recover the ethylene glycol, but excluding those emissions from the cooling tower, to be greater than 0.020 kg TOC/Mg (0.044 lb TOC/ton) product.
2) If steam-jet ejectors are used as vacuum producers and a low viscosity product is being produced using single or multiple end finishers or a high viscosity product is being produced using a single end finisher, maintain the concentration of ethylene glycol in the liquid effluent exiting the vacuum system servicing the polymerization reaction section at or below 0.35% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
3) If steam-jet ejectors are used as vacuum producers and a high viscosity product is being produced using multiple end finishers, maintain an ethylene glycol concentration in the cooling tower at or below 6.0% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
NR 440.647(3)(c)2.2. Each owner or operator of a PET process line using a terephthalic acid process shall: NR 440.647(3)(c)2.a.a. Not allow the continuous TOC emissions from the esterification vessels in the raw materials preparation section to be greater than 0.040 kg TOC/Mg (0.088 lb TOC/ton) product. NR 440.647(3)(c)2.b.b. Limit the continuous TOC emissions and, if steam-jet ejectors are used to provide vacuum to the polymerization reactors, the ethylene glycol concentration from the polymerization reaction section by complying with the following appropriate standard. The ethylene glycol concentration limits specified in subd. 2. b. 2) and 3) shall be determined by the procedures specified in sub. (6) (j). 1) Not allow continuous TOC emissions from the polymerization reaction section, including emissions from any equipment used to further recover the ethylene glycol, but excluding those emissions from the cooling tower, to be greater than 0.020 kg TOC/Mg (0.044 lb TOC/ton) product.
2) If steam-jet ejectors are used as vacuum producers and a low viscosity product is being produced using single or multiple end finishers or a high viscosity product is being produced using a single end finisher, maintain the concentration of ethylene glycol in the liquid effluent exiting the vacuum system servicing the polymerization reaction section at or below 0.35% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
3) If steam-jet ejectors are used as vacuum producers and a high viscosity product is being produced using multiple end finishers, maintain an ethylene glycol concentration in the cooling tower at or below 6.0% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
NR 440.647(3)(d)(d) Closed vent systems and control devices used to comply with this section shall be operated at all times when emissions may be vented to them. NR 440.647(3)(e)(e) Vent systems that contain valves that could divert a vent stream from a control device shall have car-sealed opened all valves in the vent system from the emission source to the control device and car-sealed closed all valves in vent system that would lead the vent stream to the atmosphere, either directly or indirectly, bypassing the control device. NR 440.647(4)(a)(a) Each owner or operator of an affected facility subject to the provisions of this section shall comply with the requirements specified in s. NR 440.62 (3) as soon as practicable, but no later than 180 days after initial startup, except that indications of liquids dripping from bleed ports in existing pumps in light liquid service are not considered to be a leak as defined in s. NR 440.62 (3) (b) 2. b. For purposes of this standard, a “bleed port” is a technologically-required feature of the pump whereby polymer fluid used to provide lubrication, cooling, or both, of the pump shaft exits the pump, thereby resulting in a visible leak of fluid. This exemption expires when the existing pump is replaced or reconstructed. NR 440.647(4)(c)(c) An owner or operator may apply to the administrator for a determination of equivalency for any means of emission limitation that achieves a reduction in emissions of VOC at least equivalent to the reduction in emissions of VOC achieved by the controls required in this section. In doing so, the owner or operator shall comply with requirements specified in 40 CFR 60.484, as in effect on July 1, 1994. NR 440.647(4)(d)(d) Each owner or operator subject to the provisions of this section shall comply with the provisions specified in s. NR 440.62 (6) except an owner or operator may use the following provision in addition to s. NR 440.62 (6) (e). Equipment is in light liquid service if the percent evaporated is greater than 10% at 150°C (302°F) as determined by ASTM D86-96, incorporated by reference in s. NR 440.17 (2) (a) 7. NR 440.647(5)(a)(a) Whenever a particular item of monitoring equipment specified in this subsection is to be installed, the owner or operator shall install, calibrate, maintain and operate according to manufacturer’s specifications that item as follows: NR 440.647(5)(a)1.1. A temperature monitoring device to measure and record continuously the operating temperature to within 1% (relative to degrees Celsius) or ±0.5°C (±0.9°F), whichever is greater. NR 440.647(5)(a)2.2. A flame monitoring device, such as a thermocouple, an ultra-violet sensor, an infrared beam sensor or similar device to indicate and record continuously whether a flare or pilot light flame is present, as specified. NR 440.647(5)(a)3.3. A flow monitoring indicator to indicate and record whether or not flow exists at least once every 15 minutes. NR 440.647(5)(a)4.4. An organic monitoring device, based on a detection principle such as infrared, photoionization or thermal conductivity, to indicate and record continuously the concentration level of organic compounds. NR 440.647(5)(a)5.5. A specific gravity monitoring device to measure and record continuously to within 0.02 specific gravity unit. NR 440.647(5)(b)(b) The owner or operator shall install, as applicable, the monitoring equipment for the control means used to comply with sub. (3) except sub. (3) (a) 1. a. 4) as follows: NR 440.647(5)(b)1.a.a. For a noncatalytic incinerator, a temperature monitoring device shall be installed in the firebox. NR 440.647(5)(b)1.b.b. For a catalytic incinerator, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalytic bed. NR 440.647(5)(b)2.a.a. A flame monitoring device shall be installed to indicate the presence of a flare flame or a flame for each pilot light, if the flare is used to comply with sub. (3) (a) 1. including those flares controlling both continuous and intermittent emissions. NR 440.647(5)(b)2.b.b. A thermocouple or equivalent monitoring device to indicate the presence of a flame at each pilot light, if used to comply with sub. (3) (a) 2. NR 440.647(5)(b)3.a.a. If the boiler or process heater has a heat input design capacity of less than 150 million Btu/hr, a temperature monitoring device shall be installed between the radiant section and the convection zone for watertube boilers and between the furnace, combustion zone, and the firetubes for firetube boilers. NR 440.647(5)(b)3.b.b. If the boiler or process heater has a heat input design capacity of 150 million Btu/hr or greater, records to indicate the periods of operation of the boiler or process heater shall be maintained. The records shall be readily available for inspection. NR 440.647(5)(b)4.a.a. A temperature monitoring device and a specific gravity monitoring device for the scrubber liquid shall be installed; or NR 440.647(5)(b)4.b.b. An organic monitoring device shall be installed at the outlet of the absorber. NR 440.647(5)(b)5.a.a. A temperature monitoring device shall be installed at the condenser exit (product side); or NR 440.647(5)(b)5.b.b. An organic monitoring device shall be installed at the outlet of the condenser. NR 440.647(5)(b)6.6. If a carbon adsorber is the final unit in a system, an organic monitoring device shall be installed at the outlet of the carbon bed. NR 440.647(5)(c)(c) Owners or operators of control devices used to comply with the provisions of this section, except sub. (3) (a) 1. a. 4) shall monitor these control devices to ensure that they are operated and maintained in conformance with their designs. NR 440.647(5)(d)(d) Owners or operators using a vent system that contains valves that could divert a vent stream from a control device used to comply with the provisions of this section shall do one or a combination of the following: NR 440.647(5)(d)1.1. Install a flow indicator immediately downstream of each valve that if opened would allow a vent stream to bypass the control device and be emitted, either directly or indirectly, to the atmosphere. The flow indicator shall be capable of recording flow at least once every 15 minutes. NR 440.647(5)(d)2.2. Monitor the valves once a month, checking the position of the valves and the condition of the car seal and identify all times when the car seals have been broken and the valve position has been changed, that is, from opened to closed for valves in the vent piping to the control device and from closed to open for valves that allow the stream to be vented directly or indirectly to the atmosphere. NR 440.647(5)(e)(e) An owner or operator complying with the standards specified under sub. (3) except sub. (3) (a) 1. a. 4) with control devices other than an incinerator, boiler, process heater, flare, absorber, condenser or carbon adsorber or by any other means shall provide to the department information describing the operation of the control device and the process parameters which would indicate proper operation and maintenance of the device. The department may request further information and will specify appropriate monitoring procedures or requirements. NR 440.647(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 specified in this subsection, except as provided under s. NR 440.08 (2). Owners or operators complying with sub. (3) (a) 1. a. 4) need not perform a performance test on the control device, provided the control device is not used to comply with any other requirement of sub. (3) (a). NR 440.647(6)(a)1.1. Whenever changes are made in production capacity, feedstock type or catalyst type or whenever there is replacement, removal or addition of a control device, each owner or operator shall conduct a performance test according to the procedures in this subsection as appropriate, in order to determine compliance with sub. (3). NR 440.647(6)(a)2.2. Where a boiler or process heater with a design heat input capacity of 150 million Btu/hr or greater is used, the requirement for an initial performance test is waived, in accordance with s. NR 440.08 (2). However, the department reserves the option to require testing at such other times as may be required, as provided for in ch. NR 439. NR 440.647(6)(a)3.3. The owner or operator shall determine the average organic concentration for each performance test run using the equipment described in sub. (5) (a) 4. The average organic concentration shall be determined from measurements taken at least every 15 minutes during each performance test run. The average of the 3 runs shall be the base value for the monitoring program. NR 440.647(6)(a)4.4. When an absorber is the final unit in the system, the owner or operator shall determine the average specific gravity for each performance test run using specific gravity monitoring equipment described in sub. (5) (a) 5. An average specific gravity shall be determined from measurements taken at least every 15 minutes during each performance test run. The average of the 3 runs shall be the base value for the monitoring program. NR 440.647(6)(a)5.5. When a condenser is the final unit in the system, the owner or operator shall determine the average outlet temperature for each performance test run using the temperature monitoring equipment described in sub. (5) (a) 1. An average temperature shall be determined from measurements taken at least every 15 minutes during each performance test run while the vent stream is normally routed and constituted. The average of the 3 runs shall be the base value for the monitoring program. NR 440.647(6)(b)(b) Except as provided for in par. (c), the owner or operator shall determine compliance with the emission concentration standard in sub. (3) (a) 1. a. 1) or (b) 1. c. if applicable. NR 440.647(6)(b)1.1. The TOC concentration 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, ppmv
Cj is the concentration of sample component j, ppm
n is the number of components in the sample
