Section 439.096. Methods and procedures for combustion optimization.

  The owner or operator of a unit subject to the combustion optimization requirements of s. NR 428.05 (2) shall comply with all applicable methods and procedures for combustion optimization listed in this section.

(1)   General. All combustion optimizations conducted shall be performed according to methods approved in writing by the department. The owner or operator responsible for combustion optimizations shall follow the procedures in this section.

(2)   Combustion optimization notification and plan submittal. The department shall be notified in writing at least 45 days in advance of a combustion optimization to provide the department an opportunity to evaluate the plan and to have a representative present to witness the combustion optimization procedures. The notice shall provide a combustion optimization plan which includes, but need not be limited to, the following information:

(a) The results of an engineering study of the process to be optimized. The engineering report shall identify and evaluate the options available for modifications to the process that would optimize combustion while minimizing NO x emissions.

(b) A description of the process or operation variables which affect the air contaminant source's emissions.

(c) A description of the process to be optimized.

(d) A description of the sampling equipment and the combustion optimization methods and procedures to be used.

(e) The date and starting time of the combustion optimization.

(f) A description of the number and location of any sampling ports and sampling points and an identification of the combustion gases to be sampled.

(g) A statement indicating the production rate and the operating conditions at which the combustion optimization will be conducted.

(3)   Combustion optimization plan evaluation. In evaluating the combustion optimization plan, the department shall respond to the source owner or operator within 15 business days of receipt of the plan and may require one or more of the following activities:

(a) A pre-combustion optimization conference which includes the owner or operator of the source, the person conducting the combustion optimization and the department to discuss any deficiencies in the plan or settle any combustion optimization procedure questions the department, the person conducting the combustion optimization or the source owner or operator might have.

(b) Any change to the sampling method that is deemed necessary by the department to conduct a proper combustion optimization.

(c) A rescheduling of the combustion optimization to accommodate witnessing or source production schedules.

(4)   Notification of combustion optimization plan revision. The source owner or operator shall notify the department of any modifications to a combustion optimization plan at least 5 business days prior to the combustion optimization. In the event the owner or operator is unable to conduct the combustion optimization on the date specified in the plan, due to unforeseeable circumstances beyond the owner or operator's control, the owner or operator shall notify the department at least 5 business days prior to the scheduled combustion optimization date and specify the date when the combustion optimization is to be rescheduled.

(5)   Proper facilities for combustion optimization. The department may require the owner or operator of a source to provide proper facilities for conducting combustion optimization tests which may include the testing facilities listed in s. NR 439.07 (5) (a) to (e) .

(6)   Witnessing requirements. The department may require that a department representative be present at any combustion optimization. The department may require the following activities:

(a) The department may require the person conducting the combustion optimization to provide the department a copy of all test data and equipment calibration data prepared or collected for the combustion optimization.

(b) The department may require the source owner or operator and person conducting the combustion optimization to correct any deficiency in the performance of the combustion optimization provided that the department notifies the source owner or operator and person conducting the combustion optimization of the deficiency as soon as it is discovered. The failure of a source owner or operator and person conducting the combustion optimization to correct any deficiency may result in the department refusing to accept the results of the combustion optimization.

(7)   Combustion optimization equipment calibration requirements. The components of any emission sampling train or associated sampling equipment listed in this subsection shall be calibrated not more than 60 days before the test. This includes the following:

(a) Any equipment used to measure gas velocity.

(b) Any equipment used to meter sample gas volume.

(c) Any equipment used to regulate sample gas flow.

(d) Any equipment used to measure temperature.

(e) Any gas sampling nozzle used during the emission test.

(f) Any equipment used to determine gas molecular weight.

(g) Any other sampling equipment that requires periodic calibration.

(8)   Procedures for conducting combustion optimizations. Any emissions testing conducted in conjunction with combustion optimization shall be conducted in accordance with s. NR 439.07 . The combustion optimization shall include the following procedures:

(a) An engineering study to identify the optimized combustion profile or equipment modifications needed to optimize combustion. The study shall address, but is not limited to, the modification of the following systems: fuel delivery, burner, primary and secondary combustion monitoring, combustion air delivery and burner management.

(b) The combustion optimization shall be based on burner tune-up procedures which result in maximum combustion efficiency and a low NO x operating curve. This curve shall determine the operating range of combustion variables such as CO and O 2 at set points within the following ranges: 20-30% load, 45-55% load, 70-80% load and 95-100% load, for those set points that represent at least 10% of boiler operating hours in a typical year.

(c) A continuous combustion analyzer shall be used to monitor the operation of the combustion unit in accordance with the combustion efficiency and low NO x operating curve required under this section. The analyzer shall monitor the combustion parameters CO and O 2 or monitor NO x directly. The fuel flow rate shall be monitored.

(9)   Combustion optimization reporting requirements. The owner or operator of a source that conducts a combustion optimization shall submit a copy of the report of the combustion optimization to the department within 60 days after its completion. If requested, the department may grant an extension of up to 30 days for combustion optimization report submittal. The failure to include the following information in a combustion optimization report may result in rejection of the combustion optimization. The combustion optimization report shall include, but need not be limited to, the following information:

(a) A detailed description of the process optimized and the procedures employed.

(b) A log of the operating conditions of the process optimized and of any associated air pollution control device.

(c) A summary of results, expressed in terms of the concentrations of NO x , O 2 and CO, prior to and following the combustion optimization.

(d) Sample calculations employing all the formulas used to calculate the results.

(e) The field and laboratory data for the optimization.

(f) The engineering study and combustion efficiency and low NO x operating curve required under sub. (8) (a) and (b) .

(g) The report of any visible emission evaluations performed during the combustion optimization.

(h) A copy of any steam, opacity or airflow charts made during the optimization.

(i) The report of any fuel analysis performed on the fuel burned during the optimization.

(j) Documentation of any process upset occurring during the optimization.

(k) If the combustion optimization being conducted is one required under sub. (10) , the changes made to the process or control device since the last test.

(10)   Additional combustion optimizations.

(a) The department may require an NO x emissions source to conduct an additional combustion optimization if the department determines that a source has not satisfied the requirements of sub. (8) or (9) .

(b) Combustion units that are modified sources with respect to NO x due to a change in the method of operation shall perform a new combustion optimization including the determination of a new combustion efficiency and low NO x operating curve.

History: Cr. Register, January, 2001, No. 541 , eff. 2-1-01.