Section 440.22. Portland cement plants.

 

(1)   Applicability and designation of affected facility.

(a) The provisions of this section are applicable to the following affected facilities in portland cement plants: Kiln, clinker cooler, raw mill system, finish mill system, raw mill dryer, raw material storage, clinker storage, finished product storage, conveyor transfer points, bagging and bulk loading and unloading systems.

(b) Any facility under par. (a) that commences construction or modification after August 17, 1971, is subject to the requirements of this section.

(2)   Definitions. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02 .

(a) "Portland cement plant" means any facility manufacturing portland cement by either the wet or dry process.

(b) "Bypass" means any system that prevents all or a portion of the kiln or clinker cooler exhaust gases from entering the main control device and ducts the gases through a separate control device. This does not include emergency systems designed to duct exhaust gases directly to the atmosphere in the event of a malfunction of any control device controlling kiln or clinker cooler emissions.

(c) "Bypass stack" means the stack that vents exhaust gases to the atmosphere from the bypass control device.

(d) "Monovent" means an exhaust configuration of a building or emission control device, for example a positive-pressure fabric filter, that extends the length of the structure and has a width very small in relation to its length, that is, length to width ratio is typically greater than 5:1. The exhaust may be an open vent with or without a roof, louvered vents or a combination of such features.

(3)   Standard for particulate matter.

(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 kiln any gases which:

1. Contain particulate matter in excess of 0.15 kg per metric ton of feed (dry basis) to the kiln (0.30 lb per ton).

2. Exhibit greater than 20% opacity.

(b) 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 clinker cooler any gases which:

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).

2. Exhibit 10% opacity, or greater.

(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.

(4)   Monitoring of operations.

(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.

(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.

(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.

(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.

(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.

(5)   Test methods and procedures.

(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) .

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

1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: - See PDF for diagram

where:

E is the emission rate of particulate matter, kg/metric ton (lb/ton) of kiln feed

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

Q sd 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)

2. Method 5 shall be used to determine the particulate matter concentration (c s ) and the volumetric flow rate (Q sd ) 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.

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.

4. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity.

(6)   Recordkeeping and reporting requirements.

(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.

(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) .

(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.

History: 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.