Section 440.51. Lime manufacturing plants.

 

(1)   Applicability and designation of affected facility.

(a) The provisions of this section are applicable to each rotary lime kiln used in the manufacture of lime.

(b) The provisions of this section are not applicable to facilities used in the manufacture of lime at kraft pulp mills.

(c) Any facility under par. (a) that commences construction or modification after May 3, 1977, 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) "Lime manufacturing plant" means any plant which uses a rotary lime kiln to produce lime product from limestone by calcination.

(b) "Lime product" means the product of the calcination process including, but not limited to, calcitic lime, dolomitic lime and dead-burned dolomite.

(c) "Positive-pressure fabric filter" means a fabric filter with the fans on the upstream side of the filter bags.

(d) "Rotary lime kiln" means a unit with an inclined rotating drum which is used to produce a lime product from limestone by calcination.

(e) "Stone feed" means limestone feedstock and millscale or other iron oxide additives that become part of the product.

(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 rotary lime kiln any gases which:

1. Contain particulate matter in excess of 0.30 kilogram per megagram of stone feed (0.60 lb/ton).

2. Exhibit greater than 15% opacity when exiting from a dry emission control device.

(4)   Monitoring of emissions and operations.

(a) The owner or operator subject to the provisions of this section shall install, calibrate, maintain and operate a continuous monitoring system, except as provided in pars. (b) and (c) , to monitor and record the opacity of a representative portion of the gases discharged into the atmosphere from any rotary lime kiln. The span of this system shall be set at 40% opacity.

(b) The owner or operator of any rotary lime kiln having a control device with a multiple stack exhaust or a roof monitor may, in lieu of the continuous opacity monitoring requirements of par. (a) , monitor visible emissions at least once per day of operation by using a certified visible emissions observer who, for each site where visible emissions are observed, will perform 3 Reference Method 9 tests and record the results. (Reference Method 9 of 40 CFR part 60 , Appendix A, is incorporated by reference in s. NR 440.17 ). Visible emission observation shall occur during normal operation of the rotary lime kiln at least once per day. For at least 3 6-minute periods, the opacity shall be recorded for any points where visible emissions are observed, and the corresponding feed rate of the kiln shall also be recorded. Records shall be maintained of any 6-minute average that is in excess of the emissions specified in sub. (3) (a) .

(c) The owner or operator of any rotary lime kiln using a wet scrubbing emission control device subject to the provisions of this section may not be required to monitor the opacity of the gases discharged as required in par. (a) , but shall install, calibrate, maintain and operate the following continuous monitoring devices:

1. A monitoring device for the continuous measurement of the pressure loss of the gas stream through the scrubber. The monitoring device shall be accurate within " 250 pascals (one inch of water).

2. A monitoring device for continuous measurement of the scrubbing liquid supply pressure to the control device. The monitoring device shall be accurate within " 5% of the design scrubbing liquid supply pressure.

(d) For the purpose of conducting a performance test under s. NR 440.08 the owner or operator of any lime manufacturing plant subject to the provisions of this section shall install, calibrate, maintain and operate a device for measuring the mass rate of stone feed to any affected rotary lime kiln. The measuring device used shall be accurate within " 5% of the mass rate over its operating range.

(e) For the purpose of reports required under s. NR 440.07 (3) periods of excess emissions that shall be reported are defined as all 6-minute periods during which the average opacity of the plume from any lime kiln subject to par. (a) is greater than 15% or, in the case of wet scrubbers, any period in which the scrubber pressure drop is greater than 30% below the rate established during the performance test. If visible emission observations are made according to par. (b) , reports of excess emissions shall be submitted semiannually.

(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 standards in sub. (3) (a) as follows:

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

E = (c s Q sd )/PK)

where:

E is the emission rate of particulate matter, kg/Mg (lb/ton) of stone 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 stone feed rate, Mg/hr (ton/hr)

K is the conversion factor, 1000 g/kg (7000 gr/lb)

2. Method 5 shall be used at negative-pressure fabric filters and other types of control devices and Method 5D shall be used at positive-pressure fabric filters 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 0.90 dscm (31.8 dscf).

3. The monitoring device of sub. (4) (d) shall be used to determine the stone feed rate (P) for each run.

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

(c) During the particulate matter run, the owner or operator shall use the monitoring devices in sub. (4) (c) 1. and 2. to determine the average pressure loss of the gas stream through the scrubber and the average scrubbing liquid supply pressure.

History: Cr. Register, January, 1984, No. 337 , eff. 2-1-84; am. (1) (a), (2), (3) (a), (4) and (5), Register, September, 1986, No. 369 , eff. 10-1-86; am. (2) (intro.), (4) (b) and (5) (c), Register, September, 1990, No. 417 , eff. 10-1-90; am. (4) (e), r. and recr. (5), Register, June, 1993, No. 450 , eff. 8-1-93; CR 06-109 : r. and recr. (5) (b) 1., am. (5) (b) 2. Register May 2008 No. 629 , eff. 6-1-08.