Section 440.69. Wool fiberglass insulation manufacturing plants.

 

(1)   Applicability and designation of affected facility.

(a) The affected facility to which the provisions of this section apply is each rotary spin wool fiberglass insulation manufacturing line.

(b) The owner or operator of any facility under par. (a) that commences construction, modification, or reconstruction after February 7, 1984, 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) "Glass pull rate" means the mass of molten glass utilized in the manufacture of wool fiberglass insulation at a single manufacturing line in a specified time period.

(b) "Manufacturing line" means the manufacturing equipment comprising the forming section, where molten glass is fiberized and a fiberglass mat is formed; the curing section, where the binder resin in the mat is thermally "set" ; and the cooling section, where the mat is cooled.

(c) "Rotary spin" means a process used to produce a wool fiberglass insulation by forcing molten glass through numerous small orifices in the side wall of a spinner to form continuous glass fibers that are then broken into discrete lengths by high velocity air flow.

(d) "Wool fiberglass insulation" means a thermal insulation material composed of glass fibers and made from glass produced or melted at the same facility where the manufacturing line is located.

(3)   Standard for particulate matter. On and after the date on which the performance test required to be conducted by s. NR 440.18 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 particulate matter in excess of 5.5 kg per Mg (11.0 lb/ton) of glass pulled.

(4)   Monitoring operations.

(a) Any owner or operator subject to the provisions of this section who uses a wet scrubbing control device to comply with the mass emission standard shall install, calibrate, maintain and operate monitoring devices that measure the gas pressure drop across each scrubber and the scrubbing liquid flow rate to each scrubber. The pressure drop monitor is to be certified by its manufacturer to be accurate within plus or minus 250 pascals ( " 1 inch water gauge) over its operating range and the flow rate monitor is to be certified by its manufacturer to be accurate within " 5% over its operating range.

(b) An owner or operator subject to the provisions of this section who uses a wet electrostatic precipitator control device to comply with the mass emission standard shall install, calibrate, maintain and operate monitoring devices that measure the primary and secondary current (amperes) and voltage in each electrical field and the inlet water flow rate. In addition the owner or operator shall determine the total residue (total solids) content of the water entering the control device once per day using Method 2450 B, "Total Solids Dried at 103-105 ° C," in Standard Methods for the Examination of Water and Wastewater, 20th edition, 1998, incorporated by reference in s. NR 440.17 (2) (e) 1. Total solids shall be reported as percent by weight. All monitoring devices required under this paragraph shall be certified by their manufacturers to be accurate within " 5% over their operating range.

(c) All monitoring devices required under this subsection are to be recalibrated quarterly in accordance with procedures under s. NR 440.13 (2) .

(5)   Recordkeeping and reporting requirements.

(a) At 30-minute intervals during each 2-hour test run of each performance test of a wet scrubber control device, and at least once every 4 hours thereafter, the owner or operator shall record the measurements required by sub. (4) (a) .

(b) At 30-minute intervals during each 2-hour test run of each performance test of a wet electrostatic precipitator control device, and at least once every 4 hours thereafter, the owner or operator shall record the measurements required by sub. (4) (b) , except that the concentration of total residue in the water shall be recorded once during each performance test and once per day thereafter.

(c) Records of the measurements required in pars. (a) and (b) must be retained for at least 2 years.

(d) Each owner or operator shall submit written semiannual reports of exceedances of control device operating parameters required to be monitored by pars. (a) and (b) and written documentation of, and a report of corrective maintenance required as a result of, quarterly calibrations of the monitoring devices required in sub. (4) (c) . For the purpose of these reports exceedances are defined as any monitoring data that are less than 70% of the lowest values or greater than 130% of the highest value of each operating parameter recorded during the most recent performance test.

(6)   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 conduct performance tests while the product with the highest loss on ignition (LOI) expected to be produced by the affected facility is being manufactured.

(c) 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/Mg (lb/ton)

C t 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 avg is the average glass pull rate, Mg/hr (ton/hr)

K is the conversion factor, 1000 g/kg (7,000 gr/lb)

2. Method 5E shall be used to determine the particulate matter concentration (C t ) and the volumetric flow rate (Q sd ) of the effluent gas. The sampling time and sample volume shall be at least 120 minutes and 2.55 dscm (90.1 dscf).

3. The average glass pull rate (P avg ) for the manufacturing line shall be the arithmetic average of 3 glass pull rate (P i ) determinations taken at intervals of at least 30 minutes during each run.

The individual glass pull rates (P i ) shall be computed using the following equation: - See PDF for diagram

where:

P i is the glass pull rate at interval "i", Mg/hr (ton/hr)

L s is the line speed, m/min (Ft/min)

W m is the trimmed mat width, m (ft)

M is the mat gram weight, g/m 2 (lb/ft 2 )

LOI is the loss on ignition, weight percent

K' is the conversion factor, 6 10 -5 (min-Mg)/(hr-g) [3 10 -2 (min-ton)/(hr-lb)]

a. ASTM Standard Test Method D2584-94, incorporated by reference in s. NR 440.17 (2) (a) 32. , shall be used to determine the LOI for each run.

b. Line speed (L s ) trimmed mat width (W m ) and mat gram weight (M) shall be determined for each run from the process information or from direct measurements.

(d) To comply with sub. (5) (d) , the owner or operator shall record measurements as required in sub. (5) (a) and (b) using the monitoring devices in sub. (4) (a) and (b) during the particulate matter runs.

History: Cr. Register, January, 1984, No. 337 , eff. 2-1-84; cr. (5) (d) and (6) (e), Cr. Register, September, 1986, No. 369 , eff. 10-1-86; am. (4) (b), r. and recr. (6), Register, July, 1993, No. 451 , eff. 8-1-93; CR 06-109 : am. (4) (b) and (6) (c) 1., 2. and 3. a. Register May 2008 No. 629 , eff. 6-1-08.