Section 440.705. Volatile organic compound emissions from synthetic organic chemical manufacturing industry (SOCMI) reactor processes.

 

(1)   Applicability and designation of affected facility.

(a) This section applies to each affected facility designated in par. (b) that is part of a process unit that produces any of the chemicals listed in sub. (8) as a product, co-product, by-product or intermediate except as provided in par. (c) .

(b) The affected facility is any of the following for which construction, modification or reconstruction commenced after June 29, 1990:

1. Each reactor process not discharging its vent stream into a recovery system.

2. Each combination of a reactor process and the recovery system into which its vent stream is discharged.

3. Each combination of 2 or more reactor processes and the common recovery system into which their vent streams are discharged.

(c) Exemptions from the provisions of par. (a) are as follows:

1. Any reactor process that is designed and operated as a batch operation is not an affected facility.

2. Each affected facility that has a total resource effectiveness (TRE) index value greater than 8.0 is exempt from all provisions of this section except for subs. (3) (c) , (5) (d) , (e) and (f) and (6) (g) , (L) 1. and 6. and (t) .

3. Each affected facility in a process unit with a total design capacity for all chemicals produced within that unit of less than one gigagram per year (1,100 tons per year) is exempt from all provisions of this section except for the recordkeeping and reporting requirements in sub. (6) (i) , (L) 5. and (n) .

4. Each affected facility operated with a vent stream flow rate less than 0.011 scm/min is exempt from all provisions of this section except for the test method and procedure and the recordkeeping and reporting requirements in subs. (5) (g) and (6) (h) , (L) 4. and (o) .

5. If the vent stream from an affected facility is routed to a distillation unit subject to s. NR 440.686 and has no other releases to the air except for a pressure relief valve, the facility is exempt from all provisions of this section except for sub. (6) (r) .

6. Any reactor process operating as part of a process unit which produces beverage alcohols or which uses, contains and produces no VOC is not an affected facility.

7. Any reactor process that is subject to the provisions of s. NR 440.647 is not an affected facility.

8. Each affected facility operated with a concentration of total organic compounds (TOC), less methane and ethane, in the vent stream less than 300 ppmv, as measured by Method 18 in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , or a concentration of TOC in the vent stream less than 150 ppmv, as measured by Method 25A in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , is exempt from all provisions of this section except for the test method and procedure and the reporting and recordkeeping requirements in subs. (5) (h) and (6) (j) , (L) 8. and (p) .

(d)

1. Owners or operators of process vents that are subject to this section may choose to comply with the provisions of 40 CFR part 65 , subpart D, as in effect on December 14, 2000, to satisfy the requirements of subs. (3) to (6) . The provisions of 40 CFR part 65 , subpart D, as in effect on December 14, 2000, also satisfy the criteria of par. (c) 2. , 4. and 8. Other provisions applying to an owner or operator who chooses to comply with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, are provided in 40 CFR 65.1 .

2. Owners or operators who choose to comply with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, shall also comply with ss. NR 440.01 , 440.02 , 440.05 , 440.06 , 440.07 (1) (a) and (d) , 440.14 and 440.15 for those process vents. All sections or subsections from ss. NR 440.01 to 440.19 not specified in this subdivision do not apply to owners or operators of process vents complying with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, except that provisions required to be met prior to implementing 40 CFR part 65 still apply. Owners or operators who choose to comply with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, shall comply with 40 CFR part 65 , subpart A.

3. Owners or operators who choose to comply with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, at initial startup shall comply with subds. 1. and 2. for each vent stream on and after the date on which the initial performance test 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 the initial startup, whichever date comes first.

4. Each owner or operator subject to the provisions of this section that chooses to comply with 40 CFR part 65 , subpart D, as in effect on December 14, 2000, at initial startup shall notify the administrator of the specific provisions of 40 CFR 65.63 (a) (1), (2) or (3), as in effect on December 14, 2000, with which the owner or operator has elected to comply. Notification shall be submitted with the notification of initial startup required by 40 CFR 65.5 (b).

(2)   Definitions. All terms not defined in this section have the meanings given in s. NR 440.02 . In this section:

(a) "Batch operation" means any noncontinuous reactor process that is not characterized by steady state conditions and in which reactants are not added and products are not removed simultaneously.

(b) "Boiler" means any enclosed combustion device that extracts useful energy in the form of steam and is not an incinerator.

(c) "By compound" means by individual stream components, not carbon equivalents.

(d) "Car-seal" means a seal that is placed on a device that is used to change the position of a valve, for example, from opened to closed, in such a way that the position of the valve cannot be changed without breaking the seal.

(e) "Combustion device" means an individual unit of equipment, such as an incinerator, flare, boiler or process heater, used for combustion of a vent stream discharged from the process vent.

(f) "Continuous recorder" means a data recording device recording an instantaneous data value at least once every 15 minutes.

(g) "Flame zone" means the portion of the combustion chamber in a boiler occupied by the flame envelope.

(h) "Flow indicator" means a device which indicates whether gas flow is present in a line.

(i) "Halogenated vent stream" means any vent stream determined to have a total concentration by volume of compounds containing halogens of 20 ppmv, by compound, or greater.

(j) "Incinerator" means an enclosed combustion device that is used for destroying organic compounds. If there is energy recovery, the energy recovery section and the combustion chambers are not of integral design. That is, the energy recovery section and the combustion section are not physically formed into one manufactured or assembled unit but are joined by ducts or connections carrying flue gas.

(k) "Primary fuel" means the fuel fired through a burner or a number of similar burners. The primary fuel provides the principal heat input to the device and the amount of fuel is sufficient to sustain operation without the addition of other fuels.

(L) "Process heater" means a device that transfers heat liberated by burning fuel directly to process streams or to heat transfer liquids other than water.

(m) "Process unit" means equipment assembled and connected by pipes or ducts to produce as intermediates or final products one or more of the chemicals in sub. (8) . A process unit can operate independently if supplied with sufficient feed or raw materials and sufficient product storage facilities.

(n) "Product" means any compound or chemical listed in sub. (8) which is produced for sale as a final product as that chemical or for use in the production of other chemicals or compounds. By-products, co-products and intermediates are considered to be products.

(o) "Reactor processes" means unit operations in which one or more chemicals or reactants, other than air, are combined or decomposed in such a way that their molecular structures are altered and one or more new organic compounds are formed.

(p) "Recovery device" means an individual unit of equipment, such as an absorber, carbon adsorber or condenser, capable of and used for the purpose of recovering chemicals for use, reuse or sale.

(q) "Recovery system" means an individual recovery device or series of recovery devices applied to the same vent stream.

(r) "Relief valve" means a valve used only to release an unplanned, nonroutine discharge. A relief valve discharge results from an operator error, a malfunction such as a power failure or equipment failure or other unexpected cause that requires immediate venting of gas from process equipment in order to avoid safety hazards or equipment damage.

(s) "Secondary fuel" means a fuel fired through a burner other than a primary fuel burner. The secondary fuel may provide supplementary heat in addition to the heat provided by the primary fuel.

(t) "Total organic compounds" or "TOC" means those compounds measured according to the procedures in sub. (5) (b) 4. For the purposes of measuring molar composition as required in sub. (5) (d) 2. a. and b. , hourly emission rate as required in sub. (5) (d) 5. and (e) and TOC concentration as required in sub. (6) (b) 4. and (f) 4. , those compounds which the department has determined do not contribute appreciably to the formation of ozone are to be excluded.

(u) "Total resource effectiveness" or "TRE index value" means a measure of the supplemental total resource requirement per unit reduction of TOC associated with a vent stream from an affected reactor process facility based on vent stream flow rate, emission rate of TOC, net heating value and corrosion properties, whether or not the vent stream contains halogenated compounds as quantified by the equation given under sub. (5) (e) .

(v) "Vent stream" means any gas stream discharged directly from a reactor process to the atmosphere or indirectly to the atmosphere after diversion through other process equipment. The vent stream excludes relief valve discharges and equipment leaks.

(3)   Standards. Each owner or operator of any affected facility shall comply with par. (a) , (b) or (c) for each vent stream on and after the date on which the initial performance test required by s. NR 440.08 and sub. (5) 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 the initial startup, whichever date comes first. Each owner or operator shall either:

(a) Reduce emissions of TOC, less methane and ethane, by 98 weight percent or to a TOC, less methane and ethane, concentration of 20 ppmv on a dry basis corrected to 3% oxygen, whichever is less stringent. If a boiler or process heater is used to comply with this paragraph, then the vent stream shall be introduced into the flame zone of the boiler or process heater; or

(b) Combust the emissions in a flare that meets the requirements of s. NR 440.18 ; or

(c) Maintain a TRE index value greater than 1.0 without use of a VOC emission control device.

(4)   Monitoring of emissions and operations.

(a) The owner or operator of an affected facility that uses an incinerator to seek to comply with the TOC emission limit specified under sub. (3) (a) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment:

1. A temperature monitoring device equipped with a continuous recorder and having an accuracy of " 1% of the temperature being monitored expressed in degrees Celsius or " 0.5 ° C, whichever is greater.

a. Where an incinerator other than a catalytic incinerator is used, a temperature monitoring device shall be installed in the firebox or in the ductwork immediately downstream of the firebox in a position before any substantial heat exchange is encountered.

b. Where a catalytic incinerator is used, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalyst bed.

2. A flow indicator that provides a record of vent stream flow diverted from being routed to the incinerator at least once every 15 minutes for each affected facility, except as provided in subd. 2. b.

a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the incinerator, resulting in its emission to the atmosphere.

b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line.

(b) The owner or operator of an affected facility that uses a flare to seek to comply with sub. (3) (b) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment:

1. A heat sensing device, such as an ultraviolet beam sensor or thermocouple at the pilot light to indicate the continuous presence of a flame.

2. A flow indicator that provides a record of vent stream flow diverted from being routed to the flare at least once every 15 minutes for each affected facility, except as provided in subd. 2. b.

a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the flare, resulting in its emission to the atmosphere.

b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line.

(c) The owner or operator of an affected facility that uses a boiler or process heater to seek to comply with sub. (3) (a) shall install, calibrate, maintain and operate according to the manufacturer's specifications the following equipment:

1. A flow indicator that provides a record of vent stream flow diverted from being routed to the boiler or process heater at least once every 15 minutes for each affected facility, except as provided in subd. 1. b.

a. The flow indicator shall be installed at the entrance to any bypass line that could divert the vent stream from being routed to the boiler or process heater, resulting in its emission to the atmosphere.

b. Where the bypass line valve is secured in the closed position with a car-seal or a lock-and-key type configuration, a flow indicator is not required. A visual inspection of the seal or closure mechanism shall be performed at least once every month to ensure that the valve is maintained in the closed position and the vent stream is not diverted through the bypass line.

2. A temperature monitoring device in the firebox equipped with a continuous recorder and having an accuracy of " 1% of the temperature being monitored expressed in degrees Celsius or " 0.5 ° C, whichever is greater, for boilers or process heaters of less than 44 MW (150 million Btu/hr) design heat input capacity. Any vent stream introduced with primary fuel into a boiler or process heater is exempt from this requirement.

(d) The owner or operator of an affected facility that seeks to demonstrate compliance with the TRE index value limit specified under sub. (3) (c) shall install, calibrate, maintain and operate according to manufacturer's specifications the following equipment unless alternative monitoring procedures or requirements are approved for that facility by the department:

1. Where an absorber is the final recovery device in the recovery system:

a. A scrubbing liquid temperature monitoring device having an accuracy of " 1% of the temperature being monitored expressed in degrees Celsius or " 0.5 ° C, whichever is greater, and a specific gravity monitoring device having an accuracy of " 0.02 specific gravity units, each equipped with a continuous recorder; or

b. An organic monitoring device used to indicate the concentration level of organic compounds exiting the recovery device based on a detection principle such as infrared, photoionization or thermal conductivity, each equipped with a continuous recorder.

2. Where a condenser is the final recovery device in the recovery system:

a. A product side condenser exit temperature monitoring device equipped with a continuous recorder and having an accuracy of " 1% of the temperature being monitored expressed in degrees Celsius or " 0.5 ° C, whichever is greater; or

b. An organic monitoring device used to indicate the concentration level of organic compounds exiting the recovery device based on a detection principle such as infrared, photoionization or thermal conductivity, each equipped with a continuous recorder.

3. Where a carbon adsorber is the final recovery device unit in the recovery system:

a. An integrating steam flow monitoring device having an accuracy of " 10% and a carbon bed temperature monitoring device having an accuracy of " 1% of the temperature being monitored expressed in degrees Celsius or " 0.5 ° C, whichever is greater, both equipped with a continuous recorder; or

b. An organic monitoring device used to indicate the concentration level of organic compounds exiting the recovery device based on a detection principle such as infrared, photoionization or thermal conductivity, each equipped with a continuous recorder.

(e) An owner or operator of an affected facility seeking to demonstrate compliance with the standards specified under sub. (3) with a control device other than an incinerator, boiler, process heater or flare, or a recovery device other than an absorber, condenser or carbon adsorber, shall provide to the administrator information describing the operation of the control device or recovery device and the process parameters which would indicate proper operation and maintenance of the device. The administrator may request further information and will specify appropriate monitoring procedures or requirements.

(5)   Test methods and procedures.

(a) For the purpose of demonstrating compliance with sub. (3) , all affected facilities shall be run at full operating conditions and flow rates during any performance test.

(b) The following methods in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , except as provided under s. NR 440.08 (2) , shall be used as reference methods to determine compliance with the emission limit or percent reduction efficiency specified under sub. (3) (a) :

1. Method 1 or 1A, as appropriate, for selection of the sampling sites. The control device inlet sampling site for determination of vent stream molar composition or TOC, less methane and ethane, reduction efficiency shall be prior to the inlet of the control device and after the recovery system.

2. Method 2, 2A, 2C or 2D, as appropriate, for determination of the gas volumetric flow rates.

3. The emission rate correction factor, integrated sampling and analysis procedure of Method 3B shall be used to determine the oxygen concentration (%O 2d ) for the purposes of determining compliance with the 20 ppmv limit. The sampling site shall be the same as that of the TOC samples, and the samples shall be taken during the same time that the TOC samples are taken. The TOC concentration corrected to 3% O 2 (C c ) shall be computed using the following equation: - See PDF for diagram

4. Method 18 to determine the concentration of TOC in the control device outlet and the concentration of TOC in the inlet when the reduction efficiency of the control device is to be determined.

a. The minimum sampling time for each run shall be one hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at approximately 15-minute intervals.

b. The emission reduction (R) of TOC, minus methane and ethane, shall be determined using the following equation:
where: - See PDF for diagram

c. The mass rates of TOC (E i , E o ) shall be computed using the following equations: - See PDF for diagram - See PDF for diagram

d. The TOC concentration (C TOC ) is the sum of the individual components and shall be computed for each run using the following equation: - See PDF for diagram

5. The requirement for an initial performance test is waived in accordance with s. NR 440.08 (2) for the following:

a. When a boiler or process heater with a design heat input capacity of 44 MW (150 million Btu/hour) or greater is used to seek compliance with sub. (3) (a) .

b. When a vent stream is introduced into a boiler or process heater with the primary fuel.

c. The department reserves the option to require testing at such other times as may be required.

6. For purposes of complying with the 98 weight percent reduction in sub. (3) (a) , if the vent stream entering a boiler or process heater with a design capacity less than 44 MW (150 million Btu/hour) is introduced with the combustion air or as secondary fuel, the weight percent reduction of TOC, minus methane and ethane, across the combustion device shall be determined by comparing the TOC, minus methane and ethane, in all combusted vent streams, primary fuels and secondary fuels with the TOC, minus methane and ethane, exiting the combustion device.

(c) When a flare is used to seek to comply with sub. (3) (b) , the flare shall comply with the requirements of s. NR 440.18 .

(d) The following test methods in Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , except as provided under s. NR 440.08 (2) , shall be used for determining the net heating value of the gas combusted to determine compliance under sub. (3) (b) and for determining the process vent stream TRE index value to determine compliance under subs. (1) (c) 2. and (3) (c) .

1.

a. Method 1 or 1A, as appropriate, for selection of the sampling site. The sampling site for the vent stream flow rate and molar composition determination prescribed in subds. 2. and 3. shall be, except for the situations outlined in subd. 1. b. , prior to the inlet of any control device, prior to any postreactor dilution of the stream with air and prior to any postreactor introduction of halogenated compounds into the process vent stream. No traverse site selection method is needed for vents smaller than 4 inches in diameter.

b. If any gas stream other than the reactor vent stream is normally conducted through the final recovery device:

2. The molar composition of the process vent stream shall be determined as follows:

a. Method 18 to measure the concentration of TOC including those containing halogens.

b. ASTM D1946-90 (reapproved 1994), incorporated by reference in s. NR 440.17 (2) (a) 24. , to measure the concentration of carbon monoxide and hydrogen.

c. Method 4 to measure the content of water vapor.

3. The volumetric flow rate shall be determined using Method 2, 2A, 2C or 2D as appropriate.

4. The net heating value of the vent stream shall be calculated using the following equation: - See PDF for diagram

5. The emission rate of TOC in the vent stream shall be calculated using the following equation: - See PDF for diagram

6. The total vent stream concentration, by volume, of compounds containing halogens (ppmv, by compound) shall be summed from the individual concentrations of compounds containing halogens which were measured by Method 18.

(e) For purposes of complying with subs. (1) (c) 2. and (3) (c) , the owner or operator of a facility affected by this section shall calculate the TRE index value of the vent stream using the equation for incineration in subd. 1. for halogenated vent streams. The owner or operator of an affected facility with a nonhalogenated vent stream shall determine the TRE index value by calculating values using both the incinerator equation in subd. 1. and the flare equation in subd. 2. and selecting the lower of the 2 values.

1. The equation for calculating the TRE index value of a vent stream controlled by an incinerator is as follows: - See PDF for diagram

a. Where for a vent stream flow rate (scm/min) at a standard temperature of 20 ° C that is greater than or equal to 14.2 scm/min:

b. For a vent stream flow rate (scm/min) at a standard temperature of 20 ° C that is less than 14.2 scm/min:

2. The equation for calculating the TRE index value of a vent stream controlled by a flare is as follows: - See PDF for diagram

(f) Each owner or operator of an affected facility seeking to comply with sub. (1) (c) 2. or (3) (c) shall recalculate the TRE index value for that affected facility whenever process changes are made. Examples of process changes include changes in production capacity, feedstock type or catalyst type or whenever there is replacement, removal or addition of recovery equipment. The TRE index value shall be recalculated based on test data or on best engineering estimates of the effects of the change on the recovery system.

1. Where the recalculated TRE index value is less than or equal to 1.0, the owner or operator shall notify the department within one week of the recalculation and shall conduct a performance test according to the methods and procedures required by this subsection in order to determine compliance with sub. (3) (a) or (b) . Performance tests shall be conducted as soon as possible after the process change but no later than 180 days from the time of the process change.

2. Where the recalculated TRE index value is less than or equal to 8.0 but greater than 1.0, the owner or operator shall conduct a performance test in accordance with s. NR 440.08 and this subsection and shall comply with subs. (4) and (6) and this subsection. Performance tests shall be conducted as soon as possible after the process change but no later than 180 days from the time of the process change.

(g) Any owner or operator subject to the provisions of this section seeking to demonstrate compliance with sub. (1) (c) 4. shall use Method 2, 2A, 2C or 2D of Appendix A to 40 CFR part 60 , incorporated by reference in s. NR 440.17 , for determination of volumetric flow rate.

(h) Each owner or operator seeking to demonstrate that a reactor process vent stream has a TOC concentration for compliance with the low concentration exemption in sub. (1) (c) 8. shall conduct an initial test to measure TOC concentration.

1. The sampling site shall be selected as specified in par. (d) 1. a.

2. Method 18 or Method 25A of Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 , shall be used to measure concentration.

3. Where Method 18 is used to qualify for the low concentration exclusion in sub. (1) (c) 8. , the procedures in par. (b) 4. a. and d. shall be used to measure TOC concentration and the procedures of par. (b) 3. shall be used to correct the TOC concentration to 3% oxygen. To qualify for the exclusion, the results shall demonstrate that the concentration of TOC corrected to 3% oxygen is below 300 ppm by volume.

4. Where Method 25A is used, the following procedures shall be used to calculate ppm by volume TOC concentration corrected to 3% oxygen:

a. Method 25A shall be used only if a single organic compound is greater than 50% of total TOC, by volume, in the reactor process vent stream. This compound shall be the principal organic compound.

b. The principal organic compound may be determined by either process knowledge or test data collected using an appropriate reference method. Examples of information that could constitute process knowledge include calculations based on material balances, process stoichiometry or previous test results provided the results are still relevant to the current reactor process vent stream conditions.

c. The principal organic compound shall be used as the calibration gas for Method 25A.

d. The span value for Method 25A shall be 300 ppmv.

e. Use of Method 25A is acceptable if the response from the high level calibration gas is at least 20 times the standard deviation of the response from the zero calibration gas when the instrument is zeroed on the most sensitive scale.

f. The owner or operator shall demonstrate that the concentration of TOC, including methane and ethane, measured by Method 25A, corrected to 3% oxygen, is below 150 ppm by volume to qualify for the low concentration exclusion in sub. (1) (c) 8.

g. The concentration of TOC shall be corrected to 3% oxygen using the procedures and equation in par. (b) 3.

(6)   Reporting and recordkeeping requirements.

(a) Each owner or operator subject to sub. (3) shall notify the department of the specific provisions of sub. (3) (a) , (b) or (c) with which the owner or operator has elected to comply. Notification shall be submitted with the notification of initial startup required by s. NR 440.07 (1) (c) . If an owner or operator elects at a later date to use an alternative provision of sub. (3) with which he or she will comply, then the department shall be notified by the owner or operator 90 days before implementing a change and, upon implementing the change, a performance test shall be performed as specified by sub. (5) no later than 180 days from initial startup.

(b) Each owner or operator subject to the provisions of this section shall keep an up to date, readily accessible record of the following data measured during each performance test, and also include the following data in the report of the initial performance test required under s. NR 440.08 . Where a boiler or process heater with a design heat input capacity of 44 MW (150 million Btu/hour) or greater is used or where the reactor process vent stream is introduced as the primary fuel to any size boiler or process heater to comply with sub. (3) (a) , a report containing performance test data need not be submitted, but a report containing the information in par. (b) 2. a. is required. The same data specified in this subsection shall be submitted in the reports of all subsequently required performance tests where either the emission control efficiency of a combustion device, outlet concentration of TOC or the TRE index value of a vent stream from a recovery system is determined.

1. Where an owner or operator subject to the provisions of this section seeks to demonstrate compliance with sub. (3) (a) through use of either a thermal or catalytic incinerator:

a. The average firebox temperature of the incinerator, or the average temperature upstream and downstream of the catalyst bed for a catalytic incinerator, measured at least every 15 minutes and averaged over the same time period of the performance testing, and

b. The percent reduction of TOC determined as specified in sub. (5) (b) achieved by the incinerator or the concentration of TOC (ppmv, by compound) determined as specified in sub. (5) (b) at the outlet of the control device on a dry basis corrected to 3% oxygen.

2. Where an owner or operator subject to the provisions of this section seeks to demonstrate compliance with sub. (3) (a) through use of a boiler or process heater:

a. A description of the location at which the vent stream is introduced into the boiler or process heater, and

b. The average combustion temperature of the boiler or process heater with a design heat input capacity of less than 44 MW (150 million Btu/hr) measured at least every 15 minutes and averaged over the same time period of the performance testing.

3. Where an owner or operator subject to the provisions of this section seeks to demonstrate compliance with sub. (3) (b) through use of a smokeless flare, flare design, for example, steam-assisted, air-assisted or nonassisted, all visible emission readings, heat content determinations, flow rate measurements and exit velocity determinations made during the performance test, continuous records of the flare pilot flame monitoring, and records of all periods of operations during which the pilot flame is absent.

4. Where an owner or operator subject to the provisions of this section seeks to demonstrate compliance with sub. (3) (c) :

a. Where an absorber is the final recovery device in the recovery system, the exit specific gravity, or alternative parameter which is a measure of the degree of absorbing liquid saturation, if approved by the department, and average exit temperature of the absorbing liquid measured at least every 15 minutes and averaged over the same time period of the performance testing, with both measured while the vent stream is normally routed and constituted; or

b. Where a condenser is the final recovery device in the recovery system, the average product side exit temperature measured at least every 15 minutes and averaged over the same time period of the performance testing while the vent stream is routed and constituted normally; or

c. Where a carbon adsorber is the final recovery device in the recovery system, the total steam mass flow measured at least every 15 minutes and averaged over the same time period of the performance test or full carbon bed cycle, temperature of the carbon bed after regeneration and within 15 minutes of completion of any cooling cycle and duration of the carbon bed steaming cycle with all measured while the vent stream is routed and constituted normally; or

d. As an alternative to subd. 4. a. , b. or c. , the concentration level or reading indicated by the organics monitoring device at the outlet of the absorber, condenser or carbon adsorber measured at least every 15 minutes and averaged over the same time period of the performance testing while the vent stream is normally routed and constituted.

e. All measurements and calculations performed to determine the TRE index value of the vent stream.

(c) Each owner or operator subject to the provisions of this section shall keep up to date, readily accessible continuous records of the equipment operating parameters specified to be monitored under sub. (4) (a) and (c) as well as up to date, readily accessible records of periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. The department may at any time require a report of these data. Where a combustion device is used to comply with sub. (3) (a) , periods of operation during which the parameter boundaries established during the most recent performance tests are exceeded are defined as follows:

1. For thermal incinerators, all 3-hour periods of operation during which the average combustion temperature was more than 28 ° C (50 ° F) below the average combustion temperature during the most recent performance test at which compliance with sub. (3) (a) was determined.

2. For catalytic incinerators, all 3-hour periods of operation during which the average temperature of the vent stream immediately before the catalyst bed is more than 28 ° C (50 ° F) below the average temperature of the vent stream during the most recent performance test at which compliance with sub. (3) (a) was determined. The owner or operator also shall record all 3-hour periods of operation during which the average temperature difference across the catalyst bed is less than 80% of the average temperature difference of the bed during the most recent performance test at which compliance with sub. (3) (a) was determined.

3. All 3-hour periods of operation during which the average combustion temperature was more than 28 ° C (50 ° F) below the average combustion temperature during the most recent performance test at which compliance with sub. (3) (a) was determined for boilers or process heaters with a design heat input capacity of less than 44 MW (150 million Btu/hr) where the vent stream is introduced with the combustion air or as a secondary fuel.

4. For boilers or process heaters, whenever there is a change in the location at which the vent stream is introduced into the flame zone as required under sub. (3) (a) .

(d) Each owner or operator subject to the provisions of this section shall keep records of the following:

1. Up to date, readily accessible continuous records of the flow indication specified under sub. (4) (a) 2. a. , (b) 2. a. and (c) 1. a. as well as up to date, readily accessible records of all periods and the duration when the vent stream is diverted from the control device.

2. Where a seal mechanism is used to comply with sub. (4) (a) 2. b. , (b) 2. b. , and (c) 1. b. , a record of continuous flow is not required. In such cases the owner or operator shall keep up to date, readily accessible records of all monthly visual inspections of the seals as well as readily accessible records of all periods and the duration when the seal mechanism is broken, the bypass line valve position has changed, the serial number of the broken car-seal has changed or when the key for a lock-and-key type configuration has been checked out.

(e) Each owner or operator subject to the provisions of this section shall keep up to date, readily accessible continuous records of the flare pilot flame monitoring specified under sub. (4) (b) as well as up to date, readily accessible records of all periods of operations in which the pilot flame is absent.

(f) Each owner or operator subject to the provisions of this section shall keep up to date, readily accessible continuous records of the equipment operating parameters specified to be monitored under sub. (4) (d) as well as up to date, readily accessible records of periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. The department may at any time require a report of these data. Where an owner or operator seeks to comply with sub. (3) (c) , periods of operation during which the parameter boundaries established during the most recent performance tests are exceeded are defined as follows:

1. Where an absorber is the final recovery device in a recovery system, and where an organic compound monitoring device is not used:

a. All 3-hour periods of operation during which the average absorbing liquid temperature was more than 11 ° C (20 ° F) above the average absorbing liquid temperature during the most recent performance test; or

b. All 3-hour periods of operation during which the average absorbing liquid specific gravity was more than 0.1 unit above or more than 0.1 unit below the average absorbing liquid specific gravity during the most recent performance test unless monitoring of an alternative parameter, which is a measure of the degree of absorbing liquid saturation, is approved by the department in which case the department will define appropriate parameter boundaries and periods of operation during which they are exceeded.

2. Where a condenser is the final recovery device in a system and where an organic compound monitoring device is not used, all 3-hour periods of operation during which the average product side exit condenser operating temperature was more than 6 ° C (11 ° F) above the average product side exit operating temperature during the most recent performance test.

3. Where a carbon adsorber is the final recovery device in a system and where an organic compound monitoring device is not used:

a. All carbon bed regeneration cycles during which the total mass steam flow was more than 10% below the total mass steam flow during the most recent performance test; or

b. All carbon bed regeneration cycles during which the temperature of the carbon bed after regeneration and after completion of any cooling cycle was more than 10% or 5 ° C greater, whichever is less stringent, than the carbon bed temperature in degrees Celsius during the most recent performance test.

4. Where an absorber, condenser or carbon adsorber is the final recovery device in the recovery system and where an organic compound monitoring device is used, all 3-hour periods of operation during which the average organic compound concentration level or reading of organic compounds in the exhaust gases is more than 20% greater than the exhaust gas organic compound concentration level or reading measured by the monitoring device during the most recent performance test.

(g) Each owner or operator of an affected facility subject to the provisions of this section and seeking to demonstrate compliance with sub. (3) (c) shall keep up to date, readily accessible records of:

1. Any changes in production capacity, feedstock type or catalyst type or of any replacement, removal or addition of recovery equipment or reactors;

2. Any recalculation of the TRE index value performed pursuant to sub. (5) (f) ; and

3. The results of any performance test performed pursuant to the methods and procedures required by sub. (5) (d) .

(h) Each owner or operator of an affected facility that seeks to comply with the requirements of this section by complying with the flow rate cutoff in sub. (1) (c) 4. shall keep up to date, readily accessible records to indicate that the vent stream flow rate is less than 0.011 scm/min and of any change in equipment or process operation that increases the operating vent stream flow rate, including a measurement of the new vent stream flow rate.

(i) Each owner or operator of an affected facility that seeks to comply with the requirements of this section by complying with the design production capacity provision in sub. (1) (c) 3. shall keep up to date, readily accessible records of any change in equipment or process operation that increases the design production capacity of the process unit in which the affected facility is located.

(j) Each owner or operator of an affected facility that seeks to comply with the requirements of this section by complying with the low concentration exemption in sub. (1) (c) 8. shall keep up to date, readily accessible records of any change in equipment or process operation that increases the concentration of the vent stream of the affected facility.

(k) Each owner or operator subject to the provisions of this section is exempt from the quarterly reporting requirements contained in s. NR 440.07 (3) .

(L) Each owner or operator that seeks to comply with the requirements of this section by complying with the requirements of sub. (1) (c) 2. , 3. or 4. or (3) shall submit to the department semiannual reports of the following recorded information. The initial report shall be submitted within 6 months after the initial startup date.

1. Exceedances of monitored parameters recorded under pars. (c) , (f) and (g) .

2. All periods and duration recorded under par. (d) when the vent stream is diverted from the control device to the atmosphere.

3. All periods recorded under par. (e) in which the pilot flame of the flare was absent.

4. Any change in equipment or process operation that increases the operating vent stream flow rate above the low flow exemption level in sub. (1) (c) 4. , including a measurement of the new vent stream flow rate, as recorded under par. (h) . These shall be reported as soon as possible after the change and no later than 180 days after the change. These reports may be submitted either in conjunction with semiannual reports or as a single separate report. A performance test shall be completed within the same time period to verify the recalculated flow value and to obtain the vent stream characteristics of heating value and E TOC . The performance test is subject to the requirements of s. NR 440.08 . Unless the facility qualifies for an exemption under any of the exemption provisions listed in sub. (1) (c) , except for the total resource effectiveness index greater than 8.0 exemption in sub. (1) (c) 2. , the facility shall begin compliance with the requirements in sub. (3) .

5. Any change in equipment or process operation as recorded under par. (i) that increases the design production capacity above the low capacity exemption level in sub. (1) (c) 3. and the new capacity resulting from the change for the reactor process unit containing the affected facility. These shall be reported as soon as possible after the change and no later than 180 days after the change. These reports may be submitted either in conjunction with semiannual reports or as a single separate report. A performance test shall be completed within the same time period to obtain the vent stream flow rate, heating value and E TOC . The performance test is subject to the requirements of s. NR 440.08 . The facility shall begin compliance with the requirements in sub. (1) (d) or (3) . If the facility chooses to comply with sub. (3) , the facility may qualify for an exemption under sub. (1) (c) 2. , 4. or 8.

6. Any recalculation of the TRE index value as recorded under par. (g) .

7. All periods recorded under par. (d) in which the seal mechanism is broken or the by-pass line valve position has changed. A record of the serial number of the car-seal or a record to show that the key to unlock the bypass line valve was checked out shall be maintained to demonstrate the period, the duration and frequency in which the bypass line was operated.

8. Any change in equipment or process operation that increases the vent stream concentration above the low concentration exemption level in sub. (1) (c) 8. , including a measurement of the new vent stream concentration as recorded under par. (j) . These shall be reported as soon as possible after the change and no later than 180 days after the change. These reports may be submitted either in conjunction with semiannual reports or as a single separate report. If the vent stream concentration is above 300 ppmv as measured using Method 18 of Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 (1) , or above 150 ppmv as measured using Method 25A of Appendix A of 40 CFR part 60 , incorporated by reference in s. NR 440.17 (1) , a performance test shall be completed within the same time period to obtain the vent stream flow rate, heating value and E TOC . The performance test is subject to the requirements of s. NR 440.08 . Unless the facility qualifies for an exemption under any of the exemption provisions listed in sub. (1) (c) , except for the TRE index greater than 8.0 exemption in sub. (1) (c) 2. , the facility shall begin compliance with the requirements in sub. (3) .

(n) Each owner or operator that seeks to demonstrate compliance with sub. (1) (c) 3. shall submit to the department an initial report detailing the design production capacity of the process unit.

(o) Each owner or operator that seeks to demonstrate compliance with sub. (1) (c) 4. shall submit to the department an initial report including a flow rate measurement using the test methods specified in sub. (5) .

(p) Each owner or operator that seeks to demonstrate compliance with sub. (1) (c) 8. shall submit to the department an initial report including a concentration measurement using the test method specified in sub. (5) .

(q) The department shall specify appropriate reporting and recordkeeping requirements where the owner or operator of an affected facility complies with the standards specified under sub. (3) other than as provided under sub. (4) (a) , (b) , (c) and (d) .

(r) Each owner or operator whose reactor process vent stream is routed to a distillation unit subject to s. NR 440.686 and who seeks to demonstrate compliance with sub. (1) (c) 5. shall submit to the department a process design description as part of the initial report. This process design description shall be retained for the life of the process. No other records or reports are required unless process changes are made.

(s) Each owner or operator who seeks to demonstrate compliance with sub. (3) (a) or (b) using a control device shall maintain on file a schematic diagram of the affected vent streams, collection system, fuel systems, control devices and bypass systems as part of the initial report. This schematic diagram shall be retained for the life of the system.

(t) Each owner or operator that seeks to demonstrate compliance with sub. (1) (c) 2. shall maintain a record of the initial test for determining the total resource effectiveness index and the results of the initial total resource effectiveness index calculation.

(7)   Reconstruction.

(a) For purposes of this section "fixed capital cost of the new components," as used in s. NR 440.15 , includes the fixed capital cost of all depreciable components which are or will be replaced pursuant to all continuous programs of component replacement which are commenced within any 2 year period following June 29, 1990. For purposes of this paragraph,"commenced" means that an owner or operator has undertaken a continuous program of component replacement or that an owner or operator has entered into a contractual obligation to undertake and complete, within a reasonable time, a continuous program of component replacement.

(8)   Chemicals affected by this section. - See PDF for table

History: Cr., Register, December, 1995, No. 480 , eff. 1-1-96; CR 06-109 : am. (1) (c) 2., 3. and 4., (5) (d) 2. b. and 4., (e) 1. a. and (f) 1., (6) (L) 1., 4., 5. and 8. and (8), cr. (1) (d) Register May 2008 No. 629 , eff. 6-1-08; correction in (1) (d) 2. made under s. 13.92 (4) (b) 7. , Stats., Register May 2008 No. 629 .

Note

The intent of these standards is to minimize emissions of VOC through the application of best demonstrated technology (BDT). The numerical emission limits in these standards are expressed in terms of TOC, measured as TOC less methane and ethane. This emission limit reflects the performance of BDT. Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 C c is the concentration of TOC corrected to 3% O 2 , dry basis ppm by volume Microsoft Windows NT 6.1.7601 Service Pack 1 C TOC is the concentration of TOC minus methane and ethane, dry basis ppm by volume Microsoft Windows NT 6.1.7601 Service Pack 1 %O 2d is the concentration of O 2 , dry basis percent by volume Microsoft Windows NT 6.1.7601 Service Pack 1 R is the emission reduction, percent by weight Microsoft Windows NT 6.1.7601 Service Pack 1 E i is the mass rate of TOC entering the control device, kg TOC/hr Microsoft Windows NT 6.1.7601 Service Pack 1 E o is the mass rate of TOC discharged to the atmosphere, kg TOC/hr Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 C ij , C oj is the concentration of sample component "j" of the gas stream at the inlet and outlet of the control device, respectively, dry basis ppm by volume Microsoft Windows NT 6.1.7601 Service Pack 1 M ij , M oj is the molecular weight of sample component "j" of the gas stream at the inlet and outlet of the control device, respectively, g/g-mole (lb/lb-mole) Microsoft Windows NT 6.1.7601 Service Pack 1 Q i , Q o is the flow rate of gas stream at the inlet and outlet of the control device respectively, dscm/min (dscf/hr) Microsoft Windows NT 6.1.7601 Service Pack 1 K 2 is a constant, 2.494 10 -6 (l/ppm) (g-mole/scm) (kg/g) (min/hr), where standard temperature for g-mole/scm is 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 C TOC is the concentration of TOC, minus methane and ethane, dry basis ppm by volume Microsoft Windows NT 6.1.7601 Service Pack 1 C j is the concentration of sample components "j", dry basis ppm by volume Microsoft Windows NT 6.1.7601 Service Pack 1 n is the number of components in the sample Microsoft Windows NT 6.1.7601 Service Pack 1 1) The sampling site for vent stream flow rate and molar composition shall be prior to the final recovery device and prior to the point at which any nonreactor stream or stream from a nonaffected reactor process is introduced. Microsoft Windows NT 6.1.7601 Service Pack 1 2) The efficiency of the final recovery device is determined by measuring the TOC concentration using Method 18 at the inlet to the final recovery device after the introduction of any vent stream and at the outlet of the final recovery device. Microsoft Windows NT 6.1.7601 Service Pack 1 3) This efficiency of the final recovery device shall be applied to the TOC concentration measured prior to the final recovery device and prior to the introduction of any nonreactor stream or stream from a nonaffected reactor process to determine the concentration of TOC in the reactor process vent stream from the final recovery device. This concentration of TOC is then used to perform the calculations outlined in subds. 4. and 5. Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 H T is the net heating value of the sample, MJ/scm, where the net enthalpy per mole of vent stream is based on combustion at 25 ° C and 760 mm Hg but the standard temperature for determining the volume corresponding to one mole is 20 ° C as in the definition of Q s (vent stream flow rate) Microsoft Windows NT 6.1.7601 Service Pack 1 K 1 is a constant, 1.740 10 -7 (l/ppm) (g-mole/scm) (MJ/kcal), where standard temperature for (g-mole/scm) is 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 C j is the concentration on a dry basis of compound "j" in ppm as measured for organics by Method 18 and measured for hydrogen and carbon monoxide by ASTM D1946-90 (reapproved 1994), incorporated by reference in s. NR 440.17 (2) (a) 24. , as indicated in subd. 2. Microsoft Windows NT 6.1.7601 Service Pack 1 H j is the net heat of combustion of compound "j", kcal/g-mole, based on combustion at 25 ° C and 760 mm Hg. The heats of combustion of vent stream components would be required to be determined using ASTM D2382-88 or D4809-95, incorporated by reference in s. NR 440.17 (2) (a) 30. and 61. , if published values are not available or cannot be calculated Microsoft Windows NT 6.1.7601 Service Pack 1 B ws is the water vapor content of the vent stream, proportion by volume Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 E TOC is the emission rate of TOC in the sample, kg/hr Microsoft Windows NT 6.1.7601 Service Pack 1 K 2 is a constant, 2.494 10 -6 (l/ppm) (g-mole/scm) (kg/g) (min/hr), where standard temperature for (g-mole/scm) is 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 C j is the concentration on a dry basis of compound "j" in ppm as measured by Method 18 as indicated in subd. 2. Microsoft Windows NT 6.1.7601 Service Pack 1 M j is the molecular weight of sample "j", g/g-mole Microsoft Windows NT 6.1.7601 Service Pack 1 Q s is the vent stream flow rate (dscm/min) at a temperature of 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 TRE is the TRE index value Microsoft Windows NT 6.1.7601 Service Pack 1 Q s is the vent stream flow rate (scm/min) at a standard temperature of 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 H T is the vent stream net heating value (MJ/scm), where the net enthalpy per mole of vent stream is based on combustion at 25 ° C and 760 mm Hg but the standard temperature for determining the volume corresponding to one mole is 20 ° C as in the definition of Q s Microsoft Windows NT 6.1.7601 Service Pack 1 Y s is Q s for all vent stream categories listed in Table 1 except for Category E vent streams where Y s = (Q s ) (H T )/3.6 Microsoft Windows NT 6.1.7601 Service Pack 1 E TOC is the hourly emissions of TOC reported in kg/hr Microsoft Windows NT 6.1.7601 Service Pack 1 a, b, c, d, e and f are coefficients. The set of coefficients that apply to a vent stream can be obtained from Table 1. Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for table Microsoft Windows NT 6.1.7601 Service Pack 1 TRE is the TRE index value Microsoft Windows NT 6.1.7601 Service Pack 1 Q s is 14.2 scm/min Microsoft Windows NT 6.1.7601 Service Pack 1 H T = (FLOW) (HVAL)/14.2 Microsoft Windows NT 6.1.7601 Service Pack 1 where the following inputs are used: Microsoft Windows NT 6.1.7601 Service Pack 1 FLOW is the vent stream flow rate (scm/min) at a standard temperature of 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 HVAL is the vent stream net heating value (MJ/scm) where the net enthalpy per mole of vent stream is based on combustion at 25 ° C and 760 mm Hg but the standard temperature for determining the volume corresponding to one mole is 20 ° C as in the definition of Q s Microsoft Windows NT 6.1.7601 Service Pack 1 Y s is 14.2 scm/min for all vent streams except for Category E vent streams where Y s = (14.2) (H T )/3.6 Microsoft Windows NT 6.1.7601 Service Pack 1 E TOC is the hourly emissions of TOC reported in kg/hr Microsoft Windows NT 6.1.7601 Service Pack 1 a, b, c, d, e and f are coefficients. The set of coefficients that apply to a vent stream can be obtained from Table 1. Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1 TRE is the TRE index value Microsoft Windows NT 6.1.7601 Service Pack 1 E TOC is the hourly emission rate of TOC reported in kg/hr Microsoft Windows NT 6.1.7601 Service Pack 1 Q s is the vent stream flow rate (scm/min) at a standard temperature of 20 ° C Microsoft Windows NT 6.1.7601 Service Pack 1 H T is the vent stream net heating value (MJ/scm) where the net enthalpy per mole of offgas is based on combustion at 25 ° C and 760 mm Hg but the standard temperature for determining the volume corresponding to one mole is 20 ° C as in the definition of Q s Microsoft Windows NT 6.1.7601 Service Pack 1 a, b, c, d and e are coefficients. The set of coefficients that apply to a vent stream can be obtained from Table 2. - See PDF for table Microsoft Windows NT 6.1.7601 Service Pack 1 Microsoft Windows NT 6.1.7601 Service Pack 1 1CAS numbers refer to the Chemical Abstracts Registry numbers assigned to specific chemicals, isomers or mixtures of chemicals. Some isomers or mixtures that are covered by the standards do not have CAS numbers assigned to them. The standards apply to all of the chemicals listed whether CAS numbers have been assigned or not. Microsoft Windows NT 6.1.7601 Service Pack 1