NR 440.647(3)(a)(a) Each owner or operator of a polypropylene, low density polyethylene or high density polyethylene process line containing a process section subject to the provisions of this section shall comply with the provisions in this subsection on and after the date on which the initial performance test required by
s. NR 440.08 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 initial startup, whichever comes first.
NR 440.647(3)(a)1.
1. 'Continuous emissions.' For each vent stream that emits continuous emissions from an affected facility as defined in
sub. (1) (a) 1., the owner or operator shall use the procedures identified in
subd. 1. b. and
c. for determining which continuous emissions are to be controlled and which level of control listed in
subd. 1. a. is to be met. The owner or operator shall use the procedures identified in
subd. 1. b. and
c. each time a process section is constructed, modified or reconstructed at the plant site.
NR 440.647(3)(a)1.a.
a. Level of control. Continuous emission streams determined to be subject to control pursuant to the procedures identified in
subd. 1. b. and
c., as applicable, shall meet one of the control levels identified in
subd. 1. a. 1) to 4). The procedures in
subd. 1. b. and
c. identify which level of control may be met. The level of control identified in
subd. 1. a. 4) is limited to certain continuous emission streams, which are identified through the procedures in
subd. 1. b. and
c.
1) Reduce emissions of total organic compounds (minus methane and ethane) (TOC) by 98 weight percent, or to a concentration of 20 parts per million by volume (ppmv) on a dry basis, whichever is less stringent. The TOC is expressed as the sum of the actual compounds, not carbon equivalents. If an owner or operator elects to comply with the 20 ppmv standard, the concentration shall include a correction to 3% oxygen only when supplemental combustion air is used to combust the vent stream.
2) Combust the emissions in a boiler or process heater with a design heat input capacity of 150 million Btu/hr or greater by introducing the vent stream into the flame zone of the boiler or process heater. If a boiler or process heater of lesser design heat capacity may be used, it shall demonstrate compliance with subd. 1. a. 1).
3) Combust the emissions in a flare that meets the conditions specified in
s. NR 440.18. If the flare is used to control both continuous and intermittent emissions, the flare shall meet the conditions specified in
s. NR 440.18 at all times, that is, when controlling continuous emissions alone or when controlling both continuous and intermittent emissions.
4) Vent the emissions to a control device located on the plant site.
NR 440.647(3)(a)1.b.
b. Uncontrolled continuous emissions. For each vent stream that emits continuous emissions from an affected facility as defined in
sub. (1) (a) 1. and that is not controlled in an existing control device, the owner or operator shall use the procedures identified in Table 3 to identify those continuous emissions from each constructed, modified or reconstructed affected facility that are to be controlled. The owner shall include in the procedure all uncontrolled continuous vent streams from previously constructed, modified, or reconstructed affected facilities at the plant site each time a process section is constructed, modified or reconstructed at the plant site. In applying the procedures shown in Table 3, the stream characteristics may be either measured or calculated as specified in
sub. (6) (d). For modified or reconstructed affected facilities, these stream characteristics are to be determined after a modification or reconstruction determination has been made by the department, but before any actual changes have been undertaken, and then again after the actual changes have been made. Figure 1 provides a summary overview of the control determination procedure described in Table 3.
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a Individual streams excluded under sub. (1) (g) from the requirements of sub. (3) are to be excluded from all calculations in this table. This paragraph exempts all individual emission streams with individual uncontrolled annual emission rates of less than 1.6 Mg/yr and all individual emission streams with individual TOC concentrations of less than 0.10% TOC by weight.
b For the 0.10 to less than 5.5 weight percent range, the following equations are used:
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where
a = (0.12 - weight percent TOC) 2.5
c = (0.3 - weight percent TOC) 2
d = (0.4 - weight percent TOC) 1.5
For the 5.5 to less than 20 weight percent range, the following equations are used:
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where:
Decision Making Process for Uncontrolled Continuous Emissions from Polypropylene and Polyethylene Affected Facilities
NR 440.647(3)(a)1.c.
c. Controlled continuous emissions. For each vent stream that emits continuous emissions from an affected facility as defined in
sub. (1) (a) 1. and that is controlled in an existing control device, each owner or operator shall determine whether the emissions entering the control device are greater than or equal to the calculated threshold emissions (CTE) level, which is to be calculated using the TOC concentration of the inlet vent stream and the equations in footnote b of Table 3. If the inlet stream's TOC concentration is equal to or greater than 20 weight percent, the calculated threshold emissions level is 18.2 Mg/yr (20.1 ton/yr). If multiple emission streams are vented to the control device, the individual streams are not to be separated into individual weight percent ranges for calculation purposes as would be done for uncontrolled emission streams. Emissions vented to an existing control device are required to be controlled as described in
subd. 1. c. 1) and 2). Figure 2 illustrates the control determination procedure for controlled continuous emissions.
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See PDF for diagram NOTE: There are no individual stream exemptions from emissions already controlled by existing control devices.
Figure 2.
Decision Making Process for Continuous Emissions
Already Controlled at Polypropylene and Polyethylene Affected Facilities.
1) If the annual emissions of the stream entering the control device are equal to or greater than the CTE levels, then compliance with one of the requirements identified in subd. 1. a. 1), 2) or 3) is required when the control device is reconstructed or replaced or has its operating conditions modified as a result of state or local regulations, including changes in the operating permit, including those instances where the control device is reconstructed, replaced or modified in its operation at the same time the existing process section is modified or reconstructed and becomes an affected facility. If the existing control device already complies with one of the requirements identified in subd. 1. a. 1), 2) or 3) no further control is required.
2) If the annual emissions of the stream entering the control device are less than the CTE level, then the requirements of subd. 1. a. 1), 2) or 3) are not applicable at that time. However, if the control device is replaced, reconstructed or modified at a later date, each owner or operator shall reevaluate the applicability of these standards. This is done by combining with the vent stream entering the control device any uncontrolled vent streams in the same weight percent range as the controlled vent stream and determining whether the annual emissions of the stream entering the control device plus the applicable uncontrolled vent streams are greater than or equal to the CTE level, which is based on the weighted TOC concentration of the controlled vent stream and the uncontrolled vent streams. If the annual emissions entering the control device, including the applicable uncontrolled vent streams, are greater than or equal to the CTE level, then compliance with one of the requirements identified in subd. 1. a. 1), 2) or 3) is required at that time for both the controlled and uncontrolled vent streams. If the annual emissions are less than the CTE level, compliance with these standards is again not required at such time. However, if the control device is again replaced, reconstructed or modified, each owner or operator shall repeat this determination procedure.
NR 440.647(3)(a)2.
2. 'Intermittent emissions.' The owner or operator shall control each vent stream that emits intermittent emissions from an affected facility as defined in
sub. (1) (a) 1. by meeting one of the control requirements specified in
subd. 2. a. and
b. If a vent stream that emits intermittent emissions is controlled in an existing flare, incinerator, boiler or process heater, the requirements of this paragraph are waived until such time the control device is reconstructed or replaced or is modified in its operating conditions as a result of state or local regulation, including changes in the operating permit. This paragraph does not apply to emergency vent streams exempted by
sub. (1) (h) and as defined in
sub. (2).
1) Designed for and operated with no visible emissions, except for periods not to exceed a total of 5 minutes during any 2 consecutive hours,
2) Operated with a flame present at all times, and
3) Designed to maintain a stable flame.
NR 440.647(3)(a)2.b.
b. Combust the emissions in an incinerator, boiler or process heater. The emissions shall be introduced into the flame zone of a boiler or process heater.
NR 440.647(3)(b)
(b) Each owner or operator of a polystyrene process line containing process sections subject to the provisions of this section shall comply with the provisions in this subsection on and after the date on which the initial performance test required by
s. NR 440.08 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 initial startup, whichever comes first. Each owner or operator of a polystyrene process line using a continuous process shall:
NR 440.647(3)(b)1.
1. Limit the continuous TOC emissions from the material recovery section by complying with one of the following:
NR 440.647(3)(b)1.a.
a. Not allow continuous TOC emissions to be greater than 0.0036 kg TOC/Mg (0.0072 lb TOC/ton) product.
NR 440.647(3)(b)1.b.
b. Not allow the outlet gas stream temperature from each final condenser in the material recovery section to exceed -25
°C (-13
°F). For purposes of this standard, temperature excursions above this limit may not be considered a violation when the excursions occur during periods of startup, shutdown or malfunction.
NR 440.647(3)(b)2.
2. If continuous TOC emissions from the material recovery section are routed through an existing emergency vapor recovery system, then compliance with these standards is required when the emergency vapor recovery system undergoes modification, reconstruction or replacement. In such instances, compliance with these standards shall be achieved no later than 180 days after completion of the modification, reconstruction or replacement.
NR 440.647(3)(c)
(c) Each owner or operator of a poly(ethylene terephthalate) process line containing process sections subject to the provisions of this section shall comply with the provisions in this subsection on and after the date on which the initial performance test required by
s. NR 440.08 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 initial startup, whichever comes first.
NR 440.647(3)(c)1.
1. Each owner or operator of a PET process line using a dimethyl terephthalate process shall:
NR 440.647(3)(c)1.a.
a. Limit the continuous TOC emissions from the material recovery section, that is, methanol recovery, by complying with one of the following:
1) Not allow the continuous TOC emissions to be greater than 0.018 kg TOC/Mg (0.040 lb TOC/ton) product.
2) Not allow the outlet gas stream temperature from each final condenser in the material recovery section, that is, methanol recovery, to exceed + 3°C (+ 37°F). For purposes of this standard, temperature excursions above this limit will not be considered a violation when the excursions occur during periods of startup, shutdown or malfunction.
NR 440.647(3)(c)1.b.
b. Limit the continuous TOC emissions and, if steam-jet ejectors are used to provide vacuum to the polymerization reactors, the ethylene glycol concentration from the polymerization reaction section by complying with the following appropriate standard. The ethylene glycol concentration limits specified in
subd. 1. b. 2) and 3) shall be determined by the procedures specified in
sub. (6) (j).
1) Not allow continuous TOC emissions from the polymerization reaction section, including emissions from any equipment used to further recover the ethylene glycol, but excluding those emissions from the cooling tower, to be greater than 0.020 kg TOC/Mg (0.044 lb TOC/ton) product.
2) If steam-jet ejectors are used as vacuum producers and a low viscosity product is being produced using single or multiple end finishers or a high viscosity product is being produced using a single end finisher, maintain the concentration of ethylene glycol in the liquid effluent exiting the vacuum system servicing the polymerization reaction section at or below 0.35% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
3) If steam-jet ejectors are used as vacuum producers and a high viscosity product is being produced using multiple end finishers, maintain an ethylene glycol concentration in the cooling tower at or below 6.0% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
NR 440.647(3)(c)2.
2. Each owner or operator of a PET process line using a terephthalic acid process shall:
NR 440.647(3)(c)2.a.
a. Not allow the continuous TOC emissions from the esterification vessels in the raw materials preparation section to be greater than 0.040 kg TOC/Mg (0.088 lb TOC/ton) product.
NR 440.647(3)(c)2.b.
b. Limit the continuous TOC emissions and, if steam-jet ejectors are used to provide vacuum to the polymerization reactors, the ethylene glycol concentration from the polymerization reaction section by complying with the following appropriate standard. The ethylene glycol concentration limits specified in
subd. 2. b. 2) and 3) shall be determined by the procedures specified in
sub. (6) (j).
1) Not allow continuous TOC emissions from the polymerization reaction section, including emissions from any equipment used to further recover the ethylene glycol, but excluding those emissions from the cooling tower, to be greater than 0.020 kg TOC/Mg (0.044 lb TOC/ton) product.
2) If steam-jet ejectors are used as vacuum producers and a low viscosity product is being produced using single or multiple end finishers or a high viscosity product is being produced using a single end finisher, maintain the concentration of ethylene glycol in the liquid effluent exiting the vacuum system servicing the polymerization reaction section at or below 0.35% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
3) If steam-jet ejectors are used as vacuum producers and a high viscosity product is being produced using multiple end finishers, maintain an ethylene glycol concentration in the cooling tower at or below 6.0% by weight, averaged on a daily basis over a rolling 14-day period of operating days.
NR 440.647(3)(d)
(d) Closed vent systems and control devices used to comply with this section shall be operated at all times when emissions may be vented to them.
NR 440.647(3)(e)
(e) Vent systems that contain valves that could divert a vent stream from a control device shall have car-sealed opened all valves in the vent system from the emission source to the control device and car-sealed closed all valves in vent system that would lead the vent stream to the atmosphere, either directly or indirectly, bypassing the control device.
NR 440.647(4)(a)(a) Each owner or operator of an affected facility subject to the provisions of this section shall comply with the requirements specified in
s. NR 440.62 (3) as soon as practicable, but no later than 180 days after initial startup, except that indications of liquids dripping from bleed ports in existing pumps in light liquid service are not considered to be a leak as defined in
s. NR 440.62 (3) (b) 2. b. For purposes of this standard, a “bleed port" is a technologically-required feature of the pump whereby polymer fluid used to provide lubrication, cooling, or both, of the pump shaft exits the pump, thereby resulting in a visible leak of fluid. This exemption expires when the existing pump is replaced or reconstructed.
NR 440.647(4)(c)
(c) An owner or operator may apply to the administrator for a determination of equivalency for any means of emission limitation that achieves a reduction in emissions of VOC at least equivalent to the reduction in emissions of VOC achieved by the controls required in this section. In doing so, the owner or operator shall comply with requirements specified in
40 CFR 60.484, as in effect on July 1, 1994.
NR 440.647(4)(d)
(d) Each owner or operator subject to the provisions of this section shall comply with the provisions specified in
s. NR 440.62 (6) except an owner or operator may use the following provision in addition to
s. NR 440.62 (6) (e). Equipment is in light liquid service if the percent evaporated is greater than 10% at 150
°C (302
°F) as determined by ASTM D86-96, incorporated by reference in
s. NR 440.17 (2) (a) 7.
NR 440.647(5)(a)(a) Whenever a particular item of monitoring equipment specified in this subsection is to be installed, the owner or operator shall install, calibrate, maintain and operate according to manufacturer's specifications that item as follows:
NR 440.647(5)(a)1.
1. A temperature monitoring device to measure and record continuously the operating temperature to within 1% (relative to degrees Celsius) or
"0.5
°C (
"0.9
°F), whichever is greater.
NR 440.647(5)(a)2.
2. A flame monitoring device, such as a thermocouple, an ultra-violet sensor, an infrared beam sensor or similar device to indicate and record continuously whether a flare or pilot light flame is present, as specified.
NR 440.647(5)(a)3.
3. A flow monitoring indicator to indicate and record whether or not flow exists at least once every 15 minutes.
NR 440.647(5)(a)4.
4. An organic monitoring device, based on a detection principle such as infrared, photoionization or thermal conductivity, to indicate and record continuously the concentration level of organic compounds.
NR 440.647(5)(a)5.
5. A specific gravity monitoring device to measure and record continuously to within 0.02 specific gravity unit.
NR 440.647(5)(b)
(b) The owner or operator shall install, as applicable, the monitoring equipment for the control means used to comply with
sub. (3) except
sub. (3) (a) 1. a. 4) as follows:
NR 440.647(5)(b)1.a.
a. For a noncatalytic incinerator, a temperature monitoring device shall be installed in the firebox.
NR 440.647(5)(b)1.b.
b. For a catalytic incinerator, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalytic bed.
NR 440.647(5)(b)2.a.
a. A flame monitoring device shall be installed to indicate the presence of a flare flame or a flame for each pilot light, if the flare is used to comply with
sub. (3) (a) 1. including those flares controlling both continuous and intermittent emissions.
NR 440.647(5)(b)2.b.
b. A thermocouple or equivalent monitoring device to indicate the presence of a flame at each pilot light, if used to comply with
sub. (3) (a) 2.
NR 440.647(5)(b)3.a.
a. If the boiler or process heater has a heat input design capacity of less than 150 million Btu/hr, a temperature monitoring device shall be installed between the radiant section and the convection zone for watertube boilers and between the furnace, combustion zone, and the firetubes for firetube boilers.
NR 440.647(5)(b)3.b.
b. If the boiler or process heater has a heat input design capacity of 150 million Btu/hr or greater, records to indicate the periods of operation of the boiler or process heater shall be maintained. The records shall be readily available for inspection.
NR 440.647(5)(b)4.a.
a. A temperature monitoring device and a specific gravity monitoring device for the scrubber liquid shall be installed; or
NR 440.647(5)(b)4.b.
b. An organic monitoring device shall be installed at the outlet of the absorber.
NR 440.647(5)(b)5.a.
a. A temperature monitoring device shall be installed at the condenser exit (product side); or
NR 440.647(5)(b)5.b.
b. An organic monitoring device shall be installed at the outlet of the condenser.
NR 440.647(5)(b)6.
6. If a carbon adsorber is the final unit in a system, an organic monitoring device shall be installed at the outlet of the carbon bed.
NR 440.647(5)(c)
(c) Owners or operators of control devices used to comply with the provisions of this section, except
sub. (3) (a) 1. a. 4) shall monitor these control devices to ensure that they are operated and maintained in conformance with their designs.
