NR 440.66 History
History: Cr.
Register, September, 1986, No. 369, eff. 10-1-86; am. (1) (c) (2) (intro.), (3) (c), (4) (b) 2. and (a),
Register, September, 1990, No. 417, eff. 10-1-90
; am. (3) (c),
Register, December, 1995, No. 480, eff. 1-1-96;
CR 06-109: am. (title), and (4) (b) 2. and (d) Register May 2008 No. 629, eff. 6-1-08.
NR 440.67
NR 440.67 Synthetic fiber production facilities. NR 440.67(1)(1)
Applicability and designation of affected facility. NR 440.67(1)(a)(a) Except as provided in
par. (b), the affected facility to which the provisions of this section apply is each solvent-spun synthetic fiber process that produces more than 500 Mg (551 ton) of fiber per year.
NR 440.67(1)(b)
(b) The provisions of this section do not apply to any facility that uses the reaction spinning process to produce spandex fiber or the viscose process to produce rayon fiber.
NR 440.67(1)(c)
(c) The provisions of this section apply to each facility as identified in
par. (a) that commences construction or reconstruction after November 23, 1982. The provisions of this section do not apply to facilities that commence modification but not reconstruction after November 23, 1982.
NR 440.67(2)
(2) Definitions. As used in this section, terms not defined in this subsection have the meanings given in
s. NR 440.02.
NR 440.67(2)(a)
(a) “Acrylic fiber" means a manufactured synthetic fiber in which the fiber-forming substance is any long-chain synthetic polymer composed of at least 85% by weight of acrylonitrile units.
NR 440.67(2)(b)
(b) “Makeup solvent" means the solvent introduced into the affected facility that compensates for solvent lost from the affected facility during the manufacturing process.
NR 440.67(2)(c)
(c) “Nongaseous losses" means the solvent that is not volatilized during fiber production and escapes the process and is unavailable for recovery or is in a form or concentration unsuitable for economical recovery.
NR 440.67(2)(d)
(d) “Polymer" means any of the natural or synthetic compounds as usually high molecular weight that consist of many repeated links each link being a relatively light and simple molecule.
NR 440.67(2)(e)
(e) “Precipitation bath" means the water, solvent, or other chemical bath into which the polymer or prepolymer (partially reacted material) solution is extruded and causes physical or chemical changes to occur in the extruded solution to result in a semihardened polymeric fiber.
NR 440.67(2)(f)
(f) “Rayon fiber" means a manufactured fiber composed of regenerated cellulose as well as manufactured fibers composed of regenerated cellulose in which substituents have replaced not more than 5 percent of the hydrogens of the hydroxyl groups.
NR 440.67(2)(g)
(g) “Reaction spinning process" means the fiber-forming process where a prepolymer is extruded into a fluid medium and solidification takes place by chemical reaction to form the final polymeric material.
NR 440.67(2)(h)
(h) “Recovered solvent" means the solvent captured from liquid and gaseous process streams that is concentrated in a control device and that may be purified for reuse.
NR 440.67(2)(i)
(i) “Solvent feed" means that the solvent introduced into the spinning solution preparation system or precipitation bath. This feed stream includes the combination of recovered solvent and makeup solvent.
NR 440.67(2)(j)
(j) “Solvent inventory variation" means the normal changes in the total amount of solvent contained in the affected facility.
NR 440.67(2)(k)
(k) “Solvent recovery system" means the equipment associated with capture, transportation, collection, concentration and purification of organic solvents. It may include enclosures, hoods, ducting, piping, scrubbers, condensers, carbon adsorbers, distillation equipment and associated storage vessels.
NR 440.67(2)(L)
(L) “Solvent-spun synthetic fiber" means any synthetic fiber produced by a process that uses an organic solvent in the spinning solution, the precipitation bath, or processing of the spun fiber.
NR 440.67(2)(m)
(m) “Solvent-spun synthetic fiber process" means the total of all equipment having a common spinning solution preparation system or a common solvent recovery system and is used in the manufacture of solvent-spun synthetic fiber. It includes spinning solution preparation, spinning, fiber processing and solvent recovery but does not include the polymer production equipment.
NR 440.67(2)(n)
(n) “Spandex fiber" means a manufactured fiber in which the fiber-forming substance is a long chain synthetic polymer comprised of at least 85% of a segmented polyurethane.
NR 440.67(2)(o)
(o) “Spinning solution" means the mixture of polymer, prepolymer, or copolymer and additives dissolved in solvent. The solution is prepared at a viscosity and solvent-to-polymer ratio that is suitable for extrusion into fibers.
NR 440.67(2)(p)
(p) “Spinning solution preparation system" means the equipment used to prepare spinning solutions; the system includes equipment for mixing, filtering, blending and storage of the spinning solutions.
NR 440.67(2)(q)
(q) “Synthetic fiber" means any fiber composed partially or entirely of materials made by chemical synthesis or made partially or entirely from chemically-modified naturally-occurring materials.
NR 440.67(2)(r)
(r) “Viscose process" means the fiber forming process where cellulose and concentrated caustic soda are reacted to form soda or alkali cellulose. This reacts with carbon disulfide to form sodium cellulose xanthate which is then dissolved in a solution of caustic soda. The solution is spun into an acid coagulating bath after ripening. This precipitates the cellulose in the form of a regenerated cellulose filament.
NR 440.67(3)
(3) Standard for volatile organic compounds. On and after the date on which the initial 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 the discharge into the atmosphere from any affected facility that produces acrylic fibers VOC emissions that exceed 10 kg/Mg (20 lb/ton) solvent feed to the spinning solution preparation system or precipitation bath. VOC emissions from affected facilities that produce both acrylic and nonacrylic fiber types may not exceed 10 kg/Mg (20 lb/ton) solvent feed. VOC emissions from affected facilities that produce only nonacrylic fiber types may not exceed 17 kg/Mg (34 lb/ton) solvent feed. Compliance with the emission limitations is determined on a 6-month rolling average basis as described in
sub. (4).
NR 440.67(4)
(4) Performance test and compliance provisions. NR 440.67(4)(b)
(b) Each owner or operator of an affected facility shall determine compliance with the applicable standard in
sub. (3) by determining and recording monthly the VOC emissions per unit mass solvent feed from each affected facility for the current and preceding 5 consecutive calendar months and using these values to calculate the 6-month average emissions. Each calculation is considered a performance test. The owner or operator of an affected facility shall use the following procedure to determine VOC emissions for each calendar month:
NR 440.67(4)(b)1.
1. Install, calibrate, maintain, and operate monitoring devices that continuously measure and permanently record for each calendar month the amount of makeup solvent and solvent feed. These values shall be used in calculating VOC emissions according to
subd. 2. All monitoring devices, meters and peripheral equipment shall be calibrated and any error recorded. Total compounded error of the flow measuring and recording devices may not exceed 1% accuracy over the operating range. As an alternative to measuring solvent feed the owner or operator may:
NR 440.67(4)(b)1.a.
a. Measure the amount of recovered solvent returned to the solvent feed storage tanks and use the following equation to determine the amount of solvent feed:
Solvent Feed = Makeup Solvent + Recovered Solvent + Change in the Amount of Solvent Contained in the Solvent Feed Holding Tank.
NR 440.67(4)(b)1.b.
b. Measure and record the amount of polymer introduced into the affected facility and the solvent-to-polymer ratio of the spinning solutions and use the following equation to determine the amount of solvent feed: -
See PDF for diagram 
where subscript “i" denotes each particular spinning solution used during the test period; values of “i" vary from one to the total number of spinning solutions, “n," used during the calendar month.
NR 440.67(4)(b)2.
2. VOC emissions shall be determined each calendar month by use of the following equations:
where all values are for the calendar month only and where:
E is the VOC emissions in kg/Mg (lb/ton) solvent
SV is the measured or calculated volume of solvent feed in liters (gallons)
SW is the weight of solvent feed in Mg (ton)
MV is the measured volume of makeup solvent in liters (gallons)
MW is the weight of makeup in kg (lb)
N is the allowance for nongaseous losses, 13 kg/Mg (26 lb/ton) solvent feed to the spinning solution preparation system and precipitation bath. This value shall be used in all cases unless an owner or operator demonstrates to the satisfaction of the department that greater nongaseous losses occur at the affected facility. In this case, the greater value may be substituted in the equation.
SP is the fraction of measured volume that is actual solvent (excludes water)
D is the density of the solvent in kg/liter (lb/gallon)
K is a conversion factor, 1000 kg/Mg (2,000 lb/ton)
I is the allowance for solvent inventory variation or changes in the amount of solvent contained in the affected facility, kg/Mg (lb/ton) solvent feed (may be positive or negative)
IS is the amount of solvent contained in the affected facility at the beginning of test period, as determined by the owner or operator, in kg (lb)
IE is the amount of solvent contained in the affected facility at the close of the test period, as determined by the owner or operator, in kg (lb)
NR 440.67(5)(a)(a) The owner or operator of an affected facility shall submit a written report to the department of the following:
NR 440.67(5)(a)2.
2. The results of subsequent performance tests that indicate that VOC emissions exceed the standards in
sub. (3). These reports shall be submitted quarterly at 3-month intervals after the initial performance test. If no exceedances occur during a particular quarter, a report stating this shall be submitted to the department semiannually.
NR 440.67(5)(b)
(b) Solvent-spun synthetic fiber producing facilities exempted from these standards in
sub. (1) (a) (those producing less than 500 Mg (551 tons) annually) shall report to the department within 30 days whenever extruded fiber for the preceding 12 calendar months exceeds 500 Mg (551 tons).
NR 440.67 History
History: Cr.
Register, September, 1986, No. 369, eff. 10-1-86; renum. (2) (a) (intro.) and 1. to 18. to be (2) (intro.) and (a) to (r) and am. (2) (intro.), am. (3) (a), r. (5) (c),
Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (b) 2. and (5) (a) 2.,
Register, July, 1993, No. 451, eff. 8-1-93;
CR 06-109: am. (1) (a), (4) (b) (intro.) and (5) (b), renum. (3) (a) to be (3) and am., r. and recr. (4) (b) 2. Register May 2008 No. 629, eff. 6-1-08. NR 440.675
NR 440.675 Volatile organic compound (VOC) emissions from the synthetic organic chemical manufacturing industry (SOCMI) air oxidation unit processes. NR 440.675(1)(1)
Applicability and designation of affected facility. NR 440.675(1)(a)(a) The provisions of this section apply to each affected facility designated in
par. (b) 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).
NR 440.675(1)(b)
(b) The affected facility is any of the following for which construction, modification or reconstruction commenced after October 21, 1983:
NR 440.675(1)(b)1.
1. Each air oxidation reactor not discharging its vent stream into a recovery system.
NR 440.675(1)(b)2.
2. Each combination of an air oxidation reactor and the recovery system into which its vent stream is discharged.
NR 440.675(1)(b)3.
3. Each combination of 2 or more air oxidation reactors and the common recovery system into which their vent streams are discharged.
NR 440.675(1)(c)
(c) Each affected facility that has a total resource effectiveness (TRE) index value greater than 4.0 is exempt from all provisions of this section except for
subs. (3),
(5) (f),
(6) (h) and
(L).
NR 440.675 Note
Note:
The intent of these standards is to minimize the emissions of VOC through the application of best demonstrated technology (BDT). The numerical emission limits in these standards are expressed in terms of total organic compounds (TOC), measured as TOC minus methane and ethane. This emission limit reflects the performance of BDT.
NR 440.675(1)(d)1.1. 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). 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.
NR 440.675(1)(d)2.
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.
NR 440.675(1)(d)3.
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.
NR 440.675(1)(d)4.
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) 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).
NR 440.675(2)
(2) Definitions. As used in this section, all terms not defined here shall have the meanings given them in
s. NR 440.02 and the following terms shall have the specific meanings given them.
NR 440.675(2)(a)
(a) “Air oxidation reactor" means any device or process vessel in which one or more organic reactants are combined with air or a combination of air and oxygen, to produce one or more organic compounds. Ammoxidation and oxychlorination reactions are included in this definition.
NR 440.675(2)(b)
(b) “Air oxidation reactor recovery train" means an individual recovery system receiving the vent stream from at least one air oxidation reactor, along with all air oxidation reactors feeding vent streams into this system.
NR 440.675(2)(c)
(c) “Air oxidation unit process" means a unit process, including ammoxidation and oxychlorination unit process, that uses air or a combination of air and oxygen, as an oxygen source in combination with one or more organic reactants to produce one or more organic compounds.
NR 440.675(2)(d)
(d) “Boilers" means any enclosed combustion device that extracts useful energy in the form of steam.
NR 440.675(2)(e)
(e) “By compound" means by individual stream components, not carbon equivalents.
NR 440.675(2)(f)
(f) “Continuous recorder" means a data recording device recording an instantaneous data value at least once every 15 minutes.
NR 440.675(2)(g)
(g) “Flame zone" means the portion of the combustion chamber in a boiler occupied by the flame envelope.
NR 440.675(2)(h)
(h) “Flow indicator" means a device which indicates whether gas flow is present in a vent stream.
NR 440.675(2)(i)
(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.
NR 440.675(2)(j)
(j) “Incinerator" means any enclosed combustion device that is used for destroying organic compounds and does not extract energy in the form of steam or process heat.
NR 440.675(2)(k)
(k) “Process heater" means a device that transfers heat liberated by burning fuel to fluids contained in tubes, including all fluids except water that is heated to produce steam.
NR 440.675(2)(L)
(L) “Process unit" means equipment assembled and connected by pipes or ducts to produce, as intermediate or final products, one or more of the chemicals in
sub. (8). A process unit can operate independently if supplied with sufficient fuel or raw materials and sufficient product storage facilities.
NR 440.675(2)(m)
(m) “Product" means any compound or chemical listed in
sub. (8) that is produced for sale as a final product as that chemical or is produced for use in a process that needs that chemical for the production of other chemicals in another facility. By-products, co-products and intermediates are considered to be products.
NR 440.675(2)(n)
(n) “Recovery device" means an individual unit of equipment, such as an absorber, condenser and carbon adsorber, capable of and used to recover chemicals for use, reuse or sale.
NR 440.675(2)(o)
(o) “Recovery system" means an individual recovery device or series of such devices applied to the same process stream.
NR 440.675(2)(p)
(p) “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) (e) 3. a., hourly emissions rate as required in
sub. (5) (e) 6. and
(f), and TOC concentration as required in
sub. (6) (b) 4. and
(g) 4., those compounds which the department has determined do not contribute appreciably to the formation of ozone are to be excluded. The compounds to be excluded are identified in
s. NR 400.02 (162).
NR 440.675(2)(q)
(q) “Total resource effectiveness (TRE) index value" means a measure of the supplemental total resource requirement per unit reduction of TOC associated with an individual air oxidation vent stream, based on vent stream flow rate, emission rate of TOC, net heating value and corrosion properties, whether or not the vent stream is halogenated, as quantified by the equation given under
sub. (5) (e).
