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).
NR 440.675(2)(r)
(r) “Vent stream" means any gas stream, containing nitrogen which was introduced as air to the air oxidation reactor, released to the atmosphere directly from any air oxidation reactor recovery train or indirectly, after diversion through other process equipment. The vent stream excludes equipment leaks and relief valve discharges including, but not limited to, pumps, compressors and valves.
NR 440.675(3)
(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:
NR 440.675(3)(a)
(a) Reduce emissions of TOC (minus methane and ethane) by 98 weight- percent or to a TOC (minus 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
NR 440.675(3)(c)
(c) Maintain a TRE index value greater than 1.0 without use of VOC emission control devices.
NR 440.675(4)(a)(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:
NR 440.675(4)(a)1.
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.
NR 440.675(4)(a)1.a.
a. Where an incinerator other than a catalytic incinerator is used, a temperature monitoring device shall be installed in the firebox.
NR 440.675(4)(a)1.b.
b. Where a catalytic incinerator is used, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalyst bed.
NR 440.675(4)(a)2.
2. A flow indicator that provides a record of vent stream flow to the incinerator at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each affected facility at a point closest to the inlet of each incinerator and before being joined with any other vent stream.
NR 440.675(4)(b)
(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:
NR 440.675(4)(b)1.
1. A heat sensing device, such as an ultra-violet sensor or thermocouple, at the pilot light to indicate the continuous presence of a flame.
NR 440.675(4)(b)2.
2. A flow indicator that provides a record of vent stream flow to the flare at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each affected facility at a point closest to the flare and before being joined with any other vent stream.
NR 440.675(4)(c)
(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:
NR 440.675(4)(c)1.
1. A flow indicator that provides a record of vent stream flow to the boiler or process heater at least once every hour for each affected facility. The flow indicator shall be installed in the vent stream from each air oxidation reactor within an affected facility at a point closest to the inlet of each boiler or process heater and before being joined with any other vent stream.
NR 440.675(4)(c)2.
2. A temperature monitoring device in the firebox equipped with a continuous recorder and having an accuracy of
" 1% of the temperature being measured 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) heat input design capacity.
NR 440.675(4)(d)
(d) The owner or operator of an affected facility that uses a boiler or process heater to comply with
sub. (3) (a) shall monitor and record the periods of operation of the boiler or process heater if the design input capacity of the boiler is 44 MW (150 million Btu/hr) or greater. The records shall be readily available for inspection.
NR 440.675(4)(e)
(e) 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:
NR 440.675(4)(e)1.
1. Where an absorber is the final recovery device in a recovery system:
NR 440.675(4)(e)1.a.
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;
NR 440.675(4)(e)1.b.
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 infra-red, photoionization or thermal conductivity, each equipped with a continuous recorder.
NR 440.675(4)(e)2.
2. Where a condenser is the final recovery device in a recovery system:
NR 440.675(4)(e)2.a.
a. A condenser exit or product side temperature monitoring device equipped with a continuous recorder and having an accuracy of
" 1% of the temperature being monitoring expressed in degrees Celsius or
"0.5
°C, whichever is greater;
NR 440.675(4)(e)2.b.
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 infra-red, photoionization or thermal conductivity, each equipped with a continuous recorder.
NR 440.675(4)(e)3.
3. Where a carbon adsorber is the final recovery device in a recovery system:
NR 440.675(4)(e)3.a.
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;
NR 440.675(4)(e)3.b.
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 infra-red, photoionization or thermal conductivity, each equipped with a continuous recorder.
NR 440.675(4)(f)
(f) An owner or operator of an affected facility seeking to demonstrate compliance with the standards specified under
sub. (3) with control devices other than an incinerator, boiler, process heater or flare; or recovery devices 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.
NR 440.675(5)(a)(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.
NR 440.675(5)(b)1.
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.
NR 440.675(5)(b)2.
2. Method 2, 2A, 2C or 2D, as appropriate, for determination of the volumetric flow rates.
NR 440.675(5)(b)3.
3. The emission rate correction factor, integrated sampling and analysis procedure of Method 3 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 equations: -
See PDF for diagram 
where:
Cc is the concentration of TOC corrected to 3% O2, dry basis, ppm by volume
CTOC is the concentration of TOC (minus methane and ethane), dry basis, ppm by volume
%O2d is the concentration of O2, dry basis, percent by volume
NR 440.675(5)(b)4.
4. Method 18 to determine 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.
NR 440.675(5)(b)4.a.
a. The sampling time for each run shall be 1 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 15-minute intervals.
where:
R is the emission reduction, percent by weight
Ei is the mass rate of TOC entering the control device, kg/hr (lb/hr)
Eo is the mass rate of TOC discharged to the atmosphere, kg/hr (lb/hr)
where:
Cij and Coj are 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
Mij and Moj are 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)
Qi and Qo are the flow rate of gas stream at the inlet and outlet of the control device, respectively, dscm/min (dscf/min)
K2 is a constant, 2.494 x 10-6 (1/ppm)(g-mole/scm)(kg/g)(min/hr) for metric units, where standard temperature for (g-mole/scm) is 20°C, and 1.557 x 10-7 (1/ppm)(lb-mole/scf)(min/hr) for English units, where standard temperature for (lb-mole/scf) is 68°F
where:
CTOC is the concentration of TOC (minus methane and ethane), dry basis, ppm by volume
Cj is the concentration of sample components in the sample
n is the number of components in the sample
NR 440.675(5)(c)
(c) 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 to comply with
sub. (3) (a), the requirement for an initial performance test is waived, in accordance with
s. NR 440.08 (2). However, the department reserves the option to require testing at such other times as may be required.
NR 440.675(5)(e)
(e) 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
sub. (3) (c).
NR 440.675(5)(e)1.
1. 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. 3. and
4. shall be, except for the situations outlined in
subd. 2., prior to the inlet of any control device, prior to any post-reactor dilution of the stream with air and prior to any post-reactor introduction of halogenated compounds into the vent stream. No transverse site selection method is needed for vents smaller than 10 centimeters (4 inches) in diameter.
NR 440.675(5)(e)2.
2. If any gas stream other than the air oxidation vent stream from the affected facility is normally conducted through the final recovery device:
NR 440.675(5)(e)2.a.
a. 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 the nonair oxidation stream is introduced.
NR 440.675(5)(e)2.b.
b. 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 nonair oxidation vent stream and at the outlet of the final recovery device.
NR 440.675(5)(e)2.c.
c. This efficiency is applied to the TOC concentration measured prior to the final recovery device and prior to the introduction of the nonair oxidation stream to determine the concentration of TOC in the air oxidation stream from the final recovery device. This concentration of TOC is then used to perform the calculations outlined in
subds. 5. and
6.
NR 440.675(5)(e)3.
3. The molar composition of the process vent stream shall be determined as follows:
NR 440.675(5)(e)3.a.
a. Method 18 to measure the concentration of TOC including those containing halogens.
NR 440.675(5)(e)4.
4. The volumetric flow rate shall be determined using Method 2, 2A, 2C or 2D, as appropriate.
