(1) APPLICABILITY AND DESIGNATION OF AFFECTED
FACILITY.
(a) The provisions of this section
are applicable to each sulfuric acid production unit, which is the affected
facility.
(b) Any facility under
par. (a) that commences construction or modification after August 17, 1971, is
subject to the requirements of this section.
(2) DEFINITIONS. As used in this section,
terms not defined in this subsection have the meanings given in s.
NR 440.02.
(a) "Acid
mist" means sulfuric acid mist, as measured by Method 8 of 40 CFR part 60,
Appendix A, incorporated by reference in s.
NR 440.17, or an equivalent or alternative
method.
(b) "Sulfuric acid
production unit" means any facility producing sulfuric acid by the contact
process by burning elemental sulfur, alkylation acid, hydrogen sulfide, organic
sulfides and mercaptans or acid sludge, but does not include facilities where
conversion to sulfuric acid is utilized primarily as a means of preventing
emissions to the atmosphere of sulfur dioxide or other sulfur
compounds.
(3) STANDARD
FOR SULFUR DIOXIDE.
(a) On and after the date
on which the 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 to be discharged into the atmosphere from any affected facility any gases
which contain sulfur dioxide in excess of 2.0 kg per metric ton of acid
produced (4.0 lb per ton), the production being expressed as 100%
H2SO4.
(4) STANDARD FOR
ACID MIST.
(a) On and after the date on which
the 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 to be discharged into the atmosphere from any affected facility any gases
which:
1. Contain acid mist, expressed as
H2SO4, in excess of 0.075 kg per metric ton of acid produced (0.15 lb per ton),
the production being expressed as 100% H2SO4.
2. Exhibit 10% opacity, or greater.
(5) EMISSION
MONITORING.
(a) A continuous monitoring
system for the measurement of sulfur dioxide shall be installed, calibrated,
maintained and operated by the owner or operator. The pollutant gas used to
prepare calibration gas mixtures under Performance Specification 2 of 40 CFR
part 60, Appendix B, incorporated by reference in s.
NR 440.17, and for calibration checks under s.
NR 440.13(4) shall be sulfur dioxide
(SO2). Method 8 of 40 CFR part 60, Appendix A, incorporated by reference in s.
NR 440.17, shall be used for conducting monitoring system
performance evaluations under s.
NR 440.13(3), except that only the
sulfur dioxide portion of the Method 8 results shall be used. The span value
shall be set at 1000 ppm of sulfur dioxide.
(b) The owner or operator shall establish a
conversion factor for the purpose of converting monitoring data into units of
the applicable standard (kg/metric ton, lb/ton). The conversion factor shall be
determined, at a minimum, 3 times daily by measuring the concentration of
sulfur dioxide entering the converter using suitable methods (e.g., the Reich
test, National Air Pollution Control Administration Publication No. 999-AP-13)
and calculating the appropriate conversion factor for each 8-hour period as
follows:
See PDF
for diagram
where:
CF is the conversion factor (kg/metric ton per ppm, lb/ton
per ppm)
k is the constant derived from material balance. For
determining CF in metric units, k = 0.0653. For determining CF in English
units, k = 0.1306.
r is the percentage of sulfur dioxide by volume entering
the gas converter. Appropriate corrections must be made for air injection
plants subject to the department's approval.
s is the percentage of sulfur dioxide by volume in the
emissions to the atmosphere determined by the continuous monitoring system
required under par. (a).
(c) The owner or operator shall record all
conversion factors and values under par. (b) from which they were computed
(i.e., CF, r, and s).
(d)
Alternatively, a source that processes elemental sulfur or an area that
contains elemental sulfur and uses air to supply oxygen may use the following
continuous emission monitoring approach and calculation procedures in
determining SO2 emission rates in terms of the standard. This procedure is not
required but is an alternative that would alleviate problems encountered in the
measurement of gas velocities or production rate. Continuous emission
monitoring systems for measuring SO2, O2 and CO2, if required, shall be
installed, calibrated, maintained and operated by the owner or operator and
subjected to the certification procedures in Performance Specifications 2 and 3
in Appendix B, 40 CFR part 60, incorporated by reference in s.
NR 440.17(1). The calibration procedure
and span value for the SO2 monitor shall be as specified in par. (b). The span
value for CO2, if required, shall be 10% and for O2 shall be 20.9% (air). A
conversion factor based on process rate data is not necessary. Calculate the
SO2 emission rate as follows:
See PDF
for diagram
where:
Es is the SO2 emission rate in kg/metric ton (lb/ton) of
100% of H2SO4 produced
Cs is the concentration of SO2, kg/dscm (lb/dscf) (see the
table in the note following this paragraph)
S is the acid production rate factor, 368 dscm/metric ton
(11,800 dscf/ton) of 100% H2SO4 produced
%O2 is the oxygen concentration, percent dry basis
A is the auxiliary fuel factor,
= 0.00 for no fuel
= 0.0226 for methane
= 0.0217 for natural gas
= 0.0196 for propane
= 0.0172 for #2 oil
= 0.0161 for #6 oil
= 0.0148 for coal
= 0.0126 for coke
%CO2 is the carbon dioxide concentration, percent dry
basis
Note: It is necessary in some cases to convert measured
concentration units to other units for these calculations. Use the following
table for such conversions:
|
From
|
To
|
Multiply by
|
| 1. |
g/scm |
kg/scm |
10-3
|
| 2. |
mg/scm |
kg/scm |
10-6
|
| 3. |
ppm (SO2) |
kg/scm |
2.660 X 10-6
|
| 4. |
ppm (SO2) |
lb/scm |
1.660 X 10-7
|
(e) For the purpose of reports under s.
NR 440.07(3), periods of excess
emissions shall be all 3-hour periods (or the arithmetic average of 3
consecutive 1-hour periods) during which the integrated average sulfur dioxide
emissions exceed the applicable standards under sub. (3).
(6) TEST METHODS AND PROCEDURES.
(a) In conducting the performance tests
required in s.
NR 440.08, the
owner or operator shall use as reference methods and procedures the test
methods in Appendix A of 40 CFR part 60, incorporated by reference in s.
NR 440.17, or other methods and procedures as specified
in this subsection, except as provided in s.
NR 440.08(2). Acceptable alternative
methods and procedures are given in par. (c).
(b) The owner or operator shall determine
compliance with the SO2 acid mist, and visible emission standards in subs. (4)
and (5) as follows:
1. The emission rate (E)
of acid mist or SO2 shall be computed for each run using the following
equation:
E = (CQsd)/(PK)
where:
E is the emission rate of acid mist or SO2 kg/metric ton
(lb/ton) of 100% H2SO4 produced
C is the concentration of acid mist or SO2, g/dscm
(lb/dscf)
Qsd is the volumetric flow rate of the effluent gas,
dscm/hr (dscf/hr)
P is the production rate of 100% H2SO4, metric ton/hr
(ton/hr)
K is the conversion factor, 1000 g/kg (1.0 lb/lb)
2. Method 8 shall be used to
determine the acid mist and SO2 concentrations (C's) and the volumetric flow
rate (Qsd) of the effluent gas. The moisture content may be considered to be
zero. The sampling time and sample volume for each run shall be at least 60
minutes and 1.15 dscm (40.6 dscf).
3. Suitable methods shall be used to
determine the production rate (P) of 100% H2SO4 for each run. Material balance
over the production system shall be used to confirm the production
rate.
4. Method 9 and the
procedures in s.
NR 440.11 shall be used to determine opacity.
(c) The owner or operator may use
the following as alternatives to the reference methods and procedures specified
in this subsection:
1. If a source processes
elemental sulfur or an ore that contains elemental sulfur and uses air to
supply oxygen, the following procedure may be used instead of determining the
volumetric flow rate and production rate:
a.
The integrated technique of Method 3 is used to determine the O2 concentration
and, if required, CO2 concentration.
b. The SO 2 or acid mist emission rate is
calculated as described in sub. (5) (d), substituting the acid mist
concentration for Cs as appropriate.
