Wisconsin Administrative Code
Department of Natural Resources
NR 400-499 - Environmental Protection - Air Pollution Control
Chapter NR 440 - Standards of performance for new stationary sources
Subchapter II - Standards of Performance
Section NR 440.46 - Glass manufacturing plants
Universal Citation: WI Admin Code ยง NR 440.46
Current through August 26, 2024
(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.
(a)
Each glass melting furnace is an affected facility to which the provisions of
this section apply.
(b) Any
facility under par. (a) that commences construction or modification after June
15, 1979, is subject to the requirements of this section.
(c) This section does not apply to hand glass
melting furnaces, glass melting furnaces designed to produce less than 4.55 Mg
(5 tons) of glass per day and all-electric melters.
(2) DEFINITIONS. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02, unless otherwise required by the context.
(a) "All-electric melter" means a glass
melting furnace in which all the heat required for melting is provided by
electric current from electrodes submerged in the molten glass, although some
fossil fuel may be charged to the furnace as raw material only.
(c)
"Container glass" means glass made of soda-lime recipe, clear or colored, which
is pressed or blown, or both, into bottles, jars, ampoules and other products
listed under SIC code 3221 in the Standard Industrial Classification Manual,
incorporated by reference in s.
NR 440.17.
(cm) "Experimental furnace" means a glass
melting furnace with the sole purpose of operating to evaluate glass melting
processes, technologies, or glass products. An experimental furnace does not
produce glass that is sold (except for further research and development
purposes) or that is used as a raw material for nonexperimental
furnaces.
(d) "Flat glass" means
glass made of soda-lime recipe and produced into continuous flat sheets and
other products listed under SIC code 3211 in the Standard Industrial
Classification Manual, incorporated by reference in s.
NR 440.17.
(dm) "Flow channels" means appendages used
for conditioning and distributing molten glass to forming apparatuses and are a
permanently separate source of emissions such that no mixing of emissions
occurs with emissions from the melter cooling system prior to their being
vented to the atmosphere.
(e)
"Glass melting furnace" means a unit comprising a refractory vessel in which
raw materials are charged, melted at high temperature, refined and conditioned
to produce molten glass. The unit includes foundations, superstructure and
retaining walls, raw material charger systems, heat exchangers, melter cooling
system, exhaust system, refractory brick work, fuel supply and electrical
boosting equipment, integral control systems and instrumentation and appendages
for conditioning and distributing molten glass to forming apparatuses. The
forming apparatuses, including the float bath used in flat glass manufacturing
and flow channels in wool fiberglass and textile manufacturing, are not
considered part of the glass melting furnace.
(f) "Glass produced" means the weight of the
glass pulled from the glass melting furnace.
(g) "Hand glass melting furnace" means a
glass furnace where the molten glass is removed from the furnace by a
glassworker using a blowpipe or a pontil.
(i)
"Pressed and blown glass" means glass which is pressed, blown, or both,
including textile fiberglass, noncontinuous flat glass, noncontainer glass and
other products listed under SIC code 3229 in the Standard Industrial
Classification Manual, incorporated by reference in s.
NR 440.17. It is separated into glass of borosilicate
recipe, glass of soda-lime and lead recipes, glass of opal, fluoride and other
recipes.
(j) "Rebricking" means
cold replacement of damaged or worn refractory parts of the glass melting
furnace. Rebricking includes replacement of the refractories comprising the
bottom, sidewalls or roof of the melting vessel; replacement of refractory work
in the heat exchanger; and replacement of refractory portions of the glass
conditioning and distribution system.
(k) "Soda-lime recipe" means glass product
composition of the following ranges of weight proportions: 60 to 75% silicon
dioxide, 10 to 17% total R2O (e.g.,
Na2O and K2O), 8 to 20% total RO
but not to include any PbO (e.g., CaO and MgO), 0 to 8% total
R2O3 (e.g.,
Al2O3) and 1 to 5% other oxides.
(km) "Textile fiberglass" means
fibrous glass in the form of continuous strands having uniform thickness.
(ks) "With modified-processes"
means using any technique designed to minimize emissions without the use of
add-on pollution controls.
(L)
"Wool fiberglass" means fibrous glass of random texture, including fiberglass
insulation, and other products listed under SIC code 3296 in the Standard
Industrial Classification Manual, incorporated by reference in s.
NR 440.17.
(3) STANDARDS FOR PARTICULATE MATTER.
(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 of a glass melting furnace subject to the
provisions of this section may cause to be discharged into the atmosphere:
1. From any glass melting furnace fired
exclusively with either a gaseous fuel or a liquid fuel, particulate matter at
emission rates exceeding those specified in Table 1, Column 2 and Column 3,
respectively, or
2. From any glass
melting furnace, fired simultaneously with gaseous and liquid fuels,
particulate matter at emission rates exceeding STD as specified by the
following equation:
where:
STD is the particulate matter emission limit, g of particulate/kg (lb of particulate/ton) of glass produced
X is the emission rate specified in Table 1 for furnaces fired with gaseous fuel (Column 2)
Y is the decimal fraction of liquid fuel heating value to total (gaseous and liquid) fuel heating value fired in the glass melting furnaces as determined in sub. (7) (b) (joules/joules)
Z is equal to (1-Y)
Table 1 - Emission Rates
[g of particulate/kg of glass produced]
| Col. 1 - Glass manufacturing plant industry segment | Col. 2- Furnace fired with gaseous fuel | Col. 3- Furnace fired with liquid fuel | |
| a. | Container glass ................ | 0.10 | 0.13 |
| b. | Pressed and blown glass | ||
| 1) Borosilicate Recipes.......... | 0.50 | 0.65 | |
| 2) SodaLime and Lead Recipes . . . | 0.10 | 0.13 | |
| 3) Other-Than Borosilicate, SodaLime, and Lead Recipes (including opal,fluoride and other recipes) ........ | 0.25 | 0.325 | |
| c. | Wool fiberglass ................ | 0.25 | 0.325 |
| d. | Flat glass ..................... | 0.225 | 0.225 |
(b) Conversion of a glass melting furnace to
the use of liquid fuel may not be considered a modification for the purposes of
s.
NR 440.14.
(c) Rebricking and the cost of rebricking may
not be considered a reconstruction for the purposes of s.
NR 440.15.
(d) An owner or operator of an experimental
furnace is not subject to the requirements of this section.
(e) During routine maintenance of add-on
pollution controls an owner or operator of a glass melting furnace subject to
the provisions of sub. (3) (a) is exempt from the provisions of this subsection
if:
1. Routine maintenance in each calendar
year does not exceed 6 days;
2.
Routine maintenance is conducted in a manner consistent with good air pollution
control practices for minimizing emissions; and
3. A report is submitted to the department 10
days before the start of the routine maintenance (if 10 days cannot be provided
the report must be submitted as soon as practicable) and the report contains an
explanation of the schedule of the maintenance.
(4) STANDARDS FOR PARTICULATE MATTER FROM GLASS MELTING FURNACE WITH MODIFIED-PROCESSES.
(a) An owner or operator of a glass melting
furnaces with modified-processes is not subject to the provisions of sub. (3)
if the affected facility complies with the provision of this
subsection.
(b) 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 of a glass melting furnace with modified
processes subject to the provisions of this section may cause to be discharged
into the atmosphere from the affected facility:
1. Particulate matter at emission rates
exceeding 0.50 gram of particulate per kilogram of glass produced (g/kg) as
measured according to par. (e) for container glass, flat glass and pressed and
blown glass with a soda-lime recipe melting furnace.
2. Particulate matter at emission rates
exceeding 1.0 g/kg as measured according to par. (e) for pressed and blown
glass with a borosilicate recipe melting furnace.
3. Particulate matter at emission rates
exceeding 0.50 g/kg as measured according to par. (e) for textile fiberglass
and wool fiberglass melting furnaces.
(c) The owner or operator of an affected
facility that is subject to emission limits specified under par. (b) shall:
1. Install, calibrate, maintain and operate a
continuous monitoring system for the measurement of the opacity of emissions
discharged into the atmosphere from the affected facility.
2. During the performance test required to be
conducted by s.
NR 440.08
conduct continuous opacity monitoring during each test run.
3. Calculate 6-minute opacity averages from
24 or more data points equally spaced over each 6-minute period during the test
runs.
4. Determine, based on the
6-minute opacity averages, the opacity value corresponding to the 99% upper
confidence level of a normal distribution of average opacity values.
5. For the purposes of s.
NR 440.07, report to the department as excess emissions
all of the 6-minute periods during which the average opacity, as measured by
the continuous monitoring system installed under par. (c) 1., exceeds the
opacity value corresponding to the 99% upper confidence level determined under
par. (c) 4.
(d)
1. After receipt and consideration of written
application, the department may approve alternative continuous monitoring
systems for the measurement of one or more process or operating parameters that
is or are demonstrated to enable accurate and representative monitoring of an
emission limit specified in par. (b).
2. After the department approves an
alternative continuous monitoring system for an affected facility, the
requirements of par. (c) 1. to 5. will not apply for that affected
facility.
(e) An owner
or operator may redetermine the opacity value corresponding to the 99% upper
confidence level as described in par. (c) 4. if the owner or operator does all
of the following:
1. Conducts continuous
opacity monitoring during each test run of a performance test that demonstrates
compliance with an emission limit of par. (b).
2. Recalculates the 6-minute opacity averages
as described in par. (c) 3.
3. Uses
the redetermined opacity value corresponding to the 99% upper confidence level
for the purposes of par. (c) 5.
(f) Test methods and procedures as specified
under sub. (7) shall be used to determine compliance with this section except
that to determine compliance for any glass melting furnace using modified
processes and fired with either a gaseous fuel or a liquid fuel containing less
than 0.50 weight percent sulfur, Method 5 of 40 CFR part 60, Appendix A,
incorporated by reference in s.
NR 440.17(1), shall be used with the
probe and filter holder heating system in the sampling train set to provide a
gas temperature of 120 "14°C (248 "25°F).
(7) TEST METHODS AND PROCEDURES.
(a) If a glass melting furnace with modified
processes is changed to one without modified processes or if a glass melting
furnace without modified processes is changed to one with modified processes,
the owner or operator shall notify the department at least 60 days before the
change is schedule to occur.
(b)
When gaseous and liquid fuels are fired simultaneously in a glass melting
furnace, the owner or operator shall determine the applicable standard under
sub. (3) (a) 2. as follows:
1. The ratio (Y)
of liquid fuel heating value to total (gaseous and liquid) fuel heating value
fired in the glass melting furnaces shall be computed for each run using the
following equation:
where:
Y is the decimal fraction of liquid fuel heating value to total fuel heating value
Hl is the gross calorific value of liquid fuel, J/kg
Hg is the gross calorific value of gaseous fuel, J/kg
L is the liquid flow rate, kg/hr
G is the gaseous flow rate, kg/hr
2. Suitable methods shall be used to
determine the rates (L and G) of fuels burned during each test period and a
material balance over the glass melting furnace shall be used to confirm the
rates.
3. ASTM Methods D240-92
(liquid fuels) and D1826-94 (gaseous fuels), incorporated by reference in s.
NR 440.17(2) (a) 9. and 21., as
applicable, shall be used to determine the gross calorific values.
(c) 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).
(d) The owner or operator shall determine
compliance with the particulate matter standards in subs. (3) and (4) as
follows:
1. The emission rate (E) of
particulate matter shall be computed for each run using the following equation:
where:
E is the emission rate of particulate matter, g/kg
cs is the concentration of particulate matter, g/dsm
Qsd is the volumetric flow rate, dscm/hr
A is the zero production rate correction = 227 g/hr for container glass, pressed and blown (soda-lime and lead) glass, and pressed and blown (other than borosilicate, soda-lime and lead) glass
= 454 g/hr for pressed and blown (borosilicate) glass, wool fiberglass, and flat glass
P is the glass production rate, kg/hr
2. Method 5 shall be used to determine the
particulate matter concentration (cs) and volumetric flow rate (Qsd) of the
effluent gas. The sampling time and sample volume for each run shall be at
least 60 minutes and 0.90 dscm (31.8 dscf). The probe and filter holder heating
system may be set to provide a gas temperature no greater than 177"14°C
(350"25°F), except under the conditions specified in sub. (4)
(e).
3. Direct measurement or
material balance using good engineering practice shall be used to determine the
amount of glass pulled during the performance test. The rate of glass produced
is defined as the weight of glass pulled from the affected facility during the
performance test divided by the number of hours taken to perform the
performance test.
4. Method 9 and
the procedures in s.
NR 440.11 shall be used to determine opacity.
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