(1) APPLICABILITY
AND DESIGNATION OF AFFECTED FACILITY.
(a) The
provisions of this section are applicable to the affected facilities listed in
par. (b) at any lead-acid battery manufacturing plant that produces or has the
design capacity to produce in one day (24 hours) batteries containing an amount
of lead equal to or greater than 5.9 Mg (6.5 tons).
(b) The provisions of this section are
applicable to the following affected facilities used in the manufacture of
lead-acid storage batteries:
1. Grid casting
facility.
2. Paste mixing
facility.
3. Three-process
operation facility.
4. Lead oxide
manufacturing facility.
5. Lead
reclamation facility.
6. Other
lead-emitting operations.
(c) Any facility under par. (b) that
commences construction or modification after January 14, 1980, 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) "Grid
casting facility" means the facility which includes all lead melting pots and
machines used for casting the grid used in battery manufacturing.
(b) "Lead-acid battery manufacturing plant"
means any plant that produces a storage battery using lead and lead compounds
for the plates and sulfuric acid for the electrolyte.
(c) "Lead oxide manufacturing facility" means
a facility that produces lead oxide from lead, including product
recovery.
(d) "Lead reclamation
facility" means the facility that remelts lead scrap and casts it into lead
ingots for use in the battery manufacturing process, and which is not a furnace
affected under s.
NR 440.29.
(e) "Other lead-emitting operation" means any
lead-acid battery manufacturing plant operation from which lead emissions are
collected and ducted to the atmosphere and which is not part of a grid casting,
lead oxide manufacturing, lead reclamation, paste mixing, 3-process operation
facility or a furnace affected under s.
NR 440.29.
(f) "Paste mixing facility" means the
facility including lead oxide storage, conveying, weighing, metering and
charging operations; paste blending, handling and cooling operations; and plate
pasting, takeoff, cooling and drying operations.
(g) "Three-process operation facility" means
the facility including those processes involved with plate stacking, burning or
strap casting, and assembly of elements into the battery case.
(3) STANDARDS FOR LEAD.
(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:
1. From any grid casting facility any gases
that contain lead in excess of 0.40 milligram of lead per dry standard cubic
meter of exhaust (0.000175 gr/dscf).
2. From any paste mixing facility any gases
that contain in excess of 1.00 milligram of lead per dry standard cubic meter
of exhaust (0.000437 gr/dscf).
3.
From any 3-process operation facility any gases that contain in excess of 1.00
milligram of lead per dry standard cubic meter of exhaust (0.000437
gr/dscf).
4. From any lead oxide
manufacturing facility any gases that contain in excess of 5.0 milligrams of
lead per kilogram of lead feed (0.010 lb/ton).
5. From any lead reclamation facility any
gases that contain in excess of 4.50 milligrams of lead per dry standard cubic
meter of exhaust (0.00197 gr/dscf).
6. From any other lead-emitting operation any
gases that contain in excess of 1.00 milligram of lead per dry standard cubic
meter of exhaust (0.000437 gr/dscf).
7. From any affected facility other than a
lead reclamation facility any gases with greater than zero percent opacity
measured according to Method 9 of 40 CFR part 60, Appendix A, incorporated by
reference in s.
NR 440.17, and rounded to the nearest whole
percentage.
8. From any lead
reclamation facility any gases with greater than 5% opacity, measured according
to Method 9 of 40 CFR part 60, Appendix A, incorporated by reference in s.
NR 440.17, and rounded to the nearest whole
percentage.
(b) When 2
or more facilities at the same plant (except the lead oxide manufacturing
facility) are ducted to a common control device, an equivalent standard for the
total exhaust from the commonly controlled facilities shall be determined as
follows:
See PDF for
diagram where:
Se is the equivalent standard for the total exhaust stream
Sa is the actual standard for each exhaust stream ducted
to the control device
N is the total number of exhaust streams ducted to the
control device
Qsda is the dry standard volumetric
flow rate of the effluent gas stream from each facility ducted to the control
device
QsdT is the total dry standard
volumetric flow rate of all effluent gas streams ducted to the control device
(4) MONITORING
OF EMISSIONS AND OPERATIONS. The owner or operator of any lead-acid battery
manufacturing facility subject to the provisions of this section and controlled
by scrubbing systems shall install, calibrate, maintain and operate a
monitoring device or devices that measure and record the pressure drop across
the scrubbing systems at least once every 15 minutes. The monitoring device
shall have an accuracy of " 5% over its operating range.
(5) 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).
(b) The owner or operator shall determine
compliance with the lead standards in sub. (3), except sub. (3) (a) 4., as
follows:
1. Method 12 shall be used to
determine the lead concentration and, if applicable, the volumetric flow rate
(Qsda) of the effluent gas. The sampling time and sample volume for each run
shall be at least 60 minutes and 0.85 dscm (30 dscf).
2. When different operations in a 3-process
operation facility are ducted to separate control devices, the lead emission
concentration (C) from the facility shall be determined as follows:
See
PDF for diagram
where:
C is the concentration of lead emissions for the entire
facility, mg/dscm (gr/dscf)
Ca is the concentration of lead emissions from facility
"a", mg/dscm (gr/dscf)
Qsda is the volumetric flow rate of effluent gas from
facility "a", dscm/hr (dscf/hr)
N is the total number of control devices to which separate
operations in the facility are ducted
3. Method 9 and the procedures in s.
NR 440.11 shall be used to determine opacity. The opacity
numbers shall be rounded off to the nearest whole percentage.
(c) The owner or operator shall
determine compliance with the lead standard in sub. (3) (a) 4. as follows:
1. The emission rate (E) from a lead oxide
manufacturing facility shall be computed for each run using the following
equation:
See
PDF for diagram
where:
E is the emission rate of lead, mg/kg (lb/ton) of lead
charged
CPbi is the concentration of lead from emission point "i",
mg/dscm (gr/dscf)
Qsdi is the volumetric flow rate of effluent gas from
emission point "i", dscm/hr (dscf/hr)
M is the number of emission points in the affected
facility
P is the lead feed rate to the facility, kg/hr (ton/hr)
K is the conversion factor, 1.0 mg/mg (7000 gr/lb)
2. Method 12 shall be used to
determine the lead concentration (CPb) and the volumetric flow rate
(Qsd) of the effluent gas. The
sampling time and sample volume for each run shall be at least 60 minutes and
0.85 dscm (30 dscf).
3. The
average lead feed rate (P) shall be determined for each run using the following
equation:
See
PDF for diagram
where:
N is the number of lead pigs (ingots) charged
W is the average mass of a pig, kg (ton)
[BITA] is the duration of run, hr
