Current through August 26, 2024
(1) APPLICABILITY
AND DESIGNATION OF AFFECTED FACILITY.
(a) The
affected facility to which the provisions of this section apply is each
ammonium sulfate dryer within an ammonium sulfate manufacturing plant in the
caprolactam by-product, synthetic and coke oven by-product sectors of the
ammonium sulfate industry.
(b) Any
facility under par. (a) that commences construction or modification after
February 4, 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)
"Ammonium sulfate dryer" means a unit or vessel into which ammonium sulfate is
charged for the purpose of reducing the moisture content of the product using a
heated gas stream. The unit includes foundations, super-structure, material
charger systems, exhaust systems and integral control systems and
instrumentation.
(b) "Ammonium
sulfate feed material streams" means the sulfuric acid feed stream to the
reactor/crystallizer for synthetic and coke oven by-product ammonium sulfate
manufacturing plants; and means the total or combined feed streams (the
oximation ammonium sulfate stream and the rearrangement reaction ammonium
sulfate stream) to the crystallizer stage, prior to any recycle
streams.
(c) "Ammonium sulfate
manufacturing plant" means any plant which produces ammonium sulfate.
(d) "Caprolactam by-product ammonium sulfate
manufacturing plant" means any plant which produces ammonium sulfate as a
by-product from process streams generated during caprolactam
manufacture.
(e) "Coke oven
by-product ammonium sulfate manufacturing plant" means any plant which produces
ammonium sulfate by reacting sulfuric acid with ammonia recovered as a
by-product from the manufacture of coke.
(f) "Synthetic ammonium sulfate manufacturing
plant" means any plant which produces ammonium sulfate by direct combination of
ammonia and sulfuric acid.
(3) STANDARDS FOR PARTICULATE MATTER. On or
after the date on which the performance test required to be conducted by s.
NR 440.08 is
completed, no owner or operator of an ammonium sulfate dryer subject to the
provisions of this section may cause to be discharged into the atmosphere, from
any ammonium sulfate dryer, particulate matter at an emission rate exceeding
0.15 kilogram of particulate per megagram of ammonium sulfate produced (0.30
pound of particulate per ton of ammonium sulfate produced) and exhaust gases
with greater than 15% opacity.
(4)
MONITORING OF OPERATIONS.
(a) The owner or
operator of any ammonium sulfate manufacturing plant subject to the provisions
of this section shall install, calibrate, maintain and operate flow monitoring
device which can be used to determine the mass flow of ammonium sulfate feed
material streams to the process. The flow monitoring device shall have an
accuracy of "5% over its range. However, if the plant uses weight scales of the
same accuracy to directly measure production rate of ammonium sulfate, the use
of flow monitoring devices is not required.
(b) The owner or operator of any ammonium
sulfate manufacturing plant subject to the provisions of this section shall
install, calibrate, maintain and operate a monitoring device which continuously
measures and permanently records the total pressure drop across the emission
control system. 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 s.
NR 440.08(2).
(b) The owner or operator shall determine
compliance with the particulate matter standards in sub. (3) as follows:
1. The emission rate (E) of particulate
matter shall be computed for each run using the following equation:
See PDF for
diagram
where:
E is the emission rate of particulate matter, kg/Mg
(lb/ton) of ammonium sulfate produced
cs is the concentration of particulate matter, g/dscm
(g/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr
(dscf/hr)
P is the production rate of ammonium sulfate, Mg/hr
(ton/hr)
K is the conversion factor, 1000 g/kg (453.6 g/lb)
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
1.50 dscm (53 dscf).
3. Direct
measurement using product weigh scales, or the results of computations using a
material balance, shall be used to determine the rate (P) of the ammonium
sulfate production. If production rate is determined by material balance, the
following equations shall be used:
a. For
synthetic and coke oven by-product ammonium sulfate plants:
P = ABCK'
where:
A is the sulfuric acid flow rate to the
reactor/crystallizer averaged over the time period taken to conduct the run,
liter/min
B is the acid density (a function of acid strength and
temperature), g/cc
C is the acid strength, decimal fraction
K' is the conversion factor, 0.0808
(Mg-min-cc)/(g-hr-liter) [0.0891 (ton- min-cc)/(g-hr-liter)]
b. For caprolactam by-product ammonium
sulfate plants:
P = DEFK,
where:
D is the total combined feed stream flow rate to the
ammonium crystallizer before the point where any recycle streams enter the
stream averaged over the time period taken to conduct the test run, liter/min
E is the density of the process stream solution, g/liter
F is the percent mass of ammonium sulfate in the process
solution, decimal fraction
K, is the conversion factor, 6.0 10 -5 (Mg-min)/(g-hr)
[6.614 10-5 (ton-min)/g-hr)]
4. Method 9 and the procedures in s.
NR 440.11 shall be used to determine the
opacity.
