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 440.59 - Asphalt processing and asphalt roofing manufacture
Universal Citation: WI Admin Code ยง NR 440.59
Current through August 26, 2024
(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITIES.
(a)
The affected facilities to which this section applies are each saturator and
each mineral handling and storage facility at asphalt roofing plants; and each
asphalt storage tank and each blowing still at asphalt processing plants,
petroleum refineries and asphalt roofing plants.
(b) Any saturator or mineral handling and
storage facility under par. (a) that commences construction or modification
after November 18, 1980 is subject to the requirements of this section. Any
asphalt storage tank or blowing still that processes or stores, or both
processes and stores, asphalt used for roofing only or for roofing and other
purposes, and that commences construction or modification after November 18,
1980 is subject to the requirements of this section. Any asphalt storage tank
or blowing still that processes or stores, or both processes and stores, only
nonroofing asphalts and that commences construction or modification after May
26, 1981 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)
"Afterburner" or "A/B" means an exhaust gas incinerator used to control
emissions of particulate matter.
(b) "Asphalt processing" means the storage
and blowing of asphalt.
(c)
"Asphalt processing plant" means a plant which blows asphalt for use in the
manufacture of asphalt products.
(d) "Asphalt roofing plant" means a plant
which produces asphalt roofing products (shingles, roll roofing, siding or
saturated felt).
(e) "Asphalt
storage tank" means any tank used to store asphalt at asphalt roofing plants,
petroleum refineries and asphalt processing plants. Storage tanks containing
cutback asphalts (asphalts diluted with solvents to reduce viscosity for low
temperature applications) and emulsified asphalts (asphalts dispersed in water
with an emulsifying agent) are not included.
(f) "Blowing still" means the equipment in
which air is blown through asphalt flux to change the softening point and
penetration rate.
(g) "Catalyst"
means a substance which, when added to asphalt flux in a blowing still, alters
the penetrating-softening point relationship or increases the rate of oxidation
of the flux.
(h) "Coating blow"
means the process in which air is blown through hot asphalt flux to produce
coating asphalt. The coating blow starts when the air is turned on and stops
when the air is turned off.
(i)
"Electrostatic precipitator" or "ESP" means an air pollution control device in
which solid or liquid particulates in a gas stream are charged as they pass
through an electric field and precipitated on a collection surface.
(j) "High velocity air filter" or "HVAF"
means an air pollution control filtration device for the removal of sticky,
oily or liquid aerosol particulate matter from exhaust gas streams.
(k) "Mineral handling and storage facility"
means the areas in asphalt roofing plants in which minerals are unloaded from a
carrier, the conveyor transfer points between the carrier and the storage silos
and the storage silos.
(L)
"Saturator" means the equipment in which asphalt is applied to felt to make
asphalt roofing products. The term saturator includes the saturator, wet looper
and coater.
(3) STANDARDS FOR PARTICULATE MATTER.
(a) On and after the
date on which s.
NR 440.08(2) requires a performance test
to be completed, no owner or operator subject to the provisions of this section
may cause to be discharged into the atmosphere from any saturator:
1. Particulate matter in excess of either of
the following:
a. 0.040 kg/Mg (0.080 lb/ton)
of asphalt shingle or mineral-surfaced roll roofing produced.
b. 0.040 kg/Mg (0.080 lb/ton) of saturated
felt or smooth-surfaced roll roofing produced.
2. Exhaust gases with opacity greater than
20%; and
3. Any visible emissions
from a saturator capture system for more than 20% of any period of consecutive
valid observations totaling 60 minutes. Saturators that were constructed before
November 18, 1980 and that have not been reconstructed since that date and that
become subject to this section through modification are exempt from the visible
emissions standard. Saturators that have been newly constructed or
reconstructed since November 18, 1980 are subject to the visible emissions
standard.
(b) On and
after the date on which s.
NR 440.08(2) requires a performance test
to be completed, no owner or operator subject to the provisions of this section
may cause to be discharged into the atmosphere from any blowing still any of
the following:
1. Particulate matter in
excess of 0.67 kg/Mg (1.3 lb/ton) of asphalt charged to the still when a
catalyst is added to the still.
2.
Particulate matter in excess of 0.71 kg/Mg (1.4 lb/ton) of asphalt charged to
the still when a catalyst is added to the still and when No. 6 fuel oil is
fired in the afterburner.
3.
Particulate matter in excess of 0.60 kg/Mg (1.2 lb/ton) of asphalt charged to
the still during blowing without a catalyst.
4. Particulate matter in excess of 0.64 kg/Mg
(1.3 lb/ton) of asphalt charged to the still during blowing without a catalyst
and when No. 6 fuel oil is fired in the afterburner.
5. Exhaust gases with an opacity greater than
zero percent unless an opacity limit for the blowing still when fuel oil is
used to fire the afterburner has been established by the administrator in
accordance with the procedures in
40 CFR
60.474(g).
(c) Within 60 days after achieving
the maximum production rate at which the affected facility will be operated,
but not later than 180 days after initial startup of such facility, no owner or
operator subject to the provisions of this section may cause to be discharged
into the atmosphere from any asphalt storage tank exhaust gases with opacity
greater than zero percent, except for one consecutive 15-minute period in any
24-hour period when the transfer lines are being blown for cleaning. The
control device may not be bypassed during this 15-minute period. If, however,
the emissions from any asphalt storage tank or tanks are ducted to a control
device for a saturator, the combined emissions shall meet the emission limit
contained in par. (a) during the time the saturator control device is
operating. At any other time the asphalt storage tank or tanks shall meet the
opacity limit specified in this paragraph for storage tanks.
(d) Within 60 days after achieving the
maximum production rate at which the affected facility will be operated, but
not later than 180 days after initial startup of such facility, no owner or
operator subject to the provisions of this section may cause to be discharged
into the atmosphere from any mineral handling and storage facility emissions
with opacity greater than one percent.
(4) MONITORING OF OPERATIONS.
(a) The owner or operator subject to the
provisions of this section, and using either an electrostatic precipitator or a
high velocity air filter to meet either the emission limit in sub. (3) (a) 1.
or (b) 1., or both, shall continuously monitor and record the temperature of
the gas at the inlet of the control device. The temperature monitoring
instrument shall have an accuracy of " 15°C (" 25°F) over its
range.
(b) The owner or operator
subject to the provisions of this section and using an afterburner to meet
either the emission limit in sub. (3) (a) 1. or (b) 1., or both, shall
continuously monitor and record the temperature in the combustion zone of the
afterburner. The monitoring instrument shall have an accuracy of " 10°C ("
18°F) over its range.
(c) An
owner or operator subject to the provisions of this section and using a control
device not mentioned in par. (a) or (b) shall provide to the department
information describing the operation of the control device and the process
parameter or parameters which would indicate proper operation and maintenance
of the device. The department may require continuous monitoring and determine
the process parameters to be monitored.
(d) The industry is exempted from the
quarterly reports required under s.
NR 440.07(3). The owner or operator is
required to record and report the operating temperature of the control device
during the performance test and, as required by s.
NR 440.07(5), maintain a file of the
temperature monitoring results for at least 2 years.
(5) TEST METHODS AND PROCEDURES.
(a) For saturators, the owner or operator
shall conduct performance tests required in s.
NR 440.08 as
follows:
1. If the final product is shingle
or mineral-surfaced roll roofing, the tests shall be conducted while 106.6-kg
(235-lb) shingle is being produced.
2. If the final product is saturated felt or
smooth-surfaced roll roofing, the tests shall be conducted while 6.8-kg (15-lb)
felt is being produced.
3. If the
final product is fiberglass shingle, the test shall be conducted while a
nominal 100-kg (220-lb) shingle is being produced.
(b) 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).
(c) 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:
E = (csQsd)/(PK)
where:
E is the emission rate of particulate matter, kg/Mg (lb/ton)
cs is the concentration of particulate matter, g/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the asphalt roofing production rate or asphalt charging rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 g/kg (7000 gr/lb)
2. Method 5A shall be used to
determine the particulate matter concentration (cs) and volumetric flow rate (Q
sd) of the effluent gas. For a saturator, the sampling time and sample volume
for each run shall be at least 120 minutes and 3.00 dscm (106 dscf), and for
the blowing still, at least 90 minutes or the duration of the coating blow or
non-coating blow, whichever is greater, and 2.25 dscm (79.4 dscf).
3. For the saturator, the asphalt roofing
production rate (P) for each run shall be determined as follows: The amount of
asphalt roofing produced on the shingle or saturated felt process lines shall
be obtained by direct measurement. The asphalt roofing production rate is the
amount produced divided by the time taken for the run.
4. For the blowing still, the asphalt
charging rate (P) shall be computed for each run using the following equation:
where:
P is the asphalt charging rate to blowing still, Mg/hr (ton/hr)
V is the volume of asphalt charged, m3 (ft3)
d is the density of asphalt, kg/m3 (lb/ft3)
K' is the conversion factor, 1000 kg/Mg (2000 lb/ton)
q here is the duration of test run, hr
a. The volume (V) of asphalt charged shall be
measured by any means accurate to within 10%.
b. The density (d) of the asphalt shall be
computed using the following equation:
d = K1 -K2Ti
where:
d is the density of the asphalt, kg/m3 (lb/ft3)
K1 is 1056.1 kg/m3 for metric units and 64.70 lb/ft3 for English units
K2 is 0.6176 kg/(m3 °C) for metric units and 0.0694 lb/(ft3 °F) for English units
Ti is the temperature at the start of the blow, °C (°F)
5.
Method 9 and the procedures in s.
NR 440.11 shall be used to determine opacity.
(d) The department shall determine
compliance with the standards in sub. (3) (a) 3. by using Method 22, modified
so that readings are recorded every 15 seconds for a period of consecutive
observations during representative conditions, in accordance with s.
NR 440.08(3), totaling 60 minutes. A
performance test shall consist of one run.
(e) The owner or operator shall use the
monitoring device in sub. (4) (a) or (b) to monitor and record continuously the
temperature during the particulate matter run and shall report the results to
the department with the performance test results.
(f) If at a later date the owner or operator
believes that the emission limits in sub. (3) (a) and (b) are being met even
though one of the conditions in subd. 1. or 2. exists, the owner or operator
may submit a written request to the department to repeat the performance test
and procedure outlined in par. (c).
1. The
temperature measured in accordance with sub. (4) (a) is exceeding that measured
during the performance test.
2. The
temperature measured in accordance with sub. (4) (b) is lower than that
measured during the performance test.
Under 40 CFR 60.474(g), if fuel oil is to be used to fire an afterburner used to control emissions from a blowing still, the owner or operator may petition the administrator in accordance with 40 CFR 60.11(e), to establish an opacity standard for the blowing still that will be the opacity standard when fuel oil is used to fire the afterburner. To obtain this opacity standard, the owner or operator must request the administrator to determine opacity during an initial, or subsequent, performance test when fuel oil is used to fire the afterburner. Upon receipt of the results of the performance test, the administrator will made a finding concerning compliance with the mass standard for the blowing still. If the administrator finds that the facility was in compliance with the mass standard during the performance test but failed to meet the zero opacity standard, the administrator will establish and promulgate in the Federal Register an opacity standard for the blowing still that will be the opacity standard when fuel oil is used to fire the afterburner. When the afterburner is fired with natural gas, the zero percent opacity remains the applicable opacity standard.
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