(1) APPLICABILITY
AND DESIGNATION OF AFFECTED FACILITY.
(a)
Except as provided in par. (b), the affected facility to which the provisions
of this section apply is each solvent-spun synthetic fiber process that
produces more than 500 Mg (551 ton) of fiber per year.
(b) The provisions of this section do not
apply to any facility that uses the reaction spinning process to produce
spandex fiber or the viscose process to produce rayon fiber.
(c) The provisions of this section apply to
each facility as identified in par. (a) that commences construction or
reconstruction after November 23, 1982. The provisions of this section do not
apply to facilities that commence modification but not reconstruction after
November 23, 1982.
(2)
DEFINITIONS. As used in this section, terms not defined in this subsection have
the meanings given in s.
NR 440.02.
(a) "Acrylic
fiber" means a manufactured synthetic fiber in which the fiber-forming
substance is any long-chain synthetic polymer composed of at least 85% by
weight of acrylonitrile units.
(b)
"Makeup solvent" means the solvent introduced into the affected facility that
compensates for solvent lost from the affected facility during the
manufacturing process.
(c)
"Nongaseous losses" means the solvent that is not volatilized during fiber
production and escapes the process and is unavailable for recovery or is in a
form or concentration unsuitable for economical recovery.
(d) "Polymer" means any of the natural or
synthetic compounds as usually high molecular weight that consist of many
repeated links each link being a relatively light and simple
molecule.
(e) "Precipitation bath"
means the water, solvent, or other chemical bath into which the polymer or
prepolymer (partially reacted material) solution is extruded and causes
physical or chemical changes to occur in the extruded solution to result in a
semihardened polymeric fiber.
(f)
"Rayon fiber" means a manufactured fiber composed of regenerated cellulose as
well as manufactured fibers composed of regenerated cellulose in which
substituents have replaced not more than 5 percent of the hydrogens of the
hydroxyl groups.
(g) "Reaction
spinning process" means the fiber-forming process where a prepolymer is
extruded into a fluid medium and solidification takes place by chemical
reaction to form the final polymeric material.
(h) "Recovered solvent" means the solvent
captured from liquid and gaseous process streams that is concentrated in a
control device and that may be purified for reuse.
(i) "Solvent feed" means that the solvent
introduced into the spinning solution preparation system or precipitation bath.
This feed stream includes the combination of recovered solvent and makeup
solvent.
(j) "Solvent inventory
variation" means the normal changes in the total amount of solvent contained in
the affected facility.
(k) "Solvent
recovery system" means the equipment associated with capture, transportation,
collection, concentration and purification of organic solvents. It may include
enclosures, hoods, ducting, piping, scrubbers, condensers, carbon adsorbers,
distillation equipment and associated storage vessels.
(L) "Solvent-spun synthetic fiber" means any
synthetic fiber produced by a process that uses an organic solvent in the
spinning solution, the precipitation bath, or processing of the spun
fiber.
(m) "Solvent-spun synthetic
fiber process" means the total of all equipment having a common spinning
solution preparation system or a common solvent recovery system and is used in
the manufacture of solvent-spun synthetic fiber. It includes spinning solution
preparation, spinning, fiber processing and solvent recovery but does not
include the polymer production equipment.
(n) "Spandex fiber" means a manufactured
fiber in which the fiber-forming substance is a long chain synthetic polymer
comprised of at least 85% of a segmented polyurethane.
(o) "Spinning solution" means the mixture of
polymer, prepolymer, or copolymer and additives dissolved in solvent. The
solution is prepared at a viscosity and solvent-to-polymer ratio that is
suitable for extrusion into fibers.
(p) "Spinning solution preparation system"
means the equipment used to prepare spinning solutions; the system includes
equipment for mixing, filtering, blending and storage of the spinning
solutions.
(q) "Synthetic fiber"
means any fiber composed partially or entirely of materials made by chemical
synthesis or made partially or entirely from chemically-modified
naturally-occurring materials.
(r)
"Viscose process" means the fiber forming process where cellulose and
concentrated caustic soda are reacted to form soda or alkali cellulose. This
reacts with carbon disulfide to form sodium cellulose xanthate which is then
dissolved in a solution of caustic soda. The solution is spun into an acid
coagulating bath after ripening. This precipitates the cellulose in the form of
a regenerated cellulose filament.
(3) STANDARD FOR VOLATILE ORGANIC COMPOUNDS.
On and after the date on which the initial 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 the discharge into the atmosphere from any affected facility that
produces acrylic fibers VOC emissions that exceed 10 kg/Mg (20 lb/ton) solvent
feed to the spinning solution preparation system or precipitation bath. VOC
emissions from affected facilities that produce both acrylic and nonacrylic
fiber types may not exceed 10 kg/Mg (20 lb/ton) solvent feed. VOC emissions
from affected facilities that produce only nonacrylic fiber types may not
exceed 17 kg/Mg (34 lb/ton) solvent feed. Compliance with the emission
limitations is determined on a 6-month rolling average basis as described in
sub. (4).
(4) PERFORMANCE TEST AND
COMPLIANCE PROVISIONS.
(a) Section
NR 440.08(6) does not apply to the
performance test procedures required by this section.
(b) Each owner or operator of an affected
facility shall determine compliance with the applicable standard in sub. (3) by
determining and recording monthly the VOC emissions per unit mass solvent feed
from each affected facility for the current and preceding 5 consecutive
calendar months and using these values to calculate the 6-month average
emissions. Each calculation is considered a performance test. The owner or
operator of an affected facility shall use the following procedure to determine
VOC emissions for each calendar month:
1.
Install, calibrate, maintain, and operate monitoring devices that continuously
measure and permanently record for each calendar month the amount of makeup
solvent and solvent feed. These values shall be used in calculating VOC
emissions according to subd. 2. All monitoring devices, meters and peripheral
equipment shall be calibrated and any error recorded. Total compounded error of
the flow measuring and recording devices may not exceed 1% accuracy over the
operating range. As an alternative to measuring solvent feed the owner or
operator may:
a. Measure the amount of
recovered solvent returned to the solvent feed storage tanks and use the
following equation to determine the amount of solvent feed:
Solvent Feed = Makeup Solvent + Recovered Solvent + Change
in the Amount of Solvent Contained in the Solvent Feed Holding Tank.
b. Measure and record the amount
of polymer introduced into the affected facility and the solvent-to-polymer
ratio of the spinning solutions and use the following equation to determine the
amount of solvent feed:
See
PDF for diagramwhere subscript "i" denotes each particular
spinning solution used during the test period; values of "i" vary from one to
the total number of spinning solutions, "n," used during the calendar
month.
2. VOC
emissions shall be determined each calendar month by use of the following
equations:
See PDF for
diagram
where all values are for the calendar month only and
where:
E is the VOC emissions in kg/Mg (lb/ton) solvent
SV is the measured or calculated volume of solvent feed in
liters (gallons)
SW is the weight of solvent feed in Mg (ton)
MV is the measured volume of makeup solvent in liters
(gallons)
MW is the weight of makeup in kg (lb)
N is the allowance for nongaseous losses, 13 kg/Mg (26
lb/ton) solvent feed to the spinning solution preparation system and
precipitation bath. This value shall be used in all cases unless an owner or
operator demonstrates to the satisfaction of the department that greater
nongaseous losses occur at the affected facility. In this case, the greater
value may be substituted in the equation.
SP is the fraction of measured volume that is actual
solvent (excludes water)
D is the density of the solvent in kg/liter
(lb/gallon)
K is a conversion factor, 1000 kg/Mg (2,000 lb/ton)
I is the allowance for solvent inventory variation or
changes in the amount of solvent contained in the affected facility, kg/Mg
(lb/ton) solvent feed (may be positive or negative)
IS is the amount of solvent contained in the affected
facility at the beginning of test period, as determined by the owner or
operator, in kg (lb)
IE is the amount of solvent contained in the affected
facility at the close of the test period, as determined by the owner or
operator, in kg (lb)
(5) REPORTING REQUIREMENTS.
(a) The owner or operator of an affected
facility shall submit a written report to the department of the following:
1. The results of the initial performance
test; and
2. The results of
subsequent performance tests that indicate that VOC emissions exceed the
standards in sub. (3). These reports shall be submitted quarterly at 3-month
intervals after the initial performance test. If no exceedances occur during a
particular quarter, a report stating this shall be submitted to the department
semiannually.
(b)
Solvent-spun synthetic fiber producing facilities exempted from these standards
in sub. (1) (a) (those producing less than 500 Mg (551 tons) annually) shall
report to the department within 30 days whenever extruded fiber for the
preceding 12 calendar months exceeds 500 Mg (551 tons).
