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Electronic Code of Federal Regulations

e-CFR Data is current as of April 16, 2014

Title 40: Protection of Environment
PART 60—STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES


Subpart Z—Standards of Performance for Ferroalloy Production Facilities


Contents
§60.260   Applicability and designation of affected facility.
§60.261   Definitions.
§60.262   Standard for particulate matter.
§60.263   Standard for carbon monoxide.
§60.264   Emission monitoring.
§60.265   Monitoring of operations.
§60.266   Test methods and procedures.

Source: 41 FR 18501, May 4, 1976, unless otherwise noted.

§60.260   Applicability and designation of affected facility.

(a) The provisions of this subpart are applicable to the following affected facilities: Electric submerged arc furnaces which produce silicon metal, ferrosilicon, calcium silicon, silicomanganese zirconium, ferrochrome silicon, silvery iron, high-carbon ferrochrome, charge chrome, standard ferromanganese, silicomanganese, ferromanganese silicon, or calcium carbide; and dust-handling equipment.

(b) Any facility under paragraph (a) of this section that commences construction or modification after October 21, 1974, is subject to the requirements of this subpart.

[42 FR 37938, July 25, 1977]

§60.261   Definitions.

As used in this subpart, all terms not defined herein shall have the meaning given them in the Act and in subpart A of this part.

(a) Electric submerged arc furnace means any furnace wherein electrical energy is converted to heat energy by transmission of current between electrodes partially submerged in the furnace charge.

(b) Furnace charge means any material introduced into the electric submerged arc furnace, and may consist of, but is not limited to, ores, slag, carbonaceous material, and limestone.

(c) Product change means any change in the composition of the furnace charge that would cause the electric submerged arc furnace to become subject to a different mass standard applicable under this subpart.

(d) Slag means the more or less completely fused and vitrified matter separated during the reduction of a metal from its ore.

(e) Tapping means the removal of slag or product from the electric submerged arc furnace under normal operating conditions such as removal of metal under normal pressure and movement by gravity down the spout into the ladle.

(f) Tapping period means the time duration from initiation of the process of opening the tap hole until plugging of the tap hole is complete.

(g) Furnace cycle means the time period from completion of a furnace product tap to the completion of the next consecutive product tap.

(h) Tapping station means that general area where molten product or slag is removed from the electric submerged arc furnace.

(i) Blowing tap means any tap in which an evolution of gas forces or projects jets of flame or metal sparks beyond the ladle, runner, or collection hood.

(j) Furnace power input means the resistive electrical power consumption of an electric submerged arc furnace as measured in kilowatts.

(k) Dust-handling equipment means any equipment used to handle particulate matter collected by the air pollution control device (and located at or near such device) serving any electric submerged arc furnace subject to this subpart.

(l) Control device means the air pollution control equipment used to remove particulate matter generated by an electric submerged arc furnace from an effluent gas stream.

(m) Capture system means the equipment (including hoods, ducts, fans, dampers, etc.) used to capture or transport particulate matter generated by an affected electric submerged arc furnace to the control device.

(n) Standard ferromanganese means that alloy as defined by ASTM Designation A99-76 or 82 (Reapproved 1987) (incorporated by reference—see §60.17).

(o) Silicomanganese means that alloy as defined by ASTM Designation A483-64 or 74 (Reapproved 1988) (incorporated by reference—see §60.17).

(p) Calcium carbide means material containing 70 to 85 percent calcium carbide by weight.

(q) High-carbon ferrochrome means that alloy as defined by ASTM Designation A101-73 or 93 (incorporated by reference—see §60.17) grades HC1 through HC6.

(r) Charge chrome means that alloy containing 52 to 70 percent by weight chromium, 5 to 8 percent by weight carbon, and 3 to 6 percent by weight silicon.

(s) Silvery iron means any ferrosilicon, as defined by ASTM Designation A100-69, 74, or 93 (incorporated by reference—see §60.17), which contains less than 30 percent silicon.

(t) Ferrochrome silicon means that alloy as defined by ASTM Designation A482-76 or 93 (incorporated by reference—see §60.17).

(u) Silicomanganese zirconium means that alloy containing 60 to 65 percent by weight silicon, 1.5 to 2.5 percent by weight calcium, 5 to 7 percent by weight zirconium, 0.75 to 1.25 percent by weight aluminum, 5 to 7 percent by weight manganese, and 2 to 3 percent by weight barium.

(v) Calcium silicon means that alloy as defined by ASTM Designation A495-76 or 94 (incorporated by reference—see §60.17).

(w) Ferrosilicon means that alloy as defined by ASTM Designation A100-69, 74, or 93 (incorporated by reference—see §60.17) grades A, B, C, D, and E, which contains 50 or more percent by weight silicon.

(x) Silicon metal means any silicon alloy containing more than 96 percent silicon by weight.

(y) Ferromanganese silicon means that alloy containing 63 to 66 percent by weight manganese, 28 to 32 percent by weight silicon, and a maximum of 0.08 percent by weight carbon.

[41 FR 18501, May 4, 1976; 41 FR 20659, May 20, 1976, as amended at 48 FR 3738, Jan. 27, 1983; 65 FR 61758, Oct. 17, 2000]

§60.262   Standard for particulate matter.

(a) On and after the date on which the performance test required to be conducted by §60.8 is completed, no owner or operator subject to the provisions of this subpart shall cause to be discharged into the atmosphere from any electric submerged arc furnace any gases which:

(1) Exit from a control device and contain particulate matter in excess of 0.45 kg/MW-hr (0.99 lb/MW-hr) while silicon metal, ferrosilicon, calcium silicon, or silicomanganese zirconium is being produced.

(2) Exit from a control device and contain particulate matter in excess of 0.23 kg/MW-hr (0.51 lb/MW-hr) while highcarbon ferrochrome, charge chrome, standard ferromanganese, silicomanganese, calcium carbide, ferrochrome silicon, ferromanganese silicon, or silvery iron is being produced.

(3) Exit from a control device and exhibit 15 percent opacity or greater.

(4) Exit from an electric submerged arc furnace and escape the capture system and are visible without the aid of instruments. The requirements under this subparagraph apply only during periods when flow rates are being established under §60.265(d).

(5) Escape the capture system at the tapping station and are visible without the aid of instruments for more than 40 percent of each tapping period. There are no limitations on visible emissions under this subparagraph when a blowing tap occurs. The requirements under this subparagraph apply only during periods when flow rates are being established under §60.265(d).

(b) On and after the date on which the performance test required to be conducted by §60.8 is completed, no owner or operator subject to the provisions of this subpart shall cause to be discharged into the atmosphere from any dust-handling equipment any gases which exhibit 10 percent opacity or greater.

§60.263   Standard for carbon monoxide.

(a) On and after the date on which the performance test required to be conducted by §60.8 is completed, no owner or operator subject to the provisions of this subpart shall cause to be discharged in to the atmosphere from any electric submerged arc furnace any gases which contain, on a dry basis, 20 or greater volume percent of carbon monoxide. Combustion of such gases under conditions acceptable to the Administrator constitutes compliance with this section. Acceptable conditions include, but are not limited to, flaring of gases or use of gases as fuel for other processes.

§60.264   Emission monitoring.

(a) The owner or operator subject to the provisions of this subpart shall install, calibrate, maintain and operate a continuous monitoring system for measurement of the opacity of emissions discharged into the atmosphere from the control device(s).

(b) For the purpose of reports required under §60.7(c), the owner or operator shall report as excess emissions all six-minute periods in which the average opacity is 15 percent or greater.

(c) The owner or operator subject to the provisions of this subpart shall submit a written report of any product change to the Administrator. Reports of product changes must be postmarked not later than 30 days after implementation of the product change.

§60.265   Monitoring of operations.

(a) The owner or operator of any electric submerged arc furnace subject to the provisions of this subpart shall maintain daily records of the following information:

(1) Product being produced.

(2) Description of constituents of furnace charge, including the quantity, by weight.

(3) Time and duration of each tapping period and the identification of material tapped (slag or product.)

(4) All furnace power input data obtained under paragraph (b) of this section.

(5) All flow rate data obtained under paragraph (c) of this section or all fan motor power consumption and pressure drop data obtained under paragraph (e) of this section.

(b) The owner or operator subject to the provisions of this subpart shall install, calibrate, maintain, and operate a device to measure and continuously record the furnace power input. The furnace power input may be measured at the output or input side of the transformer. The device must have an accuracy of ±5 percent over its operating range.

(c) The owner or operator subject to the provisions of this subpart shall install, calibrate, and maintain a monitoring device that continuously measures and records the volumetric flow rate through each separately ducted hood of the capture system, except as provided under paragraph (e) of this section. The owner or operator of an electric submerged arc furnace that is equipped with a water cooled cover which is designed to contain and prevent escape of the generated gas and particulate matter shall monitor only the volumetric flow rate through the capture system for control of emissions from the tapping station. The owner or operator may install the monitoring device(s) in any appropriate location in the exhaust duct such that reproducible flow rate monitoring will result. The flow rate monitoring device must have an accuracy of ±10 percent over its normal operating range and must be calibrated according to the manufacturer's instructions. The Administrator may require the owner or operator to demonstrate the accuracy of the monitoring device relative to Methods 1 and 2 of appendix A to this part.

(d) When performance tests are conducted under the provisions of §60.8 of this part to demonstrate compliance with the standards under §§60.262(a) (4) and (5), the volumetric flow rate through each separately ducted hood of the capture system must be determined using the monitoring device required under paragraph (c) of this section. The volumetric flow rates must be determined for furnace power input levels at 50 and 100 percent of the nominal rated capacity of the electric submerged arc furnace. At all times the electric submerged arc furnace is operated, the owner or operator shall maintain the volumetric flow rate at or above the appropriate levels for that furnace power input level determined during the most recent performance test. If emissions due to tapping are captured and ducted separately from emissions of the electric submerged arc furnace, during each tapping period the owner or operator shall maintain the exhaust flow rates through the capture system over the tapping station at or above the levels established during the most recent performance test. Operation at lower flow rates may be considered by the Administrator to be unacceptable operation and maintenance of the affected facility. The owner or operator may request that these flow rates be reestablished by conducting new performance tests under §60.8 of this part.

(e) The owner or operator may as an alternative to paragraph (c) of this section determine the volumetric flow rate through each fan of the capture system from the fan power consumption, pressure drop across the fan and the fan performance curve. Only data specific to the operation of the affected electric submerged arc furnace are acceptable for demonstration of compliance with the requirements of this paragraph. The owner or operator shall maintain on file a permanent record of the fan performance curve (prepared for a specific temperature) and shall:

(1) Install, calibrate, maintain, and operate a device to continuously measure and record the power consumption of the fan motor (measured in kilowatts), and

(2) Install, calibrate, maintain, and operate a device to continuously measure and record the pressure drop across the fan. The fan power consumption and pressure drop measurements must be synchronized to allow real time comparisions of the data. The monitoring devices must have an accuracy of ±5 percent over their normal operating ranges.

(f) The volumetric flow rate through each fan of the capture system must be determined from the fan power consumption, fan pressure drop, and fan performance curve specified under paragraph (e) of this section, during any performance test required under §60.8 to demonstrate compliance with the standards under §§60.262(a)(4) and (5). The owner or operator shall determine the volumetric flow rate at a representative temperature for furnace power input levels of 50 and 100 percent of the nominal rated capacity of the electric submerged arc furnace. At all times the electric submerged arc furnace is operated, the owner or operator shall maintain the fan power consumption and fan pressure drop at levels such that the volumetric flow rate is at or above the levels established during the most recent performance test for that furnace power input level. If emissions due to tapping are captured and ducted separately from emissions of the electric submerged arc furnace, during each tapping period the owner or operator shall maintain the fan power consumption and fan pressure drop at levels such that the volumetric flow rate is at or above the levels established during the most recent performance test. Operation at lower flow rates may be considered by the Administrator to be unacceptable operation and maintenance of the affected facility. The owner or operator may request that these flow rates be reestablished by conducting new performance tests under §60.8. The Administrator may require the owner or operator to verify the fan performance curve by monitoring necessary fan operating parameters and determining the gas volume moved relative to Methods 1 and 2 of appendix A to this part.

(g) All monitoring devices required under paragraphs (c) and (e) of this section are to be checked for calibration annually in accordance with the procedures under §60.13(b).

§60.266   Test methods and procedures.

(a) During any performance test required in §60.8, the owner or operator shall not allow gaseous diluents to be added to the effluent gas stream after the fabric in an open pressurized fabric filter collector unless the total gas volume flow from the collector is accurately determined and considered in the determination of emissions.

(b) In conducting the performance tests required in §60.8, the owner or operator shall use as reference methods and procedures the test methods in appendix A of this part or other methods and procedures as specified in this section, except as provided in §60.8(b).

(c) The owner or operator shall determine compliance with the particulate matter standards in §60.262 as follows:

(1) The emission rate (E) of particulate matter shall be computed for each run using the following equation:

eCFR graphic ec16no91.012.gif

View or download PDF

where:

E=emission rate of particulate matter, kg/MW-hr (1b/MW-hr).

n=total number of exhaust streams at which emissions are quantified.

csi = concentration of particulate matter from exhaust stream “i”, g/dscm (gr/dscf).

Qsdi = volumetric flow rate of effluent gas from exhaust stream “i”, dscm/hr (dscf/hr).

P=average furnace power input, MW.

K=conversion factor, 1000 g/kg (7000 gr/lb).

(2) Method 5 shall be used to determine the particulate matter concentration (csi) and volumetric flow rate (Qsdi) of the effluent gas, except that the heating systems specified in sections 2.1.2 and 2.1.6 are not to be used when the carbon monoxide content of the gas stream exceeds 10 percent by volume, dry basis. If a flare is used to comply with §60.263, the sampling site shall be upstream of the flare. The sampling time shall include an integral number of furnace cycles.

(i) When sampling emissions from open electric submerged arc furnaces with wet scrubber control devices, sealed electric submerged arc furnaces, or semienclosed electric arc furnaces, the sampling time and sample volume for each run shall be at least 60 minutes and 1.80 dscm (63.6 dscf).

(ii) When sampling emissions from other types of installations, the sampling time and sample volume for each run shall be at least 200 minutes and 5.66 dscm (200 dscf).

(3) The measurement device of §60.265(b) shall be used to determine the average furnace power input (P) during each run.

(4) Method 9 and the procedures in §60.11 shall be used to determine opacity.

(5) The emission rate correction factor, integrated sampling procedure of Method 3B shall be used to determine the CO concentration. The sample shall be taken simultaneously with each particulate matter sample.

(d) During the particulate matter run, the maximum open hood area (in hoods with segmented or otherwise moveable sides) under which the process is expected to be operated and remain in compliance with all standards shall be recorded. Any future operation of the hooding system with open areas in excess of the maximum is not permitted.

(e) To comply with §60.265 (d) or (f), the owner or operator shall use the monitoring devices in §60.265 (c) or (e) to make the required measurements as determined during the performance test.

[54 FR 6671, Feb. 14, 1989; 54 FR 21344, May 17, 1989, as amended at 55 FR 5212, Feb. 14, 1990; 65 FR 61758, Oct. 17, 2000]



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