Section 1200-03-16-.46 - LEAD ACID BATTERY MANUFACTURING PLANTS(1) Applicability. (a) The provisions of this rule are applicable to the affected facilities listed in subparagraph (b) of this paragraph 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 rule 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 subparagraph (b) of this paragraph the construction or modification of which is commenced after November 6, 1988, is subject to the requirements of this rule.(2) Definitions. (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 rule 1200-3-16-.12.(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, or three-process operation facility, or a furnace affected under rule 1200-3-16 - .12.(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 paragraph 1200-3-16-.01(5) is completed, no owner or operator subject to the provisions of this rule shall 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 (0.000176 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 (0.00044 gr/dscf).3. From any three-process operation facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.00044 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 (0.00198 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 (0.00044 gr/dscf).7. From any affected facility other than a lead reclamation facility any gases with greater than 0 percent opacity (measured according to Method 9 (as specified in 1200-3-16-.01(5)(g)), and rounded to the nearest whole percentage).8. From any lead reclamation facility any gases with greater than 5 percent opacity (measured according to Method 9 and rounded to the nearest whole percentage).(b) When two 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: Click to view Image
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 rule and controlled by a scrubbing system(s) shall install, calibrate, maintain, and operate a monitoring device(s) that measures and records the pressure drop across the scrubbing system(s) at least once every 15 minutes. The monitoring device shall have an accuracy of ±; 5 percent over its operating range.
(5) Test methods and procedures: (a) Reference methods in subparagraph 1200-3-16-.01(5)(g), except as provided under subparagraph 1200-3-16-.01(5)(b), shall be used to determine compliance according to paragraph 1200-3-16-.01(5) as follows: 1. Method 12 for the measurement of lead concentrations,2. Method 1 for sample and velocity traverses,3. Method 2 for velocity and volumetric flow rate, and4. Method 4 for stack gas moisture.(b) For Method 12, the sampling time for each run shall be at least 60 minutes and the sampling rate shall be at least 0.85 dscm/h (0.53 dscf/min.), except that shorter sampling times, when necessitated by process variables or other factors, may be approved by the Technical Secretary.(c) When different operations in a three-process operation facility are ducted to separate control devices, the lead emission concentration from the facility shall be determined using the equation: Click to view Image
Where:
CpbT = is the facility emission concentration for the entire facility.
N = is the number of control devices to which separate operations in the facility are ducted.
Cpba = is the emission concentration from each control device.
Qsda = is the dry standard volumetric flow rate of the effluent gas stream from each control device.
QsdT = is the total dry standard volumetric flow rate from all of the control devices.
(d) For lead oxide manufacturing facilities, the average lead feed rate to a facility, expressed in kilograms per hour, shall be determined for each test run as follows: 1. Calculate the total amount of lead charged to the facility during the run by multiplying the number of lead pigs (ingots) charged during the run by the average mass of a pig in kilograms or by another suitable method.2. Divide the total amount of lead charged to the facility during the run by the duration of the run in hours.(e) Lead emissions from lead oxide manufacturing facilities, expressed in milligrams per kilogram of lead charged, shall be determined using the following equation: Epb = Cpb Qsd / F
Where:
Epb = is the lead emission rate from the facility in milligrams per kilogram of lead charged.
Cpb = is the concentration of lead in the exhaust stream in milligrams per dry standard cubic meter as determined according to part (a)1. of this paragraph.
Qsd = is the dry standard volumetric flow rate in dry standard cubic meters per hour as determined according to part (a)3. of this paragraph.
F = is the lead feed rate to the facility in kilograms per hour as determined according to subparagraph (d) of this paragraph.
Tenn. Comp. R. & Regs. 1200-03-16-.46
Original rule filed September 21, 1988; effective November 6, 1988.Authority: T.C.A. §§ 68-25-105 and 4-5-202.