Section 1200-03-16-.50 - PHOSPHATE ROCK PLANTS(1) Applicability. (a) The provisions of this rule are applicable to the following affected facilities used in phosphate rock plants which have a maximum plant production capacity greater than 3.6 megagrams per hour (4 tons/hr): dryers, calciners, grinders, and ground rock handling and storage facilities, except those facilities producing or preparing phosphate rock solely for consumption in elemental phosphorus production.(b) Any facility under subparagraph (a) of this paragraph which commences construction, modification, or reconstruction after November 6, 1988 is subject to the requirements of this rule.(2) Definitions. (a) "Phosphate rock plant" means any plant which produces or prepares phosphate rock product by any or all of the following processes: Mining, beneficiation, crushing, screening, cleaning, drying, calcining, and grinding.(b) "Phosphate rock feed" means all material entering the process unit including, moisture and extraneous material as well as the following ore minerals: Fluorapatite, hydroxylapatite, chlorapatite, and carbonateapatite.(c) "Dryer" means a unit in which the moisture content of phosphate rock is reduced by contact with a heated gas stream.(d) "Calciner" means a unit in which the moisture and organic matter of phosphate rock is reduced within a combustion chamber.(e) "Grinder" means a unit which is used to pulverize dry phosphate rock to the final product size used in the manufacture of phosphate fertilizer and does not include crushing devices used in mining.(f) "Ground phosphate rock handling and storage system" means a system which is used for the conveyance and storage of ground phosphate rock from grinders at phosphate rock plants.(g) "Beneficiation" means the process of washing the rock to remove impurities or to separate size fractions.(3) Standards: (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 phosphate rock dryer any gases which: (i) Contain particulate matter in excess of 0.030 kilogram per megagram of phosphate rock feed (0.06 lb/ton), or(ii) Exhibit greater than 10 percent opacity.2. From any phosphate rock calciner processing unbeneficiated rock or blends of beneficiated and unbeneficiated rock, any gases which: (i) Contains particulate matter in excess of 0.12 kilogram per megagram of phosphate rock feed (0.23 lb/ton), or(ii) Exhibit greater than 10 percent opacity.3. From any phosphate rock calciner processing beneficiated rock any gases which: (i) Contain particulate matter in excess of 0.055 kilogram per megagram of phosphate rock feed (0.11 lb/ton), or(ii) Exhibit greater than 10 percent opacity.4. From any phosphate rock grinder any gases which:(i) Contain particulate matter in excess of 0.006 kilogram per megagram of phosphate rock feed (0.012 lb/ton), or(ii) Exhibit greater than zero-percent opacity.5. From any ground phosphate rock handling and storage system any gases which exhibit greater than zero-percent opacity.(4) Monitoring of emissions and operations: (a) Any owner or operator subject to the provisions of this rule shall install, calibrate, maintain, and operate a continuous monitoring system, except as provided in subparagraphs (b) and (c) of this paragraph, to monitor and record the opacity of the gases discharged into the atmosphere from any phosphate rock dryer, calciner, or grinder. The span of this system shall be set at 40 percent opacity.(b) For ground phosphate rock storage and handling systems, continuous monitoring systems for measuring opacity are not required.(c) The owner or operator of any affected phosphate rock facility using a wet scrubbing emission control device shall not be subject to the requirements in subparagraph (a) of this paragraph, but shall install, calibrate, maintain, and operate the following continuous monitoring devices: 1. A monitoring device for the continuous measurement of the pressure loss of the gas stream through the scrubber. The monitoring device must be certified by the manufacturer to be accurate within ±250 pascals (±1 inch water) gauge pressure.2. A monitoring device for the continuous measurement of the scrubbing liquid supply pressure to the control device. The monitoring device must be accurate within ±5 percent of design scrubbing liquid supply pressure.(d) For the purpose of conducting a performance test under paragraph 1200-3-16-.01(5), the owner or operator of any phosphate rock plant subject to the provisions of this rule shall install, calibrate, maintain, and operate a device for measuring the phosphate rock feed to any affected dryer, calciner, or grinder. The measuring device used must be accurate to within ±5 percent of the mass rate over its operating range.(e) For the purpose of reports required under subparagraph 1200-3-16-.01(7)(c), periods of excess emissions that shall be reported are defined as all 6-minute periods during which the average opacity of the plume from any phosphate rock dryer, calciner, or grinder subject to subparagraph (a) of this paragraph exceeds the applicable opacity limit.(f) Any owner or operator subject to the requirements under subparagraph (c) of this paragraph shall report for each calendar quarter all measurement results that are less than 90 percent of the average levels maintained during the most recent performance test conducted under paragraph 1200-3-16-.01(5) in which the affected facility demonstrated compliance with the standard under paragraph (3) of this rule.(5) Test methods and procedures: (a) Reference methods, (as specified in rule 1200-3-16-.01(5)(g)) except as provided under subparagraph 1200-3-16-.01(5)(b), shall be used to determine compliance with paragraph (3) of this rule as follows: 1. Method 5 for the measurement of particulate matter and associated moisture content,2. Method 1 for sample and velocity traverses,3. Method 2 for velocity and volumetric flow rates,4. Method 3 for gas analysis, and5. Method 9 for the measurement of the opacity of emissions.(b) For Method 5, the sampling time for each run shall be at least 60 minutes and have a minimum sampled volume of 0.84 dscm (30 dscf). However, shorter sampling times and smaller sample volumes, when necessitated by process variables or other factors, may be approved by the Technical Secretary.(c) For each run, the average phosphate rock feed rate in megagrams per hour shall be determined using a device meeting the requirements of subparagraph (4)(d) of this rule.(d) For each run, emissions expressed in kilograms per megagram of phosphate rock feed shall be determined using the following equation: Click to view Image
where:
E= Emissions of particulates in kg/Mg of phosphate rock feed.
Cs= Concentration of particulates in mg/dscm as measured by Method 5.
Qs= Volumetric flow rate in dscm/hr as determined by Method 2.
10-6= Conversion factor for milligrams to kilograms.
M= Average phosphate rock feed rate in Mg/hr.
Tenn. Comp. R. & Regs. 1200-03-16-.50
Original rule filed September 21, 1988; effective November 6, 1988.Authority: T.C.A. §§ 68-25-108 and 4-5-202.