Tenn. Comp. R. & Regs. 1200-03-16-.52

Current through December 10, 2024

Section 1200-03-16-.52 - ELECTRIC ARC FURNACES AND ARGON-OXYGEN DECARBURIZATION VESSELS

(1) Applicability and designation of affected facility.

(a) The provisions of this rule are applicable to the following affected facilities in steel plants that produce carbon, alloy, or specialty steels: electric arc furnaces, argon-oxygen decarburization vessels, and dust handling systems.

(b) The provisions of this rule apply to each affected facility identified in subparagraph (a) of this paragraph that commences construction, modification, or reconstruction after November 6, 1988.

(2) Definitions

(a) As used in this rule, all terms not defined herein shall have the meaning given them in paragraph (4) of rule 1200-3-16-.01.

1. "Argon-oxygen decarburization vessel" (AOD vessel) means any closed-bottom, refractory-lined converter vessel with submerged tuyeres through which gaseous mixtures containing argon and oxygen or nitrogen may be blown into molten steel for further refining.

2. "Capture system" means the equipment (including ducts, hoods, fans, dampers, etc.) used to capture or transport particulate matter generated by an electric arc furnace or AOD vessel to the air pollution control device.

3. "Charge" means the addition of iron and steel scrap or other materials into the top of an electric arc furnace or the addition of molten steel or other materials into the top of an AOD vessel.

4. "Control device" means the air pollution control equipment used to remove particulate matter from the effluent gas stream generated by an electric arc furnace or AOD vessel.

5. "Direct-shell evacuation control system" (DEC System) means a system that maintains a negative pressure within the electric arc furnace above the slag or metal and ducts emissions to the control device.

6. "Dust-handling system" means equipment used to handle particulate matter collected by the control device for an electric arc furnace or AOD vessel subject to this rule. For the purposes of this rule, the dust handling system shall consist of the control device dust hoppers, the dust- conveying equipment, any central dust storage equipment, the dust-treating equipment (e.g., pug mill, pelletizer), dust transfer equipment (from storage to truck), and any secondary control devices used with the dust transfer equipment (from storage to truck), and any secondary control devices used with the dust transfer equipment.

7. "Electric arc furnace" (EAF) means a furnace that produces molten steel and heats the charge materials with electric arcs from carbon electrodes. For the purposes of this rule, an EAF shall consist of the furnace shell and roof and the transformer. Furnaces that continuously feed direct-reduced iron ore pellets as the primary source of iron are not affected facilities within the scope of this definition.

8. "Heat cycle" means the period beginning when scrap is charged to an empty EAF and ending when the EAF tap is completed or beginning when molten steel is charged to an empty AOD vessel and ending when the AOD vessel tap is completed.

9. "Melting" means that phase of steel production cycle during which the iron and steel scrap is heated to the molten state.

10. "Negative-pressure fabric filter" means a fabric filter with the fans on the downstream side of the filter bags.

11. "Positive-pressure fabric filter" means a fabric filter with the fans on the upstream side of the filter bags.

12. "Refining" means that phase of the steel production cycle during which undesirable elements are removed from the molten steel and alloys are added to reach the final metal chemistry.

13. "Shop" means the building which houses one or more EAF's or AOD vessels.

14. "Shop opacity" means the arithmetic average of 24 observations of the opacity of emissions from the shop taken in accordance with Method 9.

15. "Tap" means the pouring of molten steel from an EAF or AOD vessel.

(3) Standard for particulate matter

(a) On and after the date of 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 from an EAF or an AOD vessel and gases which:

1. Exit from a control device and contain particulate matter in excess of 12 mg/dscm (0.0052 gr/dscf);

2. Exit from a control device and exhibit 3 percent opacity or greater; and

3. Exit from a shop and, due solely to the operations of any affected EAF(s) or AOD vessel(s), exhibit 6 percent opacity or greater.

(b) 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 from the dust-handling system any gases that exhibit 10 percent opacity or greater.

(4) Emission monitoring

(a) Except as provided under subparagraphs (b) and (c) of this paragraph, a continuous monitoring system for the measurement of the opacity of emissions discharged into the atmosphere from the control device(s) shall be installed, calibrated, maintained, and operated by the owner or operator subject to the provisions of this rule.

(b) No continuous monitoring system shall be required on any control device serving the dust-handling system.

(c) No continuous monitoring system shall be required on modular, multiple-stack, negative-pressure or positive-pressure fabric filters if observations of the opacity of the visible emissions from the control device are performed by a certified visible emission observer.

(5) Monitoring of operations

(a) The owner or operator subject to the provisions of this rule shall maintain records of the following information:

1. All data obtained under subparagraph (b) of this paragraph.

2. All monthly operational status inspections performed under subparagraph (c) of this paragraph.

(b) Except as provided under subparagraph (d) of this paragraph, the owner or operator subject to the provisions of this rule shall check and record on a once-per-shift basis the furnace static pressure (if DEC system is in use) and either (1) check and record the control system fan motor amperes and damper position on a once-per-shift basis; or (2) install, calibrate, and maintain a monitoring device that continuously records the volumetric flow rate through each separately ducted hood. The monitoring device(s) may be installed in any appropriate location in the exhaust duct such that reproducible flow rate monitoring will result. The flow rate monitoring device(s) shall have an accuracy of ± 10 percent over its normal operating range and shall be calibrated according to the manufacturer's instructions. The Technical Secretary may require the owner or operator to demonstrate the accuracy of the monitoring device(s) relative to Methods 1 and 2 (as specified in 1200-3-16-.01(5)(g)).

(c) When the owner or operator of an affected facility is required to demonstrate compliance with the standards of paragraph (3)(a)3. of this rule, and at any other time the Technical Secretary may require that either the control system fan motor amperes and all damper positions or the volumetric flow rate through each separately ducted hood shall be determined during all periods in which a hood is operated for the purpose of capturing emissions from the affected facility subject to the provisions of subparagraph (b) of this paragraph. The owner or operator may petition the Technical Secretary for reestablishment of these parameters whenever the owner or operator can demonstrate to the Technical Secretary's satisfaction that the affected facility operating conditions upon which the parameters were previously established are no longer applicable. The values of these parameters determined during the most recent demonstration of compliance shall be maintained at the appropriate level for each applicable period. Operation at other than baseline values may be subject to the requirements of subparagraph 1200-3-16-.52(7)(c).

(d) The owner or operator shall perform monthly operational status inspections of the equipment that is important to the performance of the total capture system (i.e., pressure sensors, dampers, and damper switches). This inspection shall include observations of the physical appearance of the equipment (e.g., presence of holes in ductwork or hoods, flow constrictions caused by dents or accumulated dust in ductwork and fan erosion). Any deficiencies shall be noted and proper maintenance performed.

(e) The owner or operator may petition the Technical Secretary to approve any alternative to monthly operational status inspections that will provide a continuous record of the operation of each emission capture system.

(f) If emissions during any phase of the heat time are controlled by the use of a DEC system, the owner or operator shall install, calibrate, and maintain a monitoring device that allows the pressure in the free space inside the EAF to be monitored. The monitoring device may be installed in any appropriate location in the EAF or DEC duct prior to the introduction of ambient air such that reproducible results will be obtained. The pressure monitoring device shall have an accuracy of ± 5mm of water gauge over its normal operating range and shall be calibrated according to the manufacturer's instructions.

(g) When the owner or operator of an EAF controlled by a DEC is required to demonstrate compliance with the standard under part rule 1200-3-16-.52(3)(a) 3. and at any other time the Technical Secretary may require the pressure in the free space inside the furnace shall be determined during the melting and refining period(s) using the monitoring device required under subparagraph (f) of this paragraph. The owner or operator may petition the Technical Secretary for reestablishment of the 15-minute integrated average of the pressure whenever the owner or operator can demonstrate to the Technical Secretary's satisfaction that the EAF operating conditions upon which the pressures were previously established are no longer applicable. The pressure determined during the most recent demonstration of compliance shall be maintained at all times when the EAF is operating in a meltdown and refining period. Operation at higher pressures may be considered by the Technical Secretary to be unacceptable operation and maintenance of the affected facility.

(h) During any performance test required under paragraph 1200-3-16-.01(5), and for any report thereof required by subparagraph (6)(d) of this rule, or to determine compliance with part (3)(a)3. of this rule, the owner or operator shall monitor the following information for all heats covered by the test:

1. Charge weights and materials, and tap weights and materials;

2. Heat times, including start and stop times, and a log of process operation, including periods of no operation during testing and the pressure inside an EAF when direct-shell evacuation control systems are used;

3. Control device operation log; and

4. Continuous monitor or Reference Method 9 (as specified in 1200-3-16-.01(5)(g)) data.

(6) Test methods and procedures.

(a) Reference methods in 1200-3-16-.01(5)(g), except as provided under 1200-3-16 - .01(5)(b), shall be used to determine compliance with the standards prescribed under paragraph 1200-3-16-.52(3) as follows:

1. Method 1 for sample and velocity traverses;

2. Method 2 for velocity and volumetric flow rate;

3. Method 3 (as specified in 1200-3-16-.01(5)(g)) for gas analysis;

4. Either Method 5 (as specified in 1200-3-16-.01(5)(g)) for negative-pressure fabric filters and other types of control devices or Method 5D for positive-pressure fabric filters for concentration of particulate matter and associated moisture content; and

5. Method 9 (as specified in 1200-3-16-.01(5)(g)) for the opacity of visible emissions.

(b) For Method 5 or 5D, the sampling time for each run shall be at least 4 hours. When a single EAF or AOD vessel is sampled, the sampling time for each run shall also include an integral number of heats. Shorter sampling times, when necessitated by process variables or other factors, may be approved by the Technical Secretary. For Method 5 or 5D, the minimum sample volume shall be 4.5 dscm (160 dscf).

(c) Visible emissions observations of modular, multiple-stack, negative-pressure or positive-pressure fabric filters shall occur at least once per day of operation. The observations shall occur when the furnace or vessel is operating in the melting or refining phase of a heat cycle. These observations shall be taken in accordance with Method 9, and, for at least three 6-minute periods, the opacity shall be recorded for any point(s) where visible emissions are observed. Where it is possible to determine that a number of visible emission sites relate to only one incident of the visible emissions, only one set of three 6-minute observations will be required. In this case, Reference Method 9 observations must be made for the site of highest opacity that directly relates to the cause (or location) of visible emissions observed during a single incident. Records shall be maintained of any 6-minute average that is in excess of the emission limit specified in subparagraph 1200-3-16-.52(3)(a).

(d) For the purpose of this rule, the owner or operator shall conduct the demonstration of compliance with subparagraph 1200-3-16-.52(3)(a) and furnish the Technical Secretary a written report of the results of the test. This report shall include the following information:

1. Facility name and address;

2. Plant representative;

3. Make and model of process, control device, and continuous monitoring equipment;

4. Flow diagram of process and emission capture equipment including other equipment or process(es) ducted to the same control device;

5. Rated (design) capacity of process equipment;

6. Those data required under subparagraph (h) of this rule;

(i) List of charge and tap weights and materials;

(ii) Heat times and process log;

(iii) Control device operation log; and

(iv) Continuous monitor or Reference Method 9 data.

7. Test dates and test times;

8. Test company;

9. Test company representative;

10. Test observers from outside agency;

11. Description of test methodology used, including any deviation from standard reference methods;

12. Schematic of sampling location;

13. Number of sampling points;

14. Description of sampling equipment;

15. Listing of sampling equipment calibrations and procedures;

16. Field and laboratory data sheets;

17. Description of sample recovery procedures;

18. Sampling equipment leak check results;

19. Description of quality assurance procedures;

20. Description of analytical procedures;

21. Notation of sample blank corrections; and

22. Sample emission calculations.

(e) During any performance test required under 1200-3-16-.01(5), no gaseous diluents may be added to the effluent gas stream after the fabric in any pressurized fabric filter collector, unless the amount of dilution is separately determined and considered in the determination of emissions.

(f) When more than one control device serves the EAF(s) or AOD vessel(s) being tested, the concentration of particulate matter shall be determined using the following equation:

Click to view Image

where

C = concentration of particulate matter in mg/dscm (gr/dscf) as determined by Method 5 or 5D.

N = total number of control devices tested.

Q = volumetric flow rate of the effluent gas stream in dscm/h (dscf/h) as determined by Method 2. (CQ)n, (Q)n = value of the applicable parameter for each control device tested.

(g) Any control device subject to the provisions of this rule shall be designed and constructed to allow measurement of emissions using applicable test methods and procedures.

(h) Where emissions from any EAF(s) or AOD vessel(s) are combined with emissions from facilities not subject to the provisions of this rule but controlled by a common capture system and control device, the owner or operator may use any of the following procedures during a performance test:

1. Base compliance on control of the combined emissions;

2. Utilize a method acceptable to the Technical Secretary that compensates for the emissions from the facilities not subject to the provisions of this rule or;

3. Any combination of the criteria of subparagraphs (h)1. and (h)2. of this paragraph.

(i) Where emissions from any EAF(s) or AOD vessel(s) are combined with emissions from facilities not subject to the provisions of this rule, determinations of compliance with 1200-03-16-.52(3)(a) 3. will only be based upon emissions originating from the affected facility(ies).

(j) Unless the presence of inclement weather makes concurrent testing infeasible, the owner or operator shall conduct concurrently the performance tests required under 1200-3-16-.01(5) to demonstrate compliance with 1200-3-16-.52(3)(a) 1., 2. and 3.

(7) Recordkeeping and reporting requirements.

(a) Records of the measurements required in paragraph (5) of this rule must be retained for at least 2 years following the date of the measurement.

(b) Each owner or operator shall submit a written report of exceedances of the control device opacity to the Technical Secretary semi- annually. For the purposes of these reports exceedances are defined as all 6-minute periods during which the average opacity is 3 percent or greater.

(c) Operation at a furnace static pressure that exceeds the value established under subparagraph (5)(g) of this rule and either operation of control system fan motor amperes at values exceeding ± 15 percent of the value established under paragraph (5)(c) of this rule or operation at flow rates lower than those established under paragraph (5)(c) of this rule may be considered by the Technical Secretary to be unacceptable operation and maintenance of the affected facility. Operation at such values shall be reported to the Technical Secretary semi-annually.

(d) When the owner or operator of an EAF or AOD is required to demonstrate compliance under parts 1200-3-16-.52(6)(h) 2. or 3., the owner or operator shall obtain approval from the Technical Secretary of the procedure(s) that will be used to determine compliance. Notification of the procedure(s) to be used must be postmarked 30 days prior to the performance test.

Tenn. Comp. R. & Regs. 1200-03-16-.52

Original rule filed September 21, 1988; effective November 6, 1988.

Authority: T.C.A. §§ 68-25-105 and 4-5-202.