Section 1200-03-16-.55 - SECONDARY EMISSIONS FROM BASIC OXYGEN PROCESS STEELMAKING FACILITIES FOR WHICH CONSTRUCTION IS COMMENCED AFTER NOVEMBER 6, 1988(1) Applicability and Designation of Affected Facilities(a) The provisions of this rule apply to the following affected facilities in an iron and steel plant: top-blown BOPF's and hot metal transfer stations and skimming stations used with bottom- blown or top-blown BOPF's.(b) This rule applies to any facility identified in subparagraph (a) of this paragraph that commences construction, modification, or reconstruction after November 6, 1988.(c) Any BOPF subject to the provisions of this rule is subject to those provisions of rule 1200-3-16-.14 applicable to affected facilities commencing construction, modification or reconstruction after November 6, 1988.(2) Definitions (a) "Basic Oxygen Process Furnace" (BOPF) means any furnace with a refractory lining in which molten steel is produced by charging scrap metal, molten iron, and flux materials or alloy additions into a vessel and by introducing a high volume of oxygen-rich gas. Open hearth, blast, and reverberatory furnaces are not included in this definition.(b) "Bottom-blown furnace" means any BOPF in which oxygen and other combustion gases are introduced to the bath of molten iron through tuyeres in the bottom of the vessel or through tuyeres in the bottom and sides of the vessel.(c) "Fume suppression system" means the equipment comprising any system used to inhibit the generation of emissions from steelmaking facilities with an inert gas, flame, or steam blanket applied to the surface of molten iron or steel.(d) "Hot metal transfer station" means the facility where molten iron is emptied from the railroad torpedo car or hot metal car to the shop ladle. This includes the transfer of molten iron from the torpedo car or hot metal car to a mixer (or other intermediate vessel) and from a mixer (or other intermediate vessel) to the ladle. This facility is also known as the reladling station or ladle transfer station.(e) "Primary oxygen blow" means the period in the steel production cycle of a BOPF during which a high volume of oxygen-rich gas is introduced to the bath of molten iron by means of a lance inserted from the top of the vessel. This definition does not include any additional, or secondary, oxygen blows made after the primary blow.(f) "Primary emission control system" means the combination of equipment used for the capture and collection of primary emissions (e.g., an open hood capture system used in conjunction with a particulate matter cleaning device such as an electrostatic precipitator or a closed hood capture system used in conjunction with a particulate matter cleaning device such as a scrubber).(g) "Primary emissions" means particulate matter emissions from the BOPF generated during the steel production cycle which are captured by, and do not thereafter escape from, the BOPF primary control system.(h) "Secondary emission control system" means the combination of equipment used for the capture and collection of secondary emissions (e.g., (1) an open hood system for the capture and collection of primary and secondary emissions from the BOPF, with local hooding ducted to a secondary emission collection device such as a baghouse for the capture and collection of emissions from the hot metal transfer and skimming station; or (2) an open hood system for the capture and collection of primaryand secondary emissions from the furnace, plus a furnace enclosure with local hooding ducted to a secondary emission collection device, such as a baghouse, for additional capture and collection of secondary emissions from the furnace, with local hooding ducted to a secondary emission collection device, such as a baghouse, for the capture and collection of emissions from hot metal transfer and skimming stations; or (3) a furnace enclosure with local hooding ducted to a secondary emission collection device such as a baghouse for the capture and collection of secondary emissions from a BOPF controlled by a closed hood primary emission control system, with local hooding ducted to a secondary emission collection device, such as a baghouse, for the capture and collection of emissions from hot metal transfer and skimming stations).(i) "Secondary emissions" means particulate matter emissions that are not captured by the BOPF primary control system, including emissions from hot metal transfer and skimming stations. This definition also includes particulate matter emissions that escape from openings in the primary emission control system, such as from lance hole openings, gaps or tears in the ductwork of the primary emission control system, or leaks in hoods.(j) "Skimming station" means the facility where slag is mechanically raked from the top of the bath of molten iron.(k) "Steel production cycle" means the operations conducted within the BOPF steelmaking facility that are required to produce each batch of steel, including the following operations: scrap charging, preheating (when used), hot metal charging, primary oxygen blowing, sampling (vessel turndown and turnup), additional oxygen blowing (when used), tapping, and deslagging. Hot metal transfer and skimming operations for the next steel production cycle are also included when the hot metal transfer station or skimming station is an affected facility.(l) "Top-blown furnace" means any BOPF in which oxygen is introduced to the bath of molten iron by means of an oxygen lance inserted from the top of the vessel.(3) Standards for Particulate Matter (a) Except as provided under subparagraphs (b) and (c) of this paragraph, on and after the date on which the performance test under paragraph 1200-3-16-.01(5) is required to be completed, no owner or operator subject to the provisions of this rule shall cause to be discharged into the atmosphere from any affected facility any secondary emissions that: 1. Exit from the BOPF shop roof monitor (or other building openings) and exhibit greater than 10 percent opacity during the steel production cycle of any top-blown BOPF or during hot metal transfer or skimming operations for any bottom- blown BOPF; except that an opacity greater than 10 percent but less than 20 percent may occur once per steel production cycle.2. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming for a top-blown or a bottom-blown BOPF and contain particulate matter in excess of 23 mg/dscm (0.010 gr/dscf).3. Exit from a control device used solely for the collection of secondary emissions from a top-blown BOPF or from hot metal transfer or skimming for a top-blown or a bottom-blown BOPF and exhibit more than 5 percent opacity.(b) A fume suppression system used to control secondary emissions from an affected facility is not subject to parts (a)2. and (a)3. of this paragraph.(c) A control device used to collect both primary and secondary emissions from a BOPF is not subjected to parts (a)2. and (a)3. of this paragraph.(4) Monitoring of Operations (a) Each owner or operator of an affected facility shall install, calibrate, operate, and maintain a monitoring device that continually measures and records for each steel production cycle the various rates or levels of exhaust ventilation at each phase of the cycle through each duct of the secondary emission capture system. The monitoring device or devices are to be placed at locations near each capture point of the secondary emission capture system to monitor the exhaust ventilation rates or levels adequately, or in alternative locations approved in advance by the Technical Secretary.(b) If a chart recorder is used, the owner or operator shall use chart recorders that are operated at a minimum chart speed of 3.8 cm/hr (1.5 in./hr.).(c) All monitoring devices are to be certified by the manufacturer to be accurate to within ± 10 percent compared to Method 2 as specified in 1200-3-16.01(5)(g)2. The owner or operator shall recalibrate and check the device(s) annually and at other times as the Technical Secretary may require, in accordance with the written instructions of the manufacturer and by comparing the device against Method 2 specified in 1200-3-16 - .01(5)(g)2.(d) Each owner or operator subject to the requirements of subparagraph (a) of this paragraph shall report on a semiannual basis all measurements of exhaust ventilation rates or levels over any 3-hour period that average more than 10 percent below the average rates or levels of exhaust ventilation 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 part (3)(a)2. of this rule. The accuracy of the respective measurements, not to exceed the values specified in subparagraph (c) of this paragraph, may be considered when determining the measurement results that must be reported.(e) If a scrubber primary emission control device is used to collect secondary emissions, the owner or operator shall report on a semiannual basis all measurements of exhaust ventilation rate over any 3-hour period that average more than 10 percent below the average levels maintained during the most recent performance test specified in paragraph 1200-3-16-.01(5) in which the affected facility demonstrated compliance with the standard under part (3)(a)1. of this rule.(5) Test Methods and Procedures (a) The reference methods contained in subparagraph 1200-3-16-.01(5)(g), except as provided in subparagraph 1200-3-16-.01(5)(b) and as noted below, shall be used to determine compliance with paragraph (3) of this rule. Applicable methods are as follows: 1. Method 1 for sample and velocity traverses;2. Method 2 for volumetric flow rate;3. Method 3 for gas analysis;4. Method 5 for concentration of particulate matter and associated moisture content; and5. Method 9 for visible emissions except as provided in subparagraph (b) of this paragraph.(b) For Method 9, the following instructions for recording observations and reducing data shall apply instead of sections 2.4 and 2.5 of Method 9.1. Section 2.4. Opacity observations shall be recorded to the nearest 5 percent at 15-second intervals. During the initial performance test conducted pursuant to paragraph 1200-3-16-.01(5), observations shall be made and recorded in this manner for a minimum of three steel production cycles. During any subsequent compliance test, observations may be made for any number of steel production cycles, although, where conditions permit, observations will generally be made for a minimum of three steel production cycles.2. Section 2.5. Opacity shall be determined as an average of 12 consecutive observations recorded at 15-second intervals. For each steel production cycle, divide the observations recorded into sets of 12 consecutive observations. Sets need not be consecutive in time, and in no case shall two sets overlap. For each set of 12 observations, calculate the average by summing the opacity of 12 consecutive observations and dividing this sum by 12.(c) For the sampling of secondary emissions by Method 5, the sampling for each run is to continue for a sufficient number of steel production cycles to ensure a total sample volume of at least 5.67 dscm (200 dscf) for each run. Shorter sampling times and smaller sample volumes, when necessitated by process variables or other factors, may be approved by the Technical Secretary. Sampling is to be conducted only during the steel production cycle.(d) For the monitoring and recording of exhaust ventilation rates or levels required by subparagraph (4)(a) of this rule, the following instructions for Reference Method 2 shall apply: 1. For devices that monitor and record the exhaust ventilaton rate, compare velocity readings recorded by the monitoring device against the velocity readings obtained by Method 2. Take Method 2 readings at a point or points that would properly characterize the monitoring device's performance and that would adequately reflect the various rates of exhaust ventilation. Obtain readings at sufficient intervals to obtain 12 pairs of readings for each duct of the secondary emission capture system. Compare the averages of the two sets to determine whether the monitoring device velocity is within ± 10 percent of the Method 2 average.2. For devices that monitor the level of exhaust ventilation and record only step changes when a set point rate is reached, compare step changes recorded by the monitoring device against the velocity readings obtained by Method 2. Take Method 2 readings at a point or points that would properly characterize the performance of the monitoring device and that would adequately reflect the various rates of exhaust ventilation. Obtain readings of sufficient intervals to obtain 12 pairs of readings for each duct of the secondary emission capture system. Compare the averages of the two sets to determine whether the monitoring device step change is within ± 10 percent of setpoint rate.(6) Compliance Provisions (a) When determining compliance with mass and visible emission limits specified in parts (3)(a)2. and 3. of this rule, the owner or operator of a BOPF shop that normally operates two furnaces with overlapping cycles may elect to operate only one furnace. If an owner or operator chooses to shut down one furnace, he shall be allowed a reasonable time period to adjust his production schedule before the compliance tests are conducted. The owner or operator of an affected facility may also elect to suspend shop operations not subject to this rule during compliance testing.(b) During compliance testing for mass and visible emission standards, if an owner or operator elects to shut down one furnace in a shop that normally operates two furnaces with overlapping cycles, the owner or operator shall operate the secondary emission control system for the furnace being tested at exhaust ventilation rates or levels for each duct of the secondary emission control system that are appropriate for single-furnace operation. Following the compliance test, the owner or operator shall operate the secondary emission control system at exhaust ventilation rates or levels for each duct of the system that are no lower than 90 percent of the exhaust ventilation values established during the most recent compliance test.(c) For the purpose of determining compliance with visible and mass emission standards, a steel production cycle begins when the scrap or hot metal is charged to the vessel (whichever operation occurs first) and terminates 3 minutes after slag is emptied from the vessel into the slag pot. Consecutive steel production cycles are not required for the purpose of determining compliance. Where a hot metal transfer or skimming station is an affected facility, the steel production cycle also includes the hot metal transfer or skimming operation for the next steel production cycle for the affected vessel. Visible emission observations for both hot metal transfer and skimming operations begin with the start of the operation and terminate 3 minutes after completion of the operation.(d) For the purpose of determining compliance with visible emission standards specified in parts (3)(a)1. and 3. of this rule, the starting and stopping times of regulated process operations shall be determined and the starting and stopping times of visible emissions data sets shall be determined accordingly.(e) To determine compliance with part (3)(a)1. of this rule, select the data sets yielding the highest and second highest 3-minute average opacities for each steel production cycle. Compliance is achieved if the highest 3-minute average for each cycle observed is less than 20 percent and the second highest 3-minute average is 10 percent or less.(f) To determine compliance with part (3)(a)2. of this rule, determine the concentration of particulate matter in exhaust gases exiting the secondary emission collection device with Method 5. Compliance is achieved if the concentration of particulate matter does not exceed 23 mg/dscm (0.010 gr/dscf).(g) To determine compliance with part (3)(a)3. of this rule, construct consecutive 3-minute averages for each steel production cycle. Compliance is achieved if no 3-minute average is more than 5 percent.Tenn. Comp. R. & Regs. 1200-03-16-.55
Original rule filed September 21, 1988; effective November 6, 1988.Authority: T.C.A. §§ 68-25-105 and 4-5-202.