Section NR 440.46 - Glass manufacturing plants(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY. (a) Each glass melting furnace is an affected facility to which the provisions of this section apply.(b) Any facility under par. (a) that commences construction or modification after June 15, 1979, is subject to the requirements of this section. (c) This section does not apply to hand glass melting furnaces, glass melting furnaces designed to produce less than 4.55 Mg (5 tons) of glass per day and all-electric melters.(2) DEFINITIONS. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02, unless otherwise required by the context. (a) "All-electric melter" means a glass melting furnace in which all the heat required for melting is provided by electric current from electrodes submerged in the molten glass, although some fossil fuel may be charged to the furnace as raw material only. See PDF for diagram
(c) "Container glass" means glass made of soda-lime recipe, clear or colored, which is pressed or blown, or both, into bottles, jars, ampoules and other products listed under SIC code 3221 in the Standard Industrial Classification Manual, incorporated by reference in s. NR 440.17. (cm) "Experimental furnace" means a glass melting furnace with the sole purpose of operating to evaluate glass melting processes, technologies, or glass products. An experimental furnace does not produce glass that is sold (except for further research and development purposes) or that is used as a raw material for nonexperimental furnaces.(d) "Flat glass" means glass made of soda-lime recipe and produced into continuous flat sheets and other products listed under SIC code 3211 in the Standard Industrial Classification Manual, incorporated by reference in s. NR 440.17. (dm) "Flow channels" means appendages used for conditioning and distributing molten glass to forming apparatuses and are a permanently separate source of emissions such that no mixing of emissions occurs with emissions from the melter cooling system prior to their being vented to the atmosphere.(e) "Glass melting furnace" means a unit comprising a refractory vessel in which raw materials are charged, melted at high temperature, refined and conditioned to produce molten glass. The unit includes foundations, superstructure and retaining walls, raw material charger systems, heat exchangers, melter cooling system, exhaust system, refractory brick work, fuel supply and electrical boosting equipment, integral control systems and instrumentation and appendages for conditioning and distributing molten glass to forming apparatuses. The forming apparatuses, including the float bath used in flat glass manufacturing and flow channels in wool fiberglass and textile manufacturing, are not considered part of the glass melting furnace.(f) "Glass produced" means the weight of the glass pulled from the glass melting furnace.(g) "Hand glass melting furnace" means a glass furnace where the molten glass is removed from the furnace by a glassworker using a blowpipe or a pontil. See PDF for diagram
(i) "Pressed and blown glass" means glass which is pressed, blown, or both, including textile fiberglass, noncontinuous flat glass, noncontainer glass and other products listed under SIC code 3229 in the Standard Industrial Classification Manual, incorporated by reference in s. NR 440.17. It is separated into glass of borosilicate recipe, glass of soda-lime and lead recipes, glass of opal, fluoride and other recipes.(j) "Rebricking" means cold replacement of damaged or worn refractory parts of the glass melting furnace. Rebricking includes replacement of the refractories comprising the bottom, sidewalls or roof of the melting vessel; replacement of refractory work in the heat exchanger; and replacement of refractory portions of the glass conditioning and distribution system.(k) "Soda-lime recipe" means glass product composition of the following ranges of weight proportions: 60 to 75% silicon dioxide, 10 to 17% total R2O (e.g., Na2O and K2O), 8 to 20% total RO but not to include any PbO (e.g., CaO and MgO), 0 to 8% total R2O3 (e.g., Al2O3) and 1 to 5% other oxides. (km) "Textile fiberglass" means fibrous glass in the form of continuous strands having uniform thickness. (ks) "With modified-processes" means using any technique designed to minimize emissions without the use of add-on pollution controls. (L) "Wool fiberglass" means fibrous glass of random texture, including fiberglass insulation, and other products listed under SIC code 3296 in the Standard Industrial Classification Manual, incorporated by reference in s. NR 440.17.(3) STANDARDS FOR PARTICULATE MATTER. (a) On and after the date on which the performance test required to be conducted by s. NR 440.08 is completed, no owner or operator of a glass melting furnace subject to the provisions of this section may cause to be discharged into the atmosphere: 1. From any glass melting furnace fired exclusively with either a gaseous fuel or a liquid fuel, particulate matter at emission rates exceeding those specified in Table 1, Column 2 and Column 3, respectively, or2. From any glass melting furnace, fired simultaneously with gaseous and liquid fuels, particulate matter at emission rates exceeding STD as specified by the following equation: See PDF for diagram
where:
STD is the particulate matter emission limit, g of particulate/kg (lb of particulate/ton) of glass produced
X is the emission rate specified in Table 1 for furnaces fired with gaseous fuel (Column 2)
Y is the decimal fraction of liquid fuel heating value to total (gaseous and liquid) fuel heating value fired in the glass melting furnaces as determined in sub. (7) (b) (joules/joules)
Z is equal to (1-Y)
Table 1 - Emission Rates
[g of particulate/kg of glass produced]
| Col. 1 - Glass manufacturing plant industry segment | Col. 2- Furnace fired with gaseousfuel | Col. 3- Furnace fired with liquid fuel |
| a. | Container glass ................ | 0.10 | 0.13 |
| b. | Pressed and blown glass |
| 1) Borosilicate Recipes.......... | 0.50 | 0.65 |
| 2) SodaLime and Lead Recipes . . . | 0.10 | 0.13 |
| 3) Other-Than Borosilicate, SodaLime, and Lead Recipes (including opal,fluoride and other recipes) ........ | 0.25 | 0.325 |
| c. | Wool fiberglass ................ | 0.25 | 0.325 |
| d. | Flat glass ..................... | 0.225 | 0.225 |
(b) Conversion of a glass melting furnace to the use of liquid fuel may not be considered a modification for the purposes of s. NR 440.14.(c) Rebricking and the cost of rebricking may not be considered a reconstruction for the purposes of s. NR 440.15.(d) An owner or operator of an experimental furnace is not subject to the requirements of this section.(e) During routine maintenance of add-on pollution controls an owner or operator of a glass melting furnace subject to the provisions of sub. (3) (a) is exempt from the provisions of this subsection if:1. Routine maintenance in each calendar year does not exceed 6 days;2. Routine maintenance is conducted in a manner consistent with good air pollution control practices for minimizing emissions; and3. A report is submitted to the department 10 days before the start of the routine maintenance (if 10 days cannot be provided the report must be submitted as soon as practicable) and the report contains an explanation of the schedule of the maintenance.(4) STANDARDS FOR PARTICULATE MATTER FROM GLASS MELTING FURNACE WITH MODIFIED-PROCESSES. (a) An owner or operator of a glass melting furnaces with modified-processes is not subject to the provisions of sub. (3) if the affected facility complies with the provision of this subsection.(b) On and after the date on which the performance test required to be conducted by s. NR 440.08 is completed, no owner or operator of a glass melting furnace with modified processes subject to the provisions of this section may cause to be discharged into the atmosphere from the affected facility: 1. Particulate matter at emission rates exceeding 0.50 gram of particulate per kilogram of glass produced (g/kg) as measured according to par. (e) for container glass, flat glass and pressed and blown glass with a soda-lime recipe melting furnace.2. Particulate matter at emission rates exceeding 1.0 g/kg as measured according to par. (e) for pressed and blown glass with a borosilicate recipe melting furnace.3. Particulate matter at emission rates exceeding 0.50 g/kg as measured according to par. (e) for textile fiberglass and wool fiberglass melting furnaces.(c) The owner or operator of an affected facility that is subject to emission limits specified under par. (b) shall: 1. Install, calibrate, maintain and operate a continuous monitoring system for the measurement of the opacity of emissions discharged into the atmosphere from the affected facility.2. During the performance test required to be conducted by s. NR 440.08 conduct continuous opacity monitoring during each test run.3. Calculate 6-minute opacity averages from 24 or more data points equally spaced over each 6-minute period during the test runs.4. Determine, based on the 6-minute opacity averages, the opacity value corresponding to the 99% upper confidence level of a normal distribution of average opacity values.5. For the purposes of s. NR 440.07, report to the department as excess emissions all of the 6-minute periods during which the average opacity, as measured by the continuous monitoring system installed under par. (c) 1., exceeds the opacity value corresponding to the 99% upper confidence level determined under par. (c) 4.(d)1. After receipt and consideration of written application, the department may approve alternative continuous monitoring systems for the measurement of one or more process or operating parameters that is or are demonstrated to enable accurate and representative monitoring of an emission limit specified in par. (b).2. After the department approves an alternative continuous monitoring system for an affected facility, the requirements of par. (c) 1. to 5. will not apply for that affected facility.(e) An owner or operator may redetermine the opacity value corresponding to the 99% upper confidence level as described in par. (c) 4. if the owner or operator does all of the following:1. Conducts continuous opacity monitoring during each test run of a performance test that demonstrates compliance with an emission limit of par. (b).2. Recalculates the 6-minute opacity averages as described in par. (c) 3.3. Uses the redetermined opacity value corresponding to the 99% upper confidence level for the purposes of par. (c) 5.(f) Test methods and procedures as specified under sub. (7) shall be used to determine compliance with this section except that to determine compliance for any glass melting furnace using modified processes and fired with either a gaseous fuel or a liquid fuel containing less than 0.50 weight percent sulfur, Method 5 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1), shall be used with the probe and filter holder heating system in the sampling train set to provide a gas temperature of 120 "14°C (248 "25°F).(7) TEST METHODS AND PROCEDURES. (a) If a glass melting furnace with modified processes is changed to one without modified processes or if a glass melting furnace without modified processes is changed to one with modified processes, the owner or operator shall notify the department at least 60 days before the change is schedule to occur.(b) When gaseous and liquid fuels are fired simultaneously in a glass melting furnace, the owner or operator shall determine the applicable standard under sub. (3) (a) 2. as follows: 1. The ratio (Y) of liquid fuel heating value to total (gaseous and liquid) fuel heating value fired in the glass melting furnaces shall be computed for each run using the following equation: See PDF for diagram
where:
Y is the decimal fraction of liquid fuel heating value to total fuel heating value
Hl is the gross calorific value of liquid fuel, J/kg
Hg is the gross calorific value of gaseous fuel, J/kg
L is the liquid flow rate, kg/hr
G is the gaseous flow rate, kg/hr
2. Suitable methods shall be used to determine the rates (L and G) of fuels burned during each test period and a material balance over the glass melting furnace shall be used to confirm the rates.3. ASTM Methods D240-92 (liquid fuels) and D1826-94 (gaseous fuels), incorporated by reference in s. NR 440.17(2) (a) 9. and 21., as applicable, shall be used to determine the gross calorific values.(c) In conducting the performance tests required in s. NR 440.08, the owner or operator shall use as reference methods and procedures the test methods in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 440.17, or other methods and procedures as specified in this subsection, except as provided in s. NR 440.08(2).(d) The owner or operator shall determine compliance with the particulate matter standards in subs. (3) and (4) as follows: 1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: See PDF for diagram
where:
E is the emission rate of particulate matter, g/kg
cs is the concentration of particulate matter, g/dsm
Qsd is the volumetric flow rate, dscm/hr
A is the zero production rate correction = 227 g/hr for container glass, pressed and blown (soda-lime and lead) glass, and pressed and blown (other than borosilicate, soda-lime and lead) glass
= 454 g/hr for pressed and blown (borosilicate) glass, wool fiberglass, and flat glass
P is the glass production rate, kg/hr
2. Method 5 shall be used to determine the particulate matter concentration (cs) and volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.90 dscm (31.8 dscf). The probe and filter holder heating system may be set to provide a gas temperature no greater than 177"14°C (350"25°F), except under the conditions specified in sub. (4) (e).3. Direct measurement or material balance using good engineering practice shall be used to determine the amount of glass pulled during the performance test. The rate of glass produced is defined as the weight of glass pulled from the affected facility during the performance test divided by the number of hours taken to perform the performance test.4. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity.Wis. Admin. Code Department of Natural Resources NR 440.46
Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (b), (e), (h) and (k), (7) (a) (intro.), cr. (2) (cm), (dm), (km), (ks), (3) (d) and (e), (4) and (7) (g),Register, September, 1986, No. 369, eff. 10-1-86; am. (2) (intro.), (3) (a) 1., 2. and Table, (4) (b), (intro.), 1. and 3., Register, September, 1990, No. 417, eff. 10-1-90; am. (2) (c), (d), (i) and (L), (3) (a) 2. and Table 1, r. and recr. (7), Register, May, 1993, No. 450, eff. 8-1-93; CR 06-109: am. (1) (c), (3) (a) 2., (4) (c) 4. and 5. and (d) 1. (intro.) and (7) (b) 3., renum. (4) (e) to be (4) (f) and am., renum. (4) (d) 3. (intro.), a., b., and c. to be (4) (e) (intro.), 1., 2. and 3. and am. Register May 2008 No. 629, eff. 6-1-08.