Section NR 440.52 - Lead-acid battery manufacturing plants(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY. (a) The provisions of this section are applicable to the affected facilities listed in par. (b) 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 section 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 par. (b) that commences construction or modification after January 14, 1980, is subject to the requirements of this section.(2) DEFINITIONS. As used in this section, terms not defined in this subsection have the meanings given in s. NR 440.02. (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 s. NR 440.29.(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, 3-process operation facility or a furnace affected under s. NR 440.29.(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 s. NR 440.08 is completed, no owner or operator subject to the provisions of this section may 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 (0.000175 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 (0.000437 gr/dscf).3. From any 3-process operation facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 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 (0.00197 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 (0.000437 gr/dscf).7. From any affected facility other than a lead reclamation facility any gases with greater than zero percent opacity measured according to Method 9 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, and rounded to the nearest whole percentage.8. From any lead reclamation facility any gases with greater than 5% opacity, measured according to Method 9 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, and rounded to the nearest whole percentage.(b) When 2 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: See PDF for diagram
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 section and controlled by scrubbing systems shall install, calibrate, maintain and operate a monitoring device or devices that measure and record the pressure drop across the scrubbing systems at least once every 15 minutes. The monitoring device shall have an accuracy of " 5% over its operating range.(5) TEST METHODS AND PROCEDURES. (a) 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).(b) The owner or operator shall determine compliance with the lead standards in sub. (3), except sub. (3) (a) 4., as follows:1. Method 12 shall be used to determine the lead concentration and, if applicable, the volumetric flow rate (Qsda) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30 dscf).2. When different operations in a 3-process operation facility are ducted to separate control devices, the lead emission concentration (C) from the facility shall be determined as follows: See PDF for diagram
where:
C is the concentration of lead emissions for the entire facility, mg/dscm (gr/dscf)
Ca is the concentration of lead emissions from facility "a", mg/dscm (gr/dscf)
Qsda is the volumetric flow rate of effluent gas from facility "a", dscm/hr (dscf/hr)
N is the total number of control devices to which separate operations in the facility are ducted
3. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity. The opacity numbers shall be rounded off to the nearest whole percentage.(c) The owner or operator shall determine compliance with the lead standard in sub. (3) (a) 4. as follows: 1. The emission rate (E) from a lead oxide manufacturing facility shall be computed for each run using the following equation: See PDF for diagram
where:
E is the emission rate of lead, mg/kg (lb/ton) of lead charged
CPbi is the concentration of lead from emission point "i", mg/dscm (gr/dscf)
Qsdi is the volumetric flow rate of effluent gas from emission point "i", dscm/hr (dscf/hr)
M is the number of emission points in the affected facility
P is the lead feed rate to the facility, kg/hr (ton/hr)
K is the conversion factor, 1.0 mg/mg (7000 gr/lb)
2. Method 12 shall be used to determine the lead concentration (CPb) and the volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30 dscf).
3. The average lead feed rate (P) shall be determined for each run using the following equation: See PDF for diagram
where:
N is the number of lead pigs (ingots) charged
W is the average mass of a pig, kg (ton)
[BITA] is the duration of run, hr
Wis. Admin. Code Department of Natural Resources NR 440.52
Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (5), Register, July, 1993, No. 451, eff. 8-1-93; correction in (5) (b) 1. made under s. 13.93(2m) (b) 7, Stats., Register, November, 1999, No. 527; CR 06-109: am. (3) (a) 1., 2., 3., 5. and 6. and (5) (c) 1. Register May 2008 No. 629, eff. 6-1-08.