Section NR 440.59 - Asphalt processing and asphalt roofing manufacture(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITIES. (a) The affected facilities to which this section applies are each saturator and each mineral handling and storage facility at asphalt roofing plants; and each asphalt storage tank and each blowing still at asphalt processing plants, petroleum refineries and asphalt roofing plants.(b) Any saturator or mineral handling and storage facility under par. (a) that commences construction or modification after November 18, 1980 is subject to the requirements of this section. Any asphalt storage tank or blowing still that processes or stores, or both processes and stores, asphalt used for roofing only or for roofing and other purposes, and that commences construction or modification after November 18, 1980 is subject to the requirements of this section. Any asphalt storage tank or blowing still that processes or stores, or both processes and stores, only nonroofing asphalts and that commences construction or modification after May 26, 1981 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) "Afterburner" or "A/B" means an exhaust gas incinerator used to control emissions of particulate matter.(b) "Asphalt processing" means the storage and blowing of asphalt.(c) "Asphalt processing plant" means a plant which blows asphalt for use in the manufacture of asphalt products.(d) "Asphalt roofing plant" means a plant which produces asphalt roofing products (shingles, roll roofing, siding or saturated felt).(e) "Asphalt storage tank" means any tank used to store asphalt at asphalt roofing plants, petroleum refineries and asphalt processing plants. Storage tanks containing cutback asphalts (asphalts diluted with solvents to reduce viscosity for low temperature applications) and emulsified asphalts (asphalts dispersed in water with an emulsifying agent) are not included.(f) "Blowing still" means the equipment in which air is blown through asphalt flux to change the softening point and penetration rate.(g) "Catalyst" means a substance which, when added to asphalt flux in a blowing still, alters the penetrating-softening point relationship or increases the rate of oxidation of the flux.(h) "Coating blow" means the process in which air is blown through hot asphalt flux to produce coating asphalt. The coating blow starts when the air is turned on and stops when the air is turned off.(i) "Electrostatic precipitator" or "ESP" means an air pollution control device in which solid or liquid particulates in a gas stream are charged as they pass through an electric field and precipitated on a collection surface.(j) "High velocity air filter" or "HVAF" means an air pollution control filtration device for the removal of sticky, oily or liquid aerosol particulate matter from exhaust gas streams.(k) "Mineral handling and storage facility" means the areas in asphalt roofing plants in which minerals are unloaded from a carrier, the conveyor transfer points between the carrier and the storage silos and the storage silos. (L) "Saturator" means the equipment in which asphalt is applied to felt to make asphalt roofing products. The term saturator includes the saturator, wet looper and coater.(3) STANDARDS FOR PARTICULATE MATTER.(a) On and after the date on which s. NR 440.08(2) requires a performance test to be completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any saturator: 1. Particulate matter in excess of either of the following:a. 0.040 kg/Mg (0.080 lb/ton) of asphalt shingle or mineral-surfaced roll roofing produced.b. 0.040 kg/Mg (0.080 lb/ton) of saturated felt or smooth-surfaced roll roofing produced.2. Exhaust gases with opacity greater than 20%; and3. Any visible emissions from a saturator capture system for more than 20% of any period of consecutive valid observations totaling 60 minutes. Saturators that were constructed before November 18, 1980 and that have not been reconstructed since that date and that become subject to this section through modification are exempt from the visible emissions standard. Saturators that have been newly constructed or reconstructed since November 18, 1980 are subject to the visible emissions standard.(b) On and after the date on which s. NR 440.08(2) requires a performance test to be completed, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any blowing still any of the following: 1. Particulate matter in excess of 0.67 kg/Mg (1.3 lb/ton) of asphalt charged to the still when a catalyst is added to the still.2. Particulate matter in excess of 0.71 kg/Mg (1.4 lb/ton) of asphalt charged to the still when a catalyst is added to the still and when No. 6 fuel oil is fired in the afterburner.3. Particulate matter in excess of 0.60 kg/Mg (1.2 lb/ton) of asphalt charged to the still during blowing without a catalyst.4. Particulate matter in excess of 0.64 kg/Mg (1.3 lb/ton) of asphalt charged to the still during blowing without a catalyst and when No. 6 fuel oil is fired in the afterburner.5. Exhaust gases with an opacity greater than zero percent unless an opacity limit for the blowing still when fuel oil is used to fire the afterburner has been established by the administrator in accordance with the procedures in 40 CFR 60.474(g).(c) Within 60 days after achieving the maximum production rate at which the affected facility will be operated, but not later than 180 days after initial startup of such facility, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any asphalt storage tank exhaust gases with opacity greater than zero percent, except for one consecutive 15-minute period in any 24-hour period when the transfer lines are being blown for cleaning. The control device may not be bypassed during this 15-minute period. If, however, the emissions from any asphalt storage tank or tanks are ducted to a control device for a saturator, the combined emissions shall meet the emission limit contained in par. (a) during the time the saturator control device is operating. At any other time the asphalt storage tank or tanks shall meet the opacity limit specified in this paragraph for storage tanks. (d) Within 60 days after achieving the maximum production rate at which the affected facility will be operated, but not later than 180 days after initial startup of such facility, no owner or operator subject to the provisions of this section may cause to be discharged into the atmosphere from any mineral handling and storage facility emissions with opacity greater than one percent.(4) MONITORING OF OPERATIONS. (a) The owner or operator subject to the provisions of this section, and using either an electrostatic precipitator or a high velocity air filter to meet either the emission limit in sub. (3) (a) 1. or (b) 1., or both, shall continuously monitor and record the temperature of the gas at the inlet of the control device. The temperature monitoring instrument shall have an accuracy of " 15°C (" 25°F) over its range.(b) The owner or operator subject to the provisions of this section and using an afterburner to meet either the emission limit in sub. (3) (a) 1. or (b) 1., or both, shall continuously monitor and record the temperature in the combustion zone of the afterburner. The monitoring instrument shall have an accuracy of " 10°C (" 18°F) over its range.(c) An owner or operator subject to the provisions of this section and using a control device not mentioned in par. (a) or (b) shall provide to the department information describing the operation of the control device and the process parameter or parameters which would indicate proper operation and maintenance of the device. The department may require continuous monitoring and determine the process parameters to be monitored. (d) The industry is exempted from the quarterly reports required under s. NR 440.07(3). The owner or operator is required to record and report the operating temperature of the control device during the performance test and, as required by s. NR 440.07(5), maintain a file of the temperature monitoring results for at least 2 years.(5) TEST METHODS AND PROCEDURES. (a) For saturators, the owner or operator shall conduct performance tests required in s. NR 440.08 as follows: 1. If the final product is shingle or mineral-surfaced roll roofing, the tests shall be conducted while 106.6-kg (235-lb) shingle is being produced.2. If the final product is saturated felt or smooth-surfaced roll roofing, the tests shall be conducted while 6.8-kg (15-lb) felt is being produced.3. If the final product is fiberglass shingle, the test shall be conducted while a nominal 100-kg (220-lb) shingle is being produced.(b) 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).(c) The owner or operator shall determine compliance with the particulate matter standards in sub. (3) as follows: 1. The emission rate (E) of particulate matter shall be computed for each run using the following equation: E = (csQsd)/(PK)
where:
E is the emission rate of particulate matter, kg/Mg (lb/ton)
cs is the concentration of particulate matter, g/dscm (gr/dscf)
Qsd is the volumetric flow rate of effluent gas, dscm/hr (dscf/hr)
P is the asphalt roofing production rate or asphalt charging rate, Mg/hr (ton/hr)
K is the conversion factor, 1000 g/kg (7000 gr/lb)
2. Method 5A shall be used to determine the particulate matter concentration (cs) and volumetric flow rate (Q sd) of the effluent gas. For a saturator, the sampling time and sample volume for each run shall be at least 120 minutes and 3.00 dscm (106 dscf), and for the blowing still, at least 90 minutes or the duration of the coating blow or non-coating blow, whichever is greater, and 2.25 dscm (79.4 dscf).3. For the saturator, the asphalt roofing production rate (P) for each run shall be determined as follows: The amount of asphalt roofing produced on the shingle or saturated felt process lines shall be obtained by direct measurement. The asphalt roofing production rate is the amount produced divided by the time taken for the run.4. For the blowing still, the asphalt charging rate (P) shall be computed for each run using the following equation: See PDF for diagram
where:
P is the asphalt charging rate to blowing still, Mg/hr (ton/hr)
V is the volume of asphalt charged, m3 (ft3)
d is the density of asphalt, kg/m3 (lb/ft3)
K' is the conversion factor, 1000 kg/Mg (2000 lb/ton)
q here is the duration of test run, hr
a. The volume (V) of asphalt charged shall be measured by any means accurate to within 10%.b. The density (d) of the asphalt shall be computed using the following equation: d = K1 -K2Ti
where:
d is the density of the asphalt, kg/m3 (lb/ft3)
K1 is 1056.1 kg/m3 for metric units and 64.70 lb/ft3 for English units
K2 is 0.6176 kg/(m3 °C) for metric units and 0.0694 lb/(ft3 °F) for English units
Ti is the temperature at the start of the blow, °C (°F)
5. Method 9 and the procedures in s. NR 440.11 shall be used to determine opacity.(d) The department shall determine compliance with the standards in sub. (3) (a) 3. by using Method 22, modified so that readings are recorded every 15 seconds for a period of consecutive observations during representative conditions, in accordance with s. NR 440.08(3), totaling 60 minutes. A performance test shall consist of one run.(e) The owner or operator shall use the monitoring device in sub. (4) (a) or (b) to monitor and record continuously the temperature during the particulate matter run and shall report the results to the department with the performance test results.(f) If at a later date the owner or operator believes that the emission limits in sub. (3) (a) and (b) are being met even though one of the conditions in subd. 1. or 2. exists, the owner or operator may submit a written request to the department to repeat the performance test and procedure outlined in par. (c). 1. The temperature measured in accordance with sub. (4) (a) is exceeding that measured during the performance test.2. The temperature measured in accordance with sub. (4) (b) is lower than that measured during the performance test.Wis. Admin. Code Department of Natural Resources NR 440.59
Cr. Register, January, 1984, No. 337, eff. 2-1-84; am. (2) (intro.), (3) (a) 1. a. and b. and (5) (k), Register, September, 1990, No. 417, eff. 10-1-90; am. (4) (d), r. and recr. (5), Register, July, 1993, No. 451, eff. 7-1-93; CR 06-109: am. (3) (a) 1., (b), (4) (a) to (c) and (5) (c) 1., r. and recr. (5) (c) 4. b., renum. (5) (f) to be (5) (f) (intro.) and am., cr. (5) (f) 1. and 2. Register May 2008 No. 629, eff. 6-1-08.Under 40 CFR 60.474(g), if fuel oil is to be used to fire an afterburner used to control emissions from a blowing still, the owner or operator may petition the administrator in accordance with 40 CFR 60.11(e), to establish an opacity standard for the blowing still that will be the opacity standard when fuel oil is used to fire the afterburner. To obtain this opacity standard, the owner or operator must request the administrator to determine opacity during an initial, or subsequent, performance test when fuel oil is used to fire the afterburner. Upon receipt of the results of the performance test, the administrator will made a finding concerning compliance with the mass standard for the blowing still. If the administrator finds that the facility was in compliance with the mass standard during the performance test but failed to meet the zero opacity standard, the administrator will establish and promulgate in the Federal Register an opacity standard for the blowing still that will be the opacity standard when fuel oil is used to fire the afterburner. When the afterburner is fired with natural gas, the zero percent opacity remains the applicable opacity standard.