Tenn. Comp. R. & Regs. 1200-03-16-.26 - STEEL PLANTS: ELECTRIC ARC FURNACES CONSTRUCTED AFTER FEBRUARY 9, 1977, AND ON OR BEFORE AUGUST 17, 1983

(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 and dust-handling systems.

(b) The provisions of this rule apply to each affected facility identified in subparagraph (a) of this paragraph that commenced construction, modification, or reconstruction after February 9, 1977 and on or before August 17, 1983.

(2) Definitions.

(a) "Electric Arc Furnace" (EAF) means a furnace that produces molten steel and heats the charge materials with electric arcs from carbon electrodes. 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.

(b) "Dust-handling equipment" means any equipment used to handle particulate matter collected by the control device and located at or near the control device for an EAF subject to this rule.

(c) "Control device" means the air pollution control equipment used to remove particulate matter generated by an EAF(s) from the effluent gas stream.

(d) "Capture system" means the equipment (including ducts, hoods, fans, dampers, etc.) used to capture or transport particulate matter generated by an EAF to the air pollution control device.

(e) "Charge" means the addition of iron and steel scrap or other materials into the top of an electric arc furnace.

(f) "Charging period" means the time period commencing at the moment an EAF starts to open and ending either three minutes after the EAF roof is returned to its closed position or six minutes after commencement of opening of the roof, whichever is longer.

(g) "Tap" means the pouring of molten steel from an EAF.

(h) "Tapping period" means the time period commencing at the moment an EAF begins to tilt to pour and ending either three minutes after an EAF returns to an upright position or six minutes after commencing to tilt, whichever is longer.

(i) "Meltdown and refining" means that phase of the steel production cycle when charge material is melted and undesirable elements are removed from the metal.

(j) "Meltdown and refining period" means the time period commencing at the termination of the initial charging period and ending at the initiation of the tapping period, excluding any intermediate charging periods.

(k) "Shop opacity" means the arithmetic average of 24 or more opacity observations of emissions from the shop taken in accordance with Method 9 (as specified in 1200-3- 16-.01(5)(g)9) for the applicable time periods.

(l) "Heat time" means the period commencing when scrap is charged to an empty EAF and terminating when the EAF tap is completed.

(m) "Shop" means the building which houses one or more EAF's.

(n) "Direct shell evacuation system (DEC System)" means any system that maintains a negative pressure within the EAF above the slag or metal and ducts these emissions to the control device.

(3) Standards for Particulate Matter and Opacity:

(a) On and after the date on which the performance test required to be conducted by paragraph .01(5) of this chapter is completed, no owner or operator subject to the provisions of this rule shall discharge or cause the discharge into the atmosphere from an electric arc furnace any 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 three percent opacity or greater.

3. Exit from a shop and, due solely to operations of any EAF(s), exhibit six percent opacity or greater except:

(i) Shop opacity less than 20 percent may occur during charging periods.

(ii) Shop opacity less than 40 percent may occur during tapping periods.

(iii) Opacity standards under part (a)3. of this paragraph shall apply only during periods when pressures and either control system fan motor amperes and damper positions or flow rates are being established under subparagraphs (5)(c) and (5)(g) of this rule.

(iv) Where the capture system is operated such that the roof of the shop is closed during the charge and the tap, and emissions to the atmosphere are prevented until the roof is opened after completion of the charge or tap, the shop opacity standards under part (a)3. of this paragraph shall apply when the roof is opened and shall continue to apply for the length of time defined by the charging and/or tapping periods.

(b) On and after the date on which the performance test required to be conducted by paragraph .01(5) of this chapter is completed, no owner or operator subject to the provisions of this rule shall discharge or cause the discharge into the atmosphere from dust-handling equipment any gases which exhibit 10 percent opacity or greater.

(4) Emission Monitoring.

(a) 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) For the purpose of reports under 1200-3-16-.01(7)(c), periods of excess emissions that shall be reported are defined as all six- minutes periods during which the average opacity is three percent or greater.

(c) No continuous monitoring system shall be required on any 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 in accordance with subpart (6)(c)6.(i) of this rule.

(5) Monitoring of Operations.

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

1. Time and duration of each charge;

2. Time and duration of each tap;

3. All flow rate data obtained under subparagraph (b) of this paragraph, or equivalent obtained under subparagraph (d) of this paragraph; and

4. All pressure data obtained under subparagraph (e) 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 a Direct Shell Evacuation system is in use) and either:

1. check and record the control system fan motor amperes and damper positions 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 ±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 EAF is required to demonstrate compliance with the standards under 1200-3-16-.26(3)(a) 3. 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 EAF subject to parts (b)1. or (b)2. 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 EAF operating conditions upon which the parameters were previously established are no longer applicable. The values of these parameters as 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 1200-3-16-.26(7)(a).

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

(e) 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 hole 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.

(f) Where emissions during any phase of the heat time are controlled by use of a direct shell evacuation system, the owner or operator shall install, calibrate, and maintain a monitoring device that continuously records the pressure in the free space inside the EAF. The pressure shall be recorded as 15-minute integrated averages. The monitoring device may be installed in any appropriate location in the EAF such that reproducible results will be obtained. The pressure monitoring device shall have an accuracy of ± 5 mm 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 is required to demonstrate compliance with the standard under 1200-3-16-.26(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 meltdown and refining period(s) using the monitoring device described in subparagraph (f) of this paragraph. The owner or operator may petition the Technical Secretary for reestablishment of the 15-minute integrated average 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 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) Where the capture system is designed and operated such that all emissions are captured and ducted to a control device, the owner or operator shall not be subject to the requirements of this paragraph.

(i) During any performance test required under 1200-3-16-.01(5), and for any report thereof required by subparagraph (6)(c) of this rule or to determine compliance with 1200-3-16-.26(3)(a) 3., 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 furnace where direct-shell evacuation systems are used;

3. Control device operation log; and

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

(6) Test methods and procedures

(a) Reference methods (as referenced in 1200-3-16-.01(5)(g) ) except as provided under 1200-3-16-.01(5)(b), shall be used to determine compliance with standards prescribed under 1200-3-16-.26(3) as follows:

1. Either Method 5 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;

2. Method 1 for sample and velocity traverses;

3. Method 2 for velocity and volumetric flow rate;

4. Method 3 for gas analysis; and

5. Method 9 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 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) For the purpose of this rule, the owner or operator shall conduct the demonstration of compliance with subparagraph (3)(a) of this rule 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 (5)(i) 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 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 corretions; and

22. Sample emission calculations.

(d) During any performance test required under 1200-3-16-.01(5)(g), 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.

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

Click to view Image

Where:

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

N = total number of control devices tested.

Qs = volumetric flow rate of the effluent gas stream in dscm/ hr (dscf/hr) as detemined by Method 2.

(CsQs)n or (Qs)n = value of the applicable parameter for each control device tested.

(f) 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.

(g) Where emissions from any EAF(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 which compensates for the emissions from the facilities not subject to this rule.

3. Any combination of the criteria of parts (g)1. and (g)2. of this paragraph.

(h) Where emissions from any EAF(s) are combined with emissions from facilities not subject to the provisions of this rule, the owner or operator may use any of the following procedures for demonstrating compliance with 1200-3-16-.26(3)(a) 3:

1. Base compliance on control of the combined emissions.

2. Shut down operation of facilities not subject to the provisions of this rule.

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

(i) 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 is operating in the melting and refining period. 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 (3)(a) of this rule.

(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)(g) to demonstrate compliance with parts 1, 2 and 3, of subparagraph 1200-3-16-.26(3)(a).

(7) Recordkeeping and reporting requirements.

(a) Operation at a furnace static pressure that exceeds the value established under subparagraph (5)(f) of this rule and either operation of control system fan motor amperes at values exceeding ±15 percent of the value established under subparagraph (5)(c) of this rule or operation at flow rates lower than those established by subparagraph (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 semiannually.

(b) When the owner or operator of an EAF is required to demonstrate compliance with the standard under parts (6)(g)2. and (6)(g)3. of this rule, 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.

Notes

Tenn. Comp. R. & Regs. 1200-03-16-.26

Original rule filed January 10, 1977; effective February 9, 1977. Amendment filed September 4, 1981; effective October 19, 1981. Amendment filed September 21, 1988; effective November 6, 1988.

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