Tenn. Comp. R. & Regs. 1200-03-16-.27 - FERROALLOY PRODUCTION FACILITIES

(1) Applicability.

The provisions of this rule are applicable to the following affected facilities commenced on or after February 9, 1977: Electric submerged arc furnaces which produce silicon metal, ferrosilicon, calcium silicon, silicomanganese zirconium, ferrochrome silicon, silvery iron, high-carbon ferrochrome, charge chrome, standard ferromanganese, silicomanganese, ferromanganese silicon, or calcium carbide; and dust handling equipment.

(2) Definitions.
(a) "Electric submerged arc furnace" means any furnace wherein electrical energy is converted to heat energy by transmission of current between electrodes partially submerged in the furnace charge.
(b) "Furnace charge" means any material introduced into the electric material arc furnace and may consist of, but is not limited to, ores, slag, carbonaceous material, and limestone.
(c) "Product change" means any change in the composition of the furnace charge that would cause the electric submerged arc furnace to become subject to a different mass standard applicable under this rule.
(d) "Slag" means the more or less completely fused and vitrified matter separated during the reduction of a metal from its ore.
(e) "Tapping" means the removal of slag or product from the electrical submerged arc furnace under normal operating conditions such as removal of metal under normal pressure and movement by gravity down the spout into the ladle.
(f) "Tapping period" means the time duration from initiation of the process of opening tap until plugging of the tap hole is completed.
(g) "Furnace cycle" means the time period from completion of a furnace product tap to the completion of the next consecutive product tap.
(h) "Tapping station" means that general area where molten product or slag is removed from the electric submerged arc furnace.
(i) "Blowing tap" means any tap in which an evolution of gas forces or projects jets of flame or metal sparks beyond the ladle, runner, or collection hood.
(j) "Furnace power input" means the resistive electrical power consumption of an electric submerged arc furnace as measured in kilowatts.
(k) "Dust-handling equipment" means any equipment used to handle particulate matter collected by the air pollution control device (and located at or near such device) serving any electric submerged arc furnace subject to this rule.
(l) "Control device" means the air pollution control equipment used to remove particulate matter generated by an electric submerged arc furnace from an effluent gas stream.
(m) "Capture system" means the equipment (including hoods, ducts, fans, dampers, etc.) used to capture or transport particulate matter generated by an affected electric submerged arc furnace to the control device.
(n) "Standard ferromanganese" means that alloy as defined by A.S.T.M. designation A99-66.
(o) "Silicomanganese" means that alloy as defined by A.S.T.M. designation A483-66.
(p) "Calcium carbide" means material containing 70 to 85 percent calcium carbide by weight.
(q) "High-carbon ferrochrome" means that alloy as defined by A.S.T.M. designation A101-66 grades HC1 through HC6.
(r) "Charge chrome" means that alloy containing 52 to 70 percent by weight chromium, 5 to 8 percent by weight carbon, and 3 to 6 percent by weight silicon.
(s) "Silvery iron" means any ferrosilicon, as defined by A.S.T.M. designation A100-69, which contains less than 30 percent silicon.
(t) "Ferrochrome silicon" means that alloy as defined by A.S.T.M. designation A482-66.
(u) "Silicomanganese zirconium" means that alloy containing 60 to 65 percent by weight silicon, 1.5 to 2.5 percent by weight calcium, 5 to 7 percent by weight zirconium, 0.75 to 1.25 percent by weight aluminum, 5 to 7 percent by weight manganese, and 2 to 3 percent by weight barium.
(v) "Calcium silicon" means that alloy as defined by A.S.T.M. designation A495-64.
(w) "Ferrosilicon" means that alloy as defined by A.S.T.M. designation A100-69 grades A, B, C, D, and E which contains 50 or more percent silicon by weight.
(x) "Silicon metal" means any silicon alloy containing more than 96 percent silicon by weight.
(y) "Ferromanganese silicon" means that alloy containing 63 to 66 percent by weight manganese, 28 to 32 percent by weight silicon, and a maximum of 0.08 percent by weight carbon.
(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 subpart shall cause to be discharged into the atmosphere from any electric submerged arc furnace any gases which:
1. Exit from a control device and contain particulate matter in excess of 0.45 kg/MW-hr (0.99 lb/MW-hr) while silicon metal, ferrosilicon, calcium silicon, or silicomanganese zirconium is being produced.
2. Exit from a control device and contain particulate matter in excess of 0.23 kg/MW-hr (0.51 lb/MW-hr) while high-carbon ferrochrome, charge chrome, standard ferromanganese, silicomanganese, calcium carbide, ferrochrome silicon, ferromanganese silicon, or silvery iron is being produced.
3. Exit from a control device and exhibit 15 percent opacity or greater.
4. Exit from an electric submerged arc furnace and escape the capture system and are visible without the aid of instruments. The requirements under this part apply only during periods when flow rates are being established under subparagraph (6) (d) of this rule.
5. Escape the capture system at the tapping station and are visible without the aid of instruments for more than 40 percent of each tapping period. There are no limitations on visible emissions under this part when a blowing tap occurs. The requirements under this subparagraph apply only during periods when flow rates are being established under subparagraph (6)(d) of this rule.
(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 subpart shall cause to be discharged into the atmosphere from any dust-handling equipment any gases which exhibit 10 percent opacity or greater.
(4) Standard for Carbon Monoxide.
(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 subpart shall cause to be discharged into the atmosphere from any electric submerged arc furnace any gases which contain, on a dry basis, 20 or greater volume percent of carbon monoxide. Combustion of such gases under conditions acceptable to the Technical Secretary constitutes compliance with this section. Acceptable conditions include, but are not limited to, flaring of gases or use of gases as fuel for other processes.
(5) Emission Monitoring.
(a) The owner or operator subject to the provisions of this rule shall install, calibrate, maintain and operate a continuous monitoring system for measurement of the opacity of emissions discharged into the atmosphere from the control device(s).
(b) For the purpose of reports required under subparagraph .01(7)(c) of this chapter, the owner or operator shall report as excess emissions all six-minute periods in which the average opacity is 15 percent or greater.
(c) The owner or operator subject to the provisions of this subpart shall submit a written report of any product change to the Technical Secretary. Reports of product changes must be postmarked not later than 30 days after implementation of the product change.
(6) Monitoring of Operations.
(a) The owner or operator of any electric submerged arc furnace subject to the provisions of this rule shall maintain daily records of the following information:
1. Product being produced.
2. Description of constituents of furnace charge, including the quantity, by weight.
3. Time and duration of each tapping period and the identification of material tapped (slag or product).
4. All furnace power input data obtained under subparagraph (b) of this paragraph.
5. All flow rate data obtained under subparagraph (e) of this paragraph or all fan motor power consumption and pressure drop data obtained under subparagraph (e) of this paragraph.
(b) The owner or operator subject to the provisions of this rule shall install, calibrate, maintain, and operate a device to measure and continuously record the furnace power input. The furnace power input may be measured at the output or input side of the transformer. The device must have an accuracy of ±5 percent over its operating range.
(c) The owner or operator subject to the provisions of this rule shall install, calibrate, and maintain a monitoring device that continuously measures and records the volumetric flow rate through each separately ducted hood of the capture system, except as provided under subparagraph (e) of this paragraph. The owner or operator of an electric submerged arc furnace that is equipped with a water cooled cover which is designed to contain and prevent escape of the generated gas and particulate matter shall monitor only the volumetric flow rate through the capture system for control of emissions from the tapping station. The owner or operator may install the monitoring device(s) in any appropriate location in the exhaust duct such that reproductible flow rate monitoring will result. The flow rate monitoring device must have an accuracy of ±10 percent over its normal operating range and must 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 relative to Methods 1. and 2. in subparagraph .01(5)(g) of this chapter.
(d) When performance tests are conducted under the provisions of paragraph .01(5) of this chapter to demonstrate compliance with the standards under parts (3)(a)4. and (3)(a)5. of this rule, the volumetric flow rate through each separately ducted hood of the capture system must be determined using the monitoring device required under subparagraph (c) of this paragraph. The volumetric flow rates must be determined for furnace power input levels at 50 and 100 percent of the nominal rated capacity of the electric submerged arc furnace. At all times the electric submerged arc furnace is operated, the owner or operator shall maintain the volumetric flow rate at or above the appropriate levels for that furnace power input level determined during the most recent performance test. If emissions due to tapping are captured and ducted separately from emissions of the electric submerged arc furnace, during each tapping period the owner or operator shall maintain the exhaust flow rates through the capture system over the tapping station at or above the levels established during the most recent performance test. Operation at lower flow rates may be considered by the Technical Secretary to be unacceptable operation and maintenance of the affected facility. The owner or operator may request that these flow rates be reestablished by conducting new performance tests under paragraph .01(5) of this rule.
(e) The owner or operator may as an alternative to subparagraph (c) of this paragraph determine the volumetric flow rate through each fan of the capture system from the fan power consumption, pressure drop across the fan and the fan performance curve. Only data specific to the operation of the affected electric submerged arc furnace are acceptable for demonstration of compliance with the requirements of this subparagraph. The owner or operator shall maintain a permanent record of the fan performance curve (prepared for a specific temperature) and shall:
1. Install, calibrate, maintain and operate a device to continuously measure and record the power consumption of the fan motor (measured in kilowatts), and
2. Install, calibrate, maintain, and operate a device to continuously measure and record the pressure drop across the fan. The fan power consumption and pressure drop measurements must be synchronized to allow real time comparisons of the data. The monitoring devices must have an accuracy of ±5 percent over their normal operating ranges.
(f) The volumetric flow rate through each fan of the capture system must be determined from the fan power consumption, fan pressure drop, and fan performance curve specified under subparagraph (e) of this paragraph, during any performance test required under paragraph .01(5)(g) of this chapter to demonstrate compliance with the standards under parts (3)(a)4. and 5. of this rule. The owner or operator shall determine the volumetric flow rate at a representative temperature for furnace power input levels of 50 and 100 percent of the nominal rated capacity of the electric submerged arc furnace. At all times the electric submerged arc furnace is operated, the owner or operator shall maintain the fan power consumption and fan pressure drop at levels such that the volumetric flow rate is at or above the levels established during the most recent performance test for the furnace power input level.

If emissions due to tapping are captured and ducted separately from emissions of the electric submerged arc furnace, during each tapping period the owner or operator shall maintain the fan power consumption and fan pressure drop at levels such that the volumetric flow rate is at or above the levels established during the most recent performance test. Operation at lower flow rates may be considered by the Technical Secretary to be unacceptable operation and maintenance of the affected facility. The owner or operator may request that these flow rates be reestablished by conducting new performance tests under paragraph .01(5) of this chapter. The Technical Secretary may require the owner or operator to verify the fan performance curve by monitoring necessary fan operating parameters and determining the gas volume moved relative to Methods 1. and 2. of subparagraph .01(5)(g) of this chapter.

(g) All monitoring devices required under subparagraphs (c) and (e) of this paragraph are to be checked for calibration annually in accordance with the procedures under paragraph .01(8) of this chapter.
(7) Test Methods and Procedures.
(a) When determining the concentration of particulate matter and the associated moisture content, the use of the heating system specified by the method outlined in part .01(5)(g) of this chapter are not to be used when the carbon monoxide content of the gas stream exceeds ten (10) percent by volume, dry basis.
(b) The sampling time for each particulate run is to include an integral number of furnace cycles. The sampling time for each run must be at least 60 minutes and the minimum sample volume must be 1.8 dscm (64 dscf) when sampling emissions from open electric submerged arc furnaces with wet scrubber control devices, sealed electric submerged arc furnaces, or semi-enclosed electric submerged arc furnaces. When sampling emissions from other types of installations, the sampling time for each run must be at least 200 minutes and the minimum sample volume must be 5.7 dscm (200 dscf). Shorter sampling times or smaller sampling volumes, when necessitated by process variables or other factors, may be approved by the Technical Secretary.
(c) During the performance test, the owner or operator shall record the maximum open hood area (in hoods with segmented or otherwise moveable sides) under which the process is expected to be operated and remain in compliance with all standards. Any future operation of the hooding system with open areas in excess of the maximum is not permitted.
(d) The owner or operator shall construct the control devices so that volumetric flow rates and particulate matter emissions can be accurately determined by applicable test methods and procedures.
(e) During any performance test required under paragraph .01(5) of this chapter, the owner or operator shall not allow gaseous diluents to be added to the effluent gas stream after the fabric in an open pressurized fabric filter collector unless the total gas volume flow from the collector is accurately determined and considered in the determination of emissions.
(f) When compliance with paragraph (4) of this rule is to be attained by combusting the gas stream in a flare, the location of the sampling site for particulate matter is to be upstream of the flare.
(g) For each run, particulate matter emissions, expressed in kg/hr (lb/hr), must be determined for each exhaust stream at which emissions are quantified using the following equation:

En= CsQs

where:

En = Emissions of particulate matter in kg/hr (lb/hr).

Cs = Concentration of particulate matter in kg/dscm (lb/dscf) as determined by Method 5 of subparagraph .01(5)(g) of this chapter.

Qs = Volumetric flow rate of the effluent gas stream in dscm/hr (dscf/hr) as determined by Method 2 of subparagraph .01(5)(g) of this chapter.

(h) For Method 5, particulate matter emissions from the affected facility, expressed in kg/MW-hr (lb/MW-hr) must be determined for each run using the following equation:

Click to view Image

where:

E = Emissions of particulate matter from the affected facility, in kg/MW- hr (lb/MW-hr) .

N = Total number of exhaust streams at which emissions are quantified.

En = Emission of particulate matter from each exhaust stream in kg/hr (lb/hr) , as determined in subparagraph (g) of this subparagraph.

p = Average furnace power input during the sampling period, in megawatts as determined according to subparagraph (6)(b) of this rule.

Notes

Tenn. Comp. R. & Regs. 1200-03-16-.27
Original rule filed January 10, 1977; effective February 9, 1977. Amendment filed September 4, 1981; effective October 19, 1981.

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

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