Tenn. Comp. R. & Regs. 1200-03-16-.35 - ASPHALT PROCESSING AND ASPHALT ROOFING MANUFACTURE

(1) Applicability and designation of affected facilities.

The affected facilities to which this rule 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 that commence construction or modification after November 6, 1988.

(2) Definitions.

(a) "Afterburner (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 asphalt (asphalts diluted with solvents to reduce viscosity for low temperature applications) and emulsified asphalts (asphalts dispersed in water with an emulsifying agent) are not subject to this regulation.

(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) "Electostatic precipitator (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 (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 1200-3-16-.01(5)(b) requires a performance test to be completed, no owner or operator subject to the provisions of this rule shall cause to be discharged into the atmosphere from any saturator:

1. Particulate matter in excess of:

(i) 0.04 kilograms of particulate per megagram (0.04 lb/1000 lb) of asphalt shingle or mineral-surfaced roll roofing producted; or

(ii) 0.4 kilograms per megagram (0.4 lb/1000 lb) of saturated felt or smooth-surfaced roll roofing produced.

2. Exhaust gases with opacity greater than 20 percent; and

3. Any visible emissions from a saturator capture system for more than 20 percent of any period of consecutive valid observations totaling 60 minutes. Saturators that were constructed before November 6, l988, and that have not been reconstructed since that date and that become subject to these standards through modification are exempt from the visible emissions standards. Saturators that have been newly constructed or reconstructed since November 6, l988 are subject to the visible emissions standard.

(b) On and after the date on which 1200-3-16-.01(5)(b) requires a performance test to be completed, no owner or operator subject to the provisions of this rule shall cause to be discharged into the atmosphere from any blowing still:

1. Particulate matter in excess of 0.67 kilograms of particulate per megagram (0.67 lb/1000 lb) of asphalt charged to the still when a catalyst is added to the still; and

2. Particulate matter in excess of 0.71 kilograms of particulate per megagram (0.71 lb/1000 lb) 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; and

3. Particulate matter in excess of 0.60 kilograms of particulate per megagram (0.6 lb/1000 lb) of asphalt charged to the still during blowing without a catalyst; and

4. Particulate matter in excess of 0.64 kilograms of particulate per megagram (0.64 lb/1000 lb) of asphalt charged to the still during blowing without a catalyst and when No. 6 fuel oil is fired in the afterburner; and

5. Exhaust gases with an opacity greater than 0 percent unless an opacity limit for the blowing still when fuel oil is used to fire the afterburner has been established by the Technical Secretary in accordance with the procedures in subparagraph (5)(k) of this rule.

(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 rule shall cause to be discharged into the atmosphere from any asphalt storage tank exhaust gases with opacity greater than 0 percent, except for one consecutive 15-minute period in any 24-hour period when the transfer lines are being blown for clearing. The control device shall not be bypassed during this 15-minute period. If, however, the emissions from any asphalt storage tank(s) are ducted to a control device for a saturator, the combined emissions shall meet the emission limit contained in subparagraph (a) of this paragraph during the time the saturator control device is operating. At any other time the asphalt storage tank(s) must meet the opacity limit specified above 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 rule shall cause to be discharged into the atmosphere from any mineral handling and storage facility emissions with opacity greater than 1 percent.

(4) Monitoring of operations.

(a) The owner or operator subject to the provisions of this rule, and using either an electrostatic precipitator or a high velocity air filter to meet the emission limit in part (3)(a)1. and/or (3)(b)1. of this rule 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 (±27°F) over its range.

(b) The owner of operator subject to the provisions of this rule and using an afterburner to meet the emission limit in (3)(a)1 and/or (3)(b)1 of this rule 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 rule and using a control device not mentioned in subparagraphs (a) and (b) of this paragraph shall provide to the Technical Secretary information describing the operation of the control device and the process parameter(s) which would indicate proper operation and maintenance of the device. The Technical Secretary may require continuous monitoring and will determine the process parameters to be monitored.

(d) The industry is exempted from the quarterly reports required under 1200-3-16 - .01(7)(c). The owner/operator is required to record and report the operating temperature of the control device during the performance test and, as required by 1200-3-16.01(7)(d), maintain a file of the temperature monitoring results for at least two years.

(5) Test methods and procedures.

(a) Reference methods in 1200-3-16-.01(5)(g), except as provided in 1200-3-16 - .01(5)(b), shall be used to determine compliance with the standards prescribed in paragraph (3) of this rule as follows:

1. Method 5A as specified in 1200-3-16-.01(5)(g) 5(ii) for the concentration of particulate matter.

2. Method 1 as specified in 1200-3-16-.01(5)(g) 1. for sample and velocity traverses;

3. Method 2 as specified in 1200-3-16-.01(5)(g) 2. for velocity and volumetric flow rate;

4. Method 3 as specified in 1200-3-16-.01(5)(g) 3. for gas analysis; and

5. Method 9 as specified in 1200-3-16.01(5)(g)9. for opacity.

(b) The Technical Secretary will determine compliance with the standards prescribed in part (3)(a)3. of this rule by using Method 22, as specified in 1200-3-16-.01(5)(g) 22., modified so that readings are recorded every 15 seconds for a period of consecutive observations during representative conditions (in accordance with 1200-3-16 - .01(5)(c)) totaling 60 minutes. A performance test shall consist of one run.

(c) For Method 5A as specified in 1200-3-16-.01(5)(g) 5.(ii), the sampling time for each run on a saturator shall be at least 120 minutes, and the sampling volume shall be at least 3 dscm. Method 5A shall be used to measure the emissions from the saturator while 106.6-kg (235-lb) asphalt shingle is being produced if the final product is shingle or mineral-surfaced roll roofing or while 6.8-kg (15-lb) saturated felt is being produced if the final product is saturated felt or smooth-surfaced roll roofing. If the saturator produces only fiberglass shingles, Method 5A shall be used to measure saturator emissions while a nominal 100-kg (220-lb) shingle is being produced. Method 5A shall be used to measure emissions from the blowing still for at least 90 minutes or for the duration of the coating blow, whichever is greater. If the blowing still is not used to blow coating asphalt, Method 5A shall be used to measure emissions from the blowing still for at least 90 minutes or for the duration of the blow, whichever is greater.

(d) The particulate emission rate, E, shall be computed as follows:

E = Qsd x Cs

Where:

1. E is the particulate emission rate, Kg/hr (lb/hr);

2. Qsd is the average volumetric flow rate, dscm/hr (dscf/hr), as determined by Method 2; and

3. Cs is the average concentration, Kg/dscm (lb/dscf), of particulate matter as determined by Method 5A.

(e) The asphalt roofing production rate, P, Mg/hr (TPH), shall be determined by dividing the weight of roofing produced on the shingle or saturated felt process lines during the performance test by the number of hours required to conduct the performance test. The roofing production shall be obtained by direct measurement.

(f) The production rate of asphalt from the blowing still, Ps, Mg/hr (TPH), shall be determined by dividing the weight of asphalt charged to the still by the time required for the performance test during an asphalt blow. The weight of asphalt charged to the still shall be determined at the starting temperature of the blow. The weight of asphalt shall be converted from the volume measurement as follows:

M = Vd

c

M = weight of asphalt in megagrams (English Units: tons)

V = volume of asphalt in cubic meters (English Units: ft3 )

d = density of asphalt in kilograms per cubic meter (English Units: lb/ft3 )

c = conversion factor 1,000 kilograms per megagram (English Units: 2,000 lb/ton)

The density of asphalt at any measured temperature is calculated by using the following equation:

d =1056.1 - (0.6176 x °C) (Metric Units) or

d =65.92 - (0.0214 x °F) (English Units)

The method of measurement shall have an accuracy of +10 percent.

(g) The saturator emission rate shall be computed as follows: R = E/P.

(h) The blowing still emission rate shall be computed as follows: Rs = E/Ps where:

1. R is the saturator emission rate, Kg/Mg (lb/ton);

2. Rs is blowing still emission rate, Kg/Mg (lb/ton);

3. E is the particulate emission rate, Kg/hr (lb/hr), from subparagraph (c) of this pararaph;

4. P is the asphalt roofing production rate, Mg/hr (TPH); and

5. Ps is the asphalt charging rate, Mg/hr (TPH).

(i) Temperature shall be measured and continuously recorded with the monitor required under subparagraph (4)(a) or (b) of this rule during the measurement of particulate by Method 5A and reported to the Technical Secretary with the performance test results.

(j) If at a later date the owner or operator believes the emission limits in subparagraphs (3)(a) and (b) of this rule are being met even though the temperature measured in accordance with subparagraph (4) of this rule is exceeding that measured during the performance test, he may submit a written request to the Technical Secretary to repeat the performance test and procedure outlined in subparagraph (h) of this paragraph.

(k) If fuel oil is to be used to fire an afterburner used to control a blowing still, the owner or operator may petition the Technical Secretary in accordance with 1200-3-16-.01(6) 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 Technical Secretary 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 Technical Secretary will make a finding concerning compliance with the mass standard for the blowing still. If the Technical Secretary finds that the facility was in compliance with the mass standard during the performance test but failed to meet the zero opacity standard, the Technical Secretary will establish as a condition on the operating permit of the source 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.

Notes

Tenn. Comp. R. & Regs. 1200-03-16-.35

Original rule filed September 21, 1988; effective November 6, 1988.

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