ILLINOIS POLLUTION CONTROL BOARD
June 22, 1979
IN THE MATTER OF:
)
PARTICULATE EMISSIONS
FROM STEEL
)
R78—10
MILLS
(Proposed Revision of Rule
203(d) of Chapter
2)
ORDER OF THE BOARD
(by Mr. Goodman):
The Board hereby proposes the following Final Draft Order
in R78—10 and orders that this proposal be published in the
Illinois Register and that the record in this matter be held
open for 60 days from the date of this Order to allow for the
submission of public comment,
In addition the Board proposes
to delete Rules 203(d)(2) and 203(d)(6) and to renumber Rule
203(d)
as
follows:
Rule 203(d)(1)
shall remain; Rule 203(d)(3)
shall be Rule 203(d)(2);
Rule 203(d)(4) shall be Rule 203(d)(3);
Rule 203(d)(5) shall
be Rule 203(d)(4);
Rule 203(d)(6)
shall be
deleted,
and the following proposed Rule shall he Rule 203(d)(5);
Rule 203(d)(7)
shall be Rule
203(d)(6);
Rule 203(d)(8)
shall be
Rule 203(d)(7);
and Rule 203(d)(9)
shall be Rule 203(d)(8).
PROPOSED FINAL DRAFT ORDER
(d)
Process Emissions
(5)
Steel Manufacturing Processes.
Except where noted,
Rules 203(a),
203(b) and 203(c)
shall not apply to the
following steel manufacturing processes.
The following
rules
shall apply:
(A)
Beehive Coke Ovens.
No person shall cause or
allow the use of beehive ovens
in any coke manu-
facturing process.
(B)
By-Product Coke Plants.
(i)
Rule 202 shall not apply to by-product coke
plants.
(ii)
Charging:
No person shall cause or allow the
emission of visible particulate matter from
any coke oven charging operation when coal
is
being charged, except for a total of no more
34—101
2
than
170 seconds over five
(5) consecutive oven
charges, or in the case of existing
five
meter
coke batteries having three charging ports, for
a total of no more than 200 seconds over
five
(5)
consecutive oven charges.
(iii)
Pushing:
All coke facilities shall be equipped
with pushing systems with particulate control
equipment which shall be designed to capture
at least 90
of all particulate emissions
from pushing operations.
The particulate
control equipment shall be operated and
maintained in a manner to achieve the design
efficiency.
If a stationary hood system is
used, the particulate emissions from the out-
let of said particulate control equipment
shall not exceed 0.03 grains per dry standard
cubic foot (0.055 milligrams per cubic meter).
If a closely hooded mobile system is used in
connection with the operation of an existing
coke oven battery with the emissions exhausted
directly to the particulate control equipment,
the particulate emissions from the outlet of
said particulate control equipment shall not
exceed 0.06 gr/dscf (0.110 mg/rn
).
(iv)
Coke Oven Doors:
(aa) No person shall cause or allow visible
emissions from more than 10
of all coke
oven doors at any time.
Compliance
shall be determined by a one pass obser-
vation of all coke oven doors on any one
battery.
(bb) No person shall cause or allow the
operation of a coke oven unless there is
on the plant premises at all times an
adequate inventory of spare coke oven
doors and seals and unless there is a
readily available coke oven door repair
facility.
(v)
Coke Oven Lids:
No person shall cause or
allow visible emission from more than 5
of
all coke oven lids at any time.
Compliance
shall be determined by a
one
pass
observation
of
all coke oven lids.
(vi)
Coke Oven Offtake Piping:
No person shall
cause or allow visible emission from more
than 10
of all coke oven offtake piping at
any time.
Compliance shall be determined by
34—102
3
a one pass observation of all coke oven off—
take piping.
(vii)
Coke Oven Combustion Stack:
No person shall
cause or allow the emission of particulate
matter from a coke oven cornbust~onstack
to
exceed 0.05 gr/dscf (0.092 mg/m
).
(viii)
Quenching:
All coke oven quench towers shall
be equipped with grit arrestors
or equipment
of comparable effectiveness.
The make—up water
utilized in quenching
shall be plant service
water.
The make-up water shall not directly
include
coke by—product plant
effluent.
Total
dissolved solids concentrations
in the make—up
water shall
not exceed 1500 mg/i.
(ix)
Work Rules:
No person shall cause or allow
the operation of a by-product coke plant
except in accordance with operating and
maintenance work rules approved by the Agency.
(C)
Sinter Processes.
Emissions
of particulate matter
from sinter processes
shall be controlled
as
follows:
(i)
Breaker Box:
No person shall cause or allow
the emission of particulate matter into the
atmosphere from the breaker stack of any sinter
process to exceed the allowable emission rate
specified by Rule 203(a).
(ii)
Main Windbox:
No person shall cause or allow
the emission of particulate matter into the
atmosphere from the main windbox of any exis-
ting sinter process
to exceed 1.2 times the
allowable emission rate specified by Rule 203(a).
(iii)
Balling Mill Drum, Mixing Drum, Pug Mill and
Cooler:
No person shall cause
or allow the
emission of visible particulate matter into the
atmosphere from any Balling Mill Drum,
Mixing
Drum,
Pug Mill or Cooler to exceed 30
opacity.
(iv)
Hot and Cold Screens:
(aa) Particulate emissions
from all hot and
cold screens shall be controlled by air
pollution control
equipment or an equiva-
lent dust suppression system.
Emissions
from said air pollution control equipment3
shall not exceed 0.03 gr/dscf
(0.055
mg/rn
).
(bb)
Provided,
however,
that
if the owner or
34—103
4
operator can establish that the particu-
late emissions from the hot screens and
cold screens do not exceed the aggregate
of the allowable emissions
as specified
by Rule 203(a) for new emission sources
or Rule 203(b)
for existing emission
sources, whichever is applicable,
then
Rule 203(d)(5)(C)(jv)(aa)
shall not
apply.
(D)
Blast Furnace Cast Houses.
(i)
Particulate emissions from the blast furnace
casting operation into the ambient air shall
not exceed the allowable emission rate speci-
fied in Rule 203(a),
calculated and measured
as follows:
(aa)
For purposes of this rule, the casting
operation for each furnace shall be
considered
as a separate operation and
the process weight
(“P”)
in the calcula-
tion shall be the total weight of the
iron and slag entering the cast house
during the casting operation.
(bb) Measurement method.
(bb—1)
~p~lication
This test procedure shall be used
to determine compliance with Rule
203(d)(5)(D)(1) Blast Furnace Cast
Houses.
If the United States Envir-
onmental Protection Agency adopts a
test procedure
to sample particulate
emissions
from blast furnace cast
houses,
that test procedure may be
substituted for the one specified
in this paragraph upon publication
in the Federal ~ister.
(bb-2)
Measurement Equipment for this
Test Procedure
The measurement equipment used for
this test procedure shall consist of
the following:
(aaa)
High Volume Air Samplers with
0.3 micron glass fiber filters shall
be used for the determination of
cast house particulate emission
concentrations.
34—104
5
(bbb)
Velocity measurements shall
be determined by the use of
a
suitable instrument designed
for the accurate determination
of velocities within the range
encountered during the sampling
duration.
(ccc)
Temperature measurements
shall
be determined by the use of a suit-
able instrument designed for the
accurate determination
of temperature
within the range encountered during
the sampling duration.
(bb-3)
Test Procedure
(aaa)
Samplin~Time Duration:
Sampling and opacity obser-
vations will initiate with the
opening of the tap hole and
terminate with the plugging of
the tap hole.
(bbb)
~pacity
Observations:
Opacity observations of the
cast house roof monitor par-
ticulate emissions into the
atmosphere shall
be performed
during the test runs by use of
the USEPA Method
9 Procedure
as published in the Federal
Register, Thursday,
August
18,
1977.
(ccc)
Number of Test Runs:
The average of six complete
sampling runs during normal
operating conditions will be
the minimum required to deter-
mine compliance with Rule
203(d) (5) (D) (1).
(ddd)
~~pled
Emission:
During the test period, par-
ticulate emissions from the
casting operation shall be
directed into the cast house
to the extent feasible and
34— 105
6
shall not create an unsafe or
hazardous condition,
Those
emissions
in and/or directed
to the cast house
shall
be
allowed to escape only at samp-
ling area locations.
Compliance
with this requirement shall be
determined by an agency—certified
observer, and any significant
visible emission from the cast
house anyplace other than a samp-
ling location will invalidate
the test.
(eec)
_________
Samplers shall
be located as
close as practicable to the
discharge point of the cast
house emissions
to the atmos-
phere and shall be oriented in
the direction of the air flow.
The sampler grid pattern shall
be divided up such that the
cross sectional area per
sampler
shall not exceed one
hundred
(100) square feet
(9.29
square meters),
If necessary
to insure representative samples,
the Agency may specify
an area
of less than one hundred
(100)
square feet
(9.29 square meters).
Each sampler shall be
located at
the approximate center of each
sampling area,
The concentra-
tion of particulate matter as
determined by each sampler shall
be considered
as the concentra-
tion
for each respective area.
(fff)
Velocity Measurement Loca-
tions:
Velocity measurements shall
be
made
as close
as possible to
each sampling point location
without interfering with the
measurement.
The average
velocity measured at each
sampling point for the entire
sample run shall
be used as
the average velocity for each
entire sampler area respectively.
34—106
7
(ggg)
Temperature
Measurement
Locations:
The same as velocity measurement
locations.
(hhh)
Emission Exhaust Pressure
Measurements:
This pressure shall be con-
sidered the barometric pressure
as measured at the cast house
floor,
(iii)
Recording of Op~~in
Parameters:
The following information
shall be recorded for those
casts tested:
(ui—i)
Material
charge weights
to the blast furnace for the
operating turn during which
cast house tests are performed;
(iii-2)
Cast weights,
total
weight
of iron plus slag enter-
ing the cast house during each
casting operation sampled;
(iii—3)
All information con-
tained in blast furnace cas-
ting logs or other similar
records,
size
of the tap hole
drill bit used for each cast
and the length
of the tap hole
for each previous cast.
(bb-4)
Calculations
(aaa)
Mass Emission Rate
(lbs./hr.)
The mass emission rate
(lbs./hr,,)
for each test run shall consist
of the sum of the mass emissions
as determined per each sample
area.
Should the sample time
duration be greater than one
hour,
the ratio calculated for
one hour divided by the sample
time duration
(hours)
shall be
multiplied by the sum of the
34—107
8
mass emissions
to obtain the
pounds per hour rate,
(ii)
Provided,
however,
that Rule 203(d)(5)(D)(i)
shall
not apply at the option of the operator
if the operator has installed and is operating
and maintaining collection equipment designed
to collect a minimum
of fifty percent
(50)
of particulate emissions from the tap hole,
the trough to the skimmers,
and the iron
spouts.
Such emissions shall be evacuated to
pollution control equipment.
Emissions from
said pollution control equipment3shall not
exceed 0,02 gr/dscf
(0,0367
mg/rn
).
(E)
~4
xenFurnaces.
Emissions of particulate
matter from Basic Oxygen Processes
shall
be con-
trolled as follows:
(I)
Charging, Refining and Tapping.
Particulate
emissions from all basic oxygen furnaces shall
be collected and ducted to pollution control
equipment,
Emissions from basic oxygen fur-
nace operations during the entire cycle (opera-
tions from the beginning of the charging pro-
cess through the end of the tapping process)
shall
not exceed the allowable emission rate
specified by Rule
203(a) for new emission
sources
or Rule 203(b)
for existing emission
sources, whichever
is applicable.
For purposes
of computing the process weight
rate for this
Rule 203(d)(5)(E)(i),
nongaseous material
charged to the furnace and process oxygen shall
be included.
No material shall be included
more than once,
(ii)
Hot Metal Transfer, Hot Metal Desulfurization,
and Ladle Lancing:
(aa) Particulate emissions
from hot metal trans-
fers to a mixer or ladle,
hot metal desul—
furization operations,
and ladle lancing
shall be collected and ducted to pollution
control
equipment, and emissions from the
pollution control equipment s~allnot ex-
ceed 0.03 gr/dscf
(0,055 mg/rn
).
(bb)
Provided,
however,
that
if the owner or
operator can establish that the total par-
ticulate emissions from hot metal trans-
fers,
hot metal desulfurization operations
and ladle
lancing operations combined do
not exceed the allowable emissions
as spec—
34—308
9
ified by Rule 203(a) for new emission
sources or Rule 203(b)
for existing emis-
sion sources, whichever is applicable,
where the process weight rate
(P)
is the
hot metal charged to the BOF vessel,
then
Rule 203(d)(5)(E)(ii)(aa)
shall not apply.
(F)
Hot Metal Desulfurization Not Located
in the BOF.
The particulate emissions from hot metal desulfuri—
zation shall
be collected and ducted to pollution
control equipment,
and emissions from the pollution
cont~olequipment
shall not exceed 0.03 gr/dscf
(0.055
mg/rn
).
(G)
Electric Arc Furnaces.
The total particulate emis-
sions
from meltdown and refining,
charging,
tapping,
slagging,
electrode port
leakage, and ladle lancing
shall not exceed the allowable emission rate
specified by Rule 203(a)
or Rule 203(b),
whichever
is applicable.
(H)
Argon—Oxygen Decarburization Vessels.
The total
particulate emissions from all charging,
refining,
alloy addition,
and tapping operations
shall not
exceed the allowable emission rate specified by
Rule 203(a) for new emission sources or Rule
203(b) for existing emission sources, whichever
is
applicable.
(I)
Liquid Steel Charging.
Particulate emissions from
liquid steel charging
in continuous casting opera-
tions
shall
be controlled by chemical or mechanical
shrouds
or methods of comparable effectiveness.
(J)
Hot Scarfing Machines.
All hot scarfing machines
shall
be controlled by pollution control equipment.
Emissions from said pollution control equ~pment
shall
not exceed 0.03 gr/dscf
(0,055
mg/rn
)
during
hot scarfing operations.
(K)
Measurement Methods.
Particulate emissions from
emission sources subject to Rule 203(d)(5) shall
be determined in accordance with procedures pub-
lished in 40 CFR Part 60, Appendix A,
Methods
1—5,
front one—half of the sampling train.
42
Fed.
Reg.
41754,
et
~.
(August 18,
1977).
Visible
emission evaluation for determining compliance
shall be conducted in accordance with procedures
published in 40 CFR Part 60, Appendix A,
Method
9.
42
Fed.
Reg,
41754,
et
~
(August 18,
1977).
34—109
10
(L)
Compliance Dates.
(i)
Every owner or operator of an emission source
the construction or modification of which is
commenced after the effective date of this
Rule 203(d)(5)
shall comply with the emission
standards and limitations
of this Rule
203(d)(5)
upon commencement
of operation.
(ii)
Every owner or operator
of an emission source
the construction or operation of which was
commenced prior to the effective date of this
Rule 203(d)(5)
as amended shall comply with
the emission standards
and limitations of
this Rule 203(d)(5) no later than December
31, 1982.
(iii)
From
the
effective date of this Rule 203(d)(5)
through December
31, 1982,
full compliance
with an approved Compliance Program and
Project Completion Schedule pursuant to Rule
104 for all sources of particulate emissions
subject to Rule 203(d)(5)
and 203(f)
as
amended under common ownership or control in
the same air quality control region shall
constitute compliance with the emission
standards and limitations contained
in this
Part II
if such Compliance Program and Project
Completion Schedule:
(aa) provides for compliance by all sources
of particulate matter subject
to Rules
203(d)(5)
and 203(f),
as amended, under
common ownership or control
in the same
air quality region,
as expeditiously as
practicable considering what
is economic-
ally reasonable and technically feasible,
and
(bb) provides
for reasonable further pro-
gress
in achieving the reductions
in
particulate emissions required by Rules
203(d)(5) and 203(f),
as amended, inclu-
ding annual increments
of reductions
such that at least one—third of the
total reductions are achieved by December
31, 1980 and at least two—thirds
of the
total reduction are achieved by December
31,
1981,
unless the owner or operator
demonstrates
in a hearing before the
Board that such increments are techni-
cally infeasible or economically unreason-
able or unless the owner or operator
34—110
11
demonstrates
in
a hearing before the
Board that some alternate schedule
represents reasonable further progress
within the meaning of Section 172(b)
of
the Clean Air Act,
42 U.S.C.
§7502(b),
(iv)
The provisions
of Rule 203(d)(5)(L)(iii)
shall not apply to any facility subject to
a
rule which is not
in full force and effect
as
a matter of state
law because of judicial
action,
and in such event the facility shall
remain subject to the regulations
in effect
at the time these amendments are adopted.
(M)
The provisions of Rule 203(d)(5)(L)
are not sever-
able,
Should any portion thereof be
found invalid
or be disapproved by U.S.
E.P.A.
as
a revision of
the state implementation plan pursuant to the
Clean Air Act,
then the entire Rule
203(d)(5)(L)
shall be null and void, the provisions
of Rules
203(d)(5)(A) and
(B)
shall become immediately
effective,
and the provisions
of existing Rules
203(a),
(b),
and
(c) and prior Rule 203(d)(2)
(in
effect from April
14, 1972 to the effective date
of this Rule)
shall
be reinstated.
Mr. Werner dissented.
I,
Christan L. Moffett,
Clerk of the Illinois Pollution
Control hoard,
he
by certify the above Order was adopted on
the~fV
day of
____,
1979 by a vote of
______
Illinois Pollution Conti
34-111