ILLINOIS POLLUTION CONTROL BOARD

September

6,

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 adopts the following amendments to the

Air Pollution Control Regulations.

In addition the Board

hereby deletes Rules 203(d)(2) and 203(d) (6) and renumbers

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 Rule shall be

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);

and Rule 203(d) (10) shall be Rule 203(d) (9).

203(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.

(1)

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

than 170 seconds over five

(5) consecutive oven

35—34 7

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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 he 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

0.07

grams per cubic meter at dry,

standard conditions

(dscmfl.

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 par-

ticulate emissions from the outlet of said

particulate control equipment shall not exceed

0.06 gr/dscf

(0.14 g/dscm).

(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 emissions from more

than 10

of all coke oven offtake piping at

any time.

Compliance shall he determined by

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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 combustion stack to

exceed 0.05 gr/dscf

(0.11 g/dscm).

(viii)

Quenching:

All coke oven quench towers

shall

be equipped with grit arrestors or equipment

of comparable effectiveness.

The make—up

water shall not directly include coke by-pro-

duct plant effluent.

Total dissolved solids

concentrations in the make-up water shall not

exceed 1500 rng/l.

Provided however that the

limitations on the quality of quench make—up

water shall not apply where the operator

employs an equivalent method of control as

determined by the Agency.

(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 Coolet

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 equipment

shall not exceed 0.03 gr/dscf

(0.07 g/dscm).

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(bb) Provided, however, that

if the owner or

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)(iv)(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)

Application

This

Lest procedure shall he used

to determine compliance with Rule

203(d)(5)(D)(1) Blast Furnace Cast

Houses.

f

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 Register.

(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 determina—

35—350

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tion of cast house particulate

emission concentrations.

(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

suitable

instrument designed for

the accurate determination of

temperature within the range

encountered during the sampling

duration.

(bb-3)

Test Procedure

(aaa)

Sampling 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)

Opacity 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) (i).

(ddd)

Sampled Emission:

During the test period, par—

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ticulate emissions from the

casting operation shall be

directed into the cast house

to the extent feasible and

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)

Sampler Locations:

Samplers shall he 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

n,easurement.

The average

velocity measured at each

35—352

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sampling point for the entire

sample run shall

be used as

the average velocity for each

entire sampler area respectively.

(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 Operating

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

35—35 3

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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

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 equipment shall not

exceed

0.02 gr/dscf

(0.046 g/dscrn).

(E)

Basic Oxygen Furnaces.

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

Lo pollution control

equipment.

Emissions from basic oxygen fur-

nace operations during

the entire cycle (opera-

tions from the beginning of the charging pro-

cess Lhrough the end of the Lapping 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 shall not ex-

ceed 0.03 gr/dscf

(0.07 g/dscm).

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(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-

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

control equipment shall not exceed 0.03 gr/dscf

(0.07 g/dscm).

(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

Scarf

ing Machines.

All hot scarfing machines

shall be controlled by pollution control equipment.

Emissions

from said pollution control equipment

shall not exceed 0.03 gr/dscf

(0.07 g/dscm)

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

35—355

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10

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).

(L)

Compliance Dates.

(i)

Every owner or operator of an emission source

the construction or modification of which

is

commenced after September

6,

1979 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 September

6,

1979 shall

comply with the emission standards and limita-

tions 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 progress

in achieving the reductions

in particulate

emissions required by Rules 203(d) (5) and

203(f),

as amended,

including annual in-

crements 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 hear-

ing before the Board that such increments

35—356

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i-i

are technically infeasible or economically

unreasonable or unless the owner or operator

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(h).

(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

Cont o~.Board, hereby certify the above Order was adopted on

the

_____

day of ~

1979 by a vote of

d/_/

Christan L. Moffett,

rk

Illinois Pollution

n rol Board

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