ILLINOIS POLLUTION CONTROL BOARD
March
29, 1979
IN THE MATTER OF:
PARTICULATE EMISSIONS FROM STEEL
)
R78—10
MILLS
(Proposed Revision of Rule
203(d)
of Chapter
2)
INTERIM ORDER OF THE BOARD
(by Mr. Goodman):
In order to meet the federal deadline for submittal
of
State Implementation Plan revisions pursuant to the Clean
Air Act,
42 U.S.C.
§7401
et
~j.
(1977),
the Board hereby
proposes the following amendments
to Chapter
2:
Air Pollution
Regulations.
The Board proposes to delete Rules 203(d) (2)
and 203(d)(6)
and to adopt the following substitute Rule
203(d)(5).
In addition,
the Board proposes 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 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).
The Board orders that the Hearing Officer set further
hearings or set aside time during the economic impact hearings
to receive testimony on this proposed Rule
203(d)(5).
This
proposal
is not a final action in this matter for any purpose.
PROPOSED ORDER
(d)
Process Emissions
(5)
Steel Manufacturing Processes
Except where noted,
Rules 203(a),
203(b) and 203(c)
shall not appy 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.
33—287
2
(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 port when coal is
being charged,
except for a total
of 125
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 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 planned to achieve the
design efficiency.
If a stationary hood
system is used,
the particulate emissions
from the outlet of said particulate control
equipment shall not exceed 0.03 gr/dscf.
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.
(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.
33—288
3
(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
a one pass observation of all coke oven
offtake piping.
(vii)
Coke Oven Combustion Stack:
(aa) No person shall cause or allow the
emission of visible particulate matter
from a coke oven combustion stack to
exceed 30
opacity except for
8 minutes
during any 60 minute period,
during
which time the visible emission shall
not exceed 60
opacity.
(bb) Provided however, if stack tests con-
ducted during normal operating condi-
tions establish that the emissions of
particulate matter from a coke oven
combustion stack do not exceed 0.05
gr/d.scf, then Rule 203(d)(5)(B)(vii)(aa)
shall not apply.
(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
be coke by-product plant effluent.
Total
dissolved solids concentrations in water used
for quenching 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
(i)
Emissions of particulate matter from sinter
processes shall be controlled
as follows:
(aa) 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).
33—289
4
(bb) Main Windbox:
No person shall cause or
allow the emission of particulate matter
into the atmosphere from the main windbox
of any existing sinter process to exceed
1.2 times the allowable emission rate
specified by Rule 203(a).
No person
shall cause or allow the emission of
particulate matter into the atmosphere
from the main windbox of any sinter
process, the construction of which
is
commenced on or after the effective date
of these regulations,
to exceed 0.03
gr/dscf.
(cc)
Balling Mill Drum,
Mixing Drum,
Pug Mill
and Cooler.
No person shall cause
or
allow the emission of visible particu-
late matter into the atmosphere from any
Balling Mill Drum, Mixing Drum, Pug Mill
or Cooler to exceed 30
opacity.
(dd) Hot and Cold Screens:
Particulate
emissions from all hot and cold screens
shall be controlled by air pollution
control equipment or an equivalent
dust
suppression system.
Emissions from said
air pollution control equipment shall
not exceed 0.03 gr/dscf.
(ii)
Provided, however,
that if the owner or
operator can establish that the total par-
ticulate emissions from the sinter processes
(breaker box,
main windbox, balling mill
drum, mixing drum, pug mill,
cooler, hot
screens and cold screens) do not exceed the
aggregate of the allowable emissions for each
individual source 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)(i) shall
not apply.
(D)
Blast Furnace Cast Houses.
(1)
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:
(a)
For purposes of this rule,
the casting
operation for each
furnace shall be
considered as a separate operation and
the process weight
(“P’t)
in the calcula-
33—290
5
tion shall
be the total weight of the
iron and slag entering the cast house
during the casting operation.
(b)
Measurement method.
(i)
Application
This test procedure or any other
equivalent procedure shall be used
to determine compliance with Rule
203(d)(5)(D)(1)
Blast Furnace Cast
Houses.
(ii)
Equipment
The measurement equipment used for
this test procedure shall consist
of the following:
(aa) High Volume Air Samplers with
glass fiber filters shall be
used for the determination of
cast house particulate emission
concentrations.
(bb) 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.
(cc) 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.
(iii)
Test Procedure
(aa) 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.
33—29 1
6
(bb)
22~ty
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
~9~er,
Thursday, August 18,
1977.
(cc) 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).
(dd) Sampled Emission:
During the test period, par-
ticulate emissions from the
casting operation shall he
directed into the cast house
to the extent feasible without
interfering with operation of
the blast furnace or cast
house 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 sampling area loca-
tions.
Compliance with this
requirement shall
he determined
by the opacity observations
conducted during the test
periods.
(ee) Sampler Locations:
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
33—292
7
hundred
(100)
square feet.
Each sampler shall
be
located
at the approximate center of
each sampling area.
The
concentration of particulate
matter
as determined by each
sampler shall be considered
as
the concentration for each
respective area.
(ff) Velocity Measurement Locations:
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 he used as
the average velocity for each
entire sampler area respectively.
(gg) Temperature Measurement Locations:
The same as velocity measurement
locations.
(hh) Emission Exhaust Pressure
Measurements:
This pressure shall be con-
sidered the barometric pressure
as measured at the cast house
floor.
(ii) Recording of Operating Parameters:
The following information
shall he recorded for those
casts tested:
(aaa)
Material charge weights
to the blast furnace for
the operating turn during
which cast house tests
are performed;
(bbb)
Cast weights,
total
weight of iron plus slag
entering the cast house
during each casting
operation sampled;
33—293
8
(ccc)
All information con-
tained in blast furnace
casting logs or other
similar records.
(iv)
Calculations
(aa) 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
mass emissions to obtain
the
pounds per hour rate.
(2)
Provided,
however,
that Rule 203(d)(5)(D)(1)
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.
(E)
Basic Oxygen Furnaces.
(i)
Emissions of particulate matter from Basic
Oxygen Processes
shall be controlled as
follows:
(aa) Charging, Refining and Tapping.
Par-
ticulate emissions
from all basic oxygen
furnaces shall
be collected and ducted
to pollution control equipment.
Emissions
from basic oxygen furnace operations
during the entire cycle
(operations from
the beginning of the charging process
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(h) for
existing emission sources, whichever is
applicable.
For purposes of computing
the process weight rate for this Rule
33—294
9
203(d)(5)(E)(i)(aa),
nongaseous material
charged to the furnace and process
oxygen shall he included.
No material
shall be included more than once.
(bb) Hot Metal Transfer, Hot Metal Desulfuri-
zation,
and Ladle Lancing.
Particulate
emissions from hot metal transfers to a
basic oxygen furnace vessel,
hot metal
desulfurization operations,
and ladle
lancing shall be collected and ducted to
pollution control equipment,
and emissions
from the pollution control equipment
shall not exceed 0,03 gr/dscf.
(ii)
Provided,
however, that
if the owner or
operator can establish that the total par-
ticulate emissions from Basic Oxygen Processes
(charging,
refining,
tapping, hot metal
transfers,
hot metal
desulfurization opera-
tions and ladle
lancing operation)
do not
exceed the aggregate of the allowable emissions
for each individual source 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)(E)(i)
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.
(G)
Electric Arc Furnaces.
The total particulate
emissions from meltdown/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.
33—295
10
(J)
Hot Scarfing 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 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 !~51•
(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
~j.,
(August 18,
1977).
(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:
a.
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
economically reasonable and technically
feasible,
and
3 3—296
11
b.
provides for reasonable further
progress
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
demonstrates in a hearing before the
Board that some alternate schedule
respresents 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.
I, Christan L.
Moffett, Clerk of the Illinois Pollution
Control Board, hereby certify the
bove Interim Order was
the
~g~1’
day of
___________,
1979 by a vote of
Illinois Pollut
~ontrol Board
33—297