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hammermills are normally used in the milling stage if applicable. The product from the
tertiary crusher or the mill is usually conveyed to a type of classifier such as a dry
vibrating screen system, a wash screen, an air separator, or a wet rake or spiral system
(if wet grinding was employed), which also dewaters the material. The oversize is
returned to the tertiary crusher or mill for further size reduction. At this point, some
mineral end products of the desired grade are conveyed directly to finished product bins,
or are stockpiled in open areas by conveyors or trucks. Other minerals such as talc or
barite may require air classification to obtain the required mesh size, and treatment by
flotation to obtain the necessary chemical purity and color.
Most nonmetallic minerals require additional processing depending on the rock
type and consumer requirements. In certain cases, especially in the crushed stone and
sand and gravel industry, washing may be required to meet particular end product
specifications or demands such as for concrete aggregate. Some minerals, especially
certain lightweight aggregates, are washed and dried, sintered, or treated prior to primary
crushing. Others are dried following secondary crushing or milling. Sand and gravel,
crushed and broken stone, and most lightweight aggregates normally are not milled and
are screened and shipped to the consumer after secondary or tertiary crushing. Figures
1 and 2 show simplified diagrams of the typical process steps required for some
nonmetallic mineral processing facilities.
In general, the factors that affect emissions from most mineral processing
operations include: the type of ore processed, the type of equipment and operating
practices employed, the moisture content of the ore, the amount of ore processed, and
a variety of geographical and seasonal factors. These factors, discussed in more detailed
below, apply to both fugitive and stack emission sources associated with processing plant
operations.
The type of ore processed is important. Soft rocks can produce a higher
percentage of fine-grained material than do hard rocks because of their greater friability
and lower resistance to fracture. Thus, it is concluded that the processing of soft rocks
results in a greater potential for uncontrolled emissions than the processing of hard rock.
Minerals arranged in order of increasing hardness are: talc, clay, gypsum, barite,
8
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SECONDARY
CRUSHER
STOCKPILE
OR BIN
12 °=
SIZE
CLASSIFIER
STOCKPILE.
OR BIN
13
STOCKPILE
OR BIN
14
Figure 2. Genera! schematic for nonmetallic minerals processing.
-------
limestone and dolomite, perlite, feldspar, and quartz. Thus, talc could be expected to
exhibit the highest uncontrolled emissions and quartz the least.
The type of equipment and operating practices employed also affect emissions.
In general, emissions from process equipment such as crushers, screens, grinders, and
conveyors depend on the size distribution of the material, the moisture content, and the
velocity that is mechanically imparted to the material.
The inherent moisture content or wetness of the ore processed can have a
substantial effect on emissions. This is especially evident during mining, initial material
handling, and initial plant process operations such as primary crushing. Surface wetness
causes fine particles to agglomerate or adhere to the faces of larger stones with a
resultant dust suppression effect. However, as new fine particles are created by crushing
and attrition, and as the moisture content is reduced by evaporation, this suppressive
effect diminishes and may even disappear. Depending on the geographical and seasonal
factors, the primary variables affecting uncontrolled particulate matter emissions are wind
parameters and moisture content of the material. Wind parameters will vary with
geographical location and season and it can certainly be expected that the level of
emissions from sources that are not enclosed (principally fugitive dust sources) will be
greater during periods of high winds than periods of low winds. The moisture content of
the material will also vary with geographical location and season. It can, therefore, be
expected that the level of uncontrolled emissions from fugitive emission sources will be
greater in arid regions of the country than in temperate ones and greater during the
summer months due to a higher evaporation rate. The effect of equipment type on
uncontrolled emissions from all sources will be more fully discussed in Section 2.
10
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SECTION 2
PROCESS EQUIPMENT EMISSIONS AND
PARTICIPATE MATTER CONTROLS
Affected facilities under 40 CFR Part 60, Subpart 000 include only the following
process equipment types: crushers, grinding mills, screening operations, bucket
elevators, belt conveyors, bagging operations, storage bins, enclosed truck or railcar
loading stations and certain crushers and grinding mills at hot mix asphalt facilities. This
section discusses the most common of these equipment types encountered in the
industry, their principles of operation, and the emission controls most frequently
employed. Because of the diversity of processes and process equipment used in the
nonmetallic mineral processing industry, the inspector requires a fundamental knowledge
of the emission sources likely encountered in the field. Many times an operating plant
may appear to be a confusing array of equipment, sometimes spread over a large area,
other times compacted into confined spaces or enclosed within buildings. The inspector
may be required to recognize subtle differences in equipment and processes to verify that
affected facilities are onsite and are operated within permitted conditions.
When conducting a compliance inspection of a nonmetallic mineral processing
plant, it is usually best to start at the beginning of the process operations and end the
inspection at the finished product loading station(s). This is especially true of the initial
plant visit when the inspector is becoming acquainted with the particular processes and
equipment types employed at the facility. A beginning-to-end approach allows the
inspector to understand the logic of plant processes as well as trace the flow of materials.
For this reason, the types of process equipment defined as affected facilities under
Subpart 000 are presented in this section in the process order most frequently found in
the industry.
11
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2.1 CRUSHERS
Typically, Subpart 000 affected facilities begin with the first crushing or grinding
operation at the plant. Plants that do not employ crushing or grinding are, by definition,
not considered nonmetallic mineral processing plants and are thus not subject to the
nonmetallic mineral processing NSPS. This does not mean, however, that affected
facilities that occur in the process line before the first crusher or grinding operation are
exempt from the NSPS requirements. For example, an affected facility belt conveyor is
subject to the standards whether it precedes the initial crusher or not.
After blasting, ripping, or breaking is completed in the quarry, the initial size
reduction of the raw material is usually accomplished in the primary crusher. Generally,
crushing is size reduction in the coarse range and grinding in the fine range. Crushing
is usually accomplished in machines having crushing or ore-contact surfaces which are
mechanically held apart. In grinders, the grinding surfaces will rub on one another if
material is not present.
The mechanical stress applied to rock fragments during crushing may be
accomplished by either compression or impaction. In impaction, the breaking force is
applied very rapidly, while in compression, the rock is slowly squeezed and forced to
fracture. All types of crushers are both compression and impaction to varying degrees,
and in all cases there is some reduction due to rubbing of stone on stone or on metal
surfaces. Generally, compression-type crushers produce less fines and impart less kinetic
energy to particles than do impaction crushers. Table 2 ranks crushers according to their
predominant crushing mechanism (from top to bottom, compression to impaction).
Because the size reduction achievable by one machine is limited, reduction in
stages is frequently required. The various stages include primary, secondary, and
perhaps tertiary crushing. Basically, the crushers used in the nonmetallic minerals
industry are: jaw, gyratory, roll, and impact crushers.
2.1.1 Jaw Crushers
Jaw crushers consist of a vertical fixed jaw and a moving inclined jaw that is
operated by a single toggle or a pair of toggles. Rock is crushed by compression as a
12
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TABLE 2. RELATIVE CRUSHING MECHANISMS
Compression
Impaction
Double roll crusher
Jaw crusher
Gyratory crusher
Single roll crusher
Rod mill (low speed)
Ball mill
Rod mill (high speed)
Hammermill (low speed)
Impact breaker
Hammermill (high speed)
result of the opening and closing action of the moveable jaw against the fixed jaw. Their
principal application in the industry is for primary crushing.
The most commonly used jaw crusher is the Blake or double-toggle type. As
illustrated in Figure 3, an eccentric shaft drives a Pitman arm that raises and lowers a pair
of toggle plates to open and close the moving jaw which is suspended from a fixed shaft.
In a single-toggle jaw crusher, the moving jaw is itself suspended from an eccentric shaft
and the lower part of the jaw supported by a rolling toggle plate (Figure 4). Rotation of
the eccentric shaft produces a circular motion at the upper end of the jaw and an elliptical
motion at the lower end. Other types, such as the Dodge and overhead eccentric are
used on a limited scale.
A jaw crusher can be categorized by its feed opening dimensions and may range
from approximately 15x30 centimeters to 213x168 centimeters (6x12 inches to 84x66
inches). The size reduction obtainable may range from 3:1 to 10:1 depending on the
nature of the rock. Capacities are quite variable depending on the unit and its discharge
setting.
2.1.2 Gyratory Crushers
Simply, a gyratory crusher may be considered to be a jaw crusher with circular
jaws between which the material flows and is crushed. However, a gyratory crusher has
a much greater capacity than a jaw crusher with an equivalent feed opening.
13
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FIXED JAW
MOVEABLE JAW
DISCHARGE
ECCENTRIC
PITMAN ARM
Figure 3. Double-toggle jaw crusher.
MOVEABLE JAW
FEED
FIXED
JAW
DISCHARGE
TOGGLE
Figure 4. Single-toggle jaw crusher.
14
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There are basically three types of gyratory crushers, the pivoted spindle, fixed
spindle, and cone. The fixed and pivoted spindle gyratories are used for primary and
secondary crushing, and cone crushers for secondary and tertiary crushing. The larger
gyratories are grouped according to feed opening and the smaller units by cone
diameters.
The pivoted spindle gyratory (Figure 5) has the crushing head mounted on a shaft
that is suspended from above and free to pivot. The bottom of the shaft is seated in an
eccentric sleeve which revolves, thus causing the crusher head to gyrate in a circular path
within a stationary concave circular chamber. The crushing action is similar to that of a
jaw crusher in that the crusher element reciprocates to and from a fixed crushing plate.
Because some part of the crusher head is working at all times, the discharge from the
gyratory is continuous rather than intermittent as in a jaw crusher. The crusher setting
is determined by the wide-side opening at the discharge end and is adjusted by raising
or lowering the crusher head.
Unlike the pivoted spindle gyratory, the fixed spindle gyratory has its crushing head
mounted on an eccentric sleeve fitted over a fixed shaft. This produces a uniform
crushing stroke from the top to the bottom of the crushing chamber.
For fine crushing, the gyratory is equipped with flatter heads and converted to a
cone crusher (Figure 6). Commonly, in the lower section a parallel zone exists. This
results in a larger discharge-to-feed area ratio which makes it extremely suitable for fine
crushing at high capacity. Also, unlike regular gyratories, the cone crusher sizes at the
closed side setting and not the open side (wide-side) setting. This assures that the
material discharge will have been crushed at least once at the closed side setting. Cone
crushers yield an elongated product and a high percentage of fines due to interparticle
crushing. They are the most commonly used crusher in the industry for secondary and
tertiary reduction.
2.1.3 Roll Crushers
These machines are used primarily at intermediate or final reduction stages and
are often used at portable plants. There are essentially two types, the single-roll and the
15
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FEED
FIXED
THROAT'
CRUSHING SURFACE
ECCENTRIC
DRIVE
DISCHARG
Figure 5. The pivoted spindle gyratory.
FEED
CRUSHING
SURFACES
DRIVE
DISCHARGE
ECCENTRIC
Figure 6. Cone crusher.
16
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double-roil. As illustrated in Figure 7, the double-roll crusher consists of two heavy
parallel rolls which are turned toward each other at the same speed. Roll speeds range
from 50 to 300 rpm. Usually, one roll is fixed and the other set by springs. Typically, roll
diameters range from 61 to 198 centimeters (24 to 78 inches) and have narrow face
widths, about half the roll diameter. Rock particles are caught between the rolls and
crushed almost totally by compression. Reduction ratios are limited and range from 3 to
4 to 1. These units produce few fines and no oversize. They are used especially for
reducing hard stone to a final product ranging from 1/4 inch to 20 mesh.
FEED
DISCHARGE
ADJUSTABLE
ROLLS
Figure 7. Double-roll crusher.
17
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The working elements of a single-roll crusher include a toothed or knobbed roll and
a curved crushing plate that may be corrugated or smooth. The crushing plate is
generally hinged at the top and its setting is held by a spring at the bottom. A toothed-
roll crusher is depicted in Figure 8. The feed caught between the roll and crushing plate
is broken by a combination of compression, impact, and shear. These units may accept
feed sizes up to 51 centimeters (20 inches) and have capacities up to 454 megagrams
per hour (500 tons/h). In contrast with the double-roll, the single roll crusher is principally
used for reducing soft materials such as limestones.
FEED
TOOTH
ROLL
CRUSHING
PLATE
DISCHARGE
Figure 8. Single-roll crusher.
18
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2.1.4 Impact Crushers
Impact crushers, including hammermills and impactors, use the force of fast
rotating massive impellers or hammers to strike and shatter free falling rock particles.
These units have extremely high reduction ratios and produce a cubical product spread
over a wide range of particle sizes with a large proportion of fines, thus making their
application in industry segments such as cement manufacturing and agstone production
extremely cost effective by reducing the need for subsequent grinding machines.
A hammermill consists of a high speed horizontal rotor with several rotor discs to
which sets of swing hammers are attached (Figure 9). As rock particles are fed into the
crushing chamber, they are impacted and shattered by the hammers which attain
tangential speeds as high as 76 meters (250 feet) per second. The shattered rock then
collides with a steel breaker plate and is fragmented even further. A cylindrical grating
or screen positioned at the discharge opening restrains oversize material until it is
reduced to a size small enough to pass between the grate bars. Rotor speeds range
from 250 to 1800 rpm and capacities to over 907 megagrams per hour (1,000 tons/h).
Product size is controlled by the rotor speed, the spacing between the grate bars, and
by hammer length.
An impact breaker (Figure 10) is similar to a hammermill except that it has no grate
or screen to act as a restraining member. Feed is broken by impact alone. Adjustable
breaker bars are used instead of plates to reflect material back into the path of the
impellers. Primary-reduction units are available that can reduce quarry run material at
over 907 megagrams per hour (1,000 tons/h) capacity to approximately 2.5 centimeters
(1 inch). These units are not appropriate for hard abrasive materials, but are ideal for soft
rocks like limestone.
2.1.5 Sources of Emissions
The generation of particulate emissions is inherent in the crushing process.
Emissions are most apparent at crusher feed and discharge points. Emissions are
influenced predominantly by the type of rock processed, the moisture content of the rock,
and the type of crusher used.
19
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FEED
BREAKER
PLATE
SWING
HAMMERS
GRATE BARS
/
DISCHARGE
Figures. Hammermill.
BREAKER
PLATE
BREAKER
BARS
FEED
/
HAMMER
ROTOR
DISCHARGE
Figure 10. Impact crusher.
20
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The most important element influencing emissions from crushing equipment is the
type of rock and the moisture content of the mineral being crushed. The crushing
mechanism employed has a substantial effect on the size reduction that a machine can
achieve; the particle size distribution of the product, especially the proportion of fines
produced; and the amount of mechanically induced energy that is imparted to
fines.
Crushing units using impaction rather than compression produce a larger
proportion of fines as noted above. In addition to generating more fines, impaction
crushers also impart higher velocity to the particles as a result of the fan-like action
produced by the fast rotating hammers. Because of this and the high proportion of fines
produced, impaction crushers generate larger quantities of uncontrolled particulate
emissions per ton of material processed than any other crusher type.
The level of uncontrolled emissions from jaw, gyratory, cone and roll crushers
closely parallels the reduction stage to which they are applied. Emissions increase
progressively from primary to secondary to tertiary crushing. Factors other than the type
of crushing mechanism (compression, impaction) also affect emissions. In all likelihood,
primary jaw crushers produce greater emissions than comparable gyratory crushers
because of the bellows effect of the jaw and because gyratory crushers are usually choke
fed to minimize the open spaces from which dust may be emitted. For subsequent
reduction stages, cone crushers produce more fines as a result of attrition and
consequently generate more dust.
2.2 GRINDING MILLS
Grinding is a further step in the reduction of material to particle sizes smaller than
those attainable by crushers. Because the material to be treated has already been
reduced to small sizes, and the force to be applied to each particle is comparatively small,
the machines used in grinding are of a different type, and may operate on a different
principle from those used in more coarse crushing. The Subpart 000 definition of a
21
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"grinding mill" includes the air conveying system, air separator, or air classifier associated
with the grinding operation where it is employed.
As with crushers, the most important element influencing emissions from grinding
mills is the reduction mechanism employed, compression or impaction. Grinding mills
generally use impaction rather than compression. Reduction by impaction will produce
a larger proportion of fines. Particulate emissions are generated from grinding mills at the
grinder's inlet and outlet. Gravity type grinding mills accept feed from a conveyor and
discharge product into a screen or classifier or onto a conveyor. These transfer points
are the source of particulate emissions. The outlet has the highest emissions potential
because of the finer material. Air-swept mills include an air conveying system and an air
separator, a classifier, or both. The air separator and classifier are generally cyclone
collectors. In some systems, the air just conveys the material to a separator for deposit
into a storage bin with the conveying air escaping via the cyclone vent. In other grinding
systems, the air is continuously recirculated. Maintaining this circulating air system under
suction keeps the mill dustless in operation, and any surplus air drawn into the system
due to the suction created by the fan is released through a vent. In both cases, the vent
gases will contain a certain amount of particulate matter.
Many types of grinding mills are manufactured for use by various industries. The
principal types of mills used are: 1) hammer, 2) roller, 3) rod, 4) pebble and ball, and 5)
fluid energy. Each of these types of mills is discussed separately below.
2.2.1 Hammermills
A hammermill consists of a high speed horizontal rotor with several rotor discs to
which sets of swing hammers are attached. As rock particles are fed into the grinding
chamber, they are impacted and shattered by the hammers, which attain peripheral
speeds greater than 76 meters (250 feet) per second. The shattered rock then collides
with a steel breaker plate and is fragmented even further. A cylindrical grate or screen
positioned at the discharge opening restrains oversize material until it is reduced to a size
small enough to pass between the grate bars. Product size is controlled by the rotor
22
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speed, the spacing between the grate bars, and by hammer length. These mills are used
for nonabrasive materials and can accomplish a size reduction of up to 12:1.
2.2.2 Roller Mill
The roller mill, also known as a Raymond Roller Mill, with its integral whizzer
separator can produce ground material ranging from 20 mesh to 325 mesh or finer. The
material is ground by rollers that travel along the inside of a horizontal stationary ring.
The rollers swing outward by centrifugal force, and trap the material between them and
the ring. The material is swept out of the mill by a stream of air to a whizzer separator,
located directly on top of the mill. Here the oversize is separated and dropped back for
further grinding while the desired fines pass up through the whizzer blades into the duct
leading to the air separator (cyclone).
2.2.3 Rod Mill
The rod mill is generally considered as a granular grinding unit, principally for
handling a maximum feed size of 2 to 4 centimeters (1 to 2 inches), and grinding to a
maximum of 65 mesh. It is normally used in a closed circuit with a sizing device, such
as classifiers or screens, and for wet or dry grinding. It will grind within the minimum of
the finer sizes, such as 100 or 200 mesh, and will handle relatively higher moisture
material without packing.
The mill in its general form consists of a horizontal, slow-speed, rotating, cylindrical
drum. The grinding media consists of a charge of steel rods, slightly shorter than the
mill's inside length and from 5 to 13 centimeters (2 to 5 inches) in diameter. The rods roll
freely inside the drum during its rotation to provide the grinding action desired.
2.2.4 Pebble and Ball Mills
The simplest form of a ball mill is cylindrical, horizontal, slow-speed rotating drum
containing a mass of balls as grinding media. When other types of grinding media such
as flint or various ceramic pebbles are used, it is known as a pebble mill. The ball mill
uses steel, flint, porcelain, or cast iron balls.
23
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The diameter of balls or pebbles as the initial charge in a mill is determined by the
size of the feed material and the desired fineness of the product. Usually, the larger
diameter ranges are used for preliminary grinding and the smaller for final grinding. Ball
mills reduce the size of the feed mostly by impaction. These grinders normally have a
speed of 10 to 40 revolutions per minute. If the shell rotates too fast, centrifugal force
keeps the balls against the shell and minimal grinding occurs.
2.2.5 Fluid Energy Mills
When the desired material size is in the range of 1 to 20 microns, an ultrafine
grinder such as the fluid energy mill is required. A typical fluid energy mill is shown in
Rgure 11. In this type of mill, the particles are suspended and conveyed by a high
velocity gas stream in a circular or elliptical path. Size reduction is caused by impaction
and rubbing against mill walls, and by interparticle attrition. Classification of the particles
takes place at the upper bend of the loop. Internal classification occurs because the
smaller particles are carried through the outlet by the gas stream while the larger particles
are thrown against the outer wall by centrifugal force. Product size can be varied by
changing the gas velocity through the grinder.
Fluid energy mills can normally reduce up to 0.91 megagrams/h (1 ton/h) of solids
from 0.149 mm (100 mesh) to particles averaging 1.2 to 10 microns in diameter. Typical
gas requirements are 0.45 and 1.8 kg (1 to 4 pounds) of steam or 2.7 to 4.1 kg (6 to 9
pounds) of air admitted at approximately 6.8 atm (100 psig) per 0.45 kg (1 pound) of
product. The grinding chambers are typically about 2.5 to 20 cm (1 to 8 inches) in
diameter.
2.2.6 Separating and Classifying
Mechanical air separators of the centrifugal type cover a distinct field and find wide
acceptance for the classification of dry materials in a relatively fine state of subdivision.
In commercial practice, the separator may be said to begin where the impact of vibrating
screens leave off, extending from 40 to 60 mesh down.
24
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Figure 11. Fluid energy mill.
25
-------
Briefly stated, the selective action of the centrifugal separator is the result of an
ascending air current generated within the machine by means of a fan, such current tends
to lift the finer particles against the combined effect of centrifugal force and gravity. In
operation, the feed opening allows the material to drop on the lower or distributing plate
where it is spread and thrown off by centrifugal force, the larger and heavier particles
being projected against an inner casing, while the small and lighter particles are picked
up by the ascending air current created by the fan. These fines are carried over into an
outer cone and deposited. Concurrently, the rejected coarse material drops into the inner
cone, passes out through a spout and is recycled back to the grinding mill.
The air, after dropping the major portion of its burden, is either recirculated back
to the grinding mill or vented. In the case of the recirculated air, a small amount of
extraneous air is entrained in the feed and frequently builds up pressure in the separator,
in which case the excess air may be vented off. Both vent gases are a source of
particulate matter.
2.3 EMISSION CONTROLS FOR CRUSHERS AND GRINDING MILLS
Generally, particulate matter emission control for crushers and grinding mills involve
one of two techniques: 1) wet dust suppression, and/or 2) dust collection by a capture
and conveying system to a control device. Wet dust suppression consists of introducing
water or amended water into the material flow, causing the fine particulate matter to be
confined and remain with the material flow rather than becoming airborne. Dust collection
involves hooding and enclosing dust-producing emission points and exhausting emissions
to a collection device.
2.3.1 Wet Dust Suppression
Wet dust suppression of dry crushing usually involves water sprays both above
and below the crusher throat. The objective of the water sprays is to prevent emissions
by keeping the material moist during the crushing process. Enough moisture must be
added to progressively wet the ore surfaces as reduction proceeds. The water spray
nozzles above the crusher throat may be positioned close to the receiving end of the
26
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throat or positioned some distance above the throat to assist in dust suppression from
truck or feeder dumping of the ore. Fog-type nozzles are capable of producing very
small water droplets. These nozzles have demonstrated varying degrees of success in
knocking-down dust at the point of generation. Figure 12 shows a spray nozzle
arrangement above the throat of a primary jaw crusher. Note that the wide spray pattern
assists in reducing truck dump emissions as well as emissions from the crusher throat.
In determining compliance with the Subpart 000 emission standards for crushers,
however, emissions from truck dumping of material into a crusher, grinding mill, screening
operation or feed hopper is exempt from the standards and must be separated from
emissions originating directly from the affected facility.
In addition to water sprays above the crusher throat, spray nozzles are normally
required below the throat where new dry surfaces and dust are generated by the fracture
of the ore. Figure 13 shows a typical arrangement for the control of emissions at the
crusher discharge.
When plain or untreated water is used, because of its unusually high surface
tension, the addition of 5 to 8 percent moisture (by weight), or greater, may be required
to adequately suppress dust. In some installations, this may not be optimum because
the excess moisture may cause downstream screen blinding or result in the coating of
mineral surfaces yielding a marginal or nonspecification product.
To counteract this effect, small quantities of wetting agents or surfactants may be
added to the water to reduce its surface tension and improve its wetting efficiency. In
addition, the use of fogging nozzles can assist in reducing water demand.
2.3.2 Dust Collection Systems
Hooding and air volume requirements for the control of crusher and grinder
emissions are quite variable depending upon the size and shape of the emission source,
the hood's position relative to the points of emission, and the velocity, nature, and
quantity of the released particles. The only established criterion is that a minimum in-draft
velocity of 61 meters per minute (200 fpm) be maintained through all open hood areas.
To achieve this, capture velocities in excess of 150 meters per minute (500 fpm) may be
27
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Figure 12. Spray nozzle arrangement above primary crusher throat.
28
-------
SUPPRESSANT
SPRAY HEADER
\
CRUSHER
FILTER
CONTROL
— VALVE
RUBBER
SHIELD
BELT
IDLERS
Figure 13. Dust suppression application at crusher discharge.
29
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necessary to overcome induced air motion, resulting from the material feed and discharge
velocities and the mechanically induced velocity (fan action) of a particular equipment
type. To achieve effective emission control, ventilation should be applied at both the
upper portion, or feed end, of the equipment and at the discharge point. An exception
to this would be at primary jaw or gyratory crushers because of the necessity to have
ready access to get at and dislodge large rocks that may get stuck in the crusher feed
opening. Where access to a device is required for maintenance, removable hood
sections may be used.
In general, the upper portion of the crusher or grinder should be enclosed as
completely as possible. The exhaust rate varies considerably depending on crusher type.
For impact crushers or grinders, exhaust volumes may range from 110 to 230 nrf/min
(4,000 to 8,000 cfm). For compression type crushers, an exhaust rate of 46 nf/min per
meter (500 cfm per foot) of discharge opening should be sufficient. The width of the
discharge opening will approximate the width of the receiving conveyor. For either impact
crushers or compression type crushers, pick-up should be applied downstream of the
crusher for a distance of at least 3.5 times the width of the receiving conveyor. A typical
hood configuration used to control particulate emissions from a cone crusher is depicted
in Rgure 14.
Grinding or milling circuits which employ air conveying systems operate at slightly
negative pressure to prevent the escape of air containing the ground rock. Because the
system is not airtight, some air is drawn into the system and must be vented. This vent
stream can be controlled by discharging it through a control device.
2.4 SCREENING OPERATIONS
Screening is the process by which a mixture of stones is separated according to
size. In screening, material is dropped onto a mesh surface with openings of desired size
and separated into two fractions, undersize which passes through the screen opening
and oversize which is retained on the screen surface. When material is passed over and
through multiple screening surfaces, it is separated into fractions of known particle size
30
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o
tt)
c
o
o
CO
o
o
•c
03
OT
,0
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TO
o
o
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o
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31
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distribution. Screening surfaces may be constructed of metal bars, perforated or slotted
metal plates, woven wire cloth, or polyurethane materials.
The capacity or size of a screen is primarily determined by the open area of the
screening surface and the physical characteristics of the feed. It is usually expressed in
tons of material per hour per square foot of screen area. Although screening may be
performed wet or dry, dry screening is the more common in crushing circuits. Screening
equipment commonly used in the nonmetallic minerals industry includes grizzlies, shaking
screens, vibrating screens, and revolving screens.
2.4.1 Grizzlies
Grizzlies usually consist of a set of uniformly spaced bars, rods, or rails. The bars
may be horizontal or inclined and are usually wider in cross section at the top than the
bottom. This prevents the clogging or wedging of stone particles between bars. The
spacing between the bars ranges from 5 to 20 centimeters (2 to 8 inches). Bars are
usually constructed of manganese steel or other highly abrasion-resistant material.
Grizzlies are primarily used to prevent oversize material from entering the crusher,
thus reducing the load. Grizzlies may be stationary (Figure 15), cantilevered (fixed at one
end with the discharge end free to vibrate), or mechanically vibrated. Vibrated grizzlies
are simple bar grizzlies mounted on eccentrics. The entire assembly is moved forward
and backward at approximately 100 strokes a minute, resulting in better flow through and
across the grizzly surface. Grizzlies that receive material from truck dumping are exempt
from the NSPS opacity limits and performance test requirements pursuant to § 60.672(d)
(Section 4.8.4).
2.4.2 Shaking Screens
The shaking screen consists of a rectangular frame with perforated plate or wire
cloth screening surfaces, usually suspended by rods or cables and inclined at an angle
of 14 degrees. The screens are mechanically shaken parallel to the plane of material flow
at speeds ranging from 60 to 800 strokes per minute and at amplitudes ranging from 2
32
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Figure 15. Stationary grizzly.
33
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to 23 centimeters (3/4 to 9 inches). Generally, they are used for screening coarse
material, 1.3 centimeters (1/2-inch) or larger.
2.4.3 Vibrating Screens
Where large capacity and high efficiency are desired, the vibrating screen has
practically replaced all other screen types. It is by far the most commonly used screen
type in the nonmetallic minerals industry. A vibrating screen (Figure 16) essentially
consists of an inclined flat or slightly convex screening surface which is rapidly vibrated
in a plane normal or nearly normal to the screen surface. The screening motion is of
small amplitude but high frequency, normally in excess of 3,000 cycles per minute. The
vibrations may be generated either mechanically by means of an eccentric shaft,
unbalanced fly wheel, cam and tappet assembly, or electrically by means of an
electromagnet.
Mechanically-vibrated units are operated at approximately 1,200 to 1,800 rpm and
at amplitudes of approximately 0.3 to 1.3 centimeters (1/8 to 1/2 inch). Electrically
vibrated screens are available in standard sizes from 30 to 180 centimeters (12 inches to
6 feet) wide and 0.76 to 6.1 meters (2-1/2 to 20 feet) long. A complete screening unit
may have one or more decks.
2.4.4 Revolving Screens
This screen type consists of an inclined cylindrical frame around which is wrapped
a screening surface of wire cloth or perforated plate. Feed material is delivered at the
upper end and, as the screen is rotated, undersized material passes through the screen
openings while the oversized is discharged at the lower end. Revolving screens are
available up to 1.2 meters (4 feet) in diameter and usually run at 15 to 200 rpm.
2.4.5 Emission Controls for Screening Operations
Dust is emitted from screening operations as a result of the agitation of dry
material. The level of uncontrolled emissions depends on the quantity of fine particles
contained in the material, the moisture content of the material and the type of screening
equipment. Generally, dry screening of fines produces higher emissions than the
34
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Figure 16. Vibrating screen.
-------
screening of coarse materials. Also, screens agitated at large amplitudes and high
frequency emit more dust than those operated at small amplitudes and low frequencies.
As with crushers and grinding mills, particulate matter emission control may be
accomplished by either wet dust suppression when the addition of moisture is not
deleterious to the process, or by dust collection and conveyance to a control device. A
full coverage hood, as depicted in Figure 17, may be used to control emissions generated
at actual screening surfaces. Required exhaust volumes vary with the surface area of the
screen and the amount of open area around the periphery of the enclosure. A well-
designed enclosure should have a space of no more than 5 to 10 centimeters (2 to 4
inches) around the periphery of the screen. A minimum exhaust rate of 15 nf/min per
square meter (50 cfm per square foot) of screen area is commonly used with no increase
for multiple decks.
Screening may be performed either wet or dry. Wet screening operations and
subsequent belt conveyors, screening operations, and bucket elevators up to but not
including the next crusher, grinding mill, or storage bin are subject to the NSPS
requirements and must comply with a no visible emissions standard (Section 3.3.6). A
wet screening operation, however, must not be confused with a screening operation
employing wet suppression. A screening operation using wet suppression for dust
control is subject to an opacity limit of 10 percent. A wet screening operation removes
unwanted material or separates marketable fines by a washing process that is designed
and operated at all times such that the product is saturated with water (see the definition
of "wet screening operation" in Section 3.2).
It should be noted, however, that some wet screening operations can be modified
for dry screening. If a wet screening operation is used for dry screening, and it was
manufactured or reconstructed after August 31, 1983, the equipment constitutes a
"screening operation" as defined in § 60.671 and must submit a report of the change
within 30 days, perform an initial performance test, and is subject to an opacity limit of 10
percent (Section 3.7.4). On the other hand, if the equipment was manufactured or
reconstructed on or before August 31,1983, operation as a dry screen will increase
36
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TO CONTROL
DEVICE
FEED
/
COMPLETE
ENCLOSURE
SCREEN
THROU6HS
Figure 17. Hood configuration for a vibrating screen.
37
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emissions causing it to become an affected facility under the modification provisions of
§ 60.14 (Appendix B).
2.5 STORAGE BINS
Storage bins for raw materials, intermediates, and final products may be charged
and unloaded by gravity, mechanically or by pneumatic conveying and loading systems.
Charging and unloading may also occur continuously or intermittently. Feed or collection
hoppers that continuously discharge material are not considered storage bins and are
exempt from the NSPS requirements.
Particulate matter emissions may occur during charging as the air head space in
the bin is displaced by product. This air head space is either discharged to the
atmosphere without controls through vents, or is collected and conveyed to a control
device.
2.5.1 Emission Controls for Storage Bins
The amount of uncontrolled particulate matter emissions generated during storage
bin charging is dependent on the material size, charging rate, moisture content and the
charging mechanism employed. Top loading of a storage bin involving free-falling
material is expected to generate the greatest emissions.
Wet suppression or water carry-over from wet suppression may be used as an
emission control method and is typically used in the stone industry. The most frequently
employed control devices used on storage bins are fabric dust collectors (baghouse) or
air pollution control cyclones. The baghouse may be positioned atop the storage bin
(Rgure 18) or may be positioned some distance away. If a cyclone is employed,
however, it is positioned above the bin charging port.
Cyclones with low circumference-to-height ratios are designed as air separators
and are not efficient in reducing fine particulate matter emissions. Figure 19 shows two
cyclones, each serving a storage bin and acting as air separators during charging. Also
note that between the cyclones are two baghouses which control emissions from the exits
of each cyclone and also serve as controls on bin venting.
38
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?^.***,----^^f^^^f .^...J^y_-. s^
»-• •' '-'»-— -«
£w' ^, •'£_** ' 'W= v>^- >--;WB*'^4*;1 "^r*5* r '' *:/" fcrw -"#^
Figure 18. Baghouse atop a storage bin.
39
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Figure 19. Cyclones and baghouses serving storage bins.
40
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2.6 BUCKET ELEVATORS
Bucket elevators are used where substantial elevation is required within a limited
space. They consist of a head and foot assembly which supports and drives an endless
single or double strand chain or belt to which buckets are attached. Figure 20 depicts
the three types most commonly used: the high-speed centrifugal-discharge, the slow
speed positive or perfect-discharge, and the continuous-bucket elevator.
The centrifugal-discharge elevator has a single strand of chain or belt to which the
spaced buckets are attached. As the buckets round the tail pulley, which is housed
within a suitable curved boot, the buckets scoop up their load and elevate it to the point
of discharge. The buckets are spaced so that at discharge, the material is thrown out by
the centrifugal action of the bucket rounding the head pulley. The positive-discharge type
also uses spaced buckets but differs from the centrifugal type in that it has a double-
strand chain and a different discharge mechanism. An additional sprocket, set below the
head pulley, effectively bends the strands back under the pulley, which causes the bucket
to be totally inverted resulting in a positive discharge.
The continuous-bucket elevator uses closely spaced buckets attached to a single
or double strand belt or chain. Material is loaded directly into the buckets during ascent
and is discharged gently as a result of using the back of the precluding bucket as a
discharge chute.
2.6.1 Emission Controls for Bucket Elevators
Particulate matter emissions generated by bucket elevators are dependent on the
particle size distribution of the material, freefall distance, moisture content, and the speed
of the elevator belt or chain. Wet suppression may be used to control emissions in some
circumstances or emission control may be applied at the top of the elevator at the point
of bucket discharge using a dust capture and conveying system to a control device,
usually a baghouse. The angle of the capture system duct penetration into the elevator
enclosure is important to avoid duct pluggage. The penetration angle should be above
or below perpendicular to the elevator. The fan draft of the capture system should be
enough to capture the fines within the enclosure, but not high enough to capture product.
41
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(b)
(c)
LEGEND
(a) centrifugal discharge
(b) positive discharge
(c) continuous discharge
Figure 20. Bucket elevator types.
42
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2.7 BELT CONVEYORS
Belt conveyors are the most widely used means of transporting, elevating, and
handling materials in the nonmetallic minerals industry. As illustrated in Figure 21, belt
conveyors consist of an endless belt that is carried on a series of idlers usually arranged
so that the belt forms a trough. The belt is stretched between a drive or head pulley and
a tail pulley. Although belts may be constructed of other material, reinforced rubber is the
most commonly used. Belt widths may range from 36 to 152 centimeters (14 to 60
inches) with 76 to 91 centimeter (24 to 36 inch) belts the most common. Normal
operating speeds may range from 60 to 120 meters per minute (200 to 400 feet/minute).
Depending on the belt speed, belt width and rock density, load capacities may be in
excess of 1360 megagrams (1,500 tons) per hour.
H
F
IDLER
I
O
u
!EAO
i H i rv - - -w
Co j
BELT \*~-^-
o u O U
O U U'~
f- -_
0 ^
f \
( o )<-
o
1
TAIL
out i rv
Figure 21. Conveyor belts and transfer point.
Subpart 000 only regulates paniculate matter emissions from transfer points to and
from affected facility belt conveyors (except transfer points to stockpiles).
43
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2.7.1 Emission Controls for Belt Conveyor Transfer Points
Particuiate matter emissions from belt conveyor transfer points are dependent on
the particle size distribution of the material conveyed, moisture content, belt speed, wind
speed, and free-fall distance. Emission control is usually applied by hooding, capturing,
and conveying to a control device or by wet suppression. Fugitive emissions are
possible, however, from the return portion of the belt (bottom) if the load material is not
completely discharged and adheres to the belt surface. Belt cleaning is usually
accomplished Immediately below the head pulley by scrapers, brushes or vibrators.
At belt-to-belt conveyor transfer points, hoods should be designed to enclose both
the head pulley of the upper belt and the tail pulley of the lower belt as completely as
possible. With careful design, the open area should be reduced to approximately 0.15
square meters per meter (0.5 square feet per foot) of belt width. Factors affecting the air
volume to be exhausted include the conveyor belt speed and the free-fall distance to
which the material is subjected. Recommended exhaust rates are 33 nf/min per meter
(350 cfm per foot) of belt width for belt speeds less than 61 meters/min (200 fpm) and
150 nf/min (500 cfm) for belt speeds exceeding 61 meters/min (200 fpm). For a beit-to-
belt transfer with less than a 0.91 meter (three foot) fall, the enclosure illustrated in Figure
22 is commonly used.
For belt-to-belt transfers with a free-fall distance greater than 0.91 meters (three
feet) and for chute-to-belt transfers, an arrangement similar to that depicted in Figure 23
is commonly used. The exhaust connection should be made as far downstream as
possible to maximize dust fallout and thus minimize needless dust entrainment. For
material containing a high percentage of fines, additional exhaust air may be required at
the tail pulley of the receiving belt. Recommended air volumes are 20 nf/min (700 cfm)
for belts 0.91 meters (three feet) wide and less, and 28 nf/min (1,000 cfm) for belts wider
than 0.91 meters (three feet).
Belt or chute-to-bin transfer points differ from the usual transfer operation in that
there is no open area downstream of the transfer point. Thus, emissions are emitted only
at the loading point. As illustrated in Figure 24, the exhaust connection is normally
44
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COMVCYOft TMANSFCM LC$S THAN
3* FALL. FOR OMATCft FALL
MOVIOC AOMTIOMAL KXMAUST AT
LOWER tCLT $€£ OCTAIL AT «CHT.
CLEARANCE FOR LOAD
OH BELT
DETAIL Of SELT OPENING
Figure 22. Hood configuration for conveyor transfer, less than 0.91 meter (3-foot) fall.
FROM CHUTE
OR BELT
ADDITIONAL
EXHAUST
n
CONVEYOR BELT
TO CONTROL
DEVICE
RUBBER
SKIRT
Figure 23. Hood configuration for a chute-to-belt or conveyor transfer, greater than
0.91 meter (3-foot) fall.
45
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BELT
LOADING
POINT
BIN
OR
HOPPER
TO CONTROL
DEVICE
t
Figure 24. Exhaust configuration at bin or hopper.
located at some point remote from the loading point and exhausted at a minimum rate
of 61 nf/min per square meter (200 cfm per square foot) of open area.
2.8 BAGGING OPERATIONS
In the nonmetallic minerals industry the valve type paper bag, either sewn or
pasted together, is widely used for shipping fine materials. The valve bag is "factory
closed," that is, the top and bottom are closed either by sewing or by pasting, and a
single small opening is left on one corner. Materials are discharged into the bag through
the valve. The valve closes automatically due to the internal pressure of the contents of
the bag as soon as it is filled.
The valve type bag is filled by means of a packing machine designed specifically
for this purpose. The material enters the bag through a nozzle inserted in the valve
opening, and the valve closes automatically when the filling is completed.
Bagging operations are a source of particulate emissions. Dust is emitted during
the final stages of filing when dust laden air is forced out of the bag. The fugitive
46
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emissions due to bagging operations are generally localized in the area of the bagging
machine.
2.8.1 Emission Controls for Bagging Operations
Bagging operations are controlled by local exhaust systems and vented to a
baghouse for product recovery. Hood face velocities on the order of 150 meters (500
feet) per minute should be used. An automatic bag filling operation and vent system is
shown in Figure 25.
It should be noted that if the baghouse serving the NSPS bagging operation also
serves other process equipment, whether or not they are Subpart 000 affected facilities,
the baghouse emissions will be subject to the Subpart 000 particulate emission standards
unless already covered by other NSPS. For certain conditions, the Subpart 000
particulate standard may be prorated with another applicable particulate standard (Section
4.8.2).
2.9 ENCLOSED TRUCK OR RAILCAR LOADING OPERATIONS
Product materials that are not bagged for shipment may be either bulk loaded into
trucks or railroad cars. The usual method of loading is gravity feeding through plastic or
fabric sleeves. Bulk loading of fine material is a source of particulate emissions because
as in the bagging operation, dust laden air is forced out of the truck or railroad car during
the loading operation.
Subpart 000 defines an enclosed truck or railcar loading station as "that portion of
a nonmetallic mineral processing plant where nonrrietallic minerals are loaded by an
enclosed conveying system into enclosed trucks or railcars." This means that the
conveying system must be enclosed as well as the truck or railcar. An enclosed
conveying system includes the enclosed apparatus that directly discharges into the truck
or railcar. To determine the termination of the enclosed conveying system, the system
should be traced from the transfer point at the truck or railcar countercurrent to material
flow to the first transfer point. Any particulate matter emissions between these two
transfer points are emissions from the enclosed conveying system.
47
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Hood attached to bin
Principal clust source
Bag
Figure 25. Bag filling vent system.
48
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Finally, the definition of enclosed truck or railcar loading station stipulates that the
truck or railcar be enclosed. Enclosure may be here defined as a hood or cover, integral
or attached to the truck or railcar, through which penetrations are afforded for loading and
displacement of air.
2.9.1 Emission Controls for Enclosed Truck or Railcar Loading Stations
Particulate emissions from enclosed truck and railcar loading of coarse material
can be minimized by eliminating any breaks in the enclosed conveying system. Shrouds,
telescoping feed tubes, and windbreaks can further reduce the fugitive emissions from
this intermittent source. Particulate emissions from loading of fine material into either
trucks or railroad cars can be controlled by an exhaust system vented to a baghouse.
The material is fed through one of the vehicle's openings and the exhaust connection is
normally at another opening. The system should be designed with a minimum amount
of open area around the periphery of the feed chute and the exhaust duct. Figure 26
shows both an enclosed truck and railcar loading station. In this example, product
material is directly loaded by gravity from storage bins through enclosed feed tubes.
Note that both the truck and railcar are also separately enclosed systems.
49
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Figure 26. Combination enclosed truck and railcar loading station.
50
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SECTION 3
REGULATORY REQUIREMENTS AND THEIR APPLICATION
Regulatory requirements for the nonmetallic mineral processing NSPS are
contained in 40 CFR Part 60, Subpart 000 as well as in the general provisions of 40 CFR
Part 60, Subpart A. This section details these requirements and provides an explanation
of the definitions, rules, and standards contained in Subpart 000 and those requirements
in Subpart A that directly affect the nonmetallic mineral processing NSPS. In addition, this
section provides guidance on the application of the NSPS requirements.
To facilitate a better understanding of the regulations and their application, the
specific requirements of Subpart 000 are presented in their entirety. Each section of the
subpart is arranged in numerical order and is divided into individual subsections or
paragraphs. Each subsection or paragraph is presented as it appears in the Federal
Register followed by a more detailed explanation of its content as well as notes on its
application. Where applicable, the provisions of Subpart A which directly affect each
subsection or paragraph are included. Finally, cross-sectional references are provided
to better explain each subsection or paragraph in the overall context of the regulations.
Although this section should be read in its entirety, it may also be used as a
reference when questions arise during actual application of the regulations.
3.1 APPLICABILITY AND DESIGNATION OF AFFECTED FACILITIES - § 60.670
3.1.1 General Applicability and Affected Facilities - § 60.670 (a}
(a)(1) Except as provided in paragraphs a(2), (b), (c), and (d) of this section, the
provisions of this subpart are applicable to the following affected facilities in fixed
or portable nonmetallic mineral processing plants: each crusher, grinding mill,
screening operation, bucket elevator, belt conveyor, bagging operation, storage
bin, enclosed truck or railcar loading station. Also, crushers and grinding mills at
51
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hot mix asphalt facilities that reduce the size of nonmetallic minerals embedded in
recycled asphalt pavement and subsequent affected facilities up to, but not
including, the first storage silo or bin are subject to the provisions of this subpart.
(2) The provisions of this subpart do not apply to the following operations: all
facilities located in underground mines; and stand-alone screening operations at
plants without crushers or grinding mills.
Explanation/Application:
Paragraphs (b), (c), and (d) will be more fully explained separately in this section.
Also, each type of affected facility (e.g., crusher, grinding mill, belt conveyor, etc.) will be
covered individually in Section 3.2.
The key term in the first part of this paragraph is "affected facility." In determining
the appropriate designation of "affected facility" for this NSPS, EPA found that a narrow
designation was most appropriate to minimize emissions by application of best
demonstrated control technology. Under this narrow designation, affected facilities are
individual pieces of operating equipment, not entire plants. Secondly, paragraph (a)
exempts any facility located in underground mines from the provisions of Subpart 000.
If the facility is moved above ground, however, it may be subject to the regulations.
Finally, paragraph (a) exempts stand-alone screening operations at plants without
crushers or grinding mills. Therefore, if neither crushing or grinding is employed at a
facility processing nonmetallic minerals, all the equipment of the facility is exempt from the
provisions of the NSPS.
See also:
o
o
o
Appendix B, § 60.2 "Affected Facility"
Section 3.1.2, 3.1.3, and 3.1.4
Section 3.2, § 60.671 "Crusher," "Grinding Mill," "Belt Conveyor,"
"Screening Operation," "Bucket Elevator," "Bagging Operation,"
"Storage Bin," "Enclosed Truck or Railcar Loading Station,"
"Nonmetallic Mineral Processing Plants," "Wet Mining Operation," and
"Wet Screening Operation"
52
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3.1.2 Facilities Subject to Other NSPS - § 60.670 ffr)
(b) An affected facility that is subject to the provisions of Subpart F or I or that
follows in the plant process any facility subject to the provisions of Subpart F or
I of this part is not subject to the provisions of this subpart.
Explanation/Application:
Subpart F is the NSPS for Portland cement plants while Subpart I is the NSPS for
asphalt concrete plants. At these types of facilities, the nonmetallic mineral processing
NSPS will apply to affected facilities that precede equipment covered by Subparts F or I.
For example, onsite crushing operations at asphalt concrete plants will be subject to the
nonmetallic mineral processing NSPS. Once the crushed stone is entered as a raw
material into the asphalt concrete process, however, equipment for handling it is covered
under Subpart I.
In addition, there has been some confusion as to where in the process at a cement
plant do the Subpart OOO affected facilities end and the Subpart F affected facilities
begin. Subpart OOO affected facilities end with the belt conveyor delivering material to
the raw material storage facility (the transfer point to the storage pile is exempt from the
10 percent opacity standard). Subpart F affected facilities begin with the first conveyor
transfer point extracting material from the raw material storage facility.
See also:
0 Appendix G, memorandum from John B. Rasnic to Bernard E. Turlinski,
November 8, 1990.
0 Appendix G, memorandum from Kathie A. Stein to William A. Spratlin,
June 12, 1995.
3.1.3 Facilities Exempted bv Plant Type/Capacity - § 60.670fc)
(c) Facilities at the following plants are not subject to the provisions of this
subpart:
(1) Fixed sand and gravel plants and crushed stone plants with capacities,
as defined in § 60.671, of 23 megagrams per hour (25 tons per hour) or
less
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(2) Portable sand and gravel plants and crushed stone plants with
capacities, as defined in § 60.671, of 136 megagrams per hour (150 tons
per hour) or less
(3) Common clay plants and pumice plants with capacities, as defined in
§ 60.671, of 9 megagrams per hour (10 tons per hour) or less.
Explanation/Application:
Economic and environmental impacts analysis conducted by EPA indicated that
at these types of facilities operating at these capacities, emissions reductions might be
unreasonably costly for the environmental benefits received.
In order to accurately identify these plant types, the definitions of "fixed plant,"
"portable plant," "capacity," and "initial crusher" must be accurately applied.
See also:
Section 3.2, § 60.671 "Fixed Plant," "Portable Plant," "Capacity," and "Initial
Crusher"
3.1.4 Exemption bv Replacement with Facilities of Equal or Smaller Size - § 60.670 fd)
(d)(1) When an existing facility is replaced by a piece of equipment of equal or
smaller size, as defined in § 60.671, having the same function as the existing
facility, the new facility is exempt from the provisions of §§ 60.672, 60.674 and
60.675 except as provided in paragraph (d)(3) of this section.
(2) An owner or operator seeking to comply with paragraph (d)(1) of this section
shall submit the information required in § 60.676 (a).
(3) An owner or operator replacing all existing facilities in a production line with
new facilities does not qualify for the exemption described in paragraph (d)(1) of
this section and must comply with the provisions of §§ 60.672,60.674, and 60.675.
Explanation/Application:
The key point in paragraph (d)(1) is the term "size." For crushers, grinding mills,
bucket elevators, bagging operations, and enclosed truck or railcar loading stations, size
is defined as the rated capacity in tons per hour. Rated capacity is the manufacturer's
highest rated capacity. To ensure that the replacement equipment is indeed of equal or
54
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smaller size, the manufacturer's highest rated capacities of both the existing equipment
and the replacement equipment should be based on the same operating criteria. For
example, the size (rated capacity) of an existing crusher may be based on the crusher
efficiency index number (CEIN) method involving variables such as the test material work
index, feed size, product size, open circuit capacities for each closed side setting, and
maximum horsepower. Regardless of rating methodology, identical or like criteria and
methods should be used to rate the capacity of replacement equipment.
It should be noted that if this exemption is applicable, the owner or operator is only
exempt from §§ 60.672, 60.674, and 60.675; all other requirements of the Subpart are
applicable.
Paragraph (d)(3) stipulates that if an entire production line is replaced with
equipment of equal or smaller size, the exemptions from the particulate matter standards
(§ 60.672), wet scrubber monitoring requirements (§ 60.674), and performance test
(§ 60.675) do not apply. This also means that if the equipment is replaced one or more
pieces at a time, the entire production line retains the exemptions until the last piece of
equipment is replaced.
Subsection 60.671 defines "production line" as all affected facilities which are
directly connected together by a conveying system. Although the definition of "conveying
system" is not limited to feeders, belt conveyors, bucket elevators and pneumatic
systems, movable equipment (i.e., trucks, front end loaders, etc.) are not to be included
in the definition of "conveying system" as it applies to the definition of "production line"
because movable equipment do not directly connect the affected facilities.
Finally, "like-for-like" replacements described in paragraph (d)(1) also means aone-
for-one replacement. For example, replacing one 100 tons/h crusher with two 50 tons/h
crushers does not qualify for the exemption.
See also:
Section 3.2, § 60.671 "Size" and "Production Line"
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3.1.5 Designation of Affected Facility bv Date of Construction. Reconstruction, or
Modification - § 60.670 (e)
(e) An affected facility under paragraph (a) of this section that commences
construction, reconstruction, or modification after August 31,1983 is subject to the
requirements of this part.
Explanation/Application:
As defined in § 60.2 of Subpart A, "commenced" means that an owner or operator
has undertaken a continuous program of construction (or reconstruction) or modification
or has entered into a contractual obligation to undertake and complete such a program.
Subsection 60.2 also defines "construction" as fabrication, erection, or installation
of an affected facility. Because of the narrow designation of affected facility under
Subpart 000, construction means the date of fabrication or manufacture of the affected
facility. For example, a crusher manufactured before August 31, 1983 but erected or
installed after this date would not be designated an affected facility under Subpart 000.
Finally, § 60.2 defines "modification" as any physical change in, or change in the
method of operation of, an existing facility which increases the amount of any air pollutant
(to which a standard applies) from that facility or results in the emission of a pollutant not
previously emitted. Most modifications to existing facilities will fall within the provisions of
§ 60.14(e) of Subpart A which, by themselves, are not considered modifications. These
provisions include: 1) maintenance, repair and replacement which the Administrator
determines to be routine, 2) an increase in production rate without a capital expenditure
on a facility, 3) an increase in the hours of operation, 4) use of alternative raw materials
if the facility was designed to accommodate them before the date of the NSPS proposal
(August 31,1983), 5) the addition or use of an air pollution control device unless it is less
environmentally beneficial, and 6) relocation or change in ownership. An increase in
production rate involving a capital expenditure, replacing a control device with another
system which is less efficient, or converting a wet screening operation to a dry screening
operation are probably the most likely ways a modification would cause an existing facility
to become subject to the NSPS requirements (see the definition of "capital expenditure"
in Appendix B, § 60.2).
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For a detailed explanation of reconstruction, see Section 3.4.
See also:
0 Appendix B, § 60.2 "Commenced," "Construction," "Modification," and
§ 60.14
0 Section 3.7.1
3.1.6 Applicable Suboart A Requirements - §60.670ffi
(f) Table 1 of this subpart specifies the provisions of subpart A of this Part 60 that
apply and those that do not apply to owners and operators of affected facilities
subject to this subpart.
Explanation/Application:
The General Provisions of 40 CFR Part 60, Subpart A are applicable to all New
Source Performance Standards except as specified in the applicable subpart. Table 1
specifically specifies which sections of Subpart A are applicable to owners or operators
of affected facilities under Subpart 000. Therefore, affected owners and operators should
carefully review and understand the applicable requirements of Subpart A.
See also:
0 Appendix B
3.2 DEFINITIONS - § 60.671
Definitions contained in § 60.671 are presented here in alphabetical order as
they appear in the regulations.
Bagging Operation-
"Bagging operation" means the mechanical process by which bags are filled with
nonmetallic minerals.
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TABLE 1. APPLICABILITY OF SUBPART A TO SUBPART OOO
Subpart A reference
60.1 Applicability
60.2 Definitions
60.3 Units and abbreviations
60.4 Address: (a)
(b)
60.5 Determination of construction
or modification
60.6 Review of plans
60.7 Notification and recordkeeping
60.8 Performance tests
60.9 Availability of information
60.10 State authority
60.1 1 Compliance with standards
and maintenance requirements
60.12 Circumvention
60.13 Monitoring requirements
60.14 Modification
60.15 Reconstruction
60.1 6 Priority list
60.17 Incorporations by reference
60.18 General control device
requirements
60.19 General notification and
reporting requirements
Applies to
Subpart OOO
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Comment
Except in (a) (2) report of anticipated date
of Initial startup is not required
I§ 60.676(h)].
Except in (d), after 30 days notice for an
initially scheduled performance test, any
rescheduled performance test requires 7
days notice, not 30 days [§ 60.675(g)].
Except in (b) under certain conditions
[§§ 60.675(c)(3) and (c)(4)], Method 9
observation may be reduced from 3 h to
1 h. Some affected facilities exempted
from Method 9 tests [§ 60.675(h)].
Rares will not be used to comply with the
emission limits.
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Explanation/Application:
By definition, only operations which mechanically fill "bags" are designated as
affected facilities. This does not include similar operations that fill boxes, .drums, or other
containers.
Belt Conveyor-
"Belt conveyor" means a conveying device that transports material from one
location to another by means of an endless belt that is carried on a series of idlers
and routed around a pulley at each end.
Explanation/Application:
Although belt conveyors are listed in § 60.670(a) as affected facilities, only transfer
points to and from belt conveyors manufactured after August 31,1983 are subject to the
requirements of Subpart OOO (except transfer points to stockpiles).
Bucket Elevator--
"Bucket elevator" means a conveying device of nonmetallic minerals consisting of
a head and foot assembly which supports and drives an endless single or double
strand chain or belt to which buckets are attached.
Explanation/Application: None
Building-
" Building" means any frame structure with a roof.
Explanation/Application:
There is no requirement that the building be enclosed on any side except the top
(roof). The roof may be any solid structure with the sole purpose of weatherizihg
whatever is covered by the roof. The key point is that the roof must be constructed solely
as a weather barrier. For example, a truck loading station beneath a silo supported by
framing members does not constitute a building because the silo was not constructed
solely as a weather barrier for the loading station.
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Capacity-
"Capacity" means the cumulative rated capacity of all initial crushers that are part
of the plant.
Explanation/Application:
Capacity is defined here as plant capacity. Therefore, plant capacity is the
cumulative total manufacturer's rated capacity of all the initial crushers that are onsite and
capable of crushing whether or not the crushers are in service at any one time. See the
explanation in Section 3.1.4 for a more detailed clarification of "rated capacity." Also, see
the definition of "initial crusher" in this section.
Capture System-
"Capture system" means the equipment (including enclosures, hoods, ducts, fans,
dampers, etc.) used to capture and transport particulate matter generated by one
or more process operations to a control device.
Explanation/Application: None
Control Device-
"Control device" means the air pollution control equipment used to reduce
particulate matter emissions released to the atmosphere from one or more process
operations at a nonmetallic mineral processing unit.
Explanation/Application:
Control devices include, but are not limited to the following: baghouses, wet
scrubbers, cyclones, multiple cyclones, and wet dust suppression systems.
Conveying System-
"Conveying system" means a device for transporting materials from one piece of
equipment or location to another location within a plant. Conveying systems
include, but are not limited, to the following: feeders, belt conveyors, bucket
elevators, and pneumatic systems.
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Explanation/Application:
Conveying system is here defined as it relates to the definition of "production line."
In this context, movable equipment (i.e., trucks, front end loaders, etc.) are not
considered part of a conveying system. See the definition of "production line" in this
section. Also see Section 3.1.4, § 60.670(d) (3).
Crusher--
"Crusher" means a machine used to crush any nonmetallic minerals, and includes,
but is not limited to, the following types: jaw, gyratory, cone, roll, rod mill,
hammermill, and impactor.
Explanation/Application: See Section 2.1
Enclosed Truck or Railcar Loading Station-
"Enclosed truck or railcar loading station" means that portion of a nonmetallic
mineral processing plant where nonmetallic minerals are loaded by an enclosed
conveying system into enclosed trucks or railcars.
Explanation/Application:
Subpart 000 defines an enclosed truck or railcar loading station as "that portion of
a nonmetallic mineral processing plant where nonmetallic minerals are loaded by an
enclosed conveying system into enclosed trucks or railcars." This means that the
conveying system must be enclosed as well as the truck or railcar. An enclosed
conveying system includes the enclosed apparatus that directly discharges into the truck
or railcar. To determine the termination of the enclosed conveying system, the system
should be traced from the transfer point at the truck or railcar countercurrent to material
flow to the first transfer point. Any particulate matter emissions between these two
transfer points are emissions from the enclosed conveying system.
Finally, the definition of enclosed truck or railcar loading station stipulates that the
truck or railcar be enclosed. Enclosure may be here defined as a hood or cover, integral
or attached to the truck or railcar, through which penetrations are afforded for loading of
material and displacement of air.
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Fixed Plant-
"Fixed plant" means any nonmetallic mineral processing plant at which the
processing equipment specified in § 60.670(a) is attached by a cable, chain,
turnbuckle, bolt or other means (except electrical connections) to any anchor, slab,
or structure including bedrock.
Explanation/Application:
The definition of a fixed plant relates to the exemptions granted fixed sand and
gravel plants and crushed stone plants with capacities of 23 megagrams per hour (25
tons per hour) or less, and fixed or portable common clay plants and purnice plants with
capacities of 9 megagrams per hour (10 tons per hour) or less. The. exception for
electrical connections in the definition includes both power connections and grounding
connections.
Fugitive Emission-
"Fugitive emission" means particulate matter that is not collected by a capture
system and is released to the atmosphere at the point of generation.
Explanation/Application:
Fugitive emissions are those particulate matter emissions not released through a
stack or vent (powered). For the purposes of this definition, a release to the atmosphere
at the point of generation includes release to the atmosphere within a building as well as
a release to the outside atmosphere at the point at which the particulate matter is first
produced.
Grinding Mill--
"Grinding mill" means a machine used for the wet or dry fine crushing of any
nonmetallic mineral. Grinding mills include, but are not limited to, the following
types: hammer, roller, rod, pebble and ball, and fluid energy. The grinding mill
includes the air conveying system, air separator, or air classifier, where such
systems are used.
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Explanation/Application:
As defined, Subpart 000 does not distinguish between wet and dry grinding.
Therefore, wet grinding operations are not exempt from the particulate matter standards,
wet scrubber monitoring requirements, or the performance test requirements of the
regulations. In determining compliance with the standards, all emission points in the total
grinding system, including the air conveying system, air separator and/or air classifier,
are subject to all the NSPS requirements.
Initial Crusher-
"Initial crusher" means any crusher into which nonmetallic minerals can be fed
without prior crushing in the plant.
Explanation/Application:
An initial crusher is the first piece of crushing equipment employed after quarry
reduction (i.e., blasting, cracking, or breaking) is achieved. The location of the initial
crusher(s) may be in the quarry or at the plant. Also, note that this definition is not
conditional as to whether or not a crusher is operating at any given time..." into which
nonmetallic minerals can be fed..." Therefore, if a crusher is onsite, and is capable of
being operated, its rated capacity must be included in the cumulative total of all initial
crushers for the purpose of establishing plant capacity. See the definitions of "capacity"
and "crusher" in this section. Also see Section 3.1.3, § 60.670(c).
Nonmetallic Mineral-
"Nonmetallic mineral" means any of the following minerals or any mixture of which
the majority is any of the following minerals.
(a) Crushed and broken stone, including limestone, dolomite, granite, traprock,
sandstone, quartz, quartzite, marl, marble, slate, shale, oil shale, and shell.
(b) Sand and gravel
(c) Clay including kaolin, fireclay, bentonite, fuller's earth, ball clay, and
common clay
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(d) Rock salt
(e) Gypsum
(f) Sodium compounds, including sodium carbonate, sodium chloride, and
sodium sulfate
(g) Pumice
(h) Gilsonite
0) Talc and pyrophyllite
0) Boron, including borax, kernite, and colemanite
(k) Barrte
0) Fluorospar
(m) Feldspar
(n) Diatomite
(o) Perlite
(p) Vermiculite
(q) Mica
(r) Kyanite, including an alusite, sillimanite, topaz, and dumortierite.
Explanation/Application:
A nonmetallic mineral, by definition, includes any one or any mixture of the listed
minerals which comprises over half of the raw material processed. For further clarification
of the applicability of Subpart OOO to recycled materials, see the guidance memorandum
from John B. Rasnic dated October 23, 1997 in Appendix G.
Nonmetallic Mineral Processing Plant-
"Nonmetallic mineral processing plant" means any combination of equipment that
is used to crush or grind any nonmetallic mineral wherever located, including lime
plants, power plants, steel mills, asphalt concrete plants, Portland cement plants,
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or any other facility processing nonmetallic minerals except as provided in
§ 60.670(b) and (c).
Explanation/Application:
To be designated as a nonmetallic mineral processing plant, a facility must employ
crushing or grinding processes. Without crushing or grinding processes, the entire plant
is exempt from the NSPS requirements.
Portable Plant-
"Portable plant" means any nonmetallic mineral processing plant that is mounted
on any chassis or skids and may be moved by the application of a lifting or pulling
force. In addition, there shall be no cable, chain, turnbuckle, bolt or other means
(except electrical connections) by which any piece of equipment is attached or
clamped to any anchor, slab, or structure, including bedrock that must be removed
prior to the application of a lifting or pulling force for the purpose of transporting
the unit.
Explanation/Application:
Although the definition of a portable plant is self-explanatory, the performance tests
required of affected facilities is somewhat different than for fixed plants. Performance
tests for portable plants are required only at the first site and not at subsequent sites to
which the plant is moved with two exceptions. First, if a new affected facility is added, a
performance test is required for the new affected facility. The second exception is that
if a portable plant is moved across State lines, the new State may require a performance
test.
Production Line-
11 Production line" means all affected facilities (crushers, grinding mills, screening
operations, bucket elevators, belt conveyors, bagging operations, storage bins,
and enclosed truck and railcar loading stations) which are directly connected or
are connected together by a conveying system.
Explanation/Application:
Production line is defined here as it relates to a replacement of an existing facility
with one of equal or smaller size. Subsection 60.670(d) (3) provides no exemption from
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the participate matter standards, wet scrubber monitoring provisions, or performance tests
if the owner or operator replaces all existing facilities in a production line with new affected
facilities. The definition of production line requires that the affected facilities be directly
connected or connected by a conveying system. Although the definition of conveying
system is not limited to explicit pieces of equipment, movable equipment (i.e., trucks, front
end loaders, etc.) is not included as part of a conveying system. Replacement of all
facilities in the production line simultaneously or the replacement of the last facility in the
production line will cause all the affected facilities in the production line to be subject to
all the requirements of Subpart 000.
Screening Operation-
"Screening operation" means a device for separating material according to size by
passing undersize material through one or more mesh surfaces (screens) in series,
and retaining oversize material on the mesh surfaces (screens).
Explanation/Application:
Screens include grizzlies, rotating screens and r»°ck-type screens. Because "wet
screening operations" are defined separately as processing "saturated" product,
"screening operations" process unsaturated product (see the definition of wet screening
operation). Also, grizzlies that receive material from truck dumping are exempt from the
10 percent opacity limit and initial performance test requirements (Section 4.8.4).
Size-
"Size" means the rated capacity in tons per hour of a crusher, grinding mill, bucket
elevator, bagging operation, or enclosed truck or railcar loading station; the total
surface area of the top screen of a screening operation; the width of a conveyor
belt; and the rated capacity in tons of a storage bin.
Explanation/Application:
Size is defined here in relation to the exemptions for replacement of existing
facilities with new facilities of equal or smaller size. Rated capacities are manufacturer's
rated capacities for crushers, grinding mills, bucket elevators, bagging operations, and
enclosed truck or railcar loading stations. For screening operations, size is determined
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by the total surface area of the top screen because screen type and mesh may be
changed in most designs. For transfer points on belt conveyors, size is determined by
belt width, while storage bins are sized by rated storage capacity in tons.
For purposes of applying the equal or smaller size exemption, rated capacity for
crushers, grinding mills, bucket elevators, bagging operations, enclosed truck or railcar
loading stations, and storage bins should be based on equal or like rating criteria. See
Section 3.1.4, § 60.670(d) (1).
Stack Emission-
"Stack emission" means the particulate matter that is released to the atmosphere
from a capture system.
Explanation/Application:
As defined, stack emissions requires the application of a capture system. The
definition of a capture system, in turn, requires the application of a control device.
Storage Bin--
"Storage bin" means a facility for storage (including surge bins) of nonmetallic
minerals prior to further processing or loading.
Explanation/Application: None
Transfer Point-
"Transfer point" means a point in a conveying operation where the nonmetallic
mineral is transferred to or from a belt conveyor except where the nonmetallic
mineral is being transferred to a stockpile.
Explanation/Application:
By definition, only transfer points to or from belt conveyors are so defined. Such
transfer points (except those to a stockpile) on affected facility belt conveyors are subject
to the NSPS requirements.
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Truck Dumping-
"Truck dumping" means the unloading of nonmetallic minerals from movable
vehicles designed to transport nonmetallic minerals from one location to another.
Movable vehicles include but are not limited to: trucks, front end loaders, skip
hoists, and railcars.
Explanation/Application:
Truck dumping is here defined in relation to § 60.672(d) which exempts emissions
from truck dumping of nonmetallic minerals into any screening operation, feed hopper,
crusher, or stock pile.
Vent-
"Vent" means an opening through which there is mechanically induced air flow for
the purpose of exhausting from a building air carrying paniculate matter emissions
from one or more affected facilities.
Explanation/Application:
Vent is here defined in relation to § 60.672(e) (2) which limits vent emissions to
0.05 g/dscm (0.02 gr/dscf) and 7 percent opacity where vents are used to exhaust
buildings containing one or more affected facilities. Note that this definition requires that
air flow through the vent be mechanically induced. Unpowered vent emissions are
therefore deemed fugitive emissions.
Wet Mining Operation-
"Wet mining operation" means a mining or dredging operation designed and
operated to extract any nonmetallic mineral regulated under this subpart from
deposits existing at or below the water table, where the nonmetallic mineral is
saturated with water.
Explanation/Application:
A wet mining operation is herein defined in relation to § 60.672 (h) which limits
screening operations, bucket elevators, and belt conveyors (up to but not including the
next crusher, grinding mill, or storage bin in the production line) processing saturated
materials downstream of wet mining operations to no visible emissions (Section 3.3.6).
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In addition, the definition of a wet mining operation is related to § 60.675(h) which waives
the initial Method 9 performance tests for the equipment listed above (Section 3.6.8).
Although not defined in § 60.671, "saturated" is defined in the response to comments
section of the June 9, 1997 revisions to Subpart OOO as "to soak or load to capacity."
Wet Screening Operation-
"Wet screening operation" means a screening operation at nonmetallic mineral
processing plant which removes unwanted material or which separates marketable
fines from the product by a washing process which is designed and operated at
all times such that the product is saturated with water.
Explanation/Application:
A wet screening operation is herein defined in relation to § 60.672(h) which limits
wet screening operations and subsequent screening operations, bucket elevators, and
belt conveyors (up to but not including the next crusher, grind mill or storage bin in the
production line) processing saturated materials to no visible emissions (Section 3.3.6).
In addition, the definition of a wet screening operation is related to § 60.675(h) which
waives the initial Method 9 performance tests for the equipment listed above (Section
3.6.8). Although not defined in § 60.671, "saturated" is defined in the response to
comments section of the June 9, 1997 revisions to Subpart OOO as "to soak or load to
capacity."
3.3 STANDARD FOR PARTICULATE MATTER - § 60.672
3.3.1 Stack Emissions Standard - § 6Q.672fa^
(a) On and after the date on which the performance test required to be conducted
by § 60.8 is completed, no owner or operator subject to the provisions of this
subpart shall cause to be discharged into the atmosphere from any transfer point
on belt conveyors or from any other affected facility any stack emissions which:
1) Contain paniculate matter in excess of 0.05 g/dscm; and 2) Exhibit greater than
7 percent opacity, unless the stack emissions are discharged from an affected
facility using a wet scrubbing control device. Facilities using a wet scrubber must
comply with the reporting provisions of § 60.676(c), (d), and (e).
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Explanation/Application:
Subsection 60.8 (a) of Subpart A requires performance tests to be conducted
within 60 days after achieving the maximum production rate at which the facility will be
operated, but no later than 180 days after initial startup of such facility. The maximum
production rate at which the affected facility will be operated is the maximum achievable
capacity based on representative performance of the affected facility. Because an
affected facility has been designated for this NSPS as an individual piece of operating
equipment, the maximum production rate is the maximum process rate at which the
individual piece of equipment is expected to operate considering the maximum plant
capacity. This may or may not be equivalent to the manufacturer's rated capacity.
Subsection 60.2 of Subpart A defines startup as the "setting in operation of an
affected facility for any purpose." Startup, therefore, is the first time the affected facility is
operated for any reason. This includes such operations as short process runs of raw
material for a determination of product quality or specification as well as full production
runs.
The stack particulate matter standard is in the form of a concentration (0.05
g/dscm). Unless a wet scrubbing control device is used, an opacity limit of 7 percent is
also applicable. In lieu of an opacity standard for wet scrubber control devices, surrogate
Indicators of compliance were chosen involving monitoring of the scrubber pressure drop
and scrubbing liquid flow rate (Sections 3.5 and 3.7.2).
Finally, it should be noted that the regulations specify that the emissions standards
take effect on and after the date on which the performance test(s) is completed.
Subsection 60.11 (d) of Subpart A, however, does require that the owner or operator
maintain and operate, at all times, any affected facility and associated control equipment
"in a manner consistent with good air pollution control practice for minimizing emissions."
In addition, any applicable State or local emission standards remain in force.
See also:
Appendix B, §§ 60.8 and 60.11 (d)
Sections 3.5 and 3.7.2
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3.3.2 Fugitive Emissions Standards - § 60.672(b) & (c)
(b) On and after the sixtieth day after achieving the maximum production rate
at which the affected facility will be operated, but not later than 180 days after initial
startup as required under § 60.11 of this part, no owner or operator subject to the
provisions of this subpart shall cause to be discharged into the atmosphere from
any transfer point on belt conveyors or from any other affected facility any fugitive
emissions which exhibit greater than 10 percent opacity, except as provided in
paragraphs (c), (d), and (e) of this section.
(c) On and after the sixtieth day after achieving the maximum production rate
at which the affected facility will be operated, but not later than 180 days after initial
startup as required under § 60.11 of this part, no owner or operator shall cause to
be discharged into the atmosphere from any crusher, at which a capture system
is not used, fugitive emissions which exhibit greater than 15 percent opacity.
Explanation/Application:
All of the provisions of paragraphs 1, 2, and 4 contained in the
"Explanation/Application" of Section 3.3.1 apply to fugitive emissions as well as stack
emissions.
In some situations it may be difficult to distinguish the equipment performing the
initial reduction at the plant as a crusher or a grinding mill. Jaw crushers, gyratory
crushers, and cone crushers are used for coarse reduction only. Roll crushers,
hammermills and impactors may be used as either crushers or grinding mills in that they
may be designed and operated for coarse or fine reduction. Some quarry material may
be sufficiently small in size that grinding mills may be employed for initial size reduction
in the plant. If a hammermill, impactor, or roll mill are installed as initial reduction
equipment, a determination may be necessary as to whether the equipment is designated
as a crusher or grinding mill for the purposes of applying the 15 percent opacity standard
for crushers without capture systems. As a guide, grinding mills generally reduce the
feed material to a 40 mesh or less.
See also:
Section 2.1 and 2.2
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3.3.3 Exemption for Truck Dumping - § 60.672 fcO
(d) Truck dumping of nonmetallic minerals into any screening operation, feed
hopper, or crusher is exempt from the requirements of this section.
Explanation/Application:
Care must be taken during opacity compliance determinations to separate
emissions from the affected facility from those of any truck dumping operation. If the
emissions cannot be separated during a Method 9 compliance test, do not interrupt
recording opacity observations, but note which observations occurred during the truck
dumping. When determining average opacity, observations during these events cannot
be used in any 24-observation (6-minute) set.
In addition, grizzlies associated with truck dumping of nonmetallic minerals are
exempt from the emission standards and performance test requirements. For a more
detailed discussion, see the memorandum from John B. Rasnic dated October 23,1997
in Appendix G.
See also:
Appendix C, Section 2.4 and 2.5
3.3.4 Affected Facilities Enclosed in Buildings - § 60.672fe)
(e) If any transfer point on a conveyor belt or any other affected facility is
enclosed in a building, then each enclosed affected facility must comply with the
emission limits in paragraphs (a), (b), and (c) of this section, or the building
enclosing the affected facility or facilities must comply with the following emission
limits:
(1) No owner or operator shall cause to be discharged into the atmosphere
from any building enclosing any transfer point on a conveyor belt or any other
affected facility any visible fugitive emissions except emissions from a vent as
defined in§ 60.671.
(2) No owner or operator shall cause to be discharged into the atmosphere
from any vent of any building enclosing any transfer point on a conveyor belt or
any other affected facility emissions which exceed the stack emissions limits in
paragraph (a) of this section.
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Explanation/Application:
Affected facilities enclosed in buildings must comply with either § 60.672(a), (b),
and (c), or exhibit no visible emissions from the building as determined by EPA Method
22. Therefore, if the affected facility is served by a control device (e.g., a baghouse) or
a powered "vent," the owner/operator must demonstrate compliance with the 7 percent
stack opacity limit and with the 0.05 g/dscm mass emission limit in § 60.672(a). If the
affected facility is not served by a control device or powered vent, the owner/operator has
two choices for demonstrating compliance: 1) no visible emissions from the building as
determined by EPA Method 22, or 2) compliance with the applicable fugitive emission
opacity standard (10 or 15%) as determined by EPA Method 9 inside the building.
Regardless of the choice of methods, it is strongly recommended that the
owner/operator submit a test protocol to the regulatory agency before the compliance
test. If Method 9 is to be employed, the test protocol should include the conditions under
which the test will be conducted and exactly how the requirements of Method 9 and §
60.675 will be achieved inside the building. It is permissible to use artificial lights within
the 140 degree sector to the observer's back provided that the artificial light source is at
least twice as bright as the ambient light within the building; in addition, artificial
contrasting backgrounds may also be used (see the Appendix G memo from Jack R.
Farmer to Winston A. Smith dated April 27,1988). Once such a test protocol is approved
by the regulatory agency, the chosen method should be used to determine compliance
on a continuing basis unless otherwise arranged by both parties.
See also:
0 Sections 4.7.1 and 4.7.2
3.3.5 Emission Standard for Enclosed Storage Bin Baahouses - § 60.672ffl & (a)
(f) On and after the sixtieth day after achieving the maximum production rate
at which the affected facility will be operated, but not later than 180 days after initial
startup as required under § 60.11 of this part, no owner or operator shall cause to
be discharged into the atmosphere from any baghouse that controls emissions
from only an individual, enclosed storage bin, stack emissions which exhibit greater
than 7 percent opacity.
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(g) Owners or operators of multiple storage bins with combined stack emissions
shall comply with the emission limits in paragraph (a)(1) and (a) (2) of this section.
Explanation/Application:
To be subject only to the opacity standard, the baghouse (fabric filter) must serve
only one enclosed storage bin. A baghouse that serves multiple enclosed storage bins
is subject to both the opacity standard (< 7% opacity) and the stack emission standard
(^ 0.05 g/dscm).
See also:
0 Sections 3.31 and 3.6.4
3.3.6 Emission Standards for Wet Screening Operations and Facilities Downstream of
Wet Mining Operations - § 60.672fh^
(h) On and after the sixtieth day after achieving the maximum production rate
at which the affected facility will be operated, but not later than 180 days
after initial startup, no owner or operator shall cause to be discharged into
the atmosphere any visible emissions from:
(1) Wet screening operations and subsequent screening operations, bucket
elevators, and belt conveyors that process saturated material in the
production line up to the next crusher, grinding mill or storage bin.
(2) Screening operations, bucket elevators, and belt conveyors in the
production line downstream of wet mining operations, where such screening
operations, bucket elevators, and belt conveyors process saturated
materials up to the first crusher, grinding mill, or storage bin in the
production line.
Explanation/Application:
Only the above listed equipment are limited to no visible emissions as determined
by Method 22. The no visible emission limit is a means to ensure that the material
processed is indeed saturated with water. The term "saturated" was defined in the
response to comments section of the June 9, 1997 Subpart OOO revisions as "to soak
or load to capacity."
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3.4 RECONSTRUCTION - § 60.673
3.4.1 Fixed Capital Cost Exemptions - § 60.673 fa)
(a) The cost of replacement of ore-contact surfaces on processing equipment
shall not be considered in calculating either the "fixed capital cost of the new
components" or the "fixed capital cost that would be required to construct a
comparable new facility" under § 60.15. Ore-contact surfaces are crushing
surfaces, screen meshes, bars, and plates, conveyor belts, and elevator buckets.
Explanation /Application:
As set forth in § 60.15 of Subpart A, reconstruction of an existing facility (e.g.,
screen, bucket elevator, crusher, etc.) means the replacement of components to such an
extent that the fixed capital cost of the new components exceeds 50 percent of the fixed
capital cost to construct a comparable new facility, and it is technologically and
economically feasible to meet the applicable standards. "Fixed capital cost" is also
defined as "the capital needed to provide all the depreciable components."
Under the provisions of Subpart 000, ore-contact surfaces of both the existing
facility and a comparable new facility are not included in calculating the fixed capital costs.
The ore-contact surfaces cited in § 60.673 (a) are the only ore-contact surfaces to be
exempted from calculating the fixed capital costs.
Some confusion may result when replacing components as to whether the
replacements are covered under the routine maintenance, repair, and replacement
provisions of § 60.14 (e) (modifications) or under the provisions of § 60.15
(reconstruction). If the replacement components are ore-contact surfaces as defined in
§ 60.673 (a), unlimited monies may be expended for their replacement without triggering
either the modification or reconstruction provisions. If the replacement components are
not ore-contact surfaces, and are considered routine replacements by the Administrator,
the modification provisions do not apply. If the replacements are not considered routine
and do not include ore-contact surfaces, the reconstruction provisions may apply, but
only depreciable components would be included in calculating fixed capital costs.
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See also:
0 Appendix B, § 60.2 "Capital expenditure," §§ 60.14 and 60.15
0 Section 3.1.5.
3.4.2 Continuous Programs of Component Replacement - § 60.673 (bl
(b) Under § 60.15, the "fixed capital cost of the new components" includes the fixed
capital cost of all depreciable components (except components specified in
paragraph (a) of this section) which are or will be replaced pursuant to all
continuous programs of component replacement commenced within any 2-year
period following August 31, 1983.
Explanation/Application:
A 2-year period begins each time the owner or operator commences a
reconstruction. "Commenced" is defined in the general provisions (§ 60.2) as meaning
that an owner or operator has undertaken a continuous program of construction or
modification or that an owner or operator has entered into a contractual obligation to
undertake or complete, within a reasonable time, a continuous program of construction
or modification.
There is not a single 2-year period that begins on any specified date. Rather, EPA
will aggregate any continuous programs of component replacement that begin within any
2-year period in determining whether "the fixed capital cost of the new components
exceeds 50 percent of the fixed capital cost that would be required to construct a
comparable entirely new facility..." [§ 60.15(b)(1)] (the "50 percent test") For example,
suppose that an owner or operator of an existing facility begins program A of component
replacement in month 1, program B in month 40, program C in month 60,.and program
D in month 80, and that programs B and C, considered together, meet the 50 percent test
in§ 60.15(b)(1). Since programs B and C commenced within a 2-year period (20 months
apart), the 50 percent test would be satisfied (regardless of programs A and D, and
regardless of when programs B and C are finished).
The affected facility for the purpose of determining the 50 percent reconstructed
threshold is the individual piece of equipment (e.g., crusher, grinding mill, etc.) as defined
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in § 60.670 and § 60.671, not the entire plant. However, replacement of an existing
affected facility with a new facility of equal or smaller size as described in § 60.670(d) is
exempt from compliance with emission limits, but is subject to the reporting and
recordkeeping requirements in § 60.676.
See also:
Appendix B, § 60.2 "Commenced," "Construction," and "Modification"
Sections 3.1.4 and 3.1.5.
3.5 MONITORING OF OPERATIONS (WET SCRUBBERS) - § 60.674
The owner or operator of any affected facility subject to the provisions of this
subpart which uses a wet scrubber to control emissions shall install, calibrate,
maintain and operate the following monitoring devices:
(a) A device for the continuous measurement of the pressure loss of the gas
stream through the scrubber. The monitoring device must be certified by the
manufacturer to be accurate within ± 250 pascals ± 1 inch water gauge pressure
and must be calibrated on an annual basis in accordance with manufacturer's
instructions.
(b) A device for the continuous measurement of the scrubbing liquid flow rate
to the wet scrubber. The monitoring device must be certified by the manufacturer
to be accurate within _+ 5 percent of design scrubbing liquid flow rate and must be
calibrated on an annual basis in accordance with manufacturer's instructions.
Explanation/Application:
The principle of operation of a wet scrubbing device involves contacting dust
particles with liquid droplets in some way and then having the wetted and unwetted
particles impinge upon a collecting surface where they can be separated and removed.
The major types of wet scrubbers are wet cyclones, mechanical, spray, self-induced
spray, and venturi scrubbers.
The standards do not include opacity requirements for wet scrubbers. In order to
verify proper operation and maintenance of wet scrubbers, the standards require the
installation, calibration, and measurement of the pressure drop across the scrubber
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including any type of mist eliminator; and installation, calibration, and measurement of the
flow rate of the scrubbing liquid. These surrogate indicators of scrubber performance can
be used to isolate typical performance problems (e.g., throat wear or pluggage,
decreased liquid-to-gas ratio, decreased pressure drop, etc.). See Section 3.7 for
recordkeeping and notification requirements.
"Monitoring device" is defined in § 60.2 of Subpart A as "the total equipment,
required under the monitoring of operations sections in applicable subparts, used to
measure and record (if applicable) process parameters." "Continuous" measurement of
the data is required under § 60.674 and recording of the data is required under § 60.676.
See also:
0 Appendix B, § 60.2 "Monitoring device," §§ 60.7(d) and 60.13(b)
0 Sections 3.6.9, and 3.7.2
3.6 TEST METHODS AND PROCEDURES - § 60.675
3.6,1 General Requirements for Performance Tests - § 60.675fa^
(a) In conducting the performance tests required in § 60.8, the owner or
operator shall use as reference methods and procedures the test methods in
Appendix A of this part or other methods and procedures as specified in this
section, except as provided in § 60.8(b). Acceptable alternative methods and
procedures are given in paragraph (e) of this section.
Explanation/Application:
Subsection 60.8 of Subpart A provides the general performance test requirements
for this and all other NSPS. These requirements include notification requirements, initial
performance test requirements, test methods and exceptions, requirements for operating
conditions during testing, and sampling facility requirements. Subsection 60.8 of Subpart
A also specifies the number of test runs (3), and that compliance is based on the average
of the three test runs unless otherwise specified in the applicable subpart.
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Appendix A of 40 CFR Part 60 contains the reference methods for determining
compliance with all NSPS. Methods applicable to the nonmetallic mineral processing
NSPS include Methods 1 through 5, 9, 17, and 22.
Subsection 60.8(b) provides authority for the Administrator (or his representative)
to specify or approve 1) equivalent methods, 2) alternative methods, 3) minor changes
in the methodology of the reference methods, 4) waivers of performance test
requirements, or 5) reduced sampling times or sampling volumes. Approved alternative
procedures for this NSPS are provided in paragraph (e) of this section. Alternative
methods and procedures bevond those given in paragraph (e) may be specified by the
Administrator or submitted by the source and approved by the Administrator as he deems
adequate to determine that the source is in compliance.
3.6.2 Test Methods and Procedures for Stack Emissions - § 60.675fcO
(b) The owner or operator shall determine compliance with the paniculate
matter standards in § 60.672(a) as follows: 1) Method 5 or Method 17 shall be
used to determine the paniculate matter concentration. The sample volume shall
be at least 1.70 dscm (60 dscf). For Method 5, if the gas stream being sampled
is at ambient temperature, the sampling probe and filter may be operated without
heaters. If the gas stream is above ambient temperature, the sampling probe and
filter may be operated at a temperature high enough, but no higher than 121°C
(250° F), to prevent water condensation on the filter, and 2) Method 9 and the
procedures in § 60.11 shall be used to determine opacity.
Explanation/Application:
As explained in the preface of 40 CFR 60, Appendix A, a "Test Methods and
Procedures" section is included within the respective subpart for each NSPS. The
purpose of § 60.675(b) is to 1) identify the applicable test method(s), and 2) identify any
special instructions or conditions to be followed such as sampling rates, volumes, or
temperatures. Paragraph (b) item (1) above provides these special instructions and
conditions for this NSPS.
Paragraph (b) item (2) above specifies Method 9 for determining compliance with
the opacity standards of this subpart. Subsection 60.11(b) of Subpart A requires that
initial compliance be determined using a minimum total time of observation for each
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affected facility of 3 hours (30-6 minute averages) unless an alternate method is approved
by the Administrator, or the Administrator waives the associated performance test.
Subsection 60.675(d) specifies Method 9 observation periods for fugitive emission
sources and for baghouses serving individual enclosed storage bins.
Subsection 60.11(e)(1) of Subpart A requires that an opacity compliance
determination be made concurrently with the performance test (stack test) unless: 1) no
performance test is required, or 2) visibility or other conditions prevent concurrent
observations. Under such conditions, see § 60.11 (e)(1) and § 60.675(g) for scheduling
or rescheduling instructions for initial opacity determinations. Subsection 60.11 also
provides other compliance and maintenance standards for performance tests and
compliance determinations.
See also:
Appendix B, §§ 60.8 and 60.11
Appendix C, Sections 2.1 through 2.5
Sections 3.3, 3.6.1, 3.6.4, 3.6.10, and 3.7.3
3.6.3 Test Methods and Procedures for Fugitive Emissions - § 60.675(^(11
(c)(1) In determining compliance with the particulate matter standards in
§ 60.672(b) and (c), the owner or operator shall use Method 9 and the procedures
in § 60.11, with the following additions:
(i) The minimum distance between the observer and the emission source shall
be 4.57 meters (15 ft).
0i) The observer shall, when possible, select a position that minimizes
interference from other fugitive emission sources (e.g., road dust). The
required observer position relative to the sun (Method 9, Section 2.1) must
be followed.
(Hi) For affected facilities using wet dust suppression for particulate matter
control, a visible mist is sometimes generated by the spray. The water mist
must not be confused with particulate matter emissions and is not to be
considered a visible emission. When a water mist of this nature is present,
the observation of emissions is to be made at a point in the plume where
the mist is no longer visible.
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Explanation/Application:
Paragraph (c)(1)(i) emphasizes a minimum distance of 15 feet from the emission
source so that opacity observations are not attempted while the observer is in the plume.
Paragraph (c)(1)(ii) emphasizes selecting a position to minimize interferences from
other sources while maintaining the required observer-to-sun angle sector of 140°.
Finally, paragraph (c)(1)(iii) emphasizes that water mists from wet suppression
systems must not be confused with source emissions. In some situations, a wet
suppression system may be activated intermittently. In such cases, two options are
possible. First, choose a point in the plume beyond which the water mist disappears.
Second, choose the point in the plume of greatest opacity when the wet dust suppression
system is not being operated and begin the Method 9 observations. When the wet dust
suppression system is operated, continue to record opacity at this point but note all such
observations on the data sheet. During data reduction, eliminate any such observations
from any 24-observation (6-minute) set.
See also:
0 Appendix B, §§ 60.8 and 60.11
0 Appendix C, Sections 2.1 through 2.5
0 Sections 3.3.2 and 3.6.1
3.6.4 Duration of Method 9 Opacity observations for Baahouses Serving Individual
Enclosed Storage Bins - § 60.675(0^2)
(2) In determining compliance with the opacity of stack emissions from any
baghouse that controls emissions only from an individual enclosed storage bin
under § 60.672(f) of this subpart, using Method 9, the duration of Method 9
observations shall be 1 hour (ten 6-minute averages).
Explanation/Application:
If the emissions from a single enclosed storage bin are controlled by an individual
baghouse serving only the one enclosed storage bin, performance test Method 9
observations are limited to one hour in all cases. If, however, the baghouse serves any
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other facility in addition to the enclosed storage bin, Method 9 observations are required
for 3 hours and the baghouse will be subject to Method 5 testing.
3.6.5 Duration of Method 9 Opacity Observations for Fugitive Emissions - § 60.675felted
(3) When determining compliance with the fugitive emissions standard for any
affected facility described under § 60.672(b) of this subpart, the duration of the
Method 9 observations may be reduced from 3 hours (thirty 6-minute averages)
to 1 hour (ten 6-minute averages) only if the following conditions apply:
(i) There are no individual readings greater than 10 percent opacity; and
(ii) There are no more than three readings of 10 percent for the 1 -hour period.
Explanation/Application:
Although § 60.11 of Subpart A requires 3 hours of Method 9 observations for any
NSPS initial performance test. This section reduces the duration of observations to 1
hour but only if the conditions in paragraphs (i) and (ii) are met. If these conditions
cannot be met, the test must continue for 3 hours.
3.6.6 Duration of Method 9 Opacity Observations for Crushers Without Capture Systems
- § 60.675fcK4)
(4) When determining compliance with the fugitive emissions standard for any
crusher at which a capture system is not used as described under § 60.672(c) of
this subpart, the duration of the Method 9 observations may be reduced from 3
hours (thirty 6-minute averages) to 1 hour (ten 6-minute averages) only if the
following conditions apply:
(i) There are no individual readings greater than 15 percent opacity; and
(ii) There are no more than 3 readings of 15 percent for the 1-hour period.
Explanation/Application:
As with the requirements of Subsection (c)(3), the duration of the Method 9
observations may be reduced to 1 hour if the conditions of paragraphs (i) and (ii) are met;
if not, the test duration will be 3 hours.
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3.6.7 Determining the Presence of Fugitive Emissions from Buildings - § 60.675fan
(d) In determining compliance with § 60.672(e), the owner or operator shall use
Method 22 to determine fugitive emissions. The performance test shall be
conducted while all affected facilities inside the building are operating. The
performance test for each building shall be at least 75 minutes in duration, with
each side of the building and the roof being observed for at least 15 minutes.
Explanation/Application:
The 75-minute duration (15 minutes per side and the roof) using Method 22 is
applicable for any performance test. To fail a Method 22 test requires only the presence
of any visible emission; Method 22 does not determine opacity.
See also:
0 Appendix D, Sections 1 through 6
0 Section 3.3.4
3.6.8 Approved Alternatives to the Test Procedures for Fugitive Emissions - § 60.675fe^
(e) The owner or operator may use the following as alternatives to the reference
methods and procedures specified in this section:
(1) For the method and procedure of paragraph (c) of this section, if emissions
from two or more facilities continuously interfere so that the opacity of fugitive
emissions from an individual affected facility cannot be read, either of the following
procedures may be used:
(i) Use for the combined emission stream the highest fugitive opacity standard
applicable to any of the individual affected facilities contributing to the emissions
stream.
(ii) Separate the emissions so that the opacity of emissions from each affected
facility can be read.
Explanation/Application:
The "highest fugitive opacity standard" cited in paragraph (e)(1)(i) is the most
restrictive and must be federally enforceable. In addition, any Method 9 opacity
observations must use the point of highest opacity whether from a single or combined
plume.
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Separation of emissions, as cited in paragraph (e)(1)(ii), may be accomplished by
construction of a physical barrier or by shutting down the interfering facility if the
maximum achievable production rate (capacity) of the affected facility being tested is not
altered or the shutting down of the interfering facility does not cause operational
problems.
See also:
Appendix C, Sections 2.1 through 2.5
Sections 3.6.1, 3.6.3, and 4.7.2
3.6.9 Wet Scrubber Monitoring Compliance - § 60.675(0
(f) To comply with § 60.676(d), the owner or operator shall record the
measurements as required in § 60.676(c) using the monitoring devices in
§ 60.674(a) and (b) during each particulate matter run and shall determine the
averages.
Explanation/Application:
To comply with the semi-annual wet scrubber monitoring notification requirements
of the standards (Section 3.7.2), the owner or operator shall record daily any changes in
scrubber pressure drop and scrubbing liquid flow rate. Pressure drop and liquid flow rate
is to be monitored using the equipment described in Section 3.5. These measurements
are to also be recorded during each run of the performance test [§ 60.676(c)] and
included in the report required by § 60.676(f).
See also:
0 Sections 3.5, 3.7.2, and 3.7.3
3.6.10 Notification Requirements for Rescheduled Performance Tests - § 60.675fg')
(g) If, after 30 days notice for an initial scheduled performance test, there is a
delay (due to operational problems, etc.) in conducting any rescheduled
performance test required in this section, the owner or operator of an affected
facility shall submit a notice to the Administrator at least 7 days prior to any
rescheduled performance test.
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Explanation /Application
Thirty days notice for any performance test including opacity observations is
required under the provisions of §60.8(d) and §60.7(a)(6). If there will be a delay in
conducting a test, this section requires at least seven days prior notice of the rescheduled
test.
3.6.11 Initial Method 9 Performance Test Exemptions - § 60.675fhl
(h) Initial Method 9 performance tests under § 60.11 of this part and § 60.675
of this subpart are not required for:
(1) Wet screening operations and subsequent screening operations, bucket
elevators, and belt conveyors that process saturated material in the production line
up to, but not including the next crusher, grinding mill or storage bin.
(2) Screening operations, bucket elevators, and belt conveyors in the
production line downstream of wet mining operations, that process saturated
materials up to the first crusher, grinding mill, or storage bin in the production line.
Explanation/Application:
This subsection exempts the affected facilities listed in items (1) and (2) above from
initial performance test requirements, however, § 60.672(h) limits these facilities to no
visible emissions. The response to comments section of the June 9, 1997 revisions to
Subpart OOO defines "saturated" as "to soak or load to capacity." If the affected facilities
listed above are used to process unsaturated materials, all of the performance test
requirements of the subpart take effect as do the fugitive or stack emission standards, as
applicable.
See also:
Section 3.3.6
"Explanation/Application" of Section 3.7.4
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3.7 Reporting and Recordkeeping - § 60.676
3.7.1 Reporting Requirements for Equal or Smaller Size Replacements - § 60.
(a) Each owner or operator seeking to comply with § 60.670(d) shall submit to
the Administrator the following information about the existing facility being replaced
and the replacement piece of equipment.
(1) For a crusher, grinding mill, bucket elevator, bagging operation, or enclosed
truck or railcar loading station:
0) The rated capacity in tons per hour of the existing facility being replaced
(ii) The rated capacity in tons per hour of the replacement equipment.
(2) For a screening operation:
(i) The total surface area of the top screen of the existing screening operation
being replaced
(ii) The total surface area of the top screen of the replacement screening
operation.
(3) For a conveyor belt:
(i) The width of the existing belt being replaced
fli) The width of the replacement conveyor belt.
(4) For a storage bin:
(i) The rated capacity in tons of the existing storage bin being replaced
(ii) The rated capacity in tons of replacement storage bins.
(b) (Removed and reserved.)
Explanation/Application:
The information above is to be forwarded to the Administrator when requesting the
exemption for replacement of existing facilities with facilities of equal or smaller size.
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See also:
Section 3.1.4
3.7.2 Wet Scrubber Requirements - § 60.676(cKdl & fe)
(c) During the initial performance test of a wet scrubber, and daily thereafter,
the owner or operator shall record the measurements of both the change in
pressure of the gas stream across the scrubber and the scrubbing liquid flow rate.
(d) After the initial performance test of a wet scrubber, the owner or operator
shall submit semiannual reports to the Administrator of occurrences when the
measurements of the scrubber pressure loss (or gain) and liquid flow rate differ by
more than _+ 30 percent from the averaged determined during the most recent
performance test.
(e) The reports required under paragraph (d) shall be postmarked within 30
days following the end of the second and fourth calendar quarters.
Explanation/Application:
Changes in pressure drop of the gas stream across the scrubber and the
scrubbing liquid flow rate are to be measured according to the procedures described in
Section 3.5. The section above requires that all "occurrences" of pressure drop and liquid
flow rate that differ by more than jf 30 percent from the average during the most recent
performance test be submitted to the Administrator. Because the requirements described
in Section 3.5 call for "continuous" measurements of the scrubber pressure drop and
liquid flow rate, and because paragraph (d) of this section requires reporting of all
occurrences of the specified changes in operating parameters, it would follow that some
type of continuous recording equipment is required to identify these occurrences on a
continuous basis.
See also:
Appendix B, § 60.13(b)
Section 3.5
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3.7.3 Performance Test Reporting Requirements - § 60.676 (f)
(f) The owner or operator of any affected facility shall submit written reports of
the results of all performance tests conducted to demonstrate compliance with the
standards set forth in § 60.672 of this subpart, including reports of opacity
observations made using Method 9 to demonstrate compliance with § 60.672 (b),
(c), and (f), and reports of observations using Method 22 to demonstrate
compliance with § 60.672(e).
Explanation/Application:
The written reports referred to in this paragraph are to be submitted to the
Administrator according to the provisions found in Subpart A, § 60.8(a).
See also:
Appendix B, § 60.8 and § 60.11
3.7.4 Reporting Requirements for Wet Screening Operations and Affected Facilities
Downstream of Wet Mining Operations - § 60.676fa1
(g) The owner or operator of any screening operation, bucket elevator, or belt
conveyor that processes saturated material and is subject to § 60.672(h) and
subsequently processes unsaturated materials, shall submit a report of this change
within 30 days following such change. This screening operation, bucket elevator,
or belt conveyor is then subject to the 10 percent opacity limit in § 60.672(b) and
the emission test requirements of § 60.11 and this subpart. Likewise a screening
operation, bucket elevator, or belt conveyor that processes unsaturated material
but subsequently process saturated material shall submit a report of this change
within 30 days following such change. This screening operation, bucket elevator,
or belt conveyor is then subject to the no visible emission limit in § 60.672(h).
Explanation/Application:
Once a change is made from processing saturated material to unsaturated
material, compliance with the 10 percent opacity limit of § 60.672(b) must be
demonstrated by performance test required under § 60.11 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 the facility. Startup is triggered once the facility
begins processing unsaturated material.
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If, however, a change is made from processing unsaturated to saturated material,
the affected facility is subject to no visible emissions on and after the day of startup
processing saturated material.
3.7.5 Notification Requirements for Anticipated and Actual Dates of Startup for Affected
Facilities - § 60.676(h) & ffl
(h) The Subpart A requirement under § 60.7(a)(2) for notification of the
anticipated date of initial startup of an affected facility shall be waived for owners
or operators of affected facilities regulated under this subpart.
(I) A notification of the actual date of initial startup of each affected facility shall
be submitted to the Administrator.
(1) For a combination of affected facilities in a production line that began actual
initial startup on the same day, a single notification of startup may be submitted by
the owner or operator to the Administrator. The notification shall be postmarked
within 15 days after such date and shall include a description of each affected
facility, equipment manufacturer, and serial number of the equipment, if available.
(2) For portable aggregate processing plants, the notification of the actual date
of initial startup shall include both the home office and the current address or
location of the portable plant.
Explanation/Application:
If a single notification of initial startup is anticipated for a combination of affected
facilities and installation or other delays prevent initial startup of all the affected facilities
on the same date, the owner/operator must submit separate notifications for each
affected facility which begins startup on different dates. It should be remembered that
"startup" is defined in § 60.1 of Subpart A as the "setting in operation of an affected facility
for any purpose."
Paragraph (2) requires the notification of initial startup for portable plants to include
both the address of the home office and the address or location of the portable plant.
If the portable plant is subsequently moved, State regulations may require a notification
of the change in address; the Federal regulations have no such requirement.
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3.7.6 Requirements Under Delegated Enforcement Authority - § 60.6760)
(j) The requirements of this section remain in force until and unless the
Agency, in delegating enforcement authority to a State under section 111 (c) of the
Act, approves reporting requirements or an alternative means of compliance
surveillance adopted by such States. In that event, affected facilities within the
State will be relieved of the obligation to comply with the reporting requirements
of this section, provided that they comply with requirements established by the
State.
Explanation/Application:
Enforcement authority can be delegated to a State, provided the requirements of
the State are at least as stringent as the requirements of this subpart. The State reporting
and recordkeeping requirements, therefore, will at least include all of the requirements of
this subpart.
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SECTION 4
COMPLIANCE DETERMINATION
(LEVEL II INSPECTION)
The purpose of this section is to provide the inspector with a logical and sequential
methodology for determining the compliance status of affected facilities subject to 40 CFR
60, Subpart 000. This methodology is consistent with a Level II compliance inspection
as outlined in the Air Compliance Manual. EPA-340/1 -85-020, September 1985, but
cannot be employed as a substitute for the initial performance test requirements
described in Subparts A and 000. A Level II inspection incorporates the following
activities:
0 "Walkthrough" evaluation of emission sources and/or devices
0 Visible emission observations
0 Data collection from and evaluation of process and control device
instrumentation
0 Checks (from outside) of internal conditions of control devices (if shut
down)
0 Routine check of continuous emission monitor (CEM) data
0 Check of source-maintained records
0 Annual determination of continued operation and process throughput of
sources that do not operate control equipment.
General procedures for a Level II inspection include the following sequential steps:
1. Pre-inspection preparation
2. Pre-entry observations
3. Entry
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4. Opening conference with source personnel
5. Source records verification
6. Field inspection procedures
7. Post-inspection conference
8. Reporting and tracking.
The remainder of this section will cover each of these Level II inspection procedures as
they specifically apply to the nonmetallic mineral processing NSPS.
4.1 PRE-INSPECTION PREPARATION
Pre-inspection preparation is always necessary to ensure effective use of the
inspector's time and the facility's time, and to ensure that the inspection is properly
focused on collecting relevant data and information. This preparation involves:
Review of facility background
Development of an inspection plan
Notifications
Equipment preparation.
4.1.1 Review of Plant Background
A review of the available background information on the plant to be inspected is
essential to the overall success of the inspection. The review should enable the inspector
to become familiar with the plant's process and emission characteristics; conduct the
inspection in a timely manner; minimize inconvenience to the plant by not requesting
unnecessary data such as that previously provided to the EPA or another agency;
conduct an efficient, but thorough inspection; clarify technical and legal issues before
entry; and prepare a useful inspection report. The following types of information should
be reviewed.
Basic Plant Information-
0 Names, titles, and phone numbers of plant representatives
0 Maps showing plant location and geographic relationship to residences, etc.
potentially impacted by emissions
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0 Process and production information
0 Flowsheets identifying affected facilities, control devices, monitors, and other
points of interest
0 Safety equipment requirements.
Pollution Control Equipment and Other Relevant Equipment Data-
0 Description and design data for control devices and relevant process
equipment
0 Sources and characterization of emissions
0 Previous inspection checklists (and reports)
0 Baseline performance data and control equipment.
Regulations, Requirements, and Limitations-
0 Most recent permits (construction and/or operating) for affected facilities
subject to the NSPS
0 Location and description of all affected facilities subject to the NSPS
standard for paniculate matter and the locations of affected facility emission
points (also included in final report)
0 Location and description of all affected facilities subject to the NSPS
recordkeeping/reporting requirements only
0 Special exemptions and waivers, if any (e.g., affected facilities previously
waived from initial compliance testing and any waiver conditions)
0 Acceptable plant operating conditions (e.g., maximum permitted throughput
or process weight rates, etc.)
0 Total top screen surface areas of all affected facility screens and belt widths
of all affected facility conveyor belts (for onsite verification)
0 Average scrubber pressure drop and scrubbing liquid flow rate from most
recent compliance test (if applicable)
0 Schedules for replacement of existing facilities with new facilities of equal or
smaller size (if any)
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0 Other applicable emission limits or opacity limits of affected facilities more
restrictive than NSPS limits (i.e., PSD, State regulations, etc.).
Facility Compliance and Enforcement History--
0 Previous inspection reports
0 Complaint history and reports
0 Past conditions of noncompliance
0 Previous enforcement actions
0 Pending enforcement actions, compliance schedules and/or variances
0 Continuous monitoring system reports
0 Startup, shutdown and malfunction reports.
4.1.2 Development of an Inspection Plan
Based on the review of the plant background information, the inspector should
develop an inspection plan addressing the following items.
Inspection objectives
Tasks sequence
Procedures
Resources
Schedule
Although the main objective of the inspection is to determine source compliance
with the NSPS provisions, the plant operating schedule or the sheer number of sources
may not be conducive to covering the entire plant in one inspection. Portions of the plant
or particular production lines may need to be covered separately or during different
inspections. This may be due to intermittent production or scheduling of maximum
operating conditions for different production lines. If necessary, the inspector should
divide the affected facilities to be inspected into manageable groups.
Once the inspector has determined which affected facilities and what plant records
are to be inspected, each individual task necessary to meet the inspection objectives
should be identified and procedures reviewed for accomplishing each task.
AH inspection tasks should also be arranged in a logical and chronological
sequence that takes into account the inspection objectives as well as possible constraints
that are anticipated at the plant. The task sequence, however, should include the
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flexibility for change if onsite conditions are not as expected or if plant operations change
during the inspection.
Finally, the resources required to complete the inspection should be reviewed.
Resources include personnel, inspection equipment, and safety equipment required at the
site.
Appendix E provides sample inspection forms that may be used to construct the
task sequence list for an inspection plan.
4.1.3 Notification of Plant and Responsible Aaencv
EPA Regional Offices and State and local agencies vary in their exact policies
concerning giving a plant advance notification of an inspection. In an EPA policy memo
entitled Final Guidance on Use of Unannounced Inspections, however, the Agency
recommends that all Regional inspection programs incorporate unannounced inspections
as part of their overall inspection approach. The advantages of the unannounced
inspection are: 1) the opportunity to observe the source under normal operating
conditions, because the source does not have time to prepare for the inspection, 2)
detection of visible emissions and O&M type problems and violations, 3) creation of an
increased level of attention by a source to its compliance status, and 4) projection of a
serious attitude toward surveillance by the Agency.
The potential negative aspects of performing unannounced inspections are 1) the
source may not be operating or key plant personnel may not be available, and 2) there
could be an adverse impact on Agency source relations. However, it has been
demonstrated by the Regional Offices who already use the unannounced inspections that,
in the majority of cases, these drawbacks can be overcome.
When using the unannounced inspection, an alternative to arriving at the source
totally unannounced is to contact the source shortly before the scheduled inspection time.
This is left to the discretion of the Regional Office and/or the inspector and must be done
so as not to alter the representativeness of the source operation. The amount of
advanced notice given should be noted in the inspection report.
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Announced inspections are performed by EPA and its authorized representatives
when some specific purpose is served by providing such notice. Situations where
announced inspections are appropriate are:
0 When specific1 information is being sought which must be prepared by the
source, or where the source must make significant accommodations for the
inspector to gather the information
0 When the assistance of specific plant personnel is necessary for the
successful performance of the inspections, i.e., the information they provide
cannot be obtained from other on-duty plant personnel or by a follow-up
information request
0 When inspecting government facilities or sources operating under
government contract where entry is restricted due to classified operations.
When the inspection is announced in advance, a lead time of five working days is
generally appropriate. Notification may be by telephone or letter and it may or may not
include the exact date and time of the inspection. Instances where written notification
Onstead of oral) is appropriate are:
0 When requested by the State/local agency or by the source
0 When extensive or specific records are being sought
0 When the inspection is to be performed solely by an EPA or State/local
contractor
0 When inspecting government facilities with classified operations or otherwise
restricted entry
0 Special-purpose inspections, e.g., to establish conditions for a source-
specific SIP revision.
The plant representative notified should have the authority to release data and
samples and to arrange for access to specific processes. In addition, when notifying a
plant of an inspection, information should be requested in regard to onsite safety
regulations. This will avoid problems concerning safety equipment at the time of the
inspection.
State and/or local agencies should be given a minimum of five working days
advance notice of unannounced or announced inspections to be conducted within their
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jurisdiction. In the case of an announced inspection, this notification should precede that
given to the source.
Notification can be written or oral, in any case, a record should be kept. The
notification and record thereof should include the following items:
Name and location of subject facility
Date and approximate time of the activity
Regional Office contact (phone number, etc.)
Reason for the inspection
Name of the State contact
Date and time of notification.
State/EPA Memorandums of Agreements should be consulted for further
information on notification procedures.
4.1.4 Equipment Preparation
Part of the pre-inspection preparation involves obtaining and preparing inspection
and safety equipment. A general list of inspection and safety equipment for a Level II
compliance inspection of nonmetallic mineral processing facilities is included in Table 3.
All safety equipment should meet Mine Safety and Health Administration (MSHA)
requirements.
TABLE 3. RECOMMENDED INSPECTION AND SAFETY EQUIPMENT
Inspection equipment
Tape measure
Flashlight
Stopwatch
Duct tape
Sample bottles
Safety equipment
Respirator with
appropriate cartridge(s)
Hard hat
Safety glasses
or goggles
Gloves
Coveralls"
Safety shoes
Ear protection
NIOSH/OSHA
Pocket Guide to Chemical Hazards
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All equipment should be checked before use. The inspector is responsible for
seeing that all equipment necessary to conduct an inspection is brought to the inspection
site.
Safety equipment required for a facility is based on the plant's response to the
inspection announcement or on the safety requirements for that facility previously
recorded in the agency files. Safety requirements must be met, not only for safety
reasons, but to ensure that the inspector is not denied entry to the plant.
Before or after equipment preparation, the inspector must also consider what
written materials, forms, documents, etc., he/she will require during the inspection. These
should also be gathered and organized before the inspection. These materials may
include any or all from the following list:
o
o
o
o
o
o
o
o
o
o
o
o
Maps
Flowcharts
Plant layout
Applicable regulations
Inspection checklists
Field notebook
Reference materials
Visible emission observation forms (Method 9 and 22 as applicable)
Inspection plan or agenda
Agency credentials
Baseline data
Information requested by facility.
4.2 PRE-ENTRY OBSERVATIONS
Two types of observations, conducted prior to plant entry, have been shown to
be valuable in determination of facility compliance. These are the observation of the plant
surroundings and the visible emission observations.
4.2.1 Plant Surroundings Observation
Observations of areas surrounding the plant before entry may reveal a variety of
signs of operational practices and pollutant emissions which can aid in the pre-entry
evaluation. These include:
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0 Obvious vegetation damage near the plant
0 Deposits on cars parked close by
0 Conditions around product and waste piles
0 Heavy dusting of standing trees or buildings
0 Proximity of sources to potential receptors.
4.2.2 Visible Emissions Observations
In addition to observing the plant.surroundings prior to entry, the inspector may
also perform visible emission observations at that time. Visible emission observations can
be performed on both stack and fugitive sources using both Method 9 and 22 as long as
the provisions of the references methods and the provisions of § 60.11 and 60.675 (c) are
met.
Although it is likely that not all emission points will be visible from a location outside
the plant property lines, elevated emission points (e.g., stacks, elevated buildings, silos,
bucket elevators, conveyor belt transfer points, etc.) may be easily read. Extreme care
should be taken, however, to ensure that the emission point is correctly identified at the
time of observation. Verification of the emission points that were observed should be
sought during the onsite inspection. Visible emission observation procedures are detailed
in Section 4.7.
4.3 PLANT ENTRY
This section details the accepted procedures under the Clean Air Act (CAA or
the Act) for entry to a facility to conduct onsite inspections. As such, these procedures
are applicable to EPA inspectors and may or may not be applicable or compatible with
State or local procedures. This section does not provide procedures for obtaining an
inspection warrant in the case of refusal of entry which are covered in detail in other
publications.
4.3.1 Authority
The Clean Air Act authorizes plant entry for the purposes of inspection. In specific,
Section 114 of the Act states:
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" the Administrator or his authorized representative, upon presentation of
his credentials shall have a right of entry to, upon or through any premises
of such person or in which any records required to be maintained are
located, and may at reasonable times have access to and copy any
records, inspect any monitoring equipment or methods and sample any
emissions which such person is required to sample "
4.3.2 Arrival
Arrival at the facility must be during normal working hours. Entry through the main
gate is recommended unless the inspector has been previously instructed otherwise. As
soon as the inspector arrives on the premises, he should locate a responsible plant
official usually the plant owner, manager, or chief environmental engineer. In the case of
an announced inspection, this person would most probably be the official to whom
notification was made. The inspector should note the name and title of this plant
representative.
4.3.3 Credentials
Upon meeting the appropriate plant official, the inspector should introduce himself
or herself as an EPA inspector and present the official with the proper EPA credentials
and state the reason for requesting entry. The credentials provide the plant official with
the assurance that the inspector is a lawful representative of the Agency. Each office of
the EPA issues its own credentials; most include the inspector's photograph, signature,
his physical description (age, height, weight, color of hair and eyes), and the authority for
the inspection. Credentials must be presented whether or not identification is requested.
After facility officials have examined the credentials, they may telephone the appropriate
EPA Office for verification of the inspector's identification. Credentials should never leave
the sight of the inspector.
4.3.4 Consent
Consent to inspect the premises must be given by the owner, operator, or his
representative at the time of the inspection. As long as the inspector is allowed to enter,
entry is considered voluntary and consensual, unless the inspector is expressly told to
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leave the premises. Express consent is not necessary; absence of an express denial
constitutes consent.
If there is difficulty in gaining consent to enter, inspectors should tactfully probe the
reasons and work with officials to overcome the obstacles. Care should be taken,
however, to avoid threats of any kind, inflammatory discussions, or deepening of
misunderstandings. Whenever the situation is beyond the authority or ability of the
inspector, he or she should contact their supervisor for guidance.
If the inspector is asked to leave the premises after the inspection has begun, the
inspector should 1) tactfully discuss the reason for denial, 2) avoid any situation that
might be construed as threatening or inflammatory, 3) withdraw from the premises and
contact his or her supervisor, 4) note the facility name, address, and the name and title
of the plant official(s) approached and the authority of the person issuing the denial, and
5) note the date, time, and reason for the denial as well as facility appearance and any
reasonable suspicion why entry was denied. These procedures also apply if the inspector
is denied entry to certain parts of the facility. After withdrawal from the premises, the
inspector should always contact the appropriate Agency office for further instructions
including a determination of whether a warrant should be obtained to inspect the facility.
4.3.5 Uncredentialed Persons Accompanying an Inspector
The consent of the owner or agent in charge must be obtained for the entry of
persons accompanying an inspector to a site if they do not have specific authorization.
If consent is not given voluntarily, these persons may not enter the premises. If consent
is given, these persons may not view confidential business information unless officially
authorized for access.
4.3.6 Waivers. Releases, and Sign-in Logs
When the facility provides a blank sign-in sheet, log, or visitor register, it is
acceptable for inspectors to sign it. Under no circumstances should EPA employees sign
any type of "waiver" or "visitor release" that would relieve the facility of responsibility for
injury or which would limit the rights of the Agency to use data obtained from the facility.
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If such a waiver or release is presented, the inspector should politely explain
he/she cannot sign and request a blank sign-in sheet. If an inspector is refused entry
because they do not sign such release, they should leave and immediately report all
pertinent facts to the appropriate supervisory and/or legal staff. All events surrounding
the refused entry should be fully documented. Problems should be discussed cordially
and professionally.
4.3.7 Nondisclosure Statements
Inspectors have, in the past, occasionally been asked to sign nondisclosure
statements or agreements. These agreements vary slightly in content from one to
another, but generally require that confidential information, disclosed to an inspector
during the course of an inspection, be handled thereafter in a specified manner. An
inspector should not sign such agreements since Federal Regulations (40 CFR Part 2, as
amended) on the confidentiality of business information already protect the business from
disclosure of confidential information.
4.4 OPENING CONFERENCE
Once legal entry has been established, the inspector should proceed with a vital
part of every inspection, the opening conference. The purpose of the opening conference
is to inform the facility officials) of the purpose of the inspection, the authorities under
which it will be conducted, and the procedures to be followed. The opening conference
also offers the inspector the opportunity to strengthen Agency - industry relations through
a positive attitude and provide relevant information and other assistance. The effective
execution of the opening conference on the inspector's part
often facilitates the remainder of the inspection.
During the opening conference, the inspector is responsible for covering the
following items:
0 Inspection Objectives - An outline of inspection objectives will inform facility
officials of the purpose and scope of the inspection and may help avoid
misunderstandings.
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inspection Agenda - Discussion of the sequence and content of the
inspection including operations and control equipment to be inspected and
their current operating status. This will help eliminate wasted time by
allowing officials time to make any preparations necessary. The types of
measurements to be made and the samples to be collected (if any) should
also be addressed.
Facility Information Verification - The inspector should verify or collect the
following information:
Correct name and address of facility
Correct names of plant management and officials
Principal produces) and production rates
Affected facilities and emission points.
List of Records - A list of records (NSPS or permit requirements) to be
inspected will allow officials to gather and make them available to the
inspector.
Accompaniment - It is imperative that a facility official accompany the
inspector during the inspection, not only to describe the plant and its
principal operating characteristics, but also to identify confidential data and
for safety and liability considerations.
Safety Requirements - The inspector should determine what facility safety
regulations including safety equipment requirements will be involved in the
inspection, and should be prepared to meet these requirements. The
inspector should also inquire about emergency warning signals and
procedures.
Meeting Schedules - A schedule of meetings with key personnel (if
necessary) will allow them to allocate a clear time to spend with the
inspector.
Closing Conference - A post-inspection meeting should be scheduled with
the appropriate officials to provide a final opportunity to gather information,
answer questions, and make confidentiality declarations.
New Requirements - The inspector should discuss any new rules and
regulations that might affect the facility and answer questions pertaining to
them. If the inspector is aware of proposed rules that might affect the
facility, he or she may wish to encourage facility officials to obtain a copy.
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0 Duplicate Samples and/or Simultaneous Measurements - Facility officials
should be informed of their right to receive a duplicate of any physical
sample collected for laboratory analysis or to conduct simultaneous
measurements such as visible emission observations.
0 Confidentiality Claims - Company officials should be advised of their right
to request confidential treatment of trade secret information.
0 Photographs - If necessary, the inspector should request permission to take
photographs during the inspection.
4.5 INSPECTION DOCUMENTATION
The air compliance inspection is generally conducted to achieve one or more of
three main objectives.
1. To provide data and other information for making a compliance
determination.
2. To provide evidentiary support for some type of enforcement action.
3. To gather the data required for other agency functions.
Taking physical samples, reviewing records, and documenting facility operations are the
methods used by the inspector to develop the documentary support required to
accomplish these objectives. The documentation from the inspection establishes the
actual conditions existing at the time of the inspection so that the evidence of these
conditions may be objectively examined at a later time in the course of an enforcement
proceeding or other compliance related activity.
Documentation is a general term referring to all print and mechanical media
produced, copied, or taken by an inspector to provide evidence of facilities status. Types
of documentation include the field notebook, field notes and checklists, visible emission
observation forms, drawings, flow sheets, maps, lab analyses of samples, chain of
custody records, statements, copies of records, printed matter, and photographs. Any
documentation gathered or produced during the inspection may eventually become part
of an enforcement proceeding. It is the inspector's responsibility to recognize this
possibility and ensure that all documentation can pass later legal scrutiny.
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4.5.1 Inspector's Field Notebook and Field Notes
The core of all documentation relating to an inspection is the inspector's field
notebook or field notes, which provide accurate and inclusive documentation of all field
activities. Even where certain data or other documentation is not actually included in the
notebook or notes, reference should be made in the notebook or notes to the additional
data or documentation such that it is completely identified and it is clear how it fits into
the inspection scheme.
The field notebook and/or notes form the basis for both the inspection report and
the evidence package and should contain only facts and pertinent observations.
Language should be objective, factual, and free of personal feelings or terminology that
might prove inappropriate.
Because the inspector may eventually be called upon to testify in an enforcement
proceeding, or his/her field data may be entered into evidence, it is imperative that
he/she keep detailed records of inspections, investigations, samples collected, and
related inspection functions. The types of information that should be entered into the field
notebook or notes include:
0 Observations - All conditions, practices, and other observations relevant to
the inspection objectives or that will contribute to valid evidence should be
recorded.
0 Procedures - Inspectors should list or reference all procedures followed
during the inspection such as those for entry, sampling, records inspection,
and document preparation. Such information could help avoid damage to
case proceedings on procedural grounds.
0 Unusual Conditions and Problems - Unusual conditions and problems
should be recorded and described in detail.
0 Documents and Photographs - All documents taken or prepared by the
inspector should be noted and related to specific inspection activities. (For
example, photographs taken should be listed, described, and related to the
subject photographed.)
0 General Information - Names and titles of facility personnel and the activities
they perform should be listed along with other general information.
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Pertinent statements made by these people should be recorded.
Information about a facility's recordkeeping procedures may be useful in
later inspections.
4.5.2 Visible Emission Observation Form
Because visible emission (VE) observations are such a frequently used
enforcement tool, a separate form has been developed for recording data from the VE
observation using EPA Method 9 (Figure 27). This form has been designed to include
all the supporting documentation necessary, in most cases, for VE observation data to
be accepted as evidence of a violation. Thus, it is recommended that the inspector use
this form for recording opacity observations; an appropriate reference should be made
to the form in the field notebook or notes. In addition, a separate form is used to record
the presence and duration of fugitive emissions from buildings enclosing NSPS affected
facilities. This is the EPA Method 22 Field Data Sheet for Outdoor Locations (Figure 28).
4.5.3 Drawings and Maps
Schematic drawings, flow sheets, maps, charts, and other graphic records can be
useful as supporting documentation. They can provide graphic clarification of emission
source location relative to the overall facility, relative height and size of objects, and other
information which, in combination with samples, photographs, and other documentation,
can produce an accurate, complete, evidence package.
Drawings and maps should be simple and free of extraneous details. Basic
measurements and compass points should be included, if necessary, to provide a scale
for interpretation.
4.5.4 Copies of Records
A facility's records and files may be stored in a variety of information retrieval
systems, including written or printed materials, computer or electronic systems, or visual
systems such as microfilm and microfiche.
When copies of records are necessary for an inspection report, storage and
retrieval methods must be taken into consideration:
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VISIBLE EMISSION OBSERVATION FORM
No.
COMPANY NAME
STREET ADDRESS
CITY
PHONE (KEY CONTACT)
STATE OP
SOURCE D NUMBER
PROCESS ECXMPMENT OPERATING UOO6
CONTROL EOUPMENT OPERATING MOOE
DESCRIBE EMISSION POWT
HEIGHT ABOVE GROUND LEVEL
DISTANCE FROM OBSERVER
Sun End
HEJQHT.RELATTVE TO OBSERVER
Start End
DIRECTION FROM OBSERVER
Start End
DESCRIBE EMISSIONS
Sun End
EMISSION COLOR
Stan En)
f WATER DROPLET PLUME
AtuctwdO OtuchrtO
POINT IN THE PLUME AT WHICH OPACITY WAS DETERMINED
Slot End
DESCRIBE PLUME BACKGROUND
Suit End
BACKGROUND COLOR
SUit End
WIND SPEED
SIM
AMBIENT TEMP
SUB
SUdc
with "
PkXTH
Sun -4-
WnJ ->-
-£•
End
End
SKY CONOmONS
Start End
WIND CKRECTON
Start End
WET BULB TEMP RH. DMOMl
SOURCE LAY
>
—-******' 1*
OUT SKETCH Onm North Araw
o
( EmUiion POM
.ObMfvWt Petition
0>^\^
Sun Location Ltn*
ADDITIONAL INFORMATION
OBSERVATION DATE
^sec
MN\
t
2
3
4
s
6
7
•
9
10
11
12
13
14
IS
18
17
1*
19
20
21
22
23
24
2S
26
27
M
29
90
0
15
30
START TIME END T1UE
«
COMMENTS
OBSERVER'S NAME (PRINT)
OBSERVER'S SIGNATURE DATE
ORGANIZATION
CERTIFIED BY DATE
CONTINUED ON VEO FORM NUMBER
Figure 27. EPA Method 9 visible emission observation form.
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FUGITIVE OR SMOKE EMISSION INSPECTION
OUTDOOR LOCATION
Company
Location .
Company repr asantativa
Obcerver .
Affliction
0«e _—.
Sky Conditions.
Pracfcttatfon _
Wind direction
Wind speed
Industry
Process unit
Sketch proetlr unft; Indieatt obtarv«r portion rtlativa to courea and sun; indicatt potential
«mlsston point* and/or actual amiasten points.
OBSERVATIONS
Btgin Observation
Clock
time
ObMrvation
p«rlod
duration.
Accumulated
amisaion
time.
min:s«c
End observation
Figure 28. EPA Method 22 field data sheet for outdoor location.
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0 Written or printed records can generally be photocopied onsite. Portable
photocopy machines may be available to inspectors through the Regional
Office. When necessary, inspectors are authorized to pay a facility a
"reasonable" price for the use of facility copying equipment. All copies
made for or by the inspector should be initialed and dated for identification
purposes.
0 Computer or electronic records may require the generation of "hard" copies
for inspection purposes. Arrangements should be made during the opening
conference, if possible, for these copies. (Photographs of computer screens
may possibly provide adequate copies of records if other means are
impossible.)
0 Visual systems (microfilm, microfiche) usually have photocopying capacity
built into the viewing machine, which can be used to generate copies.
(Photographs of the viewing screen may provide adequate copies of
records if other means are impossible.)
Immediate and adequate identification of records reviewed is essential to ensure
the ability to identify records throughout the Agency custody process and to ensure their
admissibility in court. When inspectors are called to testify in court, they must be able to
positively identify each particular document and state its source and the reason for its
collection. Initial, date, number, and record the facility's name on each record, and
reference these items in the field notebook or notes.
0 Initialing/Dating - The inspector should develop a unique system for initialing
and dating records and copies of records so that he/she can easily verify
their validity. This can be done by initialing each document in a similar
position, or by another method, at the time of collection. Both the original
and copy should be initialed. All record identification notations should be
made on the back of the document.
0 Numbering - Each document or set of documents substantiating a
suspected violation or violations should be assigned an identifying number
unique to that document. The number should be recorded on each
document and in the field notebook.
0 Loading - Documents obtained during the inspection should be entered in
the field notebook or notes according to some logical system. The system
should include the following information:
Identifying number
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Date
The reason for copying the material
The source of the record
The manner of collection.
4.5.5 Printed Matter
Brochures, literature, labels, and other printed matter may provide important
information regarding a facility's condition and operations. These materials may be
collected as documentation if, in the inspector's judgment, they are relevant. All printed
matter should be identified with the date, inspector's initials, and related sample numbers.
Reference to these materials should be made in the field notebook or notes.
4.5.6 Photographs
The documentary value of photographs ranks high as admissible evidence; clear
photos of relevant subjects, taken in proper light and at proper lens settings, provide an
objective record of conditions at the time of inspection. The use of photographic
documentation, however, often elicits a negative reaction from plant officials, thus, it is
recommended that photographic documentation be used only sparingly and only when
necessary to document an inspection finding.
When a situation arises that dictates the use of photographs, the inspector should
obtain the company's permission to take photographs. This is most conveniently
accomplished during the opening conference. The inspector may offer to provide the
official with duplicates of all photographs taken. As with other business data collected,
during and/or at the conclusion of the inspection, the inspector should ascertain whether
any of the photographs taken contain proprietary information and if the company wishes
to designate any as confidential. Photographs taken employing a Polaroid-type instant
camera allow an immediate confidentiality review and the opportunity for the inspector to
readily provide the company with duplicate shots. Photographs may always be taken
form areas of public access (e.g., outside the fence, from the road, from a parking lot,
etc.).
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A photographic log should be maintained in the inspector's field notes for all
photographs taken during an inspection, and the entries are to be made at the time the
photograph is taken. These entries are to be numerically identified so that after the film
is developed the prints can be serially numbered corresponding to the log book
descriptions and, if necessary, pertinent information can be easily transferred to the back
of the photograph.
Polaroid-type instant photos should be immediately identified on the back after
shooting with the corresponding photo ID number; photographs that require developing
and printing should be numbered as soon as possible. One recommendation which will
ensure that all prints and negatives can be positively identified is that prints and negatives
be left uncut and the photographic log be photographed at the beginning and end of
each roll of film. Photographs of a confidential nature must be developed by an
authorized contractor.
4.6 VERIFICATION OF FACILITY RECORDS
40 CFR 60, Subpart A and Subpart 000 require that the source maintain a
permanent file of required notifications, reports, measurements, and records for review
by the Administrator or authorized representative. Pursuant to § 60.7(d) of Subpart A, this
permanent file is to be retained by the source for at least two years. Integral to the
compliance inspection, these notifications and records must be verified by the inspector.
A complete records check should be accomplished before the inspector leaves the
plant. However, § 60.7(d) does not specify that the owner or operator must locate this
permanent file at the facility to be inspected. If required records are located elsewhere
(main or central corporate office), provisions should be made for the records to be made
available during the inspection. This is best accomplished during the inspection
notification to the facility. If the inspection is unannounced, the inspector should make
definite arrangements with the source during the opening conference to have the records
made available on specified dates.
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The following is a list of records required to be kept by the owner or operator of
the source under the provisions of the nonmetallic mineral processing NSPS. Each item
on the list is accompanied by its regulatory citation. Please note that records for
continuous opacity monitoring systems (COM3) are not included in the list.
Written Notifications to the Administrator--
1. The date of construction or reconstruction of any affected facility § 60.7(a)
0).
2. The date of actual initial startup of any affected facility - § 60.7(a)(3) and §
60.676(i).
3. Any physical or operational change to an existing facility which may
increase the emissions rate of any air pollutant to which a standard applies,
unless that change is specifically exempted under an applicable subpart or
in § 60.14(e) - 60.7(a)(4).
§ 60.14(e) exemptions:
0 Routine maintenance, repair and replacement
0 An increase in production rate of an existing facility without a capital
expense on that facility
0 An increase in the hours of operation
0 Use of an alternative fuel or raw material if the existing facility was designed
to accommodate same before August 31, 1983
0 The addition or use of any air pollution control device or system except
when such a device or system is removed or replaced by a system which
is less environmentally beneficial
0 Relocation or change in ownership of, an existing facility.
4. The date that initial performance test opacity observations are anticipated -
§ 60.7(a)(6).
5. Seven day advance notice of any rescheduled dates for any performance
test if operational problems- or other conditions prevent the test from being
conducted - § 60.675(g).
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6. Proposed "reconstructions" of existing facilities - § 60.15(d) (See § 60.15(d)
for information required in the notification).
7. Thirty day advance notification of any performance test of an affected facility
- § 60.8(d).
Written Reports to the Administrator-
1. Initial performance test results of all affected facilities - § 60.8(a).
Initial performance test opacity results of all affected facilities § 60.11 (e)(2).
2.
3.
4.
5.
6.
The results of all performance tests of affected facilities to demonstrate
compliance including opacity observation results (Method 9) and/or Method
22 observation results - § 60.676(f).
Semiannual reports of occurrences when scrubber pressure drop and liquid
flow rate differ from the average of the last performance test by ± 30
percent - § 60.676(d).
Proposed replacements of existing facilities with facilities of equal or smaller
size - § 60.676(a) (See § 60.676(a) for information required in the report).
Reports of changing any screening operation, bucket elevator, or belt
conveyor that process saturated material and is subject to § 60.672(h) to
processing unsaturated material and vice versa - § 60.676(g).
Records On File-
1.
Startup, shutdown, and malfunction occurrences and their durations for all
affected facilities; malfunctions of air pollution control equipment serving
affected facilities; and any periods during which continuous monitoring
systems or monitoring devices (i.e., scrubber pressure drop and liquid flow
rate measurement devices) are inoperative - § 60.7(b).
2. All measurements of monitoring devices, calibration checks, and all
adjustments and maintenance performed on these devices - § 60.7(f).
To include:
0 Daily continuous measurements of scrubber pressure drop and liquid
flow rate - § 60.676(c)
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0 Scrubber monitoring device manufacturer's accuracy certification and
annual calibration checks - § 60.674.
It should be remembered that § 60.7(f) of Subpart A requires the owner or operator
of the affected facility to maintain these notifications, reports, records, and measurements
for at least two years. Therefore, the inspector should be familiar with the chronological
history of the affected facilities to determine whether the records of the owner or operator
are current and acceptable. Accurate agency files and tracking of affected facilities, their
dates of construction, and dates of performance tests are vital for a complete and
accurate check of source records.
4.7 MEANS OF DETERMINING COMPLIANCE WITH THE STANDARD FOR
PARTICULATE MATTER
The standard for particulate matter for the nonmetallic mineral processing NSPS
is found in § 60.672 and includes a mass emission limit of 0.05 g/dscm (0.02 gr/dscf) for
point sources (i.e., stacks and powered vents) and a point source opacity limit of 7
percent, as well as an opacity limit of 10 percent for all fugitive emission sources except
15 percent for crushers without capture systems (see definition of "capture system" in
Section 3.2). It should be noted that wet suppression is not considered a capture system.
In addition, § 60.672(e) limits emissions from affected facilities enclosed in buildings to 10
or 15 percent opacity as applicable, or limits the building to no visible emissions. Finally,
§ 60.672(h) limits certain affected facilities to no visible emissions.
Determining compliance of each affected facility and/or emission point may
therefore involve visible emission observations using EPA Method 9 or Method 22 as
applicable. In the case of wet scrubbers, a compliance determination with the monitoring
provisions of § 60.674 necessarily involves checking scrubber pressure drop and liquid
flow rate data from the continuous monitoring devices.
Although the only way to determine the compliance status of stacks or powered
vents with the mass emission limit is a stack test, surrogate indicators of compliance may
be used by the inspector to make logical decisions based on engineering principals as
to the likelihood of compliance. Use of surrogate indicators of compliance is not
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appropriate for the initial performance test or any other compliance determination
requiring a stack test, but can be used as an indicator of compliance during inspections.
Such surrogate indicators of compliance may include significant variations in process
variables or pollution control equipment variables that are outside of the range recorded
during the most recent compliance test or outside of the range of good engineering
practice (e.g., broken or inoperable baghouse cleaning systems; bypassed or isolated
sections of capture systems; increased process rates of nonaffected sources co-vented
to APC equipment serving NSPS affected facilities, etc.). If these surrogate indicators of
compliance strongly suggest that the source is not in compliance with the mass emission
limit, a stack test should be required under the same or similar operating conditions
unless it is determined that the operating conditions constituted a startup, shutdown or
malfunction event.
4.7.1 Determining Compliance with Opacity During the Inspection
While § 60.11(b) and § 60.675(c) require minimum observation times using EPA
Method 9 of 3 hours and one hour, respectively, to determine compliance with the NSPS
opacity limits for the initial performance test, the inspector is not required to duplicate
these visible emission observation requirements during a compliance inspection. In the
case of affected facilities enclosed in buildings, § 60.675(d) of Subpart 000 similarly
requires a minimum observation time using EPA Method 22 of 75 minutes (15 minutes per
side and top) during the initial performance test. As with EPA Method 9, the inspector
is not required to duplicate this requirement during a compliance inspection.
The following are acceptable guidelines that may be used for performing EPA
Method 9 or Method 22 observations during a compliance inspection:
0 Continuous operating/emitting sources - Minimum observation time using
EPA Method 9 should be 18 minutes (three 6-minute observation sets).
When using EPA Method 22 for buildings, minimum observation time should
be 20 minutes (5 minutes per side and top).
0 Intermittent operating/emitting sources - Intermittent sources should be
observed for at least two or three cycles of operation. Observations should
end at the end of the process cycle and noted on the visible emission
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observation form. Observations should be continued when the next cycle
begins. A least two 6-minute observation sets should be recorded.
0 Affected facilities inside buildings - If affected facilities are enclosed within
buildings and the owner/operator has elected to demonstrate compliance
via Method 9 inside the building, the following are acceptable minor
changes to the reference method pursuant to § 60.8(b) for applying EPA
Method 9 inside the building:
1. Assume a position at least 4.57 meters (15 ft) from the source of
emissions.
2. Without available and proper sunlight, use portable directional lights
positioned within the 140° sector to the observer's back and at least
twice as bright as any ambient light inside the building.
3. If background color is sufficiently similar to emission color, artificial
backgrounds are permissible to promote color and luminous
contrast.
The inspector should check agency files before the inspection to determine
if a Method 9 performance test protocol for affected facilities inside buildings
was mutually accepted by the source and the agency. If yes, Method 9
should be applied inside the building to determine compliance.
It should be noted that EPA policy is to allow.no measurement error allowance for
conducting EPA Method 9. Thus, EPA policy prohibits dropping from consideration
marginal opacity exceedances solely because of possible reader measurement error (see
Appendix G, memorandum from John S. Seitz to Roger O. Pfaff, March 3, 1989).
The preferred approach for accounting for measurement error is to follow the
procedures for conducting Method 9 observations described in the "Quality Assurance
Handbook for Air Pollution Measurement Systems" (EPA-600/4-77-027b, 1977) and to
conductfollowup investigation whenever opacity exceedances are observed. The Method
9 guidance materials suggest various ways to augment the visible emission observation
if opacity values are in excess of the standard.
For example, in marginal violation situation, additional sets of readings over longer
time periods or even on different days may be appropriate for ensuring that the opacity
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exceedances documented truly reflect noncompliance. Finally, enforcement officials must
exercise their technical judgement carefully in the final determination of an enforceable
violation, which may be based on additional factors such as the plant operating history
and extent and duration of excessive emissions.
4.7.2 Determining Compliance with Opacifv During the Initial Performance Test
The observation duration requirements for determining compliance with the
opacity and/or visible emission standards of § 60.672 are found in § 60.11(b) of Subpart
A, and in § 60.675(c) and (d) of Subpart OOO. These requirements can only be changed
pursuant to § 60.8(b) which allows the Administrator to 1) specify or approve, in specific
cases, the use of a reference method with minor changes in methodology, 2) approve the
use of an alternative method the results of which he/she has determined to be adequate
for indicating compliance, 3) approve the use of an equivalent method, 4) waive the
requirement for a performance test because the owner or operator has demonstrated to
the Administrator's satisfaction that the affected facility is in compliance with the standard,
or 5) approve shorter sampling times and smaller sample volumes when necessitated by
process variables or other factors.
Any and all requests for changes in the performance test requirements pursuant
to § 60.8(b) must be submitted to the appropriate EPA Regional Office. Requests include
those from the owner or operator of an affected facility and from States, whether or not
the State has received from EPA delegated authority for 40 CFR 60, Subparts A or 000
or both.
4.8 FIELD INSPECTION PROCEDURES FOR AFFECTED FACILITIES
The field inspection procedures herein include those tasks to be performed in
determining the compliance status of affected facilities with the NSPS standard for
particulate matter (§ 60.672) and, if applicable, the provisions for monitoring of wet
scrubber operations (§ 60.674).
As was discussed in Section 2, it is usually best to start the inspection at the
beginning of the facility process operations and end the inspection at the finished product
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loading station(s). If, however, from pre-entry observations the inspector has discovered
possible violations at specific plant areas (e.g., excessive stack opacity or fugitive
emissions) it is usually best to begin the field inspection at these areas to document any
violations in a timely manner.
To aid the inspector in keeping track of the number and type of affected facilities
at the source and the opacity and mass emission limits applicable to each affected facility,
a master list containing this information should be carried into the field. Appendix E
contains a sample form that can be used for this purpose. In addition to affected
facilities, existing facilities and wet screening operations should be included as potentially
affected facilities in the master list. With this information, the inspector can verify that
existing facilities have not been replaced with new facilities that have not yet been
permitted under the NSPS provisions or modified in such a way as to increase emissions.
In addition to the master list of potentially affected and affected facilities, Appendix
E includes a Field Inspection Sheet that may be used to document compliance data for
individual affected facilities. The Field Inspection Sheet includes the specific items to be
inspected and serves as compliance documentation for individual affected facilities and
emission points.
Finally, Appendix E contains an example Initial Performance Test Field Sheet for
affected facilities. Similar to the Field Inspection Sheet, this form includes space to
illustrate the applicable affected facility or transfer point. The Initial Performance Test Field
Sheet may subsequently be used as a file reference document to be reviewed as
necessary before future inspections.
The following inspection techniques are specific to individual affected facilities (e.g.,
crushers, bagging operations, enclosed truck or railcar loading stations, etc.) and
individual APC systems (e.g., wet scrubbers, baghouses, wet suppression, etc.).
4.8.1 Crushers
Fugitive emissions from crushers are most apparent at crusher feed and discharge
points. Care must be taken to separate fugitive emission opacity from water mists
generated by wet suppression systems. The inspector should position himself/herself at
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least 4.57 meters (15 ft) from the emission source and in accordance with the provisions
§ 60.675(c)(1)(i). Both the crusher inlet and discharge outlet should be observed.
Previously, there has been some confusion as to whether emissions at the crusher
discharge onto a belt conveyor should be considered crusher emissions or belt conveyor
transfer point emissions. For the purposes of determining compliance with the provisions
of Subpart 000, these emissions should be considered as crusher emissions. Therefore,
if a crusher is an affected facility and the crusher is not served by a capture system,
emissions at both the inlet and discharge of the crusher are limited to 15 percent opacity.
Crusher discharge emissions onto a belt conveyor that is also an affected facility are not
considered belt conveyor transfer point emissions which are limited to 10 percent opacity.
Figure 29 shows excessive fugitive emissions from the discharge of a primary jaw crusher.
The inspector must exercise caution when observing crusher emissions, especially
at the crusher feed inlet, due to the possibility of ore fragments being violently ejected
from the crusher. Figures 30 and 31 show the inlets of two secondary cone crushers with
and without skirting, respectively. Note the waterspray supply hose around the diameter
of the crusher casing in Figure 31. The inspector should also maintain a safe distance
from any mobile equipment hauling ore to or from the crusher.
In distinguishing whether a crusher (or any other equipment) is portable as it
applies to the exemption provisions of § 60.670(c), the equipment must be mounted on
a movable chassis or skid and must not be attached to any anchor slab, or structure by
any means other than electric cabling. Figure 32 shows a portable primary crusher
mounted on a wheeled chassis.
4.8.2 Grinding Mills
As with crushers, fugitive emissions are generated at the grinder's inlet and outlet
with the majority of emissions at the outlet after reduction of raw material (i.e., more fines).
Because the definition of a grinding mill found in § 60.671 includes the air conveying
system, air separator, or air classifier, the inspector should also inspect the entire length
of these systems for any fugitive emissions as well as the emission points for mill sweep
air. Both closed-loop and open-circuit systems are common. In the closed-loop system,
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Figure 29. Fugitive emissions from a jaw crusher.
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^ -* H
-
Figure 30. Feed inlet of cone crusher with feed skirts.
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Figure 31. Open feed inlet of cone crusher.
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-=- 3»&B='g'ga.agjssatt.j - -*•>>•"»
Figure 32. Portable jaw crusher.
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dryer flue gases may be added to the mill sweep air and an equivalent amount of air bled
from the system to discharge moisture. In an open circuit system, the dryer gases
and/or mill sweep air are not recirculated. Typically, these types of systems use roller
or ball type mills.
Normally, when an affected facility is vented to the same ARC equipment and stack
as nonaffected facilities, the emission point is subject to the NSPS standard. In such
cases, performance tests of the affected facility are conducted while the nonaffected
facilities are inoperative. When dryer flue gases are vented to the sweep air of an affected
facility grinding mill, however, the dryer usually cannot be shut down during a
performance test. Dryer heat is normally required to prevent the material being reduced
from clogging the grinding mill. For these types of situations it is acceptable to prorate
emissions between the dryer and the grinding mill using the following equation:
0.05 x
!=,
0.05
(CWo)ooo
(Q3TD)r
where != = Prorated emission standard, g/dscm
= Subpart 000 emission standard, g/dscm
= Volumetric flow rate from Subpart 000 source(s), dscfm
= (O;TD)OOO + (^TD)D = total volumetric flow rate, dscfm
= Volumetric flow rate from dryer, dscfm
p = Dryer emission standard, g/dscm.
This prorating process requires measurement of both the volumetric flow rate from the
dryer and from the Subpart 000 source (mill). In addition, the test protocol must include
dryer firing rates that are commensurate with representative operating conditions.
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4.8.3 Screening Operations
Affected facility screens may be controlled for fugitive emissions by wet
suppression systems or with hooded capture systems. Figure 33 shows a vibrating deck-
type screen releasing excessive fugitive emissions (uncontrolled). Opacity observations
should be made at the point of maximum opacity in the plume.
Hooded screens should be checked for signs of ill-fitting seals or gaps in hood
integrity. Figure 34 illustrates a hooded screen with a capture system off-take at the top
of the screen. Note that the cleanout of the evacuation system pipe at the top of the off-
take is open allowing fugitive dust to escape.
If the screen is not operating during the inspection, the inspector should observe
the immediate area of the screen for signs of excess emissions during operation. Dust
buildup is not presumptive evidence of noncompliance since the time for the dust
accumulation is likely to be unknown. However, excessive dust buildup may indicate that
the nonoperating affected facility should be reinspected when operating. Figure 35 shows
a considerable dust buildup on the capture system hood and the walls of the enclosing
building around a nonoperating screen.
4.8.4 Grizzlies
Grizzlies are classified as screens; however, Method 9 performance tests under
§ 60.11 are not required, and the opacity limits of § 60.672(b) do not apply, if the grizzly
receives material from truck dumping pursuant to § 60.672(d). AH other requirements of
•Subparts A and OOO, however, do apply (e.g., notifications, etc.). If the grizzly does not
receive material from truck dumping, it is subject to all of the applicable requirements of
Subparts A and OOO.
4.8.5 Storage Bins
Venting of storage bins during loading or unloading constitutes the emission
potential for these affected facilities. Vents may be controlled or uncontrolled. Typical
APC equipment involves cyclones or baghouses.
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Figure 33. Deck-type screen with fugitive emissions.
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Figure 34. Screen hood showing open cleanout emitting fugitive dust.
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Figure 35. Enclosed screen hood showing external fugitive dust buildup.
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The inspector should observe the vent discharge points during at least one cycle
(loading or unloading). In addition, the inspector should observe the area around the
vent, accumulations of dust indicate releases of particulate matter. Absence of opacity
does not necessarily equate with no particulate emissions. Large diameter particles which
do not readily scatter light can be emitted in significant mass without appreciable opacity.
Because these large and heavier particles will fallout quickly, heavy deposits close to the
point of emissions may be readily apparent.
Pursuant to § 60.672(f), any single baghouse that controls emissions from an
individual enclosed storage bin is subject only to a 7 percent opacity limit and is not
subject to the mass emission rate standard of 0.05 g/dscm. Baghouses serving more
than a single enclosed storage bin are subject to both the 7 percent opacity limit and the
mass emission rate standard even if the other facilities served by the baghouse are not
NSPS affected facilities.
4.8.6 Bucket Elevators
Bucket elevators are normally controlled by a capture system at the top of the
elevator at the point of bucket discharge. Fugitive dust is pneumatically conveyed to an
APC system, usually a baghouse. The inspector should observe the entire length of the
elevator enclosure. If emissions are present, they are usually emitted at the capture
system atop the elevator as in Figure 36, or at the access door(s) to the elevator interior
which may be opened to allow for infiltration of makeup air.
4.8.7 Belt Conveyors
Subpart 000 applies only to transfer points to and from affected facility belt
conveyors except transfer points to storage piles. Although wet suppression is the most
frequently used method for emission control, hooding, capture, and conveying to a
control device are also used. Figure 37 shows a belt-to-belt transfer point without
controls. If the moisture content of the material being transferred is sufficient to prevent
i
the material from becoming airborne, visible emission observation can be waived for
determining compliance during the inspection. Belt conveyor transfer points after process
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Figure 36. Bucket elevator with fugitive emissions.
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Figure 37. Uncontrolled belt-to-belt transfer point.
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drying are more likely to result in airborne emissions and are normally controlled with
hooded capture systems as illustrated in Figure 38.
As with other affected facilities, nonoperating belt conveyors should be examined
at transfer points for evidence of excessive emissions (heavy dusting). Visible emission
observations should be scheduled during operation of the affected facility.
4.8.8 Bagging Operations
Bagging operations are generally controlled by a capture and conveying system
served by a control device. If not, fugitive emissions from bagging operations are
generally localized in the area of the bagging machine(s). Bagging operations are almost
always enclosed in buildings to protect these operations from the weather. In such
cases, the inspector may perform EPA Method 22 observations of the building. If Method
22 observations are positive for visible emissions, the inspector should perform EPA
Method 9 observations of the affected facilities inside of the building if the owner or
operator maintains that compliance can thus be demonstrated. If powered vents or
control devices are employed, Method 9 observations should be made accordingly.
4.8.9 Enclosed Truck or Railcar Loading Operations
As with storage bins, truck and railcar loading is an intermittent operation. Visible
emission observations should be made during at least one cycle of operation.
The inspector should completely understand the definition of an enclosed truck or
railcar loading station, which requires that both the conveying system as well as the truck
or railcar be enclosed. Figure 39 is an example of a nonenclosed truck loading station.
This type of facility is not covered by the nonmetallic mineral processing NSPS. Figure
40, however, illustrates one type of enclosed station subject to the NSPS. Note the
enclosed feed tube and the three air vents on the dome of the enclosed railcar. Also note
the fugitive emissions from the loading operation approaching 100 percent opacity
immediately above the transfer point.
Figure 41 illustrates another type of enclosed truck loading station showing some
visible emissions as the air is displaced from the truck. In this case, loadout emissions
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Figure 38. Belt-to-belt transfer point with capture hood.
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Figure 39. Nonenclosed truck loading station.
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sr:
-^.^xusiGSff^ *^* "1 e "
0 U : T • H
Figure 40. Enclosed railcar loading station with fugitive emissions.
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Figure 41. Enclosed truck loading station with flexible feed tube.
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are not controlled because the evacuation system is not connected to the off-take port
at the base of the flexible feed tube (small black square at the top of the feed tube).
4.9 FIELD INSPECTION PROCEDURES FOR AIR POLLUTION CONTROL
EQUIPMENT
The following are Level II inspection procedures for APC systems typically found
at nonmetallic mineral processing facilities.
4.9.1 Operating Pulse Jet Baahouses
Inspection Steps-
0 Method 9 observation of fabric filter discharge
0 Method 9 observation of fugitive emissions from solids handling operation
(if reentrainment is occurring)
0 Method 9 observation of fugitive emissions from process equipment
0 Counterflow checks of audible air infiltration into fan, baghouse (solids
discharge valve, access doors, shell), and ductwork; check physical
condition and location of hoods
0 Check static pressure drop across baghouse using onsite gauge; compare
with baseline data
0 Compare compressed air pressures at reservoir with baseline values; check
for audible leaks of compressed air at fittings; check operation of diaphragm
valves, record number of valves that do not appear to be working properly
0 Check inlet gas temperatures using onsite gauge
0 Observe and describe corrosion of fabric filter shell and hoppers
0 Evaluate bag failure records, gas inlet temperature records, pressure drop
data, and other maintenance information.
Evaluation--
Visible emissions greater than the standard (7 percent opacity) indicate
poor performance; inspection should include: evaluation of bag problems,
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including but not limited to abrasion, chemical attack, high temperature
damage, and improper cleaning; if conditions appear to be severe, a Level
III inspection (primary clean side checks) is recommended
0 Fugitive emissions from all process sources should be carefully
documented; reasons for poor capture should be investigated, and include
air infiltration, poor hood condition or location, fan belt slippage (listen for
squeal), fabric blinding, and poor cleaning effectiveness
0 Static pressure drop data and cleaning system performance checks
(compressed air pressures, conditions of diaphragm valves, and frequency
of cleaning) are very important
0 Check of the entire system for air infiltration is very important, because it
can lead to severe problems.
Safety Considerations-
0 Level II inspection involves some climbing and close contact with the pulse
jet baghouse; check the integrity of all supports and ladders; climb ladders
properly; avoid contact with hot ducts and roofs; avoid downward point gas
discharge
0 Because the inspector must enter the facility to conduct a Level II
inspection, all facility and agency safety precautions apply.
4.9.2 Operating Shaker and Reverse Air Baahouses
Inspection Steps-
0 Method 9 observation of fabric filter stack or individual compartment
discharge points
0 Method 9 observation of fugitive emissions from solids handling operation
(if reentrainment is occurring)
0 Method 9 observation of fugitive emissions from process equipment
0 Counterflow checks of audible air infiltration into fan, baghouse (solids
discharge valve, access doors, shell), and ductwork; check physical
condition and location of hoods
0 Check static pressure drop across collector using onsite gauges
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Evaluation-
Check static pressure drop across each compartment during cleaning;
values should be zero for shaker collectors
Confirm that reverse air fan or shaker motor is operating
Check inlet gas temperatures using onsite gauges
Observe and describe corrosion of fabric filter shell and hoppers
Evaluate bag failure records, gas inlet temperature records, pressure drop
data, and other records.
0 Visible emissions > 5 percent indicate poor performance; inspections
should include: evaluation of bag problems, including abrasion, chemical
attack, high temperature damage, and excessive cleaning intensities; if
conditions appear severe, a Level III inspection is recommended
0 Fugitive emissions from all process sources should be carefully documented
0 Static pressure drop data and cleaning system performance checks
(compartment static pressure drops during cleaning, operation of reverse
air fan) are very useful for determining if the problem is due to the unit
0 Counterflow inspection of the entire system for air infiltration is very
important because it can gradually lead to severe bag damage, and
reduced capture effectiveness at the process.
Safety Considerations-
0 Level II inspection involves some climbing and close contact with the unit;
check the integrity of all supports and ladders; climb ladders properly; avoid
contact with hot ducts and roofs; avoid poorly ventilated areas under
hoppers and between compartments
0 All plant and agency safety procedures for onsite inspections apply.
4.9.3 Nonoperatina Pulse-Jet Baahouses
Inspection Steps-
0 Confirm that unit is out-of-service and will not be brought on line during
period of inspection
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Evaluation-
Request plant personnel to open one or more access hatches on the clean
side of unit; evaluate quantity and pattern of clean side deposits
Check orientation of blow tubes (and extension nipples, if present)
Check for obvious poorly seated bags and gaps in tube sheet welds
Request that plant personnel open side access hatches if available
Check for bag abrasion against side flanges, internal walkways, and other
bags; check for bowed and bent bag/cage assemblies
Check the condition of any deflector plates on the gas inlet
Check for obvious erosion of ductwork leading to baghouse
Check operation of bag cleaning equipment.
Presence of clean side deposits (enough to make a footprint) indicates poor
performance; inspection should include an evaluation of bag failure
problems due to abrasion, excessive cleaning intensities, improper blow
tube alignment, chemical attack, and high temperature damage; potential
for leakage around top of bag and tube sheet should also be checked
Potential for bag-to-bag abrasion at bottom and for damage of the fabric
against side flanges and internal walkways can be seen from side access
hatches
Deflector serves to protect the bags from abrasive materials
Erosion of these plates could contribute to premature failures; eroded
ductwork could lead to reduced pollutant capture at the generation source
and operating temperatures below the acid dewpoint for combustion
sources.
Safety Considerations-
Hatches located on hoppers should never be opened during an inspection
because there is often dangerous accumulations of hot, free flowing solids
behind the door
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0 Inspector should never stick his or her head into the clean air plenum
because this poorly ventilated area may contain asphyxiants and/or toxic
gases
0 All hatches must be opened carefully to prevent hand injuries.
Special Notes--
0 Presence of clean side deposits or other abnormal conditions cannot be
used alone as a basis for a Notice of Violation (NOV)
0 Baghouses should be opened only with consent of plant management
personnel.
4.9.4 Nonoperatina Shaker and Reverse Air Baahouses
Inspection Steps-
0 Confirm that unit or individual compartment is out-of-service and will not be
brought on line during period of inspection
0 Request that plant personnel open access hatch of compartments isolated;
use the hatch just above the elevation of the tube sheet; evaluate quantity
and pattern of clean side deposits
0 Observe bag tension throughout the portion of the compartment that is
visible from access hatch; check tension of bags that can be reached
without entering compartment
0 Check for leaks around thimble connections or snap ring connections
0 Check for obvious bag abrasion on internal flanges
0 Check for obvious tube sheet weld failures
0 Note any holes or tears in bags visible from access hatch.
Evaluation-
Presence of clean side deposits (enough to make a footprint) indicates poor
performance; inspection should include an evaluation of bag failure
problems due to abrasion, excessive cleaning intensities, chemical attack,
and high temperature attack
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Bag tension is critical; in both reverse air and shaker collectors bags must
not sag at bottom; the reverse air bags are kept under 40 to 120 pounds
tension; shaker bags are normally hung with no measurable tension
Spatial pattern of clean side deposits can be used to indicate dust emission
problems; however, once deposits exceed several inches in depth,
diagnostic signs are essentially buried
Gaps in tube sheet welds are usually visible because the high velocity gas
stream passing through gap moves the dust deposits away from that
portion of tube sheet.
Safety Considerations--
Hatches located on hoppers should never be opened during inspection
because there is often dangerous accumulations of hot, free flowing solids
behind door
Side access hatches for each compartment should also be opened carefully
because hot clean side deposits ranging from several inches to several feet
in depth may be behind door
Under no circumstances should inspector enter the compartment
Even compartments properly isolated may have high concentrations of toxic
gases, toxic particulate, and asphyxiants; the gas temperature inside can
be quite hot due to radiation and conduction from adjacent compartments
still operating
Respirators should be worn whenever observing conditions through an
open hatch.
Special Notes-
Presence of clean side deposits or other abnormal conditions cannot be
used alone as a basis for a NOV
Unit should be opened only with consent of plant management.
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4.9.5 Sprav Tower Scrubbers
Inspection Steps-
Evaluation--
Method 9 observation (for diagnostic purposes) of stack for a period of not
less than 6 minutes; calculate average opacity and describe cycles in the
average opacity
Method 9 observation of all bypass stacks and vents and any fugitive
emissions from process equipment
Presence of rainout close to the stack or mud lips at the discharge point
Presence of fan vibration
Liquor flow rate and pressure drop indicated by onsite monitors (compare
with average of last compliance test)
Pump discharge pressure and motor current indicated by onsite gauges
Audible pump cavitation
Nozzle header pressure indicated by onsite gauge
Physical condition of shell and ductwork
Recirculation pond layout and pump intake position
Physical condition of nozzles observed through access hatch
Note means used to dispose of purged liquor.
A shift in the average opacity may be due to a decrease in the particle size
distribution of the inlet gas stream; a co-current inspection of the process
operation is often advisable
Anything that affects the nozzles will reduce performance; liquor turbidity is
related to the vulnerability to nozzle pluggage and erosion
Shell and ductwork corrosion is often caused by operation at pH levels that
are lower than desirable; measure the liquor pH using in-plant instruments,
if available .
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0 Performance of a spray tower scrubber is dependent on the liquor flow rate;
any problems that potentially reduce the flow rate should be fully examined.
Safety Considerations-
0 Check all ladders and platforms before use; safe climbing and walking
practices are important, especially in cold weather
0 Avoid poorly ventilated: areas
0 Avoid hot ducts and pipes
0 Terminate inspection if a severely vibrating fan is noted in the vicinity of the
scrubber
0 Under no circumstances should inspector attempt to look inside an
operating wet scrubber
0 Visible emission observations should be made only in secure areas.
Special Notes—
0 Observations and data do not provide conclusive evidence of
noncompliance with mass emission standards (requires stack test); these
can be used only as surrogate indicators of compliance.
4.9.6 Mechanically Aided Scrubbers
Inspection Steps-
0 Method 9 observation (for diagnostic purposes) of the stack for a period of
not less than 6 minutes; calculate average opacity
0 Method 9 observation of all bypass stacks and vents and any fugitive
emissions from process equipment
0 Presence of rainout close to the stack or mud lips at the discharge point
0 Presence of fan vibration
0 Pump discharge pressure and motor current indicated by onsite gauges
0 Audible pump cavitation
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Evaluation--
Nozzle header pressure indicated by onsite gauge
Physical condition of shell and ductwork
Recirculation pond layout and pump intake position
Note means used to dispose of purged liquor
Static pressure increase across scrubber and liquor flow rate monitored by
onsite gauges (compare with average of last compliance test).
Shift in the average opacity may be due to a decrease in the particle size
distribution of the inlet gas stream; a co-current inspection of the process
operation is often advisable
Liquor turbidity is related to the vulnerability of the fan blades to erosion
damage
Shell and ductwork corrosion is often caused by operation at pH levels
which are lower than desirable; measure liquor pH using in-plant
instruments, if available
Performance of a mechanically aided scrubber is dependent on liquor flow
rate; any problems which potentially reduce the flow rate should be fully
examined; indirect indications of liquor flow rate include pump discharge
pressure, nozzle header pressure, pump motor currents, and audible pump
cavitation.
Safety Considerations--
Check all ladders and platforms before use; safe climbing and walking
practices are important at all times
Avoid poorly ventilated areas
Avoid hot ducts and pipes
Terminate inspection if the fan is vibrating severely
Under no circumstances should inspector attempt to look inside an
operating wet scrubber
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0 Visible emission observations should be made only in secure areas.
Special Notes-
0 Inspection data and observations do not provide conclusive evidence of
violation of mass emission standards (requires stack test); these can be
used only as surrogate indicators of compliance.
4.9.7 Gas-Atomized Scrubbers
inspection Steps--
0 Method 9 observation (for diagnostic purposes) of stack for a period of not
less than 6 minutes; calculate average opacity
0 Method 9 observation of all bypass stacks and vents and any fugitive
emissions from process equipment
0 Presence of rainout close to the stack or mud lips at the discharge
0 Presence of fan vibration
0 Static pressure drop across the scrubber and liquor flow rate indicated by
onsite gauges (compare with average of last compliance test)
0 Pump discharge pressure and motor current indicated by onsite gauges
0 Audible pump cavitation
0 Nozzle header pressure indicated by onsite gauge
0 Physical condition of shell and ductwork
0 Recirculation pond layout and pump intake position
0 Physical condition of nozzles observed through access hatch
0 Means used to dispose of purged liquor should be noted.
Evaluation-
Shift in the average opacity may be due to a decrease in particle size
distribution of the inlet gas stream; a co-current inspection of the process
operation is often advisable
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0 Anything which affects the nozzles will reduce performance; liquor turbidity
is related to the vulnerability to nozzle pluggage and erosion
0 Shell and ductwork corrosion is often caused by operation at pH levels
which are lower than desirable; measure liquor pH using in-plant
instruments, if available
0 Performance of a gas-atomized scrubber is partially dependent on the liquor
flow rate; any problems which potentially reduce the flow rate should be
fully examined
0 Overall performance of a gas-atomized wet scrubber is related to the static
pressure drop except in cases where there is a particle size shift, a change
in the liquor surface tension, or gas-liquor maldistribution problems.
Safety Considerations-
0 Check all ladders and platforms before use; safe climbing and walking
practices are important at all times :
0 Avoid poorly ventilated areas
0 Avoid hot ducts and pipes
0 Terminate inspection if a severely vibrating fan is noted in the general
vicinity of the scrubber
0 Under no circumstances should inspector attempt to look inside an
operating wet scrubber
0 Visible emission observations should be made only in secure areas.
Special Notes-
0 Inspection data and observations do not provide conclusive evidence of
violation of mass emission standards (requires stack test); these can be
used only as surrogate indicators of compliance
4.9.8 Large Diameter Cyclones
Inspection Steps-
0 Method 9 observation of stack for a sufficient period to fully characterize
conditions during normal process cycles
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Evaluation-
Method 9 observation of any fugitive emissions from process equipment,
and material handling operations
Presence of accumulated dust in the vicinity of the stack
Presence of obvious holes and dents in cyclone shell
Air infiltration sites on cyclone shell, cyclone hopper, solids discharge valve,
and inlet ductwork
Obvious corrosion of cyclone
Static pressure drop across the cyclone as indicated by onsite gauge.
If the visible emissions have increased more than 5 percent since the
baseline period or if the visible emissions are within 5 percent of the
regulatory limit, a more detailed inspection is recommended
Accumulated solids near the stack generally imply high mass emissions
composed of large particles which do not scatter light effectively
Fugitive emissions from the process area can be at least partially due to air
infiltration into ductwork or collector; check process area and ductwork
Holes and dents in shell can disrupt the gas vortex, causing some
particulate reentrainment and emissions
Static pressure provides an indication of the flow rate; removal efficiency
generally increases with the static pressure.
Safety Considerations-
Positions selected for the Method 9 observations should be secure from
moving vehicles such as cars, trains, and moving machinery
Footing must be secure; stockpiles are not acceptable
All climbing and walking safety procedures are very important; some
horizontal structures may not be able to withstand the load of accumulated
solids and several people
Avoid contact with hot surfaces
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Some fugitive leaks from the cyclone body and the cyclone discharge vents
may contain high velocity materials which could cause eye injuries; avoid
potential areas of exposure.
Special Notes--
Inspection data and observations do not provide conclusive evidence of
violation of mass emission standards (requires stack test); these can be
used only as surrogate indicators of compliance.
4.9.9 Multiple Cvclon4 Collectors
Inspection Steps--
Evaluation--
Method 9 observation of stack for a sufficient period to fully characterize
conditions during normal process cycles
Method 9 observation of any fugitive emissions from process equipment,
and material handling operations
Air infiltration sites on collector shell, hopper, solids discharge valve, and
inlet ductwork
Static pressure drop across collector as indicated by onsite gauge
Inlet gas temperature as indicated by onsite gauge.
If the visible emissions have increased more than 5 percent since the
baseline period or if the visible emissions are within 5 percent of the
regulatory limit, a more detailed inspection is recommended
Fugitive emissions from the process area can be at least partially due to air
infiltration into ductwork or collector; check process area and ductwork
Static pressure provides an indication of the flow rate and the resistance to
gas flow; static pressure should be checked against baseline static pressure
drops for similar process operating rates; if the present value is higher, then
pluggage is possible; if it is lower, erosion of outlet tubes and gasket
problems are likely.
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Safety Considerations-
0 Positions selected for the Method 9 observations should be secure from
moving vehicles such as cars, trains, and moving machinery
0 Footing must be secure; stockpiles are not acceptable
0 All climbing and walking safety procedures are very important; some
horizontal structures may not be able to withstand the load of accumulated
solids and several people
0 Avoid contact with hot surfaces
0 Many multicyclone collectors are located in hot areas; avoid heat stress by
limiting the time spent in the area (moderate heat conditions) or by not
entering the area (high heat areas)
Special Notes-
0 Inspection data and observations do not provide conclusive evidence of
violation of mass emission standards (requires stack test); these can be
used only as surrogate indicators of compliance.
4.9.10 Wet Suppression Systems
Inspection Steps-
0 Check the condition of spray nozzles and spray patterns
0 Check nozzle header pressure with baseline data or last compliance test
0 Check timing cycle and actuators for intermittent operation
0 Check for use of wetting agents/surfactants
0 Are wetting agents/surfactants used at manufacturer's specifications or at
similar rates of last compliance test
0 Location of sprays versus file information
0 Check to see the equipment has been adequately winterized (if applicable).
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Evaluation-
Spray towers and nozzles should be located for maximum dust
suppression. Spray nozzles should emit an adequate spray pattern. Water
added to crusher inlets should be adequate to wet reduced ore size
Surfactants and wetting agents should be used at or near manufacturer's
specifications or at rates similar to the last compliance test
Manually operated system actuators allow for nonoperation due to human
error
High water turbidity may cause increased nozzle pluggage if water is
recycled.
Safety Considerations-
Level II inspections involve some climbing and proximity to heavy
equipment, pulleys, drive belts and moving vehicles; avoid close proximity
to equipment inlets and outlets where reduction fragments may be ejected;
do not touch operating or nonoperating nozzles.
4.10 POST-INSPECTION CONFERENCE
The closing conference with facility officials enables the inspector to "wrap up" the
inspection including answering any questions the company may have, filling in any gaps
in the data collected, and identifying information considered confidential. Thus, the
following elements generally constitute the closing conference.
0 Review of Inspection Data - At this point, the inspector can identify and fill
in any gaps in the information collected and ensure that there is general
agreement on the technical facts.
0 Inspection Follow-up Discussion - The inspector should be willing to answer
inspection related questions from facility officials, but should only state
matters of fact. Under no circumstances should the inspector make
judgments or conclusions concerning the facility's compliance status, legal
effects, or enforcement consequences.
0 Declaration of Confidential Business Information - Plant officials authorized
to make business confidentiality claims should be given the opportunity to
make a claim of confidentiality by noting such claim on documentary
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material provided to EPA. The inspector should note all information claimed
confidential and handle materials accordingly, even if a written declaration
is not made at this time.
0 Preparation of Receipts - The inspector should provide receipts for any
samples or records taken to a responsible plant individual.
Since EPA and State inspectors are often the only direct contact between the
regulatory agency and the regulated industry, the inspector should always be aware of
opportunities to improve industry-agency relations. The closing conference provides an
ideal opportunity to offer various kinds of assistance to facility officials. At this point, the
inspector has first-hand knowledge of questions, problems, and possible solutions to
problems. The inspector should consider:
0 Answering all questions within his ability and authority.
0 Referral of questions and problems to other Agency personnel when
necessary.
0 Discussion of problems and tactful suggestion of possible solutions and
assistance.
0 Tactful probing of problem areas uncovered during the inspection.
0 Offering or suggesting available resources such as technical publications,
special services available to industry, etc.
It is very important that the inspector follow up all referrals and offers to help. A
letter, phone call, or repeat visit will indicate to facility officials a genuine interest on the
part of the agency and aid the agency's industry relations.
4.11 REPORT PREPARATION AND TRACKING
During the inspection, the inspector collects and substantiates inspection data
which may later be used as evidence in an enforcement proceeding. When he/she
returns to the office it is his/her responsibility to see that this data is organized and
arranged so that other agency personnel may make maximum use of it. Thus, the file
update and inspection report preparation are an important part of the inspection process.
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These should both be done as soon as possible after the inspection to ensure that all
events of the inspection are still fresh in the inspector's memory. He/she must be able
to confirm during a later enforcement proceeding that the information contained in the
inspection report is true.
4.11.1 Computer Data Base Updates
Both the EPA and State agencies use several types of "files" for facility information
storage, which include computer data bases. State agencies may use different variations
of an Emissions Inventory System (EIS) while EPA uses data from the Aerometric
Information Retrieval System (AIRS). States with delegation and enforcement authority
for the nonmetallic mineral processing NSPS should enter the results of compliance
inspections of affected facilities into the AIRS Facility Subsystem as well as into their
respective computer data bases.
The inspector should check to see if any required information is missing or has
changed since the last update and then work within the office system to use the data
he/she has collected to update the appropriate data base.
4.11.2 Agency File Updates
The agency files usually contain the hard copies of all information, correspondence,
reports, etc. relevant to a particular facility. Examples of such items are listed below:
o
o
o
o
o
o
o
o
o
o
o
o
o
General Facility Information
Correspondence to Facility
Correspondence from Facility
Permit Applications
Permits
Facility Layout
Flow charts
Raw Data from Inspections
Inspection Reports
Source Test Reports
Excess Emission Reports
Case Emission Reports
Agency Notes, etc. on Compliance Actions.
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The inspector's data should be used to update the general facility information
including plant contact, correct address, changes in production rates, new flow charts,
layouts, etc. and of course, the inspector's raw data and inspection report will be added
to the file.
4.11.3 Report Preparation
The inspector's inspection report serves two very important purposes in agency
operations: 1) it provides other agency personnel with easy access to the inspection
information because it has been organized into a comprehensive, usable document; and
2) it constitutes a major part of the evidence package on the inspection which will be
available for subsequent enforcement proceedings and/or other types of compliance-
related follow-up activities.
Although specific information contained in the inspection report will vary depending
on the requirements of the agency, the basic format includes a narrative report and
documentary support. A typical report format is outlined below.
General Inspection Information-
o
o
o
Inspection objectives
Facility selection scheme
Inspection facts (date, time, location, plant official, etc.)
Summary of Findings-
Factual compliance findings (include problem areas)
Compliance status with applicable regulations
Administrative problems (as with entry, withdrawal of consent, etc.)
Recommended future action (if appropriate)
Facility Information-
Process information
Raw materials, production rates
Control equipment
Applicable regulations
Enforcement history
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Inspection Procedures and Detail of Findings-
0 Refer to standard procedures used
0 Describe nonroutine procedures used
0 Reference inspection data attached
0 Note and reference any statements taken
0 Reference photographs, if relevant
0 Reference any drawings, charts, etc. made
0 Reference visible emission observation forms
0 List records reviewed and address inadequacies
Sampling-
Refer to methods used
Reference analytical results attached
Attachments--
0 List of all documentary support attached
Documentary support is all evidence referred to in the inspection report. It will
include:
Inspector's field notes, forms, checklists
Drawings, charts, etc.
Photographs
Analysis results of samples collected
Statements taken
Visible emission observation forms.
Appendix F contains a typical inspection report for a nonmetallic mineral
processing facility. The inspection and the final inspection report should document
whether the inspection objectives were attained, the compliance status of the affected
facilities, and the need for any follow-on activities required as a result of the inspection.
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APPENDIX A
40 CFR 60, SUBPART OOO AND REVISIONS
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Reprinted with permission from BNA's Environmental
Library on CD. Copyright 1993-1997 by The Bureau
of National Affairs, Inc. (800-372-1033)
< http://www.bna.com >
Subpart OOO—Standards of Performance for Nonmetallic Mineral
Processing Plants
40 CFR 60.670 Applicability and designation of affected facility.
(a) (1) Except as provided in paragraphs (a)(2), (b), (c), and (d) of this section, the provisions
of this subpart are applicable to the following affected facilities in fixed or portable nonmetallic
mineral processing plants: each crusher, grinding mill, screening operation, bucket elevator, belt
conveyor, bagging operation, storage bin, enclosed truck or railcar loading station. Also, crushers
and grinding mills at hot mix asphalt facilities that reduce the size of nonmetallic minerals
embedded in recycled asphalt pavement and subsequent affected facilities up to, but not including,
the first storage silo or bin are subject to the provisions of this subpart.
(2) The provisions of this subpart do not apply to the following operations: All facilities located
in underground mines; and stand-alone screening operations at plants without crushers or grinding
mills.
(b) An affected facility that is subject to the provisions of subpart F or I or that follows in the
plant process any facility subject to the provisions of subparts F or I of this part is not subject to
the provisions of this subpart.
(c) Facilities at the following plants are not subject to the provisions of this subpart:
(1) Fixed sand and gravel plants and crushed stone plants with capacities, as defined hi §60.671,
of 23 megagrams per hour (25 tons per hour) or less;
(2) Portable sand and gravel plants and crushed stone plants with capacities, as defined hi
§60.671, of 136 megagrams per hour (150 tons per hour) or less; and
(3) Common clay plants and pumice plants with capacities, as defined in §60.671, of 9
megagrams per hour (10 tons per hour) or less.
(d) (1) When an existing facility is replaced by a piece of equipment of equal or smaller size, as
defined in §60.671, having the same function as the existing facility, the new facility is exempt
from the provisions of §§60.672,60.674, and 60.675 except as provided for hi paragraph (d)(3)
of this section.
(2) An owner or operator complying with paragraph (d)(l) of this sectionshall submit the
information required hi §60.676(a).
(3) An owner or operator replacing all existing facilities hi a production line with new facilities
does not qualify for the exemption described hi paragraph (d)(l) of this section and must comply
with the provisions of §§60.672, 60.674 and 60.675.
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(e) An affected facility under paragraph (a) of this section that commences construction,
reconstruction, or modification after August 31, 1983 is subject to the requirements of this part.
(f) Table 1 of this subpart specifies the provisions of subpart A of this Part 60 that apply and
those that do not apply to owners and operators of affected facilities subject to this subpart.
Table 1.—Applicability of Subpart A To Subpart OOO
Subpart A reference
Applies to Sub-
part OOO
Comment
60.1, Applicability
60.2, Definitions
60.3, Units and
abbreviations
60.4, Address:
(a)
(b)
60.5, Determination of
construction or modi-
fication.
60.6, Review of plans..
60.7, Notification, and
recordkeeping
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes.
60.8, Performance
tests
Yes.
60.9, Availability of
information
60.10, State
authority
60.11, Compliance with
standards and
maintenance
requirements.
Yes
Yes
Yes.
Except in (a)(2) report
of anticipated date of
initial startup is not
required ( §
60.676(h)).
Except in (d), after 30
days notice for an
initially scheduled
performance test, any
rescheduled performance
test requires 7 days
notice, not 30 days
( § 60.675(g)).
Except in (b) under
certain conditions ( §
§ 60.675(c)(3) and
(c)(4)), Method 9 ob-
servation may be re-
duced from 3 hours to 1
hour. Some affected
facilities exempted
from Method 9 tests
( § 60.675(h)).
60.12, Circumvention..
Yes
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60.13, Monitoring
requirements
60.14, Modification
60.15, Reconstruction...
60.16, Priority list....
60.17, Incorporations by
reference
60.18, General control
device
60.19, General
notification and
reporting re-
quirements .
Yes
Yes
Yes
Yes
Yes
No.
Yes
Flares will not be used
to comply with the
emission limits.
40 CFR 60.671 Definitions.
All terms used in this subpart, but not specifically denned in this section, shall have the meaning
given them in the Act and in subpart A of this part.
Bagging operation means the mechanical process by which bags are filled with nonmetallic
minerals.
Belt conveyor means a conveying device that transports material from one location to another
by means of an endless belt that is carried on a series of idlers and routed around a pulley at each
end.
Bucket elevator means a conveying device of nonmetallic minerals consisting of a head and foot
assembly which supports and drives an endless single or double strand chain or belt to which
buckets are attached.
Building means any frame structure with a roof.
Capacity means the cumulative rated capacity of all initial crushers that are part of the plant.
Capture system means the equipment (including enclosures, hoods, ducts, fans, dampers, etc.)
used to capture and transport particulate matter generated by one or more process operations to a
control device.
Control device means the air pollution control equipment used to reduce particulate matter
emissions released to the atmosphere from one or more process operations at a nonmetallic
mineral processing plant.
Conveying system means a device for transporting materials from one piece of equipment or
location to another location within a plant. Conveying systems include but are not limited to the
following: Feeders, belt conveyors, bucket elevators and pneumatic systems.
Crusher means a machine used to crush any nonmetallic minerals, and includes, but is not
limited to, the following types: jaw, gyratory, cone, roll, rod mill, hammermill, and impactor.
Enclosed truck or railcar loading station means that portion of a nonmetallic mineral
processing plant where nonmetallic minerals are loaded by an enclosed conveying system into
enclosed trucks or railcars.
Fixed plant means any nonmetallic mineral processing plant at which the processing equipment
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specified in §60.670(a) is attached by a cable, chain, turnbuckle, bolt or other means (except
electrical connections) to any anchor, slab, or structure including bedrock.
Fugitive emission means paniculate matter that is not collected by a capture system and is
released to the atmosphere at the point of generation.
Grinding mill means a machine used for the wet or dry fine crushing of any nonmetallic mineral.
Grinding mills include, but are not limited to, the following types: hammer, roller, rod, pebble and
ball, and fluid energy. The grinding mill includes the air conveying system, air separator, or air
classifier, where such systems are used.
Initial crusher means any crusher into which nonmetallic minerals can be fed without prior
crushing in the plant.
Nonmetallic mineral means any of the following minerals or any mixture of which the majority
is any of the following minerals:
(a) Crushed and Broken Stone, including Limestone, Dolomite, Granite, Traprock, Sandstone,
Quartz, Quartzite, Marl, Marble, Slate, Shale, Oil Shale, and Shell.
(b) Sand and Gravel.
(c) Clay including Kaolin, Fireclay, Bentonite, Fuller's Earth, Ball Clay, and Common Clay.
(d) Rock Salt.
(e) Gypsum.
(f) Sodium Compounds, including Sodium Carbonate, Sodium Chloride, and Sodium Sulfate.
(g) Pumice.
(h) Gilsonite.
(i) Talc and Pyrophyllite.
(j) Boron, including Borax, Kernite, and Colemanite.
(k) Barite.
(1) Fluorospar.
(m) Feldspar.
(n) Diatomite.
(o) Perlite.
(p) Vermiculite.
(q) Mica.
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(r) Kyanite, including Andalusite, Sillimanite, Topaz, and Dumortierite.
Nonmetallic mineral processing plant means any combination of equipment that is used to
crush or grind any nonmetallic mineral wherever located, including lime plants, power plants, steel
mills, asphalt concrete plants, portland cement plants, or any other facility processing nonmetallic
minerals except as provided in §60.670 (b) and (c).
Portable plant means any nonmetallic mineral processing plant that is mounted on any chassis
or skids and may be moved by the application of a lifting or pulling force. In addition, there shall
be no cable, chain, turnbuckle, bolt or other means (except electrical connections) by which any
piece of equipment is attached or clamped to any anchor, slab, or structure, including bedrock
that must be removed prior to the application of a lifting or pulling force for the purpose of
transporting the unit.
Production line means all affected facilities (crushers, grinding mills, screening operations,
bucket elevators, belt conveyors, bagging operations, storage bins, and enclosed truck and railcar
loading stations) which are directly connected or are connected together by a conveying system.
Screening operation means a device for separating material according to size by passing
undersize material through one or more mesh surfaces (screens) in series, and retaining oversize
material on the mesh surfaces (screens).
Size means the rated capacity in tons per hour of a crusher, grinding mill, bucket elevator,
bagging operation, or enclosed truck or railcar loading station; the total surface area of the top
screen of a screening operation; the width of a conveyor belt; and the rated capacity in tons of a
storage bin.
Stack emission means the paniculate matter that is released to the atmosphere from a capture
system.
Storage bin means a facility for storage (including surge bins) or nonmetallic minerals prior to
further processing or loading.
Transfer point means a point in a conveying operation where the nonmetallic mineral is
transferred to or from a belt conveyor except where the nonmetallic mineral is being transferred to
a stockpile.
Truck dumping mesas the unloading of nonmetallic minerals from movable vehicles designed to
transport nonmetallic minerals from one location to another. Movable vehicles include but are not
limited to: trucks, front end loaders, skip hoists, and railcars.
Vent means an opening through which there is mechanically induced air flow for the purpose of
exhausting from a building air carrying paniculate matter emissions from one or more affected
facilities.
Wet mining operation means a mining or dredging operation designed and operated to extract
any nonmetallic mineral regulated under this subpart from deposits existing at or below the water
table, where the nonmetallic mineral is saturated with water.
Wet screening operation means a screening operation at a nonmetallic mineral processing plant
which removes unwanted material or which separates marketable fines from the product by a
washing process which is designed and operated at all tunes such that the product is saturated
with water.
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40 CFR 60.672 Standard for participate matter.
(a) On and after the date on which the performance test required to be conducted by §60.8 is
completed, no owner or operator subject to the provisions of this subpart shall cause to be
discharged into the atmosphere from any transfer point on belt conveyors or from any other
affected facility any stack emissions which: ;
(1) Contain particulate matter in excess of 0.05 g/dscm; and
(2) Exhibit greater than 7 percent opacity, unless the stack emissions are discharged from an
affected facility using a wet scrubbing control device. Facilities using a wet scrubber must comply
with the reporting provisions of §60.676(c), (d), and (e).
(b) On and after the sixtieth day after achieving the maximum production rate at which the
affected facility will be operated, but not later than 180 days after initial startup as required under
§60.11 of this part, no owner or operator subject to the provisions of this subpart shall causeto be
discharged into the atmosphere from any transfer point on belt conveyors or from any other
affected facility any fugitive emissions which exhibit greater than 10 percent opacity, except as
provided hi paragraphs (c), (d), and (e) of this section.
(c) On and after the sixtieth day after achieving the maximum production rate at which the
affected facility will be operated, but not later than 180 days after initial startup as required under
§60.11 of this part, no owner or operator shall cause to be discharged into the atmosphere from
any crusher, at which a capture system is not used, fugitive emissions which exhibit greater than
15 percent opacity.
(d) Truck dumping of nonmetallic minerals into any screening operation, feed hopper, or
crusher is exempt from the requirements of this section.
(e) If any transfer point on a conveyor belt or any other affected facility is enclosed in a
building, then each enclosed affected facility must comply with the emission limits hi paragraphs
(a), (b) and (c) of this section, or the building enclosing the affected facility or facilities must
comply with the following emission limits:
(1) No owner or operator shall cause to be discharged into the atmosphere from any building
enclosing any transfer point on a conveyor belt or any other affected facility any visible fugitive
emissions except emissions from a vent as defined in §60.671.
(2) No owner or operator shall cause to be discharged into the atmosphere from any vent of any
building enclosing any transfer point on a conveyor belt or any other affected facilhy emissions
which exceed the stack emissions limits in paragraph (a) of this section.
(f) On and after the sixtieth day after achieving the maximum production rate at which the
affected facility will be operated, but not later than 180 days after initial startup as required under
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§ 60.11 of this part, no owner or operator shall cause to be discharged into the atmosphere from
any baghouse that controls emissions from only an individual, enclosed storage bin, stack
emissions which exhibit greater than 7 percent opacity.
(g) Owners or operators of multiple storage bins with combined stack emissions shall comply
with the emission limits in paragraph (a)(l) and (a)(2) of this section.
(h) On and after the sixtieth day after achieving the maximum production rate at which the
affected facility will be operated, but not later than 180 days after initial startup, no owner or
operator shall cause to be discharged into the atmosphere any visible emissions from:
(1) Wet screening operations and subsequent screening operations, bucket elevators, and belt
conveyors that process saturated material in the production line up to the next crusher, grinding
mill or storage bin.
(2) Screening operations, bucket elevators, and belt conveyors in the production line
downstream of wet mining operations, where such screening operations, bucket elevators, and
belt conveyors process saturated materials up to the first crusher, grinding mill, or storage bin in
the production line.
40 CFR 60.673 Reconstruction.
(a) The cost of replacement of ore-contact surfaces on processing equipment shall not be
considered in calculating either the "fixed capital cost of the new components" or the "fixed
capital cost that would be required to construct a comparable new facility" under §60.15.
Ore-contact surfaces are crushing surfaces; screen meshes, bars, and plates; conveyor belts; and
elevator buckets.
(b) Under §60.15, the fixed capital cost of the new components" includes the fixed capital cost
of all depreciable components (except components specified in paragraph (a) of this section)
which are or will be replaced pursuant to all continuous programs of component replacement
commenced within any 2-year period following August 31,1983.
40 CFR 60.674 Monitoring of operations.
The owner or operator of any affected facility subject to the provisions of this subpart which
uses a wet scrubber to control emissions shall install, calibrate, maintain and operate the following
monitoring devices:
(a) A device for the continuous measurement of the pressure loss of the gas stream through the
scrubber. The monitoring device must be certified by the manufacturer to be accurate within ±250
pascals ±1 inch water gauge pressure and must be calibrated on an annual basis in accordance
with manufacturer's instructions.
(b) A device for the continuous measurement of the scrubbing liquid flow rate to the wet
scrubber. The monitoring device must be certified by the manufacturer to be accurate within ±5
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percent of design scrubbing liquid flow rate and must be calibrated on an annual basis in
accordance with manufacturer's instructions.
40 CFR 60.675 Test methods and procedures.
(a) In conducting the performance tests required in §60.8, the owner or operator shall use as
reference methods and procedures the test methods in appendix A of this part or other methods
and procedures as specified in this section, except as provided in §60.8(b). Acceptable alternative
methods and procedures are given in paragraph (e) of this section.
(b) The owner or operator shall determine compliance with the paniculate matter standards hi
§60.672(a) as follows:
(1) Method 5 or Method 17 shall be used to determine the paniculate matter concentration. The
sample volume shall be at least 1.70 dscm (60 dscf). For Method 5, if the gas stream being
sampled is at ambient temperature, the sampling probe and filter may be operated without heaters.
If the gas stream is above ambient temperature, the sampling probe and filter may be operated at a
temperature high enough, but no higher than 121°C (250°F), to prevent water condensation on
the filter.
(2) Method 9 and the procedures in §60.11 shall be used to determine opacity.
(c) (1) In determining compliance with the paniculate matter standards hi §60.672 (b) and (c),
the owner or operator shall use Method 9 and the procedures in §60.11, with the following
additions:
(i) The minimum distance between the observer and the emission source shall be 4.57 meters
(15 feet).
(ii) The observer shall, when possible, select a position that minimizes interference from other
fugitive emission sources (e.g., road dust). The required observer position relative to the sun
(Method 9, Section 2.1) must be followed.
(iii) For affected facilities using wet dust suppression for paniculate matter control, a visible
mist is sometimes generated by the spray. The water mist must not be confused with paniculate
matter emissions and is not to be considered a visible emission. When a water mist of this nature
is present, the observation of emissions is to be made at a point in the plume where the mist is no
longer visible.
(2) In determining compliance with the opacity of stack emissions from any baghouse that
controls emissions only from an individual enclosed storage bin under §60.672(f) of this subpart,
using Method 9, the duration of the Method 9 observations shall be 1 hour (ten 6-rninute
averages).
(3) When determining compliance with the fugitive emissions standard for any affected facility
A-9
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described under §60.672(b) of this subpart, the duration of the Method 9 observations may be
reduced from 3 hours (thirty 6-minute averages) to 1 hour (ten 6-minute averages) only if the
following conditions apply:
(i) There are no individual readings greater than 10 percent opacity; and
(ii) There are no more than 3 readings of 10 percent for the 1-hour period.
(4) When determining compliance with the fugitive emissions standard for any crusher at which
a capture system is not used as described under §60.672(c) of this subpart, the duration of the
Method 9 observations may be reduced from 3 hours (thirty 6-minute averages) to 1 hour (ten
6-minute averages) only if the following conditions apply:
(i) There are no individual readings greater than 15 percent opacity; and
(ii) There are no more than 3 readings of 15 percent for the 1-hour period.
(d) In determining compliance with §60.672(e), the owner or operator shall use Method 22 to
determine fugitive emissions. The performance test shall be conducted while all affected facilities
inside the building are operating. The performance test for each building shall be at least 75
minutes in duration, with each side of the building and the roof being observed for at least 15
minutes.
(e) The owner or operator may use the following as alternatives to the reference methods and
procedures specified in this section:
(1) For the method and procedure of paragraph (c) of this section, if emissions from two or
more facilities continuously interfere so that the opacity of fugitive emissions from an individual
affected facility cannot be read, either of the following procedures may be used:
(i) Use for the combined emission stream the highest fugitive opacity standard applicable to any
of the individual affected facilities contributing to the emissions stream.
(ii) Separate the emissions so that the opacity of emissions from each affected facility can be
read.
(f) To comply with §60.676(d), the owner or operator shall record the measurements as
required §60.676(c) using the monitoring devices in §60.674(a) and (b) during each paniculate
matter run and shall determine the averages.
(g) If, after 30 days notice for an initially scheduled performance test, there is a delay (due to
operational problems, etc.) in conducting any rescheduled performance test required in this
section, the owner or operator of an affected facility shall submit a notice to the Administrator at
least 7 days prior to any rescheduled performance test.
(h) Initial Method 9performance tests under § 60.11 of this part and §60.675 of this subpart are
A-10
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not required for:
(1) wet screening operations and subsequent screening operations, bucket elevators, and belt
conveyors that process saturated material in the production line up to, but not including the next
crusher, grinding mill or storage bin.
(2) screening operations, bucket elevators, and belt conveyors in the production line
downstream of wet mining operations, that process saturated materials up to the first crusher,
grinding mill, or storage bin in the production line.
40 CFR 60.676 Reporting and recordkeeping.
(a) Each owner or operator seeking to comply with §60.670(d) shall submit to the
Administrator the following information about the existing facility being replaced and the
replacement piece of equipment.
(1) For a crusher, grinding mill, bucket elevator, bagging operation, or enclosed truck or railcar
loading station:
(i) The rated capacity in tons per hour of the existing facility being replaced and
(ii) The rated capacity hi tons per hour of the replacement equipment.
(2) For a screening operation:
(i) The total surface area of the top screen of the existing screening operation being replaced
and
(ii) The total surface area of the top screen of the replacement screening operation.
(3) For a conveyor belt:
(i) The width of the existing belt being replaced and
(ii) The width of the replacement conveyor belt.
(4) For a storage bin:
(i) The rated capacity in tons of the existing storage bin being replaced and
(ii) The rated capacity in tons of replacement storage bins.
(b) [Removed and reserved.]
(c) During the initial performance test of a wet scrubber, and daily thereafter, the owner or
operator shall record the measurements of both the change in pressure of the gas stream across
the scrubber and the scrubbing liquid flow rate.
A-11
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(d) After the initial performance test of a wet scrubber, the owner or operator shall submit
semiannual reports to the Administrator of occurrences when the measurements of the scrubber
pressure loss (or gain) and liquid flow rate differ by more than ±30 percent from the averaged
determined during the most recent performance test.
(e) The reports required under paragraph (d)shall be postmarked within 30 days following end
of the second and fourth calendar quarters.
(f) The owner or operator of any affected facility shall submit written reports of the results of
all performance tests conducted to demonstrate compliance with the standards set forth in
§60.672 of this subpart, including reports of opacity observations made using Method 9to
demonstrate compliance with §60.672(b), (c), and (f), and reports of observations using Method
22 to demonstrate compliance with sect;60.672(e).
(g) The owner or operator of any screening operation, bucket elevator, or belt conveyor that
processes saturated material and is subject to §60.672(h) and subsequently processes unsaturated
materials, shall submit a report of this change within 30 days following such change. This
screening operation, bucket elevator, or belt conveyor is then subject to the 10 percent opacity
limit in §60.672(b) and the emission test requirements of §60.11 and this subpart. Likewise a
screening operation, bucket elevator, or belt conveyor that processes unsaturated material but
subsequently processes saturated material shall submit a report of this change within 30 days
following such change. This screening.operation, bucket elevator, or belt conveyor is then subject
to the no visible emission limit in §60.672(h).
(h) The subpart A requirement under §60.7(a)(2) for notification of the anticipated date of
initial startup of an affected facility shall be waived for owners or operators of affected facilities
regulated under this subpart.
0) A notification of the actual date of initial startup of eadh affected facility shall be submitted
to the Administrator.
(1) For a combination of affected facilities in a production line that begin actual initial startup
on the same day, a single notification of startup may be submitted by the Owner or operator to the
Administrator. The notification shall be postmarked within 15 days after such date and shall
include a description of each affected facility, equipment manufacturer, and serial number of the
equipment, if available.
(2) For portable aggregate processing plants, the notification of the actual date of initial startup
shall include both the home office and the current address or location of the portable plant.
(j) The requirements of this section remain in force until and unless the Agency, in delegating
enforcement authority to a State under section 11 l(c) of the Act, approves reporting requirements
or an alternative means of compliance surveillance adopted by such States. In that event, affected
facilities within the State will be relieved of the obligation to comply with the reporting
A-12
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requirements of this section, provided that they comply with requirements established by the
State.
A-13
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APPENDIX B
40 CFR 60, SUBPART A
GENERAL PROVISIONS (ABBREVIATED)
B-1
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40 CFR Ch. I <7-l-*5 Edition)
Subport A—General Provisions
560.1 Applicability.
(a) Except as provided in subparts B
and C, the provisions of this part apply
to the owner or operator of any sta-
tionary source which contains an af-
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Environmental Protection Agency
§60.2
fected facility, the construction or
modification of which is commenced
after the date of publication in this
part of any standard (or, if earlier, the
date of publication of any proposed
standard) applicable to that facility.
(b) Any new or revised standard of
performance promulgated pursuant to
section lll(b) of the Act shall apply to
the owner or operator of any station-
ary source which contains an affected
facility, the construction or modifica-
tion of which is commenced after the
date of publication in this part of such
new or revised standard (or, if earlier,
the date of publication of any proposed
standard) applicable to that facility.
(c) In addition to complying with the
provisions of this part, the owner or
operator of an affected facility may be
required to obtain an operating permit
issued to stationary sources by an au-
thorized State air pollution control
agency or by the Administrator of the
U.S. Environmental Protection Agency
(EPA) pursuant to Title V of the Clean
Air Act (Act) as amended November 15,
1990 (42 U.S.C. 7661). For more informa-
tion about obtaining an operating per-
mit see part 70 of this chapter.
[40 FR 53346, Nov. 17, 1975, as amended at 55
PR 51382, Dec. 13. 1990; 59 PR 12427, Mar. 16,
1994]
§60.2 Definitions.
The terms used in this part are de-
fined in the Act or in this section as
follows:
Act means the Clean Air Act (42
U.S.C. 7401 et seg.)
Administrator means the Adminis-
trator of the Environmental Protection
Agency or his authorized representa-
tive.
Affected facility means, with reference
to a stationary source, any apparatus
to which a standard is applicable.
Alternative method means any method
of sampling and analyzing for an air
pollutant which is not a reference or
equivalent method but which has been
demonstrated to the Administrator's
satisfaction to, in specific cases,
produce results adequate for his deter-
mination of compliance.
Approved permit program means a
State permit program approved by the
Administrator as meeting the require-
ments of part 70 of this chapter or a
Federal permit program established in
this chapter pursuant to Title V of the
Act (42 u;S.C. 7661).
Capital expenditure means an expendi-
ture for a physical or operational
change to an existing facility which ex-
ceeds the product of the applicable
"annual asset guideline repair allow-
ance percentage" specified in the latest
edition of; Internal Revenue Service
(IBS) Publication 534 and the existing
facility's basis, as defined by section
1012 of the Internal Revenue Code.
However, the total expenditure for a
physical or operational change to an
existing facility must not be reduced
by any "excluded additions" as defined
in IRS Publication 534, as would be
done for tax purposes.
Clean coal technology demonstration
project means a project using funds ap-
propriated under the heading 'Depart-
ment of Energy-Clean Coal Tech-
nology', up to a total amount of
$2,500,000,000 for commercial dem-
onstrations of clean coal technology,
or similar; projects funded through ap-
propriations for the Environmental
Protection Agency.
Commenced means, with respect to
the definition of new source in section
lll(a)(2) of the Act, that an owner or
operator has undertaken a continuous
program of construction or modifica-
tion or that an owner or operator has
entered into a contractual obligation
to undertake and complete, within a
reasonable time, a continuous program
of construction or modification.
Construction means fabrication, erec-
tion, or installation of an affected fa-
cility.
Continuous monitoring system means
the total equipment, required under
the emission monitoring sections in ap-
plicable subparts, used to sample and
condition (if applicable), to analyze,
and to provide a permanent record of
emissions or process parameters.
Electric utility steam generating unit
means any steam electric generating
unit that is constructed for the purpose
of supplying more than one-third of its
potential electric output capacity and
more than 25 MW electrical output to
any utility power distribution system
for sale. Any steam supplied to a steam
distribution system for the purpose of
providing steam to a steam-electric
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§60.2
generator that would produce elec-
trical energy for sale is also considered
in determining the electrical energy
output capacity of the affected facility.
Equivalent method means any method
of sampling' and analyzing for an air
pollutant which has been demonstrated
to the Administrator's satisfaction to
have a consistent and quantitatively
known relationship to the reference
method, under specified conditions.
Excess Emissions and Monitoring Sys-
tems Performance Report is a report that
must be submitted periodically by a
source in order to provide data on its
compliance with stated emission limits
and operating parameters, and on the
performance of its monitoring systems.
Existing facility means, with reference
to a stationary source, any apparatus
of the type for which a standard is pro-
mulgated in this part, and the con-
struction or modification of which was
commenced before the date of proposal
of that standard; or any apparatus
which could be altered in such a way as
to be of that type.
Isokinettc sampling means sampling in
which the linear velocity of the gas en-
tering the sampling nozzle is equal to
that of the undisturbed gas stream at
the sample point.
Issuance of a part 70 permit will
occur, if the State is the permitting
authority, in accordance with the re-
quirements of part 70 of this chapter
and the applicable, approved State per-
mit program. When the EPA is the per-
mitting authority, issuance of a Title
V permit occurs immediately after the
EPA takes final action on the final per-
mit.
Malfunction means any sudden, infre-
quent, and not reasonably preventable
failure of air pollution control equip-
ment, process equipment, or a process
to operate in a normal or usual man-
ner. Failures that are caused in part by
poor maintenance or careless operation
are not malfunctions.
Modification means any physical
change in, or change in the method of
operation of, an existing facility which
increases the amount of any air pollut-
ant (to which a standard applies) emit-
ted into the atmosphere by that facil-
ity or which results in the emission of
any air pollutant (to which a standard
40 CFR Ch. I (7-1-95 Edition)
applies) into the atmosphere not pre-
viously emitted.
Monitoring device means the total
equipment, required under the mon-
itoring of operations sections in appli-
cable subparts, used to measure and
record (if applicable) process param-
eters.
Nitrogen oxides means all oxides of ni-
trogen except nitrous oxide, as meas-
ured by test methods set forth in this
part.
One-hour period means any 60-minute
period commencing on the hour.
Opacity means the degree to which
emissions reduce the transmission of
light and obscure the view of an object
in the background.
Owner or operator means any person
who owns, leases, operates, controls, or
supervises an affected facility or a sta-
tionary source of which an affected fa-
cility is a part.
Part 70 permit means any permit is-
sued, renewed, or revised pursuant to
part 70 of this chapter.
Particulate matter means any finely
divided solid or liquid material, other
than uncombined water, as measured
by the reference methods specified
under each applicable subpart, or an
equivalent or alternative method.
Permit program means a comprehen-
sive State operating permit system es-
tablished pursuant to title V of the Act
(42 U.S.C. 7661) and regulations codified
in part 70 of this chapter and applicable
State regulations, or a comprehensive
Federal operating permit system estab-
lished pursuant to title V of the Act
and regulations codified in this chap-
ter.
Permitting authority means:
(1) The State air pollution control
agency, local agency, other State agen-
cy, or other agency authorized by the
.Administrator to carry out a permit
program under part 70 of this chapter;
or
(2) The Administrator, in the case of
EPA-implemented permit programs
under title V of the Act (42 U.S.C. 7661).
Proportional sampling means sampling
at a rate that produces a constant ratio
of sampling rate to stack gas flow rate.
Reactivation of a very clean coal-fired
electric utility steam generating unit
means any physical change or change
in the method of operation associated
-------
Environmental Protection Agency
with, the commencement of commercial
operations by a coal-fired utility unit
after a period of discontinued operation
where the unit:
(1) Has not been in operation for the
two-year period prior to the enactment
of the Clean Air Act Amendments of
1990, and the emissions from such unit
continue to be carried in the permit-
ting authority's emissions inventory at
the time of enactment;
(2) Was equipped prior to shut-down
with a continuous system of emissions
control that achieves a removal effi-
ciency for sulfur dioxide of no less than
85 percent and a removal efficiency for
particulates of no less than 98 percent;
(3) Is equipped with low-NO, burners
prior to the time of commencement of
operations following reactivation; and
(4) IB otherwise in compliance with
the requirements of the Clean Air Act.
Reference method means any method
of sampling and analyzing for an air
pollutant as specified in the applicable
subpart.
Repowering means replacement of an
existing coal-fired boiler with one of
the following clean coal technologies:
atmospheric or pressurized fluidized
bed combustion, integrated gasifi-
cation combined cycle, magnetohydro-
dynamics, direct and indirect coal-fired
turbines, integrated gasification fuel
cells, or as determined by the Adminis-
trator, in consultation with the Sec-
retary of Energy, a derivative of one or
more of these technologies, and any
other technology capable of controlling
multiple combustion emissions simul-
taneously with improved boiler or gen-
eration efficiency and with signifi-
cantly greater waste reduction relative
to the performance of technology in
widespread commercial use as of No-
vember 15, 1990. Repowering shall also
include any oil and/or gas-fired unit
which has been awarded clean coal
technology demonstration funding as
of January 1, 1991, by the Department
of Energy.
Run means the net period of time
during which an emission sample is
collected. Unless otherwise specified, a
run may be either intermittent or con-
tinuous within the limits of good engi-
neering practice.
§60.3
Shutdown means the cessation of op-
eration of an affected facility for any
purpose.
Six-minute period means any one of
the 10 equal parts of a one-hour period.
Standard means a standard of per-
formance proposed or promulgated
under this part.
Standard conditions means a tempera-
ture of 293 K (68°F) and a pressure of
101.3 kilopascals (29.92 in Hg).
Startup means the setting in oper-
ation of an affected facility for any
purpose.
State means all non-Federal authori-
ties, including local agencies, inter-
state associations, and State-wide pro-
grams, that have delegated authority
to implement: (1) The provisions of this
part; and/or (2) the permit program es-
tablished under part 70 of this chapter.
The term State shall have its conven-
tional meaning where clear from the
context.
Stationary source means any building,
structure, facility, or installation
which emits or may emit any air pol-
lutant.
Title V permit means any permit is-
sued, renewed, or revised pursuant to
Federal or State regulations estab-
lished to implement title V of the Act
(42 U.S.C. 7661). A title V permit issued
by a State permitting authority is
called a part 70 permit in this part.
Volatile Organic Compound means any
organic compound which participates
in atmospheric photochemical reac-
tions; or which is measured by a ref-
erence method, an equivalent method,
an alternative method, or which is de-
termined by procedures specified under
any subpart.
[44 FR 55173, Sept. 25, 1979, as amended at 45
FR 5617, Jan. 23. 1980; 45 FR 85415. Dec. 24,
1980; 54 FR 6662, Feb. 14. 1989; 55 FR 51382,
Dec. 13,1990; 57 FR 32338, July 21, 1992; 59 FR
12427, Mar. 16,1994]
§ 60.3 Units and abbreviations.
Used in this part are abbreviations
and symbols of units of measure. These
are defined as follows:
(a) System International (SI) units of
measure:
A—ampere
g—-gram
Hz—hertz
J—Joule
-------
§60.4
40 CFR Ch. I (7-1-95 Edition)
K—degree Kelvin
kg—kilogram
m—meter
m»—cubic meter
mg—milligram—10-s gram
mm—millimeter—10-3 meter
Mg—megagram—10s gram
mol—mole
N—newton
ng—nanogram—10-» gram
am—nanometer—10~9 meter
Pa—pascal
s—second
V—volt
W—watt
a—ohm
pg—mlcrogram—10- • gram
(b) Other units of measure:
Btu—British thermal unit
•O—degree Celsius (centigrade)
c*l—calorie
elm—cubic feet per minute
cu ft—cubic feet
dcf—dry cubic feet
dcm—dry cubic meter
dscf—dry cubic feet at standard conditions
dscm—dry cubic meter at standard condi-
tions
eq—equivalent
•F—degree Fahrenheit
ft—feet
gal—gallon
gr—grain
g-eq—firam equivalent
hr—hour
In—Inch
k—1,000
1—liter
1pm—liter per minute
Ib—pound
meq—milllequivalent
mln—minute
ml—mlUlHter
mol. wt.—molecular weight
ppb—parts per billion
ppm—parts per million
pslfc—pounds per square Inch absolute
pelg-rpounds per square Inch gage
•iR—degree Rankine
scf—cubic feet at standard conditions
Bcfh—cubic feet per hour at standard condi-
tions
scm—cubic meter at standard conditions
sec—second
sq ft—equare feet
std—at standard conditions
(c) Chemical nomenclature:
CdS—cadmium sulfide
CO—carbon monoxide
COy—carbon dioxide
HC1—hydrochloric acid
Hg—mercury
HaO—water
HsS—hydrogen sulfide
HaSO*—sulfurlc acid
Na—nitrogen
NO—nitric oxide
NOa—nitrogen dioxide
NOx—nitrogen oxides
Or-oxygen
SOa—sulfur dioxide
SOs—sulfur trloxide
SOx—sulfur oxides
(d) Miscellaneous:
A.S.T.M.—American Society for Testing and
Materials
[42 PR 37000. July 19, 1977; 42 FR 38178. July
27.1977]
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Envkonmentcrt Protection Agency
§60.7
§60.5 Determination of construction
or modification.
(a) When requested to do so by an
owner or operator, the Administrator
will make a determination of whether
action taken or intended to be taken
by such owner or operator constitutes
construction (including reconstruction)
or modification or the commencement
thereof within the meaning of this
part.
(b) The Administrator will respond to
any request for a determination under
paragraph (a) of this section within 30
days of receipt of such request.
[40 FB 58418, Deo. 16,1975]
S 60.6 Review of plans.
(a) When requested to do so by an
owner or operator, the Administrator
will review plans for construction or
modification for the purpose of provid-
ing technical advice to the owner or
operator.
(b)(l) A separate request shall be sub-
mitted for each construction or modi-
fication project.
(2) Each request shall identify the lo-
cation of such project, and be accom-
panied by technical information de-
scribing the proposed nature, size, de-
sign, and method of operation of each
affected facility involved in such
project, including information on any
equipment to be used for measurement
or control of emissions.
(c) Neither a request for plans review
nor advice furnished by the Adminis-
trator in response to such request shall
(1) relieve an owner or operator of legal
responsibility for compliance with any
provision of this part or of any applica-
ble State or local requirement, or (2)
prevent the Administrator from imple-
menting or enforcing any provision of
this part or taking any other action
authorized by the Act.
[36 FR 24877, Dec. 23, 1971, as amended at 39
FR9314, Mar. 8,1974]
§ 60.7 Notification and record keeping.
(a) Any owner or operator subject to
the provisions of this part shall furnish
the Administrator written notification
as follows:
(1) A notification of the date con-
struction (or reconstruction as defined
under §60.15) of an affected facility is
commenced postmarked no later than
30 days after such date. This require-
ment shall not apply in the case of
mass-produced facilities which are pur-
chased in completed form.
(2) A notification of the anticipated
date of initial startup of an affected fa-
cility postmarked not more than 60
days nor less than 30 days prior to such
date.
(3) A notification of the actual date
of initial startup of an affected facility
postmarked within 15 days after such
date.
(4) A notification of any physical or
operational change to an existing facil-
ity which may increase the emission
rate of any air pollutant to which a
standard applies, unless that change is
specifically exempted under an applica-
ble subpart or in §60.l4(e). This notice
shall be postmarked 60 days or as soon
as practicable before the change is
commenced and shall include informa-
tion describing the precise nature of
the change, present and proposed emis-
sion control systems, productive capac-
ity of the facility before and after the
change, and the expected completion
date of the change. The Administrator
may request additional relevant infor-
mation subsequent to this notice.
(5) A notification of the date upon
which demonstration of the continuous
monitoring system performance com-
mences in accordance with §60.13(c).
Notification shall be postmarked not
less than 30 days prior to such date.
(6) A notification of the anticipated
date for conducting the opacity obser-
vations required by §60.11(e)(l) of this
part. The notification shall also in-
clude, if appropriate, a request for the
Administrator to provide a visible
emissions reader during a performance
test. The notification shall be post-
marked not less than 30 days prior to
such date.
(7) A notification that continuous
opacity monitoring system data results
will be used to determine compliance
with the applicable opacity standard
during a performance test required by
§60.8 in lieu of Method 9 observation
data as allowed by §60.11(e)(5) of this
part. This notification shall be post-
marked not less than 30 days prior to
the date of the performance test.
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§60.7
40 CFR Ch. I <7-l-*5 Edition)
(b) Any owner or operator subject to
the provisions of this part shall main-
tain records of the occurrence and du-
ration of any startup, shutdown, or
malfunction in the operation of an af-
fected facility; any malfunction of the
air pollution control equipment; or any
periods during which a continuous
monitoring system or monitoring de-
vice is inoperative.
(c) Each owner or operator required
to install a continuous monitoring sys-
tem (CMS) or monitoring device shall
submit an excess emissions and mon-
itoring systems performance report
(excess emissions are defined in appli-
cable subparts) and/or a summary re-
port form (see paragraph (d) of this sec-
tion) to the Administrator semiannu-
ally, except when: more frequent re-
porting is specifically required by an
applicable subpart; or the CMS data
are to be used directly for compliance
determination, in which case quarterly
reports shall be submitted; or the Ad-
ministrator, on a case-by-case basis,
determines that more frequent report-
ing is necessary to accurately assess
the compliance status of the source.
All reports shall be postmarked by the
80th day following the end of each cal-
endar half (or quarter, as appropriate).
Written reports of excess emissions
shall include the following informa-
tion:
(1) The magnitude of excess emis-
sions computed in accordance with
§60.13(h), any conversion factors) used,
and the date and time of commence-
ment and completion of each time pe-
riod of excess emissions. The process
operating time during the reporting pe-
riod.
(2) Specific identification of each pe-
riod of excess emissions that occurs
during startups, shutdowns, and mal-
functions of the affected facility. The
nature and cause of any malfunction (if
known), the corrective action taken or
preventative measures adopted.
(3) The date and time identifying
each period during which the continu-
ous monitoring system was Inoperative
except for zero and span checks and the
nature of the system repairs or adjust-
ments.
(4) When no excess emissions have oc-
curred or the continuous monitoring
system(s) have not been inoperative,
repaired, or adjusted, such information
shall be stated in the report.
(d) The summary report form shall
contain the information and be in the
format shown in figure 1 unless other-
wise specified by the Administrator.
One summary report form shall be sub-
mitted for each pollutant monitored at
each affected facility.
(1) If the total duration of excess
emissions for the reporting period is
less than 1 percent of the total operat-
ing time for the reporting period and
CMS downtime for the reporting period
is less than 5 percent of the total oper-
ating time for the reporting period,
only the summary report form shall be
submitted and the excess emission re-
port described in §60.7(c) need not be
submitted unless requested by the Ad-
ministrator.
(2) If the total duration of excess
emissions for the reporting period is 1
percent or greater of the total operat-
ing time for the reporting period or the
total CMS downtime for the reporting
period is 5 percent or greater of the
total operating time for the reporting
period, the summary report form and
the excess emission report described in
§60.7(c) shall both be submitted.
FIGURE 1—SUMMARY REPORT—GASEOUS
AND OPACITY EXCESS EMISSION AND
MONITORING SYSTEM PERFORMANCE
Pollutant (Circle One—SOVNOx/TRS/EfeS/CCV
Opacity)
Reporting period dates: From to
Company:
Emission Limitation .
Address:
Monitor Manufacturer and Model No.
Date of Latest CMS Certification or Audit —
Process Unites) Description:
Total source operating: time in reporting: pe-
riod1 . _
Emission data summary1
CMS performance summary *
1. Duration of excess emissions In reporting period
due to:
a. Startup/shutdown ...............................................
b. Control equipment problems .
c. Process problems ._...„_._........„
1. CMS downtime In reporting period due to:
a Monitor equipment malfunctions.
b. Non-Monitor equipment malfunctions ....
c. Quality assurance calibration
-------
Environmental Protection Agency
§60.7
Emission data summary1
d. Other known causes
e. Unknown causes
2. Total duration of excess emission „
3. Total duration of excess emissions x (100) {Total %2
source operating time].
CMS performance summary1
d. Other known causes ....
e. Unknown causes
2. Total CMS Downtime
3. [Total CMS Downtime] x (100) [Total source op-
erating time]. '
%2
1 For opacity, record all times in minutes. For gases, record all times in hours.
z For the reporting period: If the total duration of excess emissions is 1 percent or greater of the total operating time or the total
CMS downtime is 5 percent or greater of the total operating time, both the summary report form and the excess emission report
described in §60.7(c) shall be submitted.
On a separate page, describe any changes
since last quarter in CMS, process or con-
trols. I certify that the information con-
tained in this report is true, accurate, and
complete.
Name
Signature
Title
Date
(e)(l) Notwithstanding the frequency
of reporting requirements specified in
paragraph (c) of this section, an owner
or operator who is required by an appli-
cable subpart to submit excess emis-
sions and monitoring systems perform-
ance reports (and summary reports) on
a quarterly (or more frequent) basis
may reduce the frequency of reporting
for that standard to semiannual if the
following conditions are met:
(i) For 1 full year (e.g., 4 quarterly or
12 monthly reporting periods) the af-
fected facility's excess emissions and
monitoring systems reports submitted
to comply with a standard under this
part continually demonstrate that the
facility is in compliance with the ap-
plicable standard;
(ii) The owner or operator continues
to comply with all recordkeeping and
monitoring requirements specified in
this subpart and the applicable stand-
ard; and
(iii) The Administrator does not ob-
ject to a reduced frequency of reporting
for the affected facility, as provided in
paragraph (e)(2) of this section.
(2) The frequency of reporting of ex-
cess emissions and monitoring systems
performance (and summary) reports
may be reduced only after the owner or
operator notifies the Administrator in
writing of his or her intention to make
such a change and the Administrator
does not object to the intended change.
In deciding whether to approve a re-
duced frequency of reporting, the Ad-
ministrator may review information
concerning the source's entire previous
performance history during the re-
quired recordKeeping period prior to
the intended change, including per-
formance test results, monitoring data,
and evaluations of an owner or opera-
tor's confonnance with operation and
maintenance requirements. Such infor-
mation may be used by the Adminis-
trator to make a judgment about the
source's potential for noncompliance in
the future. If the Administrator dis-
approves the owner or operator's re-
quest to reduce the frequency of re-
porting, the Administrator will notify
the owner or operator in writing within
45 days after receiving notice of the
owner or operator's intention. The no-
tification from the Administrator to
the owner or operator will specify the
grounds on which the disapproval is
based. In the absence of a notice of dis-
approval within 45 days, approval is
automatically granted.
(3) As soon as monitoring data indi-
cate that the affected facility is not in
compliance with any emission limita-
tion or operating parameter specified
in the applicable standard, the fre-
quency of reporting shall revert to the
frequency specified in the applicable
standard, and the owner or operator
shall submit an excess emissions and
monitoring systems performance re-
port (and summary report, if required)
at the next appropriate reporting pe-
riod following the noncomplying event.
After demonstrating compliance with
the applicable standard for another full
year, the owner or operator may again
request approval from the Adminis-
trator to reduce the frequency of re-
porting for that standard as provided
for in paragraphs (e)(l) and (e)(2) of.this
section.
-------
§60.8
40 CFR Ch. I (7-1-95 Edition)
(f) Any owner or operator subject to
the provisions of this part shall main-
tain a file of all measurements, includ-
ing continuous monitoring system,
monitoring1 device, and performance
testing measurements; all continuous
monitoring system performance eval-
uations; all continuous monitoring sys-
tem or monitoring device calibration
checks; adjustments and maintenance
performed on these systems or devices;
and all other information required by
this part recorded in a permanent form
suitable for inspection. The file shall
be retained for at least two years fol-
lowing the date of such measurements,
maintenance, reports, and records.
(g) If notification substantially simi-
lar to that in paragraph (a) of this sec-
tion is required by any other State or
local agency, sending the Adminis-
trator a copy of that notification will
satisfy the requirements of paragraph
(a) of this section.
(h) Individual subparts of this part
may include specific provisions which
clarify or make inapplicable the provi-
sions set forth in this section.
[86 PR 24877, Dec. 28, 1971, as amended at 40
FR 46254, Oct. 6, 1975; 40 FR 58418, Deo. 16,
1975; 45 FR 5617, Jan. 23. 1980; 48 FR 48335,
Oct. 18, 1983; 50 FR 53113, Dec. 27, 1985; 52 FR
8781, Mar. 26. 1987; 55 FR 51382. Dec. 13. 1990;
69 FR 12428, Mar. 16.1994; 59 FR 47265, Sep. 15.
1994]
§60.8 Performance tests.
(a) 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 and at such
other times as may be required by the
Administrator under section 114 of the
Act, the owner or operator of such fa-
cility shall conduct performance test(s)
and furnish the Administrator a writ-
ten report of the results of such per-
formance test
-------
Environmental Protection Agency
. IT
(3) Safe access to sampling
platform(s).
(4) Utilities for sampling and testing
equipment.
(f) Unless otherwise specified in the
applicable subpart, each performance
test shall consist of three separate runs
using the applicable test method. Each
run shall be conducted for the time and
under the conditions specified in the
applicable standard. For the purpose of
determining compliance with an appli-
cable standard, the arithmetic means
of results of the three runs shall apply.
In the event that a sample is acciden-
tally lost or conditions occur in which
one of the three runs must be discon-
tinued because of forced shutdown, fail-
ure of an irreplaceable portion of the
sample train, extreme meteorological
conditions, or other circumstances, be-
yond the owner or operator's control.
compliance may, upon the Administra-
tor's approval, be determined using the
arithmetic mean of the results of the
two other runs.
[36 FR 24877, Dec. 23, 1971. as amended at 39
FR 9314, Mar. 8,1974; 42 FR 57126, Nov. 1,1977;
44 FR 33612, June 11,1979; 54 FR 6662, Feb. 14,
1989; 54 FR 21344, May 17.1989]
§ 60.9 Availability of information.
The availability to the public of in-
formation provided to. or otherwise ob-
tained by, the Administrator under
this part shall be governed by part 2 of
this chapter. (Information submitted
voluntarily to the Administrator for
the purposes of §§60.5 and 60.6 is gov-
erned by §§2.201 through 2.213 of this
chapter and not by §2.301 of this chap-
ter.)
§60.10 State authority.
The provisions of this part shall not
be construed in any manner to preclude
any State or political subdivision
thereof from:
(a) Adopting and enforcing any emis-
sion standard or limitation applicable
to an affected facility, provided that
such emission standard or limitation is
not less stringent than the standard
applicable to such facility.
(b) Requiring the owner or operator
of an affected facility to obtain per-
mits, license's, or approvals prior to ini-
tiating construction, modification, or
operation of such facility.
§ 60.11 Compliance with standards and
maintenance requirements.
(a) Compliance with standards in this
part, other than opacity standards,
shall be determined only by perform-
ance tests established by §60.8, unless
otherwise specified in the applicable
standard.
(b) Compliance with opacity stand-
ards in this part shall be determined by
conducting observations in accordance
with Reference Method 9 in appendix A
of this part, any alternative method
that is approved by the Administrator.
or as provided in paragraph (eX5) of
this section. For purposes of determin-
ing initial compliance, the
total time of observations shall be 3
hours (80 6-minute averages) for the
performance test or other set of obser-
vations (meaning those fugitive-type
emission sources subject only to an
opacity standard).
(c) The opacity standards set forth in
this part shall apply at all times except
during periods of startup, shutdown,
malfunction, and as otherwise provided
in the applicable standard.
(d) At all times, including periods of
startup, shutdown, and malfunction,
owners and operators shall, to the ex-
tent practicable, maintain and operate
any affected facility including associ-
ated air pollution control equipment in
a manner consistent with good air pol-
lution control practice for minimizing
emissions. Determination of whether
acceptable operating and maintenance
procedures are being used will be based
on information available to the Admin-
istrator which may include, but is not
limited to, monitoring results, opacity
observations, review of operating and
maintenance procedures, and inspec-
tion of the source.
(e)(l) For the purpose of demonstrat-
ing initial compliance, opacity obser-
vations shall be conducted concur-
rently with the initial performance
test required in §60.8 unless one of the
following conditions apply. If no per-
formance test under §60.8 is required.
then opacity observations shall be con-
ducted within 60 days after achieving
the maximum production rate at which
the affected facility will be operated
but no later than 180 days after initial
startup of the facility. If visibility or
other conditions prevent the opacity
-------
§60.11
40 CFR Ch. I (7-1-95 Edition)
observations from being conducted
concurrently with the initial perform-
ance test required under §60.8, the
source owner or operator shall resched-
ule the opacity observations as soon
after the initial perforjnance test as
possible, but not later than 80 days
thereafter, and shall advise the Admin-
istrator of the rescheduled date. In
these cases, the 30-day prior notifica-
tion to the Administrator required in
§60.7(a)(6) shall be waived. The resched-
uled opacity observations shall be con-
ducted (to the extent possible) under
the same operating conditions that ex-
isted during the initial performance
test conducted under §60.8. The visible
emissions observer shall determine
whether visibility or other conditions
prevent the opacity observations from
being made concurrently with the ini-
tial performance test in accordance
with procedures contained in Reference
Method 9 of appendix B of this part.
Opacity readings of portions of plumes
which contain condensed, uncombined
water vapor shall not be used for pur-
poses of determing compliance with
opacity standards. The owner or opera-
tor of an affected facility shall make
available, upon request by the Admin-
istrator, such records as may be nec-
essary to determine the conditions
under which the visual observations
were made and shall provide evidence
indicating proof of current visible ob-
server emission certification. Except as
provided in paragraph (e)(5) of this sec-
tion, the results of continuous mon-
itoring by transmissometer which indi-
cate that the opacity at the time vis-
ual observations were made was not in
excess of the standard are probative
but not conclusive evidence of the ac-
tual opacity of an emission, provided
that the source shall meet the burden
of proving that the instrument used
meets (at the time of the alleged viola-
tion) Performance Specification 1 in
appendix B of this part, has been prop-
erly maintained and (at the time of the
alleged violation) that the resulting
data have not been altered in any way,
(2) Except as provided in paragraph
(e)(3) of this section, the owner or oper-
ator of an affected facility to which an
opacity standard in this part applies
shall conduct opacity observations in
accordance with paragraph (b) of this
section, shall record the opacity of
emissions, and shall report to the Ad-
ministrator the opacity results along
with the results of the initial perform-
ance test required under §60.8. The in-
ability of an owner or operator to se-
cure a visible emissions observer shall
not be considered a reason for not con-
ducting the opacity observations con-
current with the initial performance
test.
(3) The owner or operator of an af-
fected facility to which an opacity
standard in this part applies may re-
quest the Administrator to determine
and to record the opacity of emissions
from the affected facility during the
initial performance test and at such
times as may be required. The owner or
operator of the affected facility shall
report the opacity results. Any request
to the Administrator to determine and
to record the opacity of emissions from
an affected facility shall be included in
the notification required in §60.7(a)(6).
If, for some reason, the Administrator
cannot determine and record the opac-
ity of emissions from the affected facil-
ity during the performance test, then
the provisions of paragraph (e)(l) of
this section shall apply.
(4) An owner or operator of an af-
fected facility using a continuous opac-
ity monitor (transmissometer) shall
record the monitoring data produced
during the initial performance test re-
quired by §60.8 and shall furnish the
Administrator a written report of the
monitoring results along with Method
9 and §60.8 performance test results.
(5) An owner or operator of an af-
fected facility subject to an opacity
standard may submit, for compliance
purposes, continuous opacity monitor-
ing system (COMS) data results pro-
duced during any performance test re-
quired under §60.8 in lieu of Method 9
observation data. If an owner or opera-
tor elects to submit COMS data for
compliance with the opacity standard,
he shall notify the Administrator of
that decision, in writing, at least 30
days before any performance test re-
quired under §60.8 is conducted. Once
the owner or operator of an affected fa-
cility has notified the Administrator to
that effect, the COMS data results will
be used to determine opacity compli-
ance during subsequent tests required
-------
Environmental Protection Agency
§60.13
under §60.8 until the owner or operator
notifies the Administrator, in writing:,
to the contrary. For the purpose of de-
termining compliance with the opacity
standard during a performance test re-
quired under §60.8 using COMS data,
the minimum total time of COMS data
collection shall be averages of all 6-
minute continuous periods within the
duration of the mass emission perform-
ance test. Results of the COMS opacity
determinations shall be submitted
along with the results of the perform-
ance test required under §60.8. The
owner or operator of an affected facil-
ity using a COMS for compliance pur-
poses is responsible for demonstrating
that the COMS meets the requirements
specified in §60.13(c) of this part, that
the COMS has been properly main-
tained and operated, and that the re-
sulting data have not been altered in
any way. If COMS data results are sub-
mitted for compliance with the opacity
standard for a period of time during
which Method 9 data indicates non-
compliance, the Method 9 data will be
used to determine opacity compliance.
(6) Upon receipt from an owner or op-
erator of the written reports of the re-
sults of the performance tests required
by §60.8, the opacity observation re-
sults and observer certification re-
quired by §60.11(e)(l), and the COMS re-
sults, if applicable, the Administrator
will make a finding concerning compli-
ance with opacity and other applicable
standards. If COMS data results are
used to comply with an opacity stand-
ard, only those results are required to
be submitted along with the perform-
ance test results required by §60.8. If
the Administrator finds that an af-
fected facility is in compliance with all
applicable standards for which per-
formance tests are conducted in ac-
cordance with §60.8 of this part but
during the time such performance tests
are being conducted fails to meet any
applicable opacity standard, he shall
notify the owner or operator and advise
him that he may petition the Adminis-
trator within 10 days of receipt of noti-
fication to make appropriate adjust--
ment to the opacity standard for the
affected facility.
(7) The Administrator will grant such
a petition upon a demonstration by the
owner or operator that the affected fa-
cility and associated air pollution con-
trol equipment was operated and main-
tained in a manner to minimize the
opacity of emissions during the per-
formance tests; that the performance
tests were performed under the condi-
tions established by the Administrator;
and that the affected facility and asso-
ciated air pollution control equipment
were incapable of being adjusted or op-
erated to meet the applicable opacity
standard.
(8) The Administrator will establish
an opacity standard for the affected fa-
cility meeting the above requirements
at a level at which the source will be
able, as indicated by the performance
and opacity tests, to meet the opacity
standard at all times during which the
source is meeting the mass or con-
centration emission standard. The Ad-
ministrator will promulgate the new
opacity standard in the FEDERAL REG-
ISTER.
(0 Special provisions set forth under
an applicable subpart of this part shall
supersede any conflicting provisions of
this section.
[38 PR 28565, Oct. 15, 1973, as amended at 39
FR 39873, Nov. 12, 1974; 43 ER 8800. Mar. 3.
1978; 45 FR 23379. Apr. 4. 1980; 48 FR 48335,
Oct. 18.1983; 50 FR 53113, Deo. 27.1985; 51 FR
1790. Jan. 15.1986; 52 FR 9781. Mar. 26,1987]
§60.12 Circumvention.
No owner or operator subject to the
provisions of this part shall build,
erect, install, or use any article, ma-
chine, equipment or process, the use of
which conceals an emission which
would otherwise constitute a violation
of an applicable standard. Such con-
cealment includes, but is not limited
to, the use of gaseous diluents to
achieve compliance with an opacity
standard or with a standard which is
based on the concentration of a pollut-
ant in the gases discharged to the at-
mosphere.
[39 FR 9314, Mar. 8,1974]
§ 60.13 Monitoring requirements.
(a) For the purposes of this section,
all continuous monitoring systems re-
quired under applicable subparts shall
be subject to the provisions of this sec-
tion upon promulgation of performance
specifications for continuous monitor-
ing systems under appendix B to this
-------
§60.13
40 CFR Ch. I (7-1-95 Edition)
part and, if the continuous monitoring'
system is used to demonstrate compli-
ance with emission limits on a continu-
ous basis, appendix F to this part, un-
less otherwise specified in an applica-
ble subpart or by the Administrator.
Appendix F is applicable December 4,
(b) All continuous monitoring sys-
tems and monitoring devices shall be
installed and operational prior to con-
ducting performance tests under §60.8.
Verification of operational status
shall, as a minimum, include comple-
tion of the manufacturer's written re-
quirements or recommendations for in-
stallation, operation, and calibration
of the device.
(o) If the owner or operator of an af-
fected facility elects to submit
continous opacity monitoring system
(COM8) data for compliance with the
opacity standard as provided under
§60.11(e)(5), he shall conduct a perform-
ance evaluation of the COM3 as speci-
fied in Performance Specification 1, ap-
pendix B, of this part before the per-
formance test required under §60.8 is
conducted. Otherwise, the owner or op-
erator of an affected facility shall con-
duct a performance evaluation of the
COM3 or continuous emission monitor-
ing' system (GEMS) during any per-
formance test required under §60.8 or
within 30 days thereafter in accordance
with the applicable performance speci-
fication in appendix B of this part, The
owner or operator of an affected facil-
ity shall conduct COMS or GEMS per-
formance evaluations at such other
times as may be required by the Ad-
ministrator under section 114 of the
Act.
(1) The owner or operator of an af-
fected facility using a COMS to deter-
mine opacity compliance during any
performance test required under §60.8
and as described in §60.11(e)(5) shall
furnish the Administrator two or, upon
request, more copies of a written re-
port of the results of the COMS per-
formance evaluation described in para-
graph (c) of this section at least 10 days
before the performance test required
under §60.8 is conducted.
(2) Except as provided in paragraph
(c)(l) of this section, the owner or oper-
ator of an affected facility shall fur-
nish the Administrator within 60 days
of completion two or, upon request,
more copies of a written report of the
results of the performance evaluation.
(d)(l) Owners and operators of all
continuous emission monitoring sys-
tems installed in accordance with the
provisions of this part shall check the
zero (or low-level value between 0 and
20 percent of span value) and span (50
to 100 percent of span value) calibra-
tion drifts at least once daily in ac-
cordance with a written procedure. The
zero and span shall, as a minimum, be
adjusted whenever the 24-hour zero
drift or 24-hour span drift exceeds two
times the limits of the applicable per-
formance specifications in appendix B.
The system must allow the amount of
excess zero and span drift measured at
the 24-hour interval checks to be re-
corded and quantified, whenever speci-
fied. For continuous monitoring sys-
tems measuring opacity of emissions,
the optical surfaces exposed to the ef-
fluent gases shall be cleaned prior to
performing the zero and span drift ad-
justments except that for systems
using automatic zero adjustments. The
optical surfaces shall be cleaned when
the cumulative automatic zero com-
pensation exceeds 4 percent opacity.
(2) Unless otherwise approved by the
Administrator, the following proce-
dures shall be followed for continuous
monitoring systems measuring opacity
of emissions. Minimum procedures
shall include a method for producing a
simulated zero opacity condition and
an upscale (span) opacity condition
using a certified neutral density filter
or other related technique to produce a
known obscuration of the light beam.
Such procedures shall provide a system
check of the analyzer internal optical
surfaces and all electronic circuitry in-
cluding the lamp and photodetector as-
sembly.
(e) Except for system breakdowns, re-
pairs, calibration checks, and zero and
span adjustments required under para-
graph (d) of this section, all continuous
monitoring systems shall be in contin-
uous operation and shall meet mini-
mum frequency of operation require-
ments as follows:
(1) All continuous monitoring sys-
tems referenced by paragraph (c) of
this section for measuring opacity of
emissions shall complete a minimum of
-------
Environmental Protection Agency
§60.13
one cycle of sampling and analyzing for
each successive 10-second period and
one cycle of data recording for each
successive 6-minute period.
(2) All continuous monitoring sys-
tems referenced by paragraph (c) of
this section for measuring emissions,
except opacity, shall complete a mini-
mum of one cycle of operation (sam-
pling, analyzing, and data recording)
for each successive 15-minute period.
(f) All continuous monitoring sys-
tems or monitoring .devices shall be in-
stalled sucn that representative meas-
urements of emissions or process pa-
rameters from the affected facility are
obtained. Additional procedures for lo-
cation of continuous monitoring sys-
tems contained In the applicable Per-
formance Specifications of appendix B
of this part shall be used.
(g) When the effluents from a single
affected facility or two or more af-
fected facilities subject to the same
emission standards are combined be-
fore being released to the atmosphere,
the owner or operator may install ap-
plicable continuous monitoring sys-
tems on each effluent or on the com-
bined effluent. When the affected facili-
ties are not subject to the same emis-
sion standards, separate continuous
monitoring systems shall be installed
on each effluent. When the effluent
from one affected facility is released to
the atmosphere through more than one
point, the owner or operator shall in-
stall an applicable continuous monitor-
ing system on each separate effluent
unless the installation of fewer sys-
tems is approved by the Administrator.
When more than one continuous mon-
itoring system is used to measure the
emissions from one affected facility
(e.g., multiple breechings, multiple
outlets), the owner or operator shall
report the results as required from
each continuous monitoring system.
(h) Owners or operators of all contin-
uous monitoring systems for measure-
ment of opacity shall reduce all data to
6-minute averages and for continuous
monitoring systems other than opacity
to 1-hour averages for time periods as
defined in §60.2. Six-minute opacity
averages shall be calculated from 36 or
more data points equally spaced over
each 6-minute period. For continuous
monitoring systems other than opac-
ity, 1-hour averages shall be computed
from four or more data points equally
spaced over each 1-hour period. Data
recorder during periods of continuous
monitoring system breakdowns, re-
pairs, calibration checks, and zero and
span adjustments shall not be included
in the data averages computed under
this paragraph. An arithmetic or inte-
grated average of all data may be used.
The data may be recorded in reduced or
nonreduced form (e.g., ppm pollutant
and percent 02 or ng/J of pollutant).
All excess emissions shall be converted
into units of the standard using the ap-
plicable conversion procedures speci-
fied in 'subparts. After conversion into
units of the standard, the data may be
rounded to the same number of signifi-
cant digits as used in the applicable
subparts to specify the emission limit
(e.g., rounded to the nearest 1 percent
opacity).
(i) After receipt and consideration of
written application, the Administrator
may approve alternatives to any mon-
itoring' procedures or requirements of
this part including, but not limited to
the following:
(1) Alternative monitoring require-
ments when installation of a continu-
ous monitoring system or monitoring
device specified by this part would not
provide accurate measurements due to
liquid water or other interferences
caused by substances with the effluent
gases.
(2) Alternative monitoring require-
ments when the affected facility is in-
frequently operated.
(3) Alternative monitoring require-
ments to accommodate continuous
monitoring systems that require addi-
tional measurements to correct for
stack moisture conditions.
(4) Alternative locations for install-
ing continuous monitoring systems or
monitoring devices when the owner or
operator can demonstrate that instal-
lation at alternate locations will en-
able accurate and representative meas-
urements.
(5) Alternative methods of converting
pollutant concentration measurements
to units of the standards.
(6) Alternative procedures for per-
forming daily checks of zero and span
drift that do not involve use of.span
gases or test cells.
-------
§60.13
40 CFR Ch. I (7-1-95 Edition)
(7) Alternatives to the A.S.T.M. test
methods or sampling procedures speci-
fied by any subpart.
(8) Alternative continuous monitor-
ing1 systems that do not meet the de-
sign or performance requirements in
Performance Specification 1, appendix
B, but adequately demonstrate a defi-
nite and consistent relationship be-
tween its measurements and the meas-
urements of opacity by a system com-
plying with the requirements in Per-
formance Specification 1. The Adminis-
trator may require that such dem-
onstration be performed for each af-
fected facility.
(9) Alternative monitoring require-
ments when the effluent from a single
affected facility or the combined efflu-
ent from two or more affected facilities
are released to the atmosphere through
more than one point.
(j) An alternative to the relative ac-
curacy test specified in Performance
Specification 2 of appendix B may be
requested as follows:
(1) An alternative to the reference
method tests for determining relative
accuracy is available for sources with
emission rates demonstrated to be less
than 50 percent of the applicable stand-
ard. A source owner or operator may
petition the Administrator to waive
the relative accuracy test in section 7
of Performance Specification 2 and
substitute the procedures in section 10
if the results of a performance test con-
ducted according to the requirements
in §60.8 of this subpart or other tests
performed following the criteria in
§60.8 demonstrate that the emission
rate of the pollutant of interest in the
units of the applicable standard is less
than 50 percent of the applicable stand-
ard. For sources subject to standards
expressed as control efficiency levels, a
source owner or operator may petition
the Administrator to waive the rel-
ative accuracy test and substitute the
procedures in section 10 of Performance
Specification 2 if the control device ex-
haust emission rate is less than 50 per-
cent of the level needed to meet the
control efficiency requirement. The al-
ternative procedures do not apply if
the continuous emission monitoring
system is used to determine compli-
ance continuously with the applicable
standard. The petition to waive the rel-
ative accuracy test shall include a de-
tailed description of the procedures to
be applied. Included shall be location
and procedure for conducting the alter-
native, the concentration or response
levels of the alternative RA materials,
and the other equipment checks in-
cluded in the alternative procedure.
The Administrator will review the peti-
tion for completeness and applicabil-
ity. The determination to grant a waiv-
er will depend on the intended use of
the OEMS data (e.g., data collection
purposes other than NSPS) and may re-
quire specifications more stringent
than in Performance Specification 2
(e.g., the applicable emission limit is
more stringent than NSPS).
(2) The waiver of a OEMS relative ac-
curacy test will be reviewed and may
be rescinded at such time following
successful completion of the alter-
native RA procedure that the OEMS
data indicate the source emissions ap-
proaching the level of the applicable
standard. The criterion for reviewing
the waiver is the collection of GEMS
data showing that emissions have ex-
ceeded 70 percent of the applicable
standard for seven, consecutive, aver-
aging periods as specified by the appli-
cable regulation(s). For sources subject
to standards expressed as control effi-
ciency levels, the criterion for review-
ing the waiver is the collection of
OEMS data showing that exhaust emis-
sions have exceeded 70 percent of the
level needed to meet the control effi-
ciency requirement for seven, consecu-
tive, averaging periods as specified by
the applicable regulation(s) [e.g.,
§60.45(g) (2) and (3), §60.73(e). and
§60.84(e)]. It is the responsibility of the
source operator to maintain records
and determine the level of emissions
relative to the criterion on the waiver
of relative accuracy testing. If tills cri-
terion is exceeded, the owner or opera-
tor must notify the Administrator
within 10 days of such occurrence and
include a description of the nature and
cause of the increasing emissions. The
Administrator will review the notifica-
tion and may rescind the waiver and
require the owner or operator to con-
duct a relative accuracy test of "the
-------
Environmental Protection Agency
GEMS as specified in section 7 of Per-
formance Specification 2.
[40 FR 46255, Oct. 6, 1975; 40 FR 59205, Dec. 22,
1975, as amended at 41 FR 35185, Aug. 20,1976;
48 FR 13326, Mar. 30, 1983; 48 FR 23610, May 25,
1983; 48 FR 32986, July 20, 1983; 52 FR 9782,
Mar. 26, 1987; 52 FR 17555, May 11, 1987; 52 FR
21007, June 4,1987]
§60.14 Modification.
(a) Except as provided under para-
graphs (e) and (f) of this section, any
physical or operational change to an
existing facility which results in an in-
crease in the emission rate to the at-
mosphere of any pollutant to which a
standard applies shall be considered a
modification within the meaning of
section 111 of the Act. Upon modifica-
tion, an existing facility shall become
an affected facility'for each pollutant
to which a standard applies and for
which there is an increase in the emis-
sion rate to the atmosphere.
(b) Emission rate shall be expressed
as kg/hr of any pollutant discharged
into the atmosphere for which a stand-
ard is applicable. The Administrator
shall use the following to determine
emission rate:
(1) Emission factors as specified in
the latest issue of "Compilation of Air
Pollutant Emission Factors," EPA
Publication No. AP-42, or other emis-
sion factors determined by the Admin-
istrator to be superior to AP-42 emis-
sion factors, in cases where utilization
of emission factors demonstrate that
the emission level resulting from the
physical or operational change will ei-
ther clearly increase or clearly not in-
crease.
(2) Material balances, continuous
monitor data, or manual emission tests
in cases where utilization of emission
factors as referenced in paragraph
(b)(l) of this section does not dem-
onstrate to the Administrator's satis-
faction whether the emission level re-
sulting from the physical or oper-
ational change will either clearly in-
crease or clearly not increase, or where
an owner or operator demonstrates to
the Administrator's satisfaction that
there are reasonable grounds to dispute
the result obtained by the Adminis-
trator utilizing emission factors as ref-
erenced in paragraph (b)(l) of this sec-
tion. When the emission rate is based
on results from manual emission tests
or continuous monitoring systems, the
procedures specified in appendix C of
this part shall be used to determine
whether an increase in emission rate
has occurred. Tests shall be conducted
under such conditions as the Adminis-
trator shall specify to the owner or op-
erator based on representative per-
formance of the facility. At least three
valid test runs must be conducted be-
fore and at least three after the phys-
ical or operational change. All operat-
ing parameters which may affect emis-
sions must be held constant to the
maximum feasible degree for all test
runs.
(c) The addition of an affected facil-
ity to a stationary source as an expan-
sion to that source or as a replacement
for an existing facility shall not by it-
self bring within the applicability of
this part any other facility within that
source.
(d) [Reserved]
(e) The following shall not, by them-
selves, be considered modifications
under this part:
(1) Maintenance, repair, and replace-
ment which the Administrator deter-
mines to be routine for a source cat-
egory, subject to the provisions of
paragraph (c) of this section and §60.15.
(2) An increase in production rate of
an existing facility, if that increase
can be accomplished without a capital
expenditure on that facility.
(3) An increase in the hours of oper-
ation.
(4) Use of an alternative fuel or raw
material if, prior to the date any
standard under this part becomes ap-
plicable to that source type, as pro-
vided by §60.1, the existing facility was
designed to accommodate that alter-
native use. A facility shall be consid-
ered to be designed to accommodate an
alternative fuel or raw material if that
use could be accomplished under the
facility's construction specifications as
amended prior to the change. Conver-
sion to coal required for energy consid-
erations, as specified in section
lll(a)(8) of the Act, shall not be consid-
ered a modification.
(5) The addition or use of any system
or device whose primary function is the
reduction of air pollutants, except
when an emission control system is re-
-------
§60.15
moved or is replaced by a system which
the Administrator determines to be
less environmentally beneficial.
(6) The relocation or change in own-
ership of an existing facility.
(f) Special provisions set forth under
an applicable subpart of this part shall
supersede any conflicting provisions of
this section.
(g) Within 180 days of the completion
of any physical or operational change
subject to the control measures speci-
fied in paragraph (a) of this section,
compliance with all applicable stand-
ards must be achieved.
(h) No physical change, or change in
the method of operation, at an existing
electric utility steam generating unit
shall be treated as a modification for
the purposes of this section provided
that such change does not increase the
maximum hourly emissions of any pol-
lutant regulated under this section
above the maximum hourly emissions
achievable at that unit during the 5
years prior to the change.
(i) Bepowering projects that are
awarded funding from the Department
of Energy as permanent clean coal
technology demonstration projects (or
similar projects funded by EPA) are ex-
empt from the requirements of this
section provided chat such change does
not increase the mtL-nTn^m hourly
emissions of any jx>llutant regulated
under this section above the .maximum
hourly emissions achievable at that
unit during the five years prior to the
change.
(j)(l) Bepowering projects that qual-
ify for an extension under section
409(b) of the Clean Air Act are exempt
from the requirements of this section,
provided that such change does not in-
crease the actual hourly .emissions of
any pollutant regulated under this sec-
tion above the actual hourly emissions
achievable at that unit during the 5
years prior to the change.
(2) This exemption shall not apply to
any new unit that:
(i) Is designated as a replacement for
an existing unit;
(ii) Qualifies under section 409(b) of
the Clean Air Act for an extension of
an emission limitation compliance
date under section 405 of the Clean Air
Act; and
40 CFR Ch. I (7-1-95 Edition)
(iii) Is located at a different site than
the existing unit.
(k) The installation, operation, ces-
sation, or removal of a temporary
clean coal technology demonstration
project is exempt from the require-
ments of this section. A temporary clean
coal control technology demonstration
project, for the purposes of this section
is a clean coal technology demonstra-
tion project that is operated for a pe-
riod of 5 years or less, and which com-
plies with the State implementation
plan, for tne State in which the project
is located and other requirements nec-
essary to attain and. maintain the na-
tional ambient air quality standards
during the project and after it is termi-
nated.
(1) The reactivation of a very clean
coal-fired electric utility steam gener-
ating unit is exempt from the require-
ments of this section.
[40 PR 58419, Dec. 16, 1975, amended at 43 FR
34347, Aug. 3.1978; 45 PR 5617. Jan. 23,1980; 57
FR 32339, July 21.1992]
S 80.15 Reconstruction.
(a) An existing facility, upon recon-
struction, becomes an affected facility,
irrespective of any change in emission
rate.
(b) "Reconstruction" means the re-
placement of components of an exist-
ing facility to such an extent that:
(1) The fixed capital cost of the new
components exceeds 50 percent of the
fixed capital cost that would be re-
quired to construct a comparable en-
tirely new facility, and
(2) It is technologically and economi-
cally feasible to meet the applicable
standards set forth in this part.
(c) "Fixed capital cost" means the
capital needed to provide all the depre-
ciable components.
(d) If an owner or operator of an ex-
isting faculty proposes to replace com-
ponents, and the fixed capital cost of
the new components exceeds 50 percent
of the fixed capital cost that would be
required to construct a comparable en-
tirely new facility, he shall notify the
Administrator of the proposed replace-
ments. The notice must be postmarked
60 days (or as soon as practicable) be-
fore construction of the replacements
is commenced and must include, the
following information:
-------
Environmental Protection Agency
§60.16
(1) Name and address of the owner or
operator.
(2) The location of the existing facil-
ity.
(3) A brief description of the existing
facility and the components which are
to be replaced.
(4) A description of the existing air
pollution control equipment and the
proposed air pollution control equip-
ment.
(5) An estimate of the fixed capital
cost of the replacements and of con-
structing a comparable entirely new fa-
cility.
(6) The estimated life of the existing
facility after the replacements.
(7) A discussion of any economic or
technical limitations the facility may
have In complying with the applicable
standards of performance after the pro-
posed replacements.
(e) The Administrator will deter-
mine, within 30 days of the receipt of
the notice required by paragraph (d) of
this section and any additional Infor-
mation he may reasonably require,
whether the proposed replacement con-
stitutes reconstruction.
(f) The Administrator's determina-
tion under paragraph (e) shall be based
on:
(1) The fixed capital cost of the re-
placements in comparison to the fixed
capital cost that would be required to
construct a comparable entirely new
facility;
(2) The estimated life of the facility
after the replacements compared to the
life of a comparable entirely new facil-
ity;
(3) The extent to which the compo-
nents being replaced cause or contrib-
ute to the emissions from the facility;
and
(4) Any economic or technical limita-
tions on compliance with applicable
standards of performance which are in-
herent in the proposed replacements.
(g) Individual subparts of this part
may include specific provisions which
refine and delimit the concept of recon-
struction set forth in this section.
[40 FR 58420; Dec. 16.1975]
§60.16 Priority list.
PRIORITIZED MAJOR SOURCE CATEGORIES
Prior-
ity
Num-
ber*
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Source Category
Synthetic Organic Chemical Manufacturing Industry
(SOCMI) and Volatile Organic Liquid Storage Ves-
sels and Handling Equipment
(a) SOCMI unit processes
(b) Volatile organic liquid (VOL) storage vessels and
handling equipment
(c) SOCMI fugitive sources
(d) SOCMI secondary sources
Industrial Surface Coating: Cans
Petroleum Refineries: Fugitive Sources
Industrial Surface Coating: Paper
Dry Cleaning
(a) PereWoroeBiytena
(b) Petroleum solvent
Graphic Artt
Polymer* and Resins: Acrylic Resins
Mtaral Wool (Deleted)
Stationary Internal Combustion Engines
Industrial Surfacs Coating: Fabric
IndustriaK/ommereiaMnstitulional Steam Generating
Units.
Incineration: Non-Municipal (Deleted}
Non-Metattte Mneral Processing
Metallic Mneral Processing
Secondary Copper (Deleted)
Phosphate Rock Preparation
Foundries: Steel and Gray Iron
Polymers and Restns^Polyethyiene
Charcoal Production
Synthetic Rubber
(a) Tire manufacture
(b) SBR production
Vegetable OB
Industrial Surface Coating: Metal Coi
Petroleum Transportation and Marketing
By-Product Coke Ovens
Synthetic Fibers
Plywood Manufacture
Industrial Surface Coating: Automobiles
Industrial Surface Coating: Large Appliances
Crude Oil and Natural Gas Production
Secondary Aluminum
Potash (Deleted)
Lightweight Aggregate Industry: day. Shale, and
Slate*
Glass
Gypsum
Sodium Carbonate
Secondary Zinc (Deleted)
Polymers and Resins: Phenolic
Polymers and Resins: Urea-Metamine
Ammonia (Deleted)
Polymers and Resins: Polystyrene
Polymers and Resins: ABS-SAN Resins
Ffoerglass
Polymers and Resins: Polypropylene
Textile Processing
Asphalt Processing and Asphalt Roofing Manufacture
Brick and Related Clay Products
Ceramic day Manufacturing (Deleted}
Ammonium Nitrate Fertilizer
Castable Refractories (Deleted)
Borax and Boric Add (Deleted)
Polymers and Resins: Polyester Resins
Ammonium Sulfate
-------
§60.17
40 CFR Ch. I (7-1-95 Edition)
PRIORITIZED MAJOR SOURCE CATEGORIES—
Continued
Prior-
ity
Num-
ber*
Source Category
53. Starch
54. PerIHe
55. Phosphoric Add: Thennal Process (Deleted)
56. Uranium Refining
57. Animal Feed Defluorinatlon (Deleted)
58. Urea (for fertilizer and polymers)
59. Detergent (Deleted)
Other Source Categories
Lead add battery manufacture3
Organic solvent cleaning3
Industrial.surface coating: metal furniture3
Stationary gas turbines4
1 Low numbers have highest priority, e.g.. No. 1 b high pri-
ority. No. 59 Is low priority.
a Formerly titled "SMering: Clay and Fly Ash".
3 Minor source category. But Included on list since an NSPS
Is being developed (or that source category.
4 Not prioritized; since an NSPS for this major source cat-
egory has already been promulgated.
[47 FR 951, Jan. 8, 1982, as amended at 47 PR
31876, July 23, 1982; 51 FR 42796, Nov. 25, 1986;
52 FR 11428, Apr. 8.1987]
§ 60.17 Incorporations by reference.
The materials listed below are incor-
porated by reference in the correspond-
ing sections noted. These
incorporations by reference were ap-
proved by the Director of the Federal
Register on the date listed. These, ma-
terials are incorporated as they exist
on the date of the approval, and a no-
tice of any change in these materials
will be published in the FEDERAL REG-
ISTER. The materials are available for
purchase at the corresponding address
noted below, and all are available for
inspection at the Office of the Federal
Register, 800 North Capitol Street,
NW., suite 700, Washington, DC and at
the Library (MD-35), U.S. EPA, Re-
search Triangle Park, NC.
(a) The following materials are avail-
able for purchase from at least one of
the following addresses: American So-
ciety for Testing and Materials
(ASTM), 1916 Race Street, Philadel-
phia, Pennsylvania 19103; or the Uni-
versity Microfilms International, 300
North Zeeb Road, Ann Arbor, MI 48106.
(1) ASTM D388-77, Standard Specification
for Classification of Coals by Rank, incorpo-
ration by reference (IBR) approved for
§§60.41(f); 60.45(f)(4)(i), (ii). (vi); 60.41a; 60.41b;
60.41c; 60.25(b). (c).
(2) ASTM D3178-73. Standard Test Methods
for Carbon and Hydrogen in the Analysis
Sample of Coal and Coke, IBR approved Jan-
uary 27,1983 for §60.45(f)(5)(i).
(3) ASTM D3176-74, Standard Method for
Ultimate Analysis of Coal and Coke, IBR ap-
proved January 27, 1983, for §60.45(f)(5)(i); ap-
pendix A to part 60, Method 19.
(4) ASTM D1137-53 (Reapproved 1975).
Standard Method for Analysis of Natural
Gases and Related Types of Gaseous Mix-
tures by the Mass Spectrometer, IBR ap-
proved January 27,1983 for §60.45(f)(5)(i).
(5) ASTM D1945-64 (Reapproved 1976).
Standard Method for Analysis of Natural Gas
by Gas Chromatography, IBR approved Janu-
ary 27,1983 for §60.45(0(5X1).
(6) ASTM D1946-77, Standard Method for
Analysis of Reformed Gas by Gas Chroma-
tography, IBR approved for §§60.45
-------
Environmental Protection Agency
§6O.J7
(19) ASTM A495-76. Standard Specification
for Calcium-Silicon and Calcium Manganese-
Silicon, IBR approved January 27, 1983 for
§60.261.
(20) ASTM D 1072-80, Standard Method for
Total Sulfur in Fuel Gases, IBR approved
July 31,1984 for §60.335(b)(2).
(21) ASTM D2986-71 (Reapproved 1978).
Standard Method for Evaluation of Air,
Assay Media by the Monodisperse DOP
(Dioctyl Phthalate) Smoke Test, IBR ap-
proved January 27. 1983 for appendix A to
part 60, Method 5, par. 3.1.1; Method 12, par.
4.1.1; Method 17, par. 3.1.1.
(22) ASTM D 1193-77, Standard Specifica-
tion for Reagent Water, for appendix A to
part 60. Method 6, par. 3.1.1; Method 7, par.
3.2.2; Method 7C. par. 3.1.1; Method 7D, par.
3.1.1; Method 8. par. 3.1.3; Method 12, par.
4.1.3; Method 25D, par. 3.2.2.4; Method 26A.
par. 3.1.1.
(23) [Reserved]
(24) ASTM D2234-76. Standard Methods for
Collection of a Gross Sample of Coal, IBR ap-
proved January 27. 1983, for appendix A to
part 60, Method 19.
(25) ASTM D3173-73, Standard Test Method
for Moisture in the Analysis Sample of Coal
and Coke, IBR approved January 27,1983, for
appendix A to part 60, Method 19.
(26) ASTM D3177-75, Standard Test Meth-
ods for Total Sulfur in the Analysis Sample
of Coal and Coke, IBR approved January 27,
1983, for appendix A to part 60. Method 19.
(27) ASTM D2013-72, Standard Method of
Preparing Coal Samples for Analysis. IBR
approved January 27.1983, for appendix A to
part 60. Method 19.
(28) ASTM D270-65 (Reapproved 1975).
Standard Method of Sampling Petroleum
and Petroleum Products, IBR approved Jan-
uary 27,1983, for appendix A to part 60, Meth-
od 19.
(29) ASTM D737-85, Standard Test Method
for Air Permeability of Textile Fabrics, IBR
approved January 27,1983 for §61.23(a).
(30) ASTM D1475-60 (Reapproved 1980),
Standard Test Method for Density of Paint,
Varnish, Lacquer, and Related Products, IBR
approved January 27. 1983 for §60.435(d)(l).
appendix A to part 60, Method 24, par. 2.1,
and Method 24A. par. 2.2.
(31) ASTM D2369-81, Standard Test Method
for Volatile Content of Coatings, IBR ap-
proved January 27, 1983 for appendix A to
part 60, Method 24.
(32) ASTM D3792-79, Standard Method for
Water Content of Water-Reducible Paints by
Direct Injection Into a Gas Chromatograph,
EBR approved January 27,1983 for appendix A
to part 60, Method 24, par. 2.3.
(33) ASTM D4017-S1. Standard Test Method
for Water in Paints and Paint Materials by
the Karl Fischer Titration Method, IBR ap-
proved January 27, 1983 for appendix A to
part 60, Method 24, par. 2.4.
(34) ASTM E169-«3 (Reapproved 1977), Gen-
eral Techniques of Ultraviolet Quantitative
Analysis, IBR approved for 560.485(d),
§60.593(b), and §60.632(f).
(35) ASTM E168-67 (Reapproved 1977). Gen-
eral Techniques of Infrared Quantitative
Analysis, IBR approved for §60.485(d),
§60.593(b), and §60.632(0.
(36) ASTM E260-73, General Gas Chroma-
tography Procedures, IBR approved for
§60.485(d), §60.59305), and §60.632(f).
(37) ASTM D2879-83, Test Method for Vapor
Pressure—Temperature Relationship and Ini-
tial Decomposition Temperature of Liquids
by Isoteniscope, IBR approved April 8. 1987
for S§60.485(e). 60.1111X0(3), 60.116b(e)(3Xii).
and60.116b(fX2)(i).
(38) ASTM D2382-76, Heat of Combustion of
Hydrocarbon Fuels by Bomb Calorimeter
[High-Precision Method], IBR approved for
«60.18(f), 60.485(fir). 60.614(d)(4). 60.66«dX4),
and 60.564(f). and 60.704(dX4).
(39) ASTM D2504-67 (Reapproved 1977),
Nonoondensable Gases in Q» and Lighter Hy-
drocarbon Products by Gas Chromatography,
IBR approved for f 60.485(g).
(40) ASTM D86-78. Distillation of Petro-
leum Products, EBR approved for §60.593(d).
|60.633(h), and §60.562-2(d).
(41) [Reserved]
(42) ASTM D 3031-81, Standard Test Method
for Total Sulfur in Natural Gas by Hydro-
genation, IBR approved July 31, 1984 for
§60.335(bX2).
(43) ASTM D 4084-82, Standard Method for
Analysis of Hydrogen Sulflde in Gaseous
Fuels (Lead Acetate Reaction Rate Method).
IBR approved July 31,1984 for §60.335(b)(2).
(44) ASTM D 3246-81. Standard Method for
Sulfur ,in Petroleum Gas by Oxi dative
Microcoulometry, EBR approved July 31.1984
for§60.335(b)(2).
(45) ASTM D2584-68. Standard Test Method
for Ignition Loss of Cured Reinforced Resins,
EBR-approved February 25, 1985 for §60.685(e).
(46) ASTM D3431-80. Standard Test Method
for Trace Nitrogen in Liquid Petroleum Hy-
drocarbons (Microcoulometric Method), EBR
approved November 25. 1986. for appendix A
to part 60, Method 19.
(47) ASTM D129-64 (reapproved 1978).
Standard Test Method for Sulfur in Petro-
leum Products (General Bomb Method), EBR
approved for appendix A to part 60, Method
19.
(48) ASTM D1552-83. Standard Test Method
for Sulfur in Petroleum Products (High Tem-
perature Method), EBR approved for appendix
A to part 60, Method 19.
(49) ASTM D1835-86, Standard Specification
for Liquefied Petroleum (LP) Gases, to be
approved for §60.41b.
(50) ASTM D1835-S6, Standard Specification
for Liquefied Petroleum (LP) Gases, EBR ap-
proved for §§60.41b; 60.41c.
(51) ASTM D4057-81, Standard Practice for
Manual Sampling of Petroleum and Petro-
-------
§60.17
40 CFR Ch. I (7-1-95 Edition)
leum Products, IBR approved for appendix A
to part 60, Method 19.
(52) ASTM D4239-85, Standard Test Meth-
ods for Sulfur in the Analysis Sample of Coal
and Coke Using High Temperature Tube Fur-
nace Combustion Methods, IBR approved for
appendix A to part 60, Method 19.
(53) ASTM D2016-74 (Reapproved 1983).
Standard Test Methods for Moisture Content
of Wood * * * for appendix A, Method 28.
(54) ASTM D4442-84, Standard Test Meth-
ods for Direct Moisture Content Measure-
ment in Wood and Wood-base
Materials * * * for appendix A, Method 28.
(55) [Reserved)
(56) ASTM D129-64 (Reapproved 1978).
Standard Test Method for Sulfur in Petro-
leum Products (General Bomb Method). IBR
approved August 17.1989. for §60.106(J)(2).
(67) ASTM D1552-83, Standard Test Method
for Sulfur In Petroleum Products (High-Tem-
perature Method). IBR approved August 17.
1989. for §60.106(j)(2).
(58) ASTM D2622-87. Standard Test Method
for Sulfur In Petroleum Products by X-Ray
Spectrometry, IBR approved August 17.1989,
for§60.106(J)(2>
(69) ASTM D1266-87. Standard Test Method
for Sulfur In Petroleum Products (Lamp
Method). IBR approved August 17, 1989. for
I60.106UX2).
(60) ASTM D2908-74. Standard Practice for
Measuring Volatile Organic Matter in Water
by Aqueous-Injection Gas Chromatography,
IBR approved for §60.564(J).
(61) ASTM D3370-76. Standard Practices for
Sampling Water. IBR approved for §60.564(j).
(62) ASTM D4457-85 Test Method for Deter-
mination of Dlchloromethane and 1,1,1-
Trlohloroethane in Paints and Coatings by
Direct Injection into a Gas Chromatograph,
IBR approved for appendix A, Method 24.
(b) The following material is avail-
able for purchase from the Association
of Official Analytical Chemists. 1111
North 19th Street, Suite 210, Arlington,
VA 22209.
(1) AOAC Method 9. Official Methods of
Analysis of the Association of Official Ana-
lytical Chemists, llth edition, 1970. pp. 11-12,
XBR approved January 27. 1983 for
iS60.204(d)(2), 60.214(d)(2), 60.224(d)(2),
60.234(dX2). 60.244(0(2).
(c) The following material is avail-
able for purchase from the American
Petroleum Institute, 1220 L Street NW.,
Washington, DC 20005.
(1) API Publication 2517, Evaporation Loss
from External Floating Roof Tanks, Second
Edition, February 1980, IBR approved Janu-
ary 27, 1983. for §§60.111(i), 60.111a(f),
60.111a(f)(l) and 60.116b(e)(2)(i).
(d) The following material is avail-
able for purchase from the Technical
Association of the Pulp and Paper In-
dustry (TAPPI), Dunwoody Park, At-
lanta, GA 30341.
(1) TAPPI Method T624 03-68, IBR approved
January 27,1983 for §60.285(d)(4).
(e) The following material is avail-
able for purchase from the Water Pol-
lution Control Federation (WPCF), 2626
Pennsylvania Avenue NW., Washing-
ton, DC 20037.
(1) Method 209A, Total Residue Dried at
103-105 °C, in Standard Methods for the Exam-
ination of Water and Wastewater, 15th Edition,
1980, IBR approved February 25, 1985 for
|60.683(b).
(f) The following material is avail-
able for purchase from the following
address: Underwriter's Laboratories,
Inc. (UL), 333 Pfingsten Road, North-
brook, IL 60062.
(1) UL 103. Sixth Edition revised as of Sep-
tember 3. 1986, Standard for Chimneys, Fac-
tory-built, Residential Type and Building
Heating Appliance.
(g) The following material is avail-
able for purchase from the following
address: West Coast Lumber Inspection
Bureau, 6980 SW. Barnes Road, Port-
land, OR 97223.
(1) West Coast Lumber Standard Grading
Rules No. 16, pages 5-21 and 90 and 91, Sep-
tember 3.1970, revised 1984.
(h) The following material is avail-
able for purchase from the American
Society of Mechanical Engineers
(ASME), 345 East 47th Street. New
York, NY 10017.
(1) ASME QRO-1-1989. Standard for
the Qualification and Certification of
Resource Recovery Facility Operators.
IBR Approved for §60.56a.
(2) ASME PTC 4.1. Power Test Codes:
Test Code for Steam Generating Units
(1972). D3R Approved for §§60.46b and
60.58a(h).
(3) ASME Interim Supplement 19.5 on
Instruments and Apparatus; Applica-
tion. Part H of Fluid Meters, 6th Edi-
tion (1971). IBR Approved for §60.58a(h).
[48 FR 3735, Jan. 27,1983]
EDITORIAL NOTE: For FEDERAL REGISTER ci-
tations affecting §60.17, see the List of CFR
Sections Affected in the Finding Aids sec-
tion of this volume.
-------
Environmental Protection Agency
§60.18
§60.18 General control device require-
ments.
(a) Introduction. This section contains
requirements for control devices vised
to comply with applicable subparts of
parts 60 and 61. The requirements are
placed here for administrative conven-
ience and only apply to facilities cov-
ered by subparts referring: to this sec-
tion.
(b) Flares. Paragraphs (c) through (f)
apply to flares.
(c)(l) Flares shall be designed for and
operated with no visible emissions as
determined by the methods specified in
paragraph (f). except for periods not to
exceed a total of 5 minutes during any
2 consecutive hours.
(2) Flares shall be operated with a
flame present at all times, as deter-
mined by the methods specified in
paragraph (f).
(3) Flares shall be used only with the
net heating value of the gas being com-
busted being 11.2 MJ/scm (300 Btu/scf)
or greater if the flare is steam-assisted
or air-assisted; or with the net heating
value of the gas being combusted being
7.45 MJ/scm (200 Btu/scf) or greater if
the flare is nonassisted. The net heat-
ing value of the gas being combusted
shall be determined by the methods
specified in paragraph (f).
(4)(i) Steam-assisted and nonassisted
flares shall be designed for and oper-
ated with an exit velocity, as deter-
mined by the methods specified in
paragraph (f)(4), less than 18.3 m/sec (60
ft/sec), except as provided in para-
graphs (b)(4) (ii) and (iii).
(ii) Steam-assisted and nonassisted
flares designed for and operated with
an exit velocity, as determined by the
methods specified in paragraph (f)(4),
equal to or greater than 18.3 m/sec (60
ft/sec) but less than 122 m/sec (400 ft/
sec) are allowed if the net heating
value of the gas being combusted is
greater than 37.3 MJ/scm (1,000 Btu/scf).
(iii) Steam-assisted and nonassisted
flares designed for and operated with
an exit velocity, as determined by the
methods specified in paragraph (f)(4),
less than the velocity, Vm«, as deter-
mined by the method specified in para-
graph (f)(5), and less than 122 m/sec (400
ft/sec) axe allowed.
(5) Air-assisted flares shall be de-
signed and operated with an exit veloc-
ity less than the velocity, Vn««, as de-
termined by the method specified in
paragraph (f)(6).
(6) Flares used to comply with this
section shall be steam-assisted, air-as-
sisted, or nonassisted.
(d) Owners or operators of flares used
to comply with the provisions of this
subpart shall monitor these control de-
vices to ensure that they are operated
and maintained in conformance with
their designs. Applicable subparts will
provide provisions stating how owners
or operators of flares shall monitor
these control devices.
(e) Flares used to comply with provi-
sions of this subpart shall be operated
at all times when emissions may be
vented to them.
(f)(D Reference Method 22 shall be
used to determine the compliance of
flares with the visible emission provi-
sions of this subpart. The observation
period is 2 hours and shall be used ac-
cording to Method 22.
(2) The presence of a flare pilot flame
shall be monitored using a thermo-
couple or any other equivalent device
to detect the presence of a flame.
(3) The net heating value of the gas
being combusted in a flare shall be cal-
culated using the following equation:
n
£
1-1
C1H1
where:
Hr=Net heating: value of the sample, MJ/scm;
where the net enthalpy per mole of offgas
is based on combustion at 25 °C and 760
mm H?, but the standard temperature
for determining: the volume correspond-
ing: to one mole is 20 °C;
-------
§60.19
40 CFR Ch. I (7-1-95 Edition)
K = Constant, 7
•\ tAe\ „ in"
/g mo1e\ / MJ
1 scm ' v
where the standard temperature for /g mo1e\ Is 20°C;
* cr-m •
scm
CpConcentration of sample component 1 in
ppm on a wet basis, as measured for
organics by Reference Method 18 and
measured for hydrogen and carbon mon-
oxide by ASTM D1946-77 (Incorporated by
reference as specified in §60.17); and
Hi=Net heat of combustion of sample compo-
nent i, kcal/g mole at 25 *C and 760 mm
Her. The heats of combustion may be de-
termined using ASTM D2382-76 (incor-
porated by reference as specified in
§60.17) if published values are not avail-
able or cannot be calculated.
(4) The actual exit velocity of a flare
shall be determined by dividing the
volumetric flowrate (in units of stand-
ard temperature and pressure), as de-
termined by Reference Methods 2, 2A,
2C, or 2D as appropriate; by the unob-
structed (free) cross sectional area of
the flare tip.
(6) The maximum permitted velocity,
Vm»x, for flares complying with para-
graph (c)(4)(iii) shall be determined by
the following equation.
lK>gio (Vra»)=(H,H-28.8)/31.7
V»ux=Maximum permitted velocity, M/sec
28.8=Constant
31.7=Constant
HT=The net heating value as determined in
paragraph (f)(3).
(6) The maximum permitted velocity,
Vmaxi for air-assisted flares shall be de-
termined by the following equation.
Vnu«=8.706+0.7084 (HT)
Vm«=Maximuni permitted velocity, m/sec
8.706=Constant
0.7084=Constant
Hi=The net heating value as determined in
paragraph (f)(3).
[61 PR 2701, Jan. 21,1986]
§60.19 General notification and re-
porting requirements.
(a) For the purposes of this part,
time periods specified in days shall be
measured in calendar days, even if the
word "calendar" is absent, unless oth-
erwise specified in an applicable re-
quirement.
(b) For the purposes of this part, if an
explicit postmark deadline is not speci-
fied in an applicable requirement for
the submittal of a notification, appli-
cation, report, or other written com-
munication to the Administrator, the
owner or operator shall postmark the
submittal on or before the number of
days specified in the applicable re-
quirement. For example, if a notifica-
tion must be submitted 15 days before
a particular event is scheduled to take
place, the notification shall be post-
marked on or before 15 days preceding
the event; likewise, if a notification
must be submitted 15 days after a par-
ticular event takes place, the notifica-
tion shall be delivered or postmarked
on or before 15 days following the end
of the event. The use of reliable non-
Government mail carriers that provide
indications of verifiable delivery of in-
formation required to be submitted to
the Administrator, similar to the post-
mark provided by the U.S. Postal Serv-
ice, or alternative means of delivery
agreed to by the permitting authority,
is acceptable.
(c) Notwithstanding time periods or
postmark deadlines specified in this
part for the submittal of information
to the Administrator by an owner or
operator, or the review of such infor-
mation by the Administrator, such
time periods or deadlines may be
changed by mutual agreement between
the owner or operator and the Adminis-
trator. Procedures governing the im-
plementation of this provision are
specified in paragraph (f) of this sec-
tion.
(d) If an owner or operator of an af-
fected facility in a State with dele-
gated authority is required to submit
periodic reports under this part to the
State, and if the State has an estab-
lished timeline for the submission of
-------
Environmental Protection Agency
§60.21
periodic reports that is consistent with
the reporting frequency(ies) specified
for such facility under this part, the
owner or operator may change the
dates by which periodic reports under
this part shall be submitted (without
changing the frequency of reporting) to
be consistent with the State's schedule
by mutual agreement between the
owner or operator and the State. The
allowance in the previous sentence ap-
plies in each State beginning 1 year
after the affected facility is required to
be in compliance with the applicable
subpart in this part. Procedures gov-
erning the implementation of this pro-
vision are specified in paragraph (f) of
this section.
(e) If an owner or operator supervises
one or more stationary sources affected
by standards set under this part and
standards set under part 61, part 63, or
both such parts of this chapter, he/she
may arrange by mutual agreement be-
tween the owner or operator and the
Administrator (or the State with an
approved permit program) a common
schedule on which periodic reports re-
quired by each applicable standard
shall be submitted throughout the
year. The allowance in the previous
sentence applies in each State begin-
ning 1 year after the stationary source
is required to be in compliance with
the applicable subpart in this part, or 1
year after the stationary source is re-
quired to be in compliance with the ap-
plicable 40 CPR part 61 or part 63 of
this chapter standard, whichever is lat-
est. Procedures governing the imple-
mentation of this provision are speci-
fied in paragraph (f) of this section.
(f)(l)(i) Until an adjustment of a time
period or postmark deadline has been
approved by the Administrator under
paragraphs (f)(2) and (f)(3) of this sec-
tion, the owner or operator of an af-
fected facility remains strictly subject
to the requirements of this part.
(ii) An owner or operator shall re-
quest the adjustment provided for in
paragraphs (f)(2) and (f)(3) of this sec-
tion each time he or she wishes to
change an applicable time period or
postmark deadline specified in this
part.
(2) Notwithstanding time periods or
postmark deadlines specified in this
part for the submittal of information
to the Administrator by an owner or
operator, or the review of such infor-
mation by the Administrator, such
time periods or deadlines may be
changed by mutual agreement between
the owner or operator and the Adminis-
trator. An owner or operator who wish-
es to request a change in a time period
or postmark deadline for a particular
requirement shall request the adjust-
ment in writing as soon as practicable
before the subject activity is required
to take place. The owner or operator
shall include in the request whatever
information he or she considers useful
to convince the Administrator that an
adjustment is warranted.
(3) If, in the Administrator's judg-
ment, an owner or operator's request
for an adjustment to a particular time
period or postmark deadline is war-
ranted, the Administrator will approve
the adjustment. The Administrator
will notify the owner or operator in
writing of approval or disapproval of
the request for an adjustment within 15
calendar days of receiving sufficient in-
formation to evaluate the request.
(4) If the Administrator is unable to
meet a specified deadline, he or she
will notify the owner or operator of
any significant delay and inform the
owner or operator of the amended
schedule.
[59 PR 12428, Max. 16.1994]
-------
-------
APPENDIX C
EPA METHOD 9 - VISUAL DETERMINATION OF
EMISSIONS FROM STATIONARY SOURCES
C-1
-------
40 CFR Ch. I (7-1-95 Edition)
METHOD 9—VISUAL DETERMINATION OP THE
OPACITY OF EMISSIONS FROM STATIONARY
SOURCES
Many stationary sources discharge visible
emissions into the atmosphere; these emis-
sions are usually in the shape of a plume.
This method involves the determination of
plume opacity by qualified observers. The
method includes procedures for the training
and certification of observers, and proce-
dures to be used in the field for determina-
tion of plume opacity. The appearance of a
plume as viewed by an observer depends upon
a number of variables, some of which may be
controllable and some of which may not be
controllable in the field. Variables which can
be controlled to an extent to which they no
longer exert a significant influence upon
plume appearance include; Angle of the ob-
server with respect to the plume; angle of
the observer with respect to the sun; point of
observation of attached and detached steam
plume; and angle of the observer with re-
spect to a plume emitted from a rectangrular
stack with a large lengtn to width ratio. The
method includes specific criteria applicable
to these variables.
Other variables which may not be control-
lable in the field are luminescence and color
contrast between the plume and the back-
ground against which the plume is viewed.
These variables exert an influence upon the
appearance of a plume as viewed by an ob-
server, and can affect the ability of the ob-
server to accurately assign opacity values to
the observed plume. Studies of the theory of
plume opacity and field studies have dem-
onstrated that a plume is most visible and
presents the greatest apparent opacity when
viewed against a contrasting background. It
follows from this, and is confirmed by field
trials, that the opacity of a plume, viewed
under conditions where a contrasting back-
ground is present can be assigned with the
greatest degree of accuracy. However, the
potential for a positive error is also the
greatest when a plume is viewed under such
contrasting conditions. Under conditions
presenting a less contrasting background.
the apparent opacity of a plume is less and
approaches zero as the color and lumines-.
cence contrast decrease toward zero. As a re-
sult, significant negative bias and negative
errors can be made when a plume is viewed
under less contrasting conditions. A negative
bias decreases rather than increases the pos-
sibility that a plant operator will be cited
for a violation of opacity standards due to
observer error.
Studies have been undertaken to deter-
mine the magnitude of positive errors which
can be made by qualified observers while
reading plumes under contrasting conditions
-------
Environmental Protection Agency
Pt. 60, App. A, Mefh. 9
and using the procedures set forth in this
method. The results of these studies (field
trials) which involve a total of 769 sets of 25
readings each are as follows:
(1) For black plumes (133 sets at a smoke
generator), 100 percent of the sets were read
with a positive error1 of less than 7.5 percent
opacity; 99 percent were read with a positive
error of less than 5 percent opacity.
(2) For white plumes (170 sets at a smoke
generator, 168 sets at a coal-fired power
plant, 298 sets'at a sulfuric acid plant), 99
percent of the sets were read with a positive
error of less than 7.5 percent opacity; 95 'per-
cent were read with a positive error of less
than 5 percent opacity.
The positive observational error associated
with an average of twenty-five' readings is
therefore established. The accuracy of the
method .must be taken into account when de-
termining possible violations of applicable
opacity standards.
1. Principle ana Applicability
1.1 Principle. The opacity of emissions
from stationary sources is determined .vis-
ually by a qualified observer.
1.2 Applicability. This method is applicable
for the determination'of the opacity of emis-
sions from, stationary sources pursuant to
§60.11(b) and for qualifying observers for vis-
ually determining opacity of emissions.
2. Procedures
The observer qualified in accordance with
section 3 of this method shall use the follow-
ing procedures for visually determining the
opacity of emissions:
2.1 Position. The qualified observer shall
stand at a distance sufficient to provide a
clear view of the emissions with the sun ori-
ented in the 140° sector to his back. Consist-
ent with maintaining the above requirement,
the observer shall, as much as possible, make
his observations from a position such that
his line of vision is approximately per-
pendicular to the plume direction, and when
observing opacity of emissions from rectan-
gular outlets (e.g., roof monitors, open
baghouses, noncircular stacks), approxi-
mately perpendicular- to the longer axis of
the : outlet. The observer's line of sight
should not include more than one plume at a
time when multiple stacks are involved, and
in any case the observer should make his ob-
servations with his line of sight perpendicu-
lar to the longer axis of such a set of mul-
tiple stacks (e.g., stub stacks on baghouses).
2.2 Field Records. The observer shall record
the name of the plant, emission location,
type facility, observer's name and affili-
ation, a sketch of the observer's position rel-
1 For a set, positive error = average opacity
determined by observers' 25 observations—
average opacity determined from transmls-
someter's 25 recordings.
ative to the source, and the date on a field
data sheet (Figure 9-1). The time, estimated
distance to the emission location, approxi-
mate wind direction, estimated wind speed,
description of the sky condition (presence
and color of clouds), and plume background
are recorded on a field data sheet at the time
opacity readings are initiated and com-
pleted.
2.3 Observations. Opacity observations
shall be made at the point of greatest opac-
ity in that portion of the plume where con-
densed water vapor is not present. The ob-
server shall not look continuously at the
plume, but instead shall-observe the plume
momentarily at 15-second intervals.
2.3.1 Attached Steam Plumes. When con-
densed water vapor is present within the
plume as it emerges from the emission out-
let, opacity observations shall be made be-
yond the point in the plume at which con-
densed water vapor is no longer visible. The
observer shall'record the approximate dis-
tance from the emission outlet to the point
in the plume at which the observations are
made.
2.3.2 Detached Steam Plume. When water
vapor in the plume condenses and becomes
visible at a distinct distance from the emis-
sion outlet, the opacity of emissions should
be evaluated at the emission outlet prior to
the condensation of water vapor and the for-
mation of the steam plume.
2.4 Recording Observations. Opacity obser-
vations shall be recorded to the nearest 5
percent at 15-second intervals on an observa-
tional record sheet. (See Figure 9-2 for an ex-
ample.) A minimum of 24 observations shall
be recorded. Each momentary observation
recorded shall be deemed to represent the av-
erage opacity of emissions for a 15-second pe-
riod.
2.5 Data Reduction. Opacity shall be deter-
mined as ah average of 24 consecutive obser-
vations recorded at 15-second intervals. Di-
vide the observations recorded on the record
sheet into sets of 24 consecutive observa-
tions. A set is composed of any 24 consecu-
tive observations. Sets need not be consecu-
tive in time and in no case shall two sets
overlap. For each set of 24 observations, cal-
culate the average by summing the opacity
of the 24 observations-and dividing this sum
by 24. If an applicable standard specifies an
averaging time requiring more than 24 obser-
vations, calculate the average for all obser-
vations made during the specified time pe-
riod. Record the average opacity on a record
sheet. (See Figure 9-1 for an example.)
3. Qualifications and Testing
3.1 Certification Requirements. To receive
certification as a qualified observer, a can-
didate must be tested and demonstrate the
ability to assign opacity readings in 5 per-
cent increments to 25 different black plumes
and 25 different white plumes, with an error
-------
Pt. 60, App. A, Math. 9
40 CFR Ch. I (7-1-95 Edition)
not to exceed 15 percent opacity on any one
reading and an average error not to exceed
7.6 percent opacity in each category. Can-
didates snail be tested according to the pro-
cedures described in section 3.2. Smoke gen-
erators used pursuant to section 3.2 shall be
equipped with a smoke meter which meets
the requirements of section 3.3.
The certification shall be valid for a period
of 6 months, at which time the qualification
procedure must be repeated by any observer
in order to retain certification.
3.2 Certification Procedure. The certifi-
cation test consists of showing the candidate
a complete run of 50 plumes—25 black plumes
and 25 white plumes—generated by a smoke
generator. Plumes within each set of 25
black and 25 white runs shall be presented in
random order. The candidate assigns an
opacity value to each plume and records his
observation on a suitable form. At the com-
pletion of each run of 50 readings, the score
of the candidate is determined. If a can-
didate fails to qualify, the complete run of 50
readings must be repeated in any retest. The
smoke test may be administered as part of a
smoke school or training program, and may
be preceded by training or familiarization
runs of the smoke generator during which
candidates are shown black and white
plumes of known opacity.
3.3 Smoke Generator Specifications. Any
smoke generator used for the purposes of
section 3.2 shall be equipped with a smoke
meter installed to measure opacity across
the diameter of the smoke generator stack.
The smoke meter output shall display
instaok opacity based upon a pathlength
equal to the stack exit diameter, on a full 0
to 100 percent chart recorder scale. The
smoke meter optical design and performance
shall meet the specifications shown in Table
9-1. The smoke meter shall be calibrated as
prescribed in section 3.3.1 prior to the con-
duct of each smoke reading test. At the com-
pletion of each test, the zero and span drift
shall be checked and if the drift exceeds ±1
percent opacity, the condition shall be cor-
rected prior to conducting any subsequent
test runs. The smoke meter shall be dem-
onstrated, at the time of Installation, to
meet the specifications listed in Table 9-1.
This demonstration shall be repeated follow-
ing any subsequent repair or replacement of
the photocell or associated electronic cir-
cuitry including the chart recorder or output
meter, or every 6 months, whichever occurs
first.
TABLE 9-1—SMOKE METER DESIGN AND
PERFORMANCE SPECIFICATIONS
Parameter
a. Light source
b. Spectral response of
photocell
c. Angle of view ........—
d. Angle of projection _„
e. Cafibratton error
f. Zero and span drift _..
g. Response time
Specification
Incandescent lamp operated at
nominal rated voltage.
Photopto {daylight spectral re-
sponse of the human eye—Ci-
tation 3).
15* maximum total angle.
15* maximum total angle.
±3% ooacity, maximum.
±1% opacity, 30 minutes
5 seconds.
3.3.1 Calibration. The smoke meter is cali-
brated after allowing a minimum of 30 min-
utes warmup by alternately producing simu-
lated opacity of 0 percent and 100 percent.
When stable response at 0 percent or 100 per-
cent is noted, the smoke meter is adjusted to
produce an output of 0 percent or 100 per-
cent, as appropriate. This calibration shall
be repeated until stable 0 percent and 100
percent readings are produced without ad-
justment. Simulated 0 percent and 100 per-
cent opacity values may be produced by al-
ternately switching the power to the light
source on and off while the smoke generator
is not producing smoke.
3.3.2 Smoke Meter Evaluation. The smoke
meter design and performance are to be eval-
uated as follows:
3.3.2.1 Light Source. Verify from manufac-
turer's data and from voltage measurements
made at the lamp, as installed, that the lamp
is operated within ±5 percent of the nominal
rated voltage.
3.3.2.2 Spectral Response of Photocell. Ver-
ify from manufacturer's data that the photo-
cell has a photopic response; i.e., the spectral
sensitivity of the cell shall closely approxi-
mate the standard spectral-luminosity curve
for photopic vision which is referenced in (b)
of Table 9-1.
-------
Environmental Protection Agency
Pf. 60, App. A, Mofh. 9
^
t
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CERTIFICATION DATE
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-------
Pt. 60, App. A, Meth. 9
40 CFR Ch. I (7-1-95 Edition)
Company
Location...—
Test Number
Date.
FIGURE 9-2—OBSERVATION RECORD
Page of.
Observer
Type facility
Point of emissions
Hf.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Seconds
0
15
30
45
Steam plume (check if applicable)
Attached
Detached
Comments
-------
Environmental Protection Agency
Pt. 60, App. A, M&th. 9
Company
Location
Test Number
Date.
FIGURE 9-2—OBSERVATION RECORD—(CONTINUED)
Page of
Observer :.
Type facility
Point of emissions
Hr.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Seconds
0
15
30
45
Steam plume (check if applicable)
Attached
Detached :
•
•
••
Comments
-------
Pt. 60, App. A, Aft. Meth.
40 CFR Ch. I (7-1-95 Edition)
3.3.2.3 Angle of View. Check construction
geometry to ensure that the total angle of
view of the smoke plume, as seen by the pho-
tocell, does not exceed 15°. The total angle of
view may be calculated from: 9=2 tan- 1d/2L,
where 6=total angle of view; d=the sum of
the photocell diameter+the diameter of the
limiting1 aperture; and L=the distance from
the photocell to the limiting aperture. The
limiting aperture is the point in the path be-
tween the photocell and the smoke plume
where the angle of view is most restricted. In
smoke generator smoke meters this is nor-
mally an orifice plate.
3.3.2.4 Angle*of Projection. Check construc-
tion geometry to ensure that the total angle
of projection of the lamp on the smoke
plume does not exceed 15°. The total angle of
projection may be calculated from: 6=2
tan-Jd/2Ij, where 6= total angle of projec-
tion; d= the sum of the length of the lamp
filament + the diameter of the limiting aper-
ture; and L= the distance from the lamp to
the limiting aperture.
3.3.2.5 Calibration Error. Using neutral-
density filters of known opacity, check the
error between the actual response and the
theoretical linear response of the smoke
meter. This check is accomplished by first
calibrating the smoke meter according to
3.3.1 and then inserting a series of three neu-
tral-density filters of nominal opacity of 20,
60, and 75 percent in the smoke meter
pathlength. Filters calibrated within ±2 per-
cent shall be used. Care should be taken
when inserting the filters to prevent stray
light-from affecting the meter. Make a total
of live nonconsecutive readings for each fil-
ter. The maximum error on any one reading
shall be 3 percent opacity.
3.3.2.6 Zero and Span Drift. Determine the
zero and span drift by calibrating and oper-
ating the smoke generator in a normal man-
ner over a 1-hour period. The drift is meas-
ured by checking the zero and span at the
end of this period.
3.3.2.7 Response Time. Determine the re-
sponse time by producing the series of five
simulated 0 percent and 100 percent opacity
values and observing the time required to
reach stable response. Opacity values of 0
percent and 100 percent may be simulated by
alternately switching the power to the light
source off and on while the smoke generator
is not operating.
4. Bibliography.
1. Air Pollution Control. District Rules and
Regulations, Los Angeles County Air Pollu-
tion Control District, Regulation IV, Prohi-
bitions, Rule 50.
2. Weisburd, Melvin L, Field Operations
and Enforcement Manual for Air, U.S. Envi-
ronmental Protection Agency, Research Tri-
angle Park, NC. APTD-1100, August 1972, pp.
4.1-4.38.
3. Condon, E.U., and Odishaw, H., Hand-
book of Physics, McGraw-Hill Co., New York,
NY, 1958, Table 3.1, p. 6-52.
-------
APPENDIX D
EPA METHOD 22 - VISUAL DETERMINATION OF FUGITIVE
EMISSIONS FROM MATERIAL SOURCES AND SMOKE
EMISSIONS FROM FLARES
D-1
-------
40 CFR Ch. I (7-1-95 Edition)
METHOD 22—VISUAL DETERMINATION OF FUGI-
TIVE EMISSIONS FROM MATERIAL SOURCES
AMD SMOKE EMISSIONS FROM FLARES
1. Introduction
This method involves the visual deter-
mination of fugitive emissions, i.e.. emis-
sions not emitted directly from a process
stack or duct. Fugitive emissions include
emissions that (1) escape capture by process
equipment exhaust hoods; (2) are emitted
during material transfer; (3) are emitted
from buildings housing material processing
or handling equipment; and (4) are emitted
directly from process equipment. This meth-
od Is used also to determine visible smoke
emissions from flares used for combustion of
waste process materials.
This method determines the amount of
time that any visible emissions occur during
the observation period, i.e., the accumulated
emission time. This method does not require
that the opacity of emissions be determined.
Since this procedure requires only the deter-
mination of whether a visible emission oc-
curs and does not require the determination
of opacity levels, observer certification ac-
cording to the procedures of Method 9 are
not required. However, it is necessary that
the observer is educated on the general pro-
cedures for determining the presence of visi-
ble emissions. As a minimum, the observer
must be trained and knowledgeable regard-
ing the effects on the visibility of emissions
caused by background contrast, ambient
lighting, observer position relative to light-
ing, wind, and the presence of uncombined
water (condensing water vapor). This train-
Ing is to be obtained from written materials
found in Citations 1 and 2 of Bibliography or
from the lecture portion of the Method 9 cer-
tification course.
2. Applicability and Principle
2.1 Applicability. This method applies to
the determination of the frequency of fugi-
tive emissions from stationary sources (lo-
cated indoors or outdoors) when specified as
the test method for determining compliance
with new source performance standards.
This method also is applicable for the de-
termination of the frequency of visible
smoke emissions from flares.
2.2 Principle. Fugitive emissions produced
during material processing, handling, and
transfer operations or smoke emissions from
.flares are visually determined by an observer
without the aid of instruments.
3. Definitions
3.1 Emission Frequency. Percentage of
time that emissions are visible during the
observation period.
3.2 Emission Time. Accumulated amount
of time that emissions are visible during the
observation period.
3.3 Fugitive Emissions. Pollutant gen-
erated by an affected facility which is not-
collected by a capture system and is released
to the atmosphere.
3.4 Smoke Emissions. Pollutant generated
by combustion in a flare and occurring im-
mediately downstream of the flame. Smoke
occurring within the flame, but not down-
stream of the flame, is not considered a
smoke emission.
3.5 Observation Period. Accumulated time
period during which observations are con-
ducted, not to be less than the period speci-
fied in the applicable regulation.
4. Equipment
4.1 Stopwatches. Accumulative type with
unit divisions of at least 0.5 seconds; two re-
quired.
4.2 Light Meter. Light meter capable of
measuring illuminance in the 50- to 200-lux
range; required for indoor observations only.
5. Procedure
5.1 Position. Survey the affected facility
or building or structure housing the process
to be observed and determine the locations
of potential emissions.. If the affected facil-
ity is located inside a building, determine an
observation location that is consistent with
the requirements of the applicable regula-
tion (i.e., outside observation of emissions
escaping the building/structure or inside ob-
servation of emissions directly emitted from
the affected facility process unit). Then se-
lect a position that enables a clear view of
the potential emission point(s) of the af-
fected facility or of the building or structure
housing the affected facility, as appropriate
for the applicable subpart. A position at
least 15 feet, but not more than 0.25 miles,
from the emission source is recomme'hded.
For outdoor locations, select a position
-------
Environmental Protection Agency
Ph 60, App. A. Moth. 22
where the sun is not directly in the observ-
er's eyes.
5.2 Field Records.
5.2.1 Outdoor Location. Record the follow-
ing- information on the field data sheet (Fig-
ure 22-1): company name, industry, process
unit, observer's name, observer's affiliation,
and date. Record also the estimated wind
speed, wind direction, and sky condition.
Sketch the process unit being observed and
note the observer location relative to the
source and the sun. Indicate the potential
and actual emission points on the sketch.
5.2.2 Indoor Location. Record the follow-
ing information on the field data sheet (Fig-
ure 22-2): company name, industry, process
unit, observer's name, observer's affiliation,
and date. Record as appropriate the type, lo-
cation, and intensity of lighting on the data
sheet. Sketch the process unit being ob-
served and note observer location relative to
the source. Indicate the potential and actual
fugitive emission points on the sketch.
5.3 Indoor Lighting Requirements. For in-
door locations, use a light meter to measure
the level of Illumination at a location as
close to the emission source(s) as is feasible.
An illumination of greater than 100 lux (10
foot candles) is considered necessary for
proper application of this method.
5.4 Observations. Record the clock time
when observations begin. Use one stopwatch
to monitor the duration of the observation
period; start this stopwatch when the obser-
vation period begins. If the observation pe-
riod is divided into two or more segments by
process shutdowns or observer rest breaks,
stop the stopwatch when a break begins and
restart it without resetting when the break
ends. Stop the stopwatch at the end of the
observation period. The accumulated time
indicated by this stopwatch is the duration
of the observation period. When the observa-
tion period is completed, record the clock
time.
During the observation period, continously
watch the emission source. Upon observing
an emission (condensed water vapor is not
considered an emission), start the second ac-
cumulative stopwatch; stop the watch when
the emission stops. Continue this procedure
for the entire observation period. The accu-
mulated elapsed time on this stopwatch is
the total time emissions were visible during
the observation period, i.e., the emission
time.
5.4.1 Observation Period. Choose an obser-
vation period of sufficient length to meet the
requirements for determining compliance
with the emission regulation in the applica-
ble subpart. When the length of the observa-
tion period is specifically stated in the appli-
cable subpart, it may not be necessary to ob-
serve the source for this entire period if the
emission time required to indicate non-
compliance (based on the specified observa-
tion period) is observed in a shorter time pe-
riod. In other words, if the regulation pro-
hibits emissions for more than 6 minutes in
any hour, 'then observations may (optional)
be stopped after an emission time of 6 min-
utes is exceeded. Similarly, when the regula-
tion is expressed as an emission frequency
and the regulation prohibits emissions for
greater than 10 percent of the time in any
hour, then observations may (optional) be
terminated after 6 minutes of emissions are
observed since 6 minutes is 10 percent of an
hour. In any case, the observation period
shall not be less than 6 minutes in duration.
In some cases, the process operation may be
intermittent or cyclic. In such cases, it may
be convenient for the observation period to
coincide with the length of the process cycle.
5.4.2 Observer Rest Breaks. Do not ob-
serve emissions continuously for a period of
more than 15 to 20 minutes without taking a
rest break. For sources requiring observation
periods of greater than 20 minutes, the ob-
server shall take a break of not less than 5
minutes and not more than 10 minutes after
every 15 to 20 minutes of observation. If con-
tinuous observations are desired for extended
time periods, two observers can alternate be-
tween making observations and takiug
breaks.
5.4.3 Visual Interference. Occasionally, fu-
gitive emissions from sources other than the
affected facility (e.g., road dust) may pre-
vent a clear view of the affected facility.
This may particularly be a problem during
periods of high wind. If the view of the po-
tential emission points is obscured to such a
degree that the observer questions the valid-
ity of continuing observations, then the ob-
servations are terminated, and the observer
clearly notes this fact on the data form.
5.5 Recording Observations. Record the
accumulated time of the observation period
on the data sheet as the observation period
duration. Record the accumulated time
emissions were observed on the data sheet as
the emission time. Record the clock time the
observation period began and ended, as well
as the clock time any observer breaks began
and ended. ;
6. Calculations
If the applicable subpart requires that the
emission rate be expressed as an emission
frequency (in percent), determine this value
as follows: Divide the accumulated emission
time (in seconds) by the duration of the ob-
servation period (in seconds) or by any mini-
mum observation period required in the ap-
plicable subpart, if the acutal observation
period is less than the required period and
multiply this quotient by 100.
7. Bibliography
1. Missan, Robert and Arnold Stein.
Guidelines for Evaluation of Visible Emis-
sions Certification, Field Procedures, Legal
Aspects, and Background Material. "EPA
Publication No. EPA-340/1-75-007. April 1975
-------
Pt. 60, App. A, Meth. 22
40 CFR Ch. I (7-1-95 Edition)
2. Wohlsohlegel, P. and D. E. Wagoner.
Guideline for Development of a Quality As-
surance Program: Volume IX—Visual Deter-
mination of Opacity Emissions From Sta-
tionary Sources. EPA Publication No. EPA-
650/4-74-005-i. November 1975.
FUGITIVE OR SMOKE EMISSION INSPECTION
OUTDOOR LOCATION
Company ________
Location _____________
Company representative
ObMfvcr .
Affiliation
Oat* ___
Sky Conditions
ftacipitetion _
Wind direction
WindspMd
Industry
Process unit
Sketch process- unit: indicate observer peshion ralativa to sourea and sun; indent potential
emission points and/or actual emission points:
OBSERVATIONS
Begin Observation
Clock
time
Observation
period
duration.
min:sec
Accumulated
emission
time.
min:sec
End observation
Figure 22-1
-------
Pt. 60, App. A, Meth. 22
Fugitive Mission Inspection Indoor Location Table
40 CFR Ch. I <7-7-95 Edition)
FUGITIVE EMISSION INSPECTION
INDOOR LOCATION
CoBpany
Location
CbBpany Represe
Industry
Light type (flu
tight location
Illuninance (lu
Sketch process
emission points
Observer
Affiliation
ntative Date
Process unit
orescent, incandescent, natural.
(overhead, behind observer, etc.)
x or Cootcandles)
unit; indicate observer position relative to source; indicate potential
and/or actual emission points.
OBSERVATIONS
Beginning obse
Did observatio
Observation Accunulated
period emission.
Clock duration, tiae,
tine roinisec minrsec
tvation
n
Figure 22-2
-------
-------
APPENDIX E
SAMPLE INSPECTION FORMS
E-1
-------
-------
Nonmetallic Mineral Processing Plants
- Plant Information -
Plant ID/permit number:
Plant name and address:
Name of plant contact:
Phone: ( )
ext.
Plant mailing address
(if different from plant address):
Owner/operator name and address
(if different from plant name/address):
Owner/operator phone: ( )
Nonmetalic minerals processed:
ext
Plant portability: D portable D nonportable
Cummulative rated capacity of all initial crashers:.
.tons/year
Plant exempt by plant type/capacity: D yes D no
Plant emission source type: O Al CH A2 d B
(particulate matter) (S 100l/yr actual) (SlOOt/yr potential) <<100t/yr actual & potential)
U.S. EPA plant ID number/s (as applicable):
• National Emissions Data System (NEDS)
Aerometric Information Retrieval System (AIRS)
Attach a detailed flow diagram of the plant showing the locations of all potentially
affected and affected facilities under 40 CFR Pan 60, Subpart OOO.
-------
t*
te
(Fcrlroiftf
tin totottr
d?
-------
Initial Performance Test Field Sheet
Date:
Affected facility:
Sketch of Affected Facility or Transfer Point:
Source ID number
Description/location:
Source enclosed: rn yes r~i no
Source controlled: Q yes r-i no
If yes, type of control device: _
Scrubber AP
inches W.G.
Scrubber liquid flow rate
GPM
Comments:
YE method employed: Q Method 9 D Method 22
Compliance status: Q compliance D noncompliance d not determined (explain in comments)
Attach appropriate VE Observation Form Signature:
Initial Performance Test Field Sheet
Date:
Affected facility:
Sketch of Affected Facility or Transfer Point:
Source ID number:
Description/location:
Source enclosed: r—i yes r-\ no
Source controlled: QJ yes r-j no
If yes, type of control device:
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
VE method employed: D Method 9 D Method 22
Comments:
Compliance status: Q compliance d noncompliance O not determined (explain in comments)
Attach appropriate VE Observation Form Signature: :
-------
Affected facility:
Field Inspection Sheet
Date of inspection:
Source ID number:
Comments:
Description/location:
Source enclosed: rn yes r~i no
Source controlled: £] yes Q no
If yes, type of control device:
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
Baghouse AP
inches W.G.
Bag cleaning: d operative d inoperative
VE method employed: d Method 9 d Method 22 Attach appropriate VE Observation Form
Compliance status: d compliance d noncompliance d not determined (explain in comments)
Inspector's signature:
Affected facility:
Field Inspection Sheet
Date of inspection:
Source ID number:
Comments:
Description/location:
Source enclosed: Q yes
Source controlled: Q yes
If yes, type of control device:
D no
D no
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
Baghouse AP
inches W.G.
Bag cleaning: d operative d inoperative
VE method employed: d Method 9 d Method 22 Attach appropriate VE Observation Form
Compliance status: d compliance d noncompliance d not determined (explain in comments)
Inspector's signature:
-------
APPENDIX F
SAMPLE INSPECTION REPORT
F-1
-------
LEVEL II COMPLIANCE INSPECTION OF
BREAKSTONE LIMESTONE COMPANY
ANYWHERE, USA
Inspection Date: January 5, 1990
Inspector: Joe Brown
Inspection Report Date: January 10, 1990
F-2
-------
INSPECTION PROCEDURES AND CONCLUSIONS
Procedures
On January 5, 1990, an inspection was conducted at Breakstone Limestone Co.
for the purpose of determining compliance of the plant's affected facilities under 40 CFR
60, Subpart OOO. This inspection was unannounced and one of several inspections of
nonmetallic mineral processing facilities in the State.
Entry into the plant was gained without difficulty at 9:00 a.m. Mr. John Smith,
Environmental Manager, acted as the official plant representative and also served as plant
escort for the inspection.
Company records concerning the NSPS affected facilities at this site were
inspected. The following written notifications to the EPA Administrator for each affected
facility were checked and found to meet all regulatory requirements:
Date of construction
Dates of actual startup
Date of anticipated initial performance test opacity observations
Thirty day advance notice of all compliance tests.
Notification for 1) proposed replacements of existing facilities with facilities of equal or
smaller size, 2) proposed reconstructions of existing facilities, and 3) notifications of
modification of existing facilities pursuant to the provisions of § 60.14(e) were not
applicable to any existing facility at the plant at the time of inspection.
The following written reports to the EPA Administrator for each affected facility were
checked and found to meet all regulatory requirements:
0 All performance test results and results of all performance test opacity
observations.
F-3
-------
All pertinent records on file at the plant were checked and found to meet all
regulatory requirements.
Because no affected facility at this plant is served by a wet scrubber, the reporting
and recordkeeping requirements for wet scrubbers pursuant to Subparts A and OOO are
not applicable.
Because no emission problems were observed outside of the plant boundary
during pre-entry observations, the field inspection began at 10:00 a.m. at the primary
crusher and proceeded through the process flow to the two bagging machines. During
the inspection the plant was operating at a rate of 275 tons/h, which is below the
operating rate recorded for the last compliance test. All existing facilities on the master
list were still operating on site. No modifications to existing facilities were observed and
no new equipment was apparent.
NSPS Sources
Both transfer points from belt conveyor No. 13 were observed using Method 9 for
18 minutes. The highest average 6-minute observation period opacity was 0 percent.
These transfer points were in compliance with the NSPS opacity limit.
TheTy-Rock screen No. 20 was observed using EPA Method 9 for 18 minutes, the
highest average 6-minute observation period opacity was 0 percent. The No. 20 screen
was in compliance with the NSPS opacity limit.
The building enclosing the No. 25 Raymond mill was observed for 20 minutes
employing EPA Method 22 with no visible emissions observed. The cyclone air separator
serving the No. 25 Raymond mill was observed using EPA Method 9 for 18 minutes. The
highest average 6-minute observation period opacity was 0 percent. The pulse-jet
baghouse was inspected externally; all diaphragm valves were operating and air reservoir
pressure was comparable to that of the last compliance test. No evidence of breaches
in shell integrity were observed. Pressure drop across the baghouse was recorded at 4.0
in. W.G. indicating proper operation.
Product storage bin No. 46 was observed during three loading cycles. The stack
of the storage bin baghouse was observed for a total of 40 minutes using Method 9 with
F-4
-------
two sets of consecutive 6-minute observations recorded during the two cycles. The
highest average 6-minute observation period opacity was 26 percent. During the two
cycles, stack emissions were characterized by cyclic puffs indicating the possibility of a
hole(s) in bags. Pressure drop was recorded across the baghouse at 2.5 in. W.G. which
is low for this type of pulse-jet baghouse and 2 in. W.G. below the average pressure drop
recorded during the last compliance test. Air reservoir pressure was normal and all
diaphragm valves appeared to be operable. No breaches in shell integrity were observed.
Conclusions
The following conclusions are drawn from the inspection:
0 Transfer points on the No. 13 belt conveyor were in compliance with the
NSPS opacity standard
0 The No. 20 Ty-Rock screen was in compliance with the NSPS opacity
standard
0 Emissions from the No. 25 Raymond mill building, cyclone air separator,
and baghouse were in compliance with the NSPS opacity standard
0 Emissions from the baghouse serving the No. 46 storage bins were not in
compliance with the NSPS opacity standard
0 All existing facilities on the master list were on site and showed no
indications of modifications that would increase paniculate matter emissions
0 No new equipment that would be subject to the NSPS were observed on
the plant property
0 All notifications, reports, and records required by the NSPS were available
at the plant upon request and met all NSPS requirements.
F-5
-------
-------
Nonmetallic Mineral Processing Plants
- Plant Information -
Name of plant contact:
Phone:
ft
Plant ID/permit number:
Plant name and address: l3>-rft
A
//>>.
ext
Plant mailing address
(if different from plant address):
/A
Owner/operator name and address
(if different from plant name/address):
/*?>-.
Owner/operator phone: ( ) 5 A Avt< ext
Nonmetalic minerals processed:
Plant portability: D portable K! nonportable
Cummulative rated capacity of all initial crushers: "2. /*?
tons/year
Plant exempt by plant type/capacity: D yes E3 no
Plant emission source type: IE Al D A2 D B
(paniculate matter) (S 100!/yr actual) (SlOOl/yr potential) (<100tfyr actual & potential)
U.S. EPA plant ID number/s (as applicable):
• National Emissions Data System (NEDS)
Aerometric Information Retrieval System (AIRS)
Attach a detailed flow diagram of the plant showing the locations of all potentially
affected and affected facilities under 40 CFR Part 60, Subpart OOO.
-------
-------
1"
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-------
Affected facility: _
Source ID number
/So-
Field Inspection Sheet
!l Date of inspection:
Comments:
I* ~T
u i.
-j~0
Description/location:
l -Pis'; i r/i/
/i/-<
r'y 5 i6>Jv S
k f /f- SSA, V fyp l.
tj
Source enclosed: Q yes
Source controlled: Q yes
If yes, type of control device:
no
no
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
BaghouseAP inches W.G.
Bag cleaning: d operative d inoperative
VE method employed: JS1 Method 9 d Method 22 Attach appropriate VE Observation Form
Compliance status: E3 compliance d noncompliance d not determined (explain in comments)
Inspector's signature: $*-/»A/«;
. /?
Source enclosed: Q yes
Source controlled: Q yes
If yes, type of control device:
no
no
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
Baghouse AP
Bag cleaning:
inches W.G.
operative d inoperative
VE method employed: E3 Method 9 D Method 22 Attach appropriate VE Observation Form
Compliance status: ES] compliance CU noncompliance d not determined (explain in comments)
Inspector's signature: J;
-------
Affected facility:
Field Inspection Sheet
Sc K g e A/> Date of inspection:
Source ID number:
Comments:
Description/location:
5lrr>it Bi-o
Source enclosed: r-i yes
Source controlled: Q yes
ff yes, type of control device:
no
no
Scrubber AP inches W.G.
Scrubber liquid flow rate • GPM
Baghouse AP
inches W.G.
Bag cleaning: fl operative Q inoperative
VE method employed: 0 Method 9 D Method 22 AttocA appropriate VE Observation Form
Compliance status: 0 compliance Q noncompliance C] not determined (explain in comments)
Inspector's signature:
Affected facility:
Field Inspection Sheet
/lill Date of inspection:
Source ID number: A/0.
Comments:
Description/location:
cJ r/
-------
Field Inspection Sheet
Affected facility: ^Toi-A^e BI*J Date of inspection:
Source ID number: /v. */-(& Comments: ///V'W"
Description/location:
Source enclosed: r~\ yes
Source controlled: ^ yes
If yes, type of control device:
Cclic.
«
t'kl*.
no
no
Scrubber AP inches W.G.
Scrubber liquid flow rate GPM
BaghouseAP 2'T inches W.G.
Bag cleaning: O operative d inoperative
VE method employed: S Method 9 D Method 22 Attach appropriate VE Observation Form
Compliance status: d compliance E3 noncompliance d not determined (explain in comments)
Inspector's signature: —
Affected facility:
Field Inspection Sheet
Date of inspection:
Source ID number:
Comments:
Description/location:
Source enclosed: Q yes
Source controlled: Q yes
If yes, type of control device:
no
no
Scrubber AP _ inches W.G. --
Scrubber liquid flow rate _ GPM
BaghouseAP _ inches W.G.
Bag cleaning: [3 operative £] inoperative
VE method employed: Q Method 9 D Method 22 Attach appropriate VE Observation Form
Compliance status: d compliance EH noncompliance D not determined (explain in comments)
Inspector's signature: -
-------
APPENDIX G
COMPILATION OF EPA POLICY MEMORANDA
CONCERNING 40 CFR 60, SUBPART OOO
Additional policy memoranda may be obtained
from the U.S. EPA website at:
http://ttnwww.rtpnc.epa.gov/html/sscd/compli.htmSSSJM
G-1
-------
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
OCT 2 3 J99T
OFFICE OF
ENFORCEMENT AND
COMPLIANCE ASSURANCE
MEMORANDUM
SUBJECT:
FROM:
TO:
Applicability of NSPS OOO to Affected Facilities in the Nonmetallic Mineral
Processing Industry
JohnB.RasriicJDirecto
Manufacturing, Energy, and TransportatiZSn Division
Office of Compliance
Addressees
The purpose of this memorandum is to clarify several New Source Performance Standards
(NSPS), Standards of Performance for Nonmetallic Mineral Processing Plants, Subpart OOO
applicability issues raised by the National Stone Association (NS A) . The following are responses
to the 13 issues for which NS A requested clarification.
1 . Are grizzlies classified as screens and therefore subject to NSPS OOO?
Section 60.672 (d) states that "[t]ruck dumping of nonmetallic minerals into any screening
operation, feed hopper, or crusher is exempt from the requirements of this section." Therefore,
grizzlies which serve as screening operations for truck dumping facilities are exempt from the
standard. Grizzlies which are not associated with truck dumping are subject to the rule.
2. If an aggregate plant does not have a crusher, (i.e., is a screening facility only) is it
subject to Subpart OOO?
Subpart OOO does not apply to stand-alone screening operations at plants without
crushers or grinders.
3. At -what point does a plant begin?
There has been conflicting guidance regarding this issue, and the Agency is currently
planning a Federal Register notice clarifying the subject. Section 60.670 (a) lists the affected
facilities in fixed or portable nonmetallic mineral processing plants. This list includes each
crusher, grinding mill, screening operation, bucket elevator, belt conveyor, bagging operation,
storage bin, and enclosed truck or railcar loading station. The clear intent of the regulation is that
R.cycted/R.cycUblo . Printed with Vegetable OB Based Inks on 100% Recycled Paper (40% Postconsumer)
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all of the facilities listed in § 60.670 (a) are subject to Subpart OOO In a 1991 Regulatory and
Inspection Manual for Nonmetalic Mineral Processing Plants, it was stated that "Subpart OOO
facilities begin at the first crushing or grinding operation at the plant." This statement is incorrect.
While Subpart OOO affected operations typically have crushers or grinding mills located at or
near the beginning of the nonmetallic mineral processing line, this is not always the case (e.g.,
some plants may convey, screen or otherwise process materials without first utilizing a crusher
located in the plant). As long as crushing or grinding occurs anywhere at a non-metallic mineral
processing plant, any facility listed in § 60.670 (a) is subject to Subpart OOO regardless of its
location within the plant. EPA expects that plants that have not considered faciities prior to the
first crushing or grinding operation as affected facilities, will now ensure that those affected
facilities will meet all of the applicable regulatory requirements. In light of the conflicting
guidance that has existed regarding this issue, EPA will enforce this interpretation prospectively.
4. Are recycled asphalt pavement plants subject to Subpart OOO? Concrete? Glass?
Brick?
Plants which recycle material such as asphalt concrete, concrete or brick are subject to
Subpart OOO if they are using affected facilities listed in § 60.670 (a) to crush or grind any
nonmetallic mineral. Glass is not considered a nonmetallic mineral, and therefore its recycling
would not be subject.
5. Are feed hoppers, hoppers under screens, or surge bins located over crushers considered
to be "storage bins" and subject to the rule? At -what point do you read the bin, at the discharge
or at the loading point?
Feed hoppers and hoppers under screens are typically used to collect and convey material
to the next process. When these units are used in this fashion, they would not be considered
storage bins. However, if these units are used to temporarily store material, they would be
considered "storage bins" as defined in § 60.671. Where applicable, Method 9 readings should
be conducted at both discharge and loading points.
6. Once apiece of equipment is classified as exempt under the "like-for-like "provisions, is
that equipment always exempt wherever it is moved? What about portable plants?
If an existing facility is simply relocated it does not become subject to the regulation.
However, if during the relocation the facility undergoes a physical or operational change that
results in an emissions increase, the facility would be modified and become subject to the rule. If
an existing portable plant undergoes a "modification" as defined in 40 CFR § 60.2, it would
become an affected facility.
7. Are open truck/rail car loading facilities subject to the rule?
Subpart OOO does not apply to open truck or railcar loading facilities.
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8. When grading a visible emissions (VE) test, should a consecutive 6 minute average, or a
rolling average, be used?
A consecutive 6 minute average should be used.
9. Can a regulatory agency (Regional, state, or local) be given the authority to -waive test
requirements of affected facilities that do not produce any visible emissions due to the saturated
nature of the material being mined?
§ 60.8 allows for performance tests to be waived if the owner or operator can demonstrate
by other means that the affected facility is in compliance with the standard. The EPA Regional
offices have been delegated the authority to waive performance tests. In addition, some Regions
have delegated this authority to State agencies. The issue regarding the mining of saturated
materials has been addressed in the revision to Subpart OOO.
10. Are cyclones, log-washers, classifiers, sand screws, cement silos, and chutes considered
to be affected facilities under the rule?
Cyclones, log washers, classifiers, sand screws, cement silos and chutes are not
considered affected facilities.
11. Are transfer points from crushers and screens to belt conveyors considered to be transfer
points that require testing, or are belt-to-belt transfer points the only points required to be
tested!
Transfer points from crushers and screens to belt conveyors and belt-to-belt transfer
points require testing. Transfer points from a belt to a stockpile are not subject to Subpart OOO
12. Is changing a -wet screen to a dry screen considered a modification? Dry screen to a wet
screen?
Changing from a wet screen to a dry screen, or a dry screen to a wet screen, would be
considered a physical or operational change. If the change resulted in an increase in emissions, it
would be considered a "modification" as defined in § 60.2.
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13. In regards to a hot mix asphalt plant connected to an aggregate plant, at -which point
does the applicability to Subpart OOO end and Subpart I begin? What about a concrete plant
or cement plant connected to an aggregate plant?
Applicability for Subpart OOO at an aggregate plant would end at the first affected
storage silo or bin at a hot mix asphalt facility, where 40 CFR Part 60, Subpart I would then
apply. The same answer applies to cement plants subject to 40 CFR Part 60, Subpart F.
If you have any questions regarding these issues, please contact Scott Throwe of my staff
at (202) 564-7013.
Addressees:
Linda Murphy, Director
Office of Ecosystem Protection, Region 1
Kathleen Callahan, Director
Division of Environmental Planning and Protection, Region n
Judith Katz, Director
Air Protection Division, Region HI
Winston Smith, Director
Air, Pesticides and Toxics Management Division, Region IV
David Kee, Director
Air and Radiation Division, Region V
Al Davis, Director
Multimedia Planning and Permitting Division, Region VI
William Spratlin, Director
Air, RCRA, and Toxics Division, Region VII
Dick Long, Director
Air program, Region VIII
David Howekamp, Director
Air and Toxics Division, Region DC
Anita Frankel, Director
Office of Air Quality, Region X
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Regional Counsels I-X
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
APR 2 7 1988
MEMORANDUM
SUBJECT:
FROM:
TO:
Request for Assistance -
Jack R. Farmer, Dire
Emission Standards D
of 40 CFR Part 60, Subpart 000
Winston A. Smith, Director
Air, Pesticides and Toxics Management Division
Region III
In your memo of April 19, 1988, you requested technical assistance to
evaluate a problem that the Kentucky Department for Air Quality (DAQ) has raised
concerning the enforcement of Subpart 000 - Standards of Performance for Non-
metallic Mineral Processing Plants. The assistance you requested was for
either James Eddinger or William Harnett, of the Emission Standards Division,
to participate in an inspection of a specific Subpart 000 facility in Kentucky.
In considering your request, we contacted Mr. Gregory Copley of the Kentucky
DAO on April 20, 1988, to discuss their concerns. It is our understanding
that their principal concern is the ability to perform Method 9 opacity
readings inside a building. Mr. Copley indicated that due to the dusty
condition and poor background existing inside the buildings, it is difficult
to obtain accurate readings of opacity. He is also under the impression that
Method 9 is not applicable for observing visible emissions inside buildings.
Furthermore, the plant selected for an EPA visit is apparently not known to be
experiencing enforcement problems, under Subpart 000, but was selected only
as an example of the difficult conditions, with respect to Method 9, being
encountered inside buildings at rock processing facilities located throughout
the State. (A building at this plant encloses both NSPS and non-NSPS affected
fad 1 itiei^^fctMJble emissions are apparently discharged from the building;
hence, coflBHpc&r the NSPS affected facilities would be determined by
making M^^^§ot)seryations inside the building.)
Copley, the ability to perform Method 9 readings
inside bufWPfl^viras considered during the development of the NSPS. The
Method 9 data used to support the NSPS include data that were obtained inside
buildings. We are well aware that problems may occur when performing Method 9
observations inside buildings but there are alternatives for resolving
these problems. Additional lighting, improved access to equipment, and
temporary installation of contrasting backgrounds are possible alternatives.
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In view of the above, I believe that there is no need for ESD personnel
to participate in this inspection. It appears that this is primarily an
enforcement issue and, therefore, the Stationary Source Compliance Division
would be a more appropriate contact regarding this issue. The Emission
Measurement Branch (EMB) of OAQPS was responsible for conducting the test
program for the NSPS development and Ed McCarley (FTS 629-5546) may be contacted
regarding questions on Method 9 procedures.
If you have any questions concerning this memorandum, please contact
James Eddinger at FTS 629-5426.
cc:
J.,Eddinger, ISB (MD-13)
Farrell, SSCD (EN-341)
W. Harnett, SOB (MD-13)
E. McCarley, EMB (MD-14)
G. Walsh, EMB (MD-14)
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Date: 06/12/1995
MEMORANDUM
SUBJECT: Applicability of NSPS Subparts F and OOO at
Portland Cement Plants
FROM: Kathie A. Stein, Director
Air Enforcement Division
TO: William A. Spratlin, Director
Air, RCRA, and Toxics Division
Region VII
We received and reviewed a memorandum submitted to U.S. EPA
Headquarters by your Region about the applicability of New
Source Performance Standards (NSPS) Subparts F and OOO for
Portland cement plants with on-site quarries. The
memorandum asks about the definition of a raw mill system
and a conveyor transfer point as used in Subpart F.
Subpart F is applicable to several portland cement plant
facilities that include raw mill system and conveyor
transfer points. Subpart F (40 CFR 60.60) does not provide
a definition of these two facilities.
Subpart OOO (40 CFR 60.670) regulates non-metallic mineral
processing plant facilities (quarries) that include
crusher(s) . The Subpart OOO definition of the crushers,
however, does not indicate if a quarry crushing system is
part of the raw mill system. Section 60.670(b) states that
"an affected facility that is subject to the provisions of
Subpart F...is not subject to the provisions of this
subpart." This section is apparently prone to
misinterpretation as Part 60 does not make clear where
Subpart OOO facilities end and Subpart F facilities start.
Based on information provided by the Office of Air Quality
Planning and Standards, we have determined that the raw
mill of Subpart F does not include the quarry crushing
system (that includes both primary and secondary crushers)
which is always subject to Subpart OOO. The product from
the secondary crusher is stored in a raw material storage
facility until ready for grinding. The nonmetallic mineral
processing plant ends after the secondary crusher conveyor
and the raw mill system (Subpart F) begins with the raw
material storage facility. The first conveyor transfer
point subject to Subpart F is the transfer
point associated with the conveyor transferring material
from the raw material storage to the grinding operations.
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At a stand-alone quarry, not followed by a port land cement
plant (or any other plant), both the raw material storage
facility and the raw material storage facility conveyor (if
used) are subject to the requirements of Subpart OOO.
If you have any questions, please call Zofia Kosim, P.E.,
of my staff at 202-564-8733.
cc: James Crowder, OAQPS
Leslye Fraser, OGC
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
*****
NOV 8 1990
OFFICE Of
AIR AND RADIATION
MEMORANDUM
SUBJECT:
FROM:
TO:
Applicability of NSPS Subpart F to Kilns and Clinker
Coolers Using a Common Exhaust Stack
John B. Rasnic, Acting Director
Stationary Source Compliance Division (EN-341)
Office of Air Quality Planning and Standards
Bernard E. Turlinski, Chief
Air Enforcement Branch
Region III
I have received your memorandum of May 1, 1990, requesting a
determination of applicability of Subpart F (Portland Cement
Plants) to a single exhaust stack used by the kiln and clinker
cooler at a portland cement plant in Virginia. I have also
received your more recent draft letter, addressing the same issue,
to the State of Virginia. I apologize for the delay in our
response to your earlier memorandum.
Your request is for a procedure to determine compliance with
New Source Performance Standards (NSPS) from two NSPS facilities
with different opacity standards, which have a combined exhaust
stream. The facts in your memoranda state that the exhaust stream
from the affected facility with the 10% opacity standard (the
clinker cooler) is introduced into the preheater of the affected
facility with the 20% opacity standard (the kiln) . The combined
emissions are then routed to the control device and then released
into the atmosphere.
Section 60.63 of the Subpart requires each owner or operator
to install, calibrate, maintain, and operate (in accordance with
§ 60.13) a Continuous Opacity Monitoring System (COMS) to measure
opacity from any kiln or clinker cooler subject to the Subpart.
Section 60.13(g) of the General Provisions requires two or more
affected facilities which are not subject to the same emission
standard to install an applicable continuous monitoring system on
each separate effluent, unless the installation of fewer systems
is approved by the Administrator.
Printed on Recycled Paper
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-2-
Therefore, as indicated in your draft letter to the State, a
COM3 would need to be installed on the ductwork leading from the
clinker cooler to the preheater. That COM3 must show compliance
with the 10% standard. Another COM3 installed on the kiln exhaust
would show compliance with the 20% opacity standard, as your draft
letter stated.
If, however, due to the configuration of the ductwork or for
some other reason approved by the Administrator, installation of
separate COM3 is impossible, the owner or operator may install an
applicable COM3 on the stack to monitor the combined effluent. If
this is done, our concern is that no circumvention of an
applicable opacity standard be permitted as a result of this
configuration. Section 60.12 (Circumvention) of the General
Provisions explicitly prohibits "...the use of gaseous diluents to
achieve compliance with an opacity standard " To ensure that
the provisions of § 60.12 are complied with, and that compliance
with the standard for'clinker coolers is achieved (10% opacity),
this common stack must meet the more stringent opacity requirement
o-f 10%. Whether the clinker cooler emissions are ducted directly
to the same stack as the kiln, or to the preheater, the 10%
standard still applies.
Furthermore, § 60.13(i)(1-9) allows the Administrator to
consider approval of alternatives to any monitoring procedures or
requirements upon receipt of a written application from the
source. This application may cite factors which interfere with
the accuracy of the monitoring system, may attempt to demonstrate
that the COM3 can be installed at an alternate location and still
provide accurate and representative measurements, or make an
argument for other alternative procedures, methods, or
specifications. Any such alternatives approved by the
Administrator for the COM3 on, the clinker cooler must adequately
demonstrate compliance with the 10% standard for clinker coolers.
Turning to a further point you made in your more recent
submittal, you believe that the effluent from the clinker cooler,
after entering the preheater, undergoes a physical and chemical
change, and therefore becomes part of the kiln effluent. You feel
that, because of this transformation, effluent from the clinker
cooler becomes subject to the 20% opacity limit of the kiln, and
not the 10% opacity limit of the cooler. As the above discussion
indicates, we do not agree with that interpretation, given, in
part, the need to ensure compliance with the clinker cooler
standard. Please note that the source may apply to EPA for an
alternative opacity limit under the provisions of § 60.11(e).
However, as noted above, the source should first explore
alternative monitoring methods which will enable direct monitoring
of the effluent from the clinker cooler prior to its introduction
into the preheater.
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-3-
To ensure consistency, this response has been reviewed by the
Emission Standards Division and the Office of Enforcement. My
staff has also been in touch with your staff to discuss this
request. I am also enclosing a copy of a 1989 letter from
Region IV which illustrates application of the COM3 requirements
in situations similar to this one. Please contact Ken Malmberg of
my staff (FTS 382-2870) if you have any questions about this
memorandum.
Attachment
cc: Roger Pfaff, Region IV
Ed Buckner, Region VII '
Shirley Tabler, ISBf BSD (MD-13)
Ron Meyers, ISB, BSD (MD-13)
Justina Fugh, AED
John Rudd, AED
Peter Fontaine, AED
Howard Wright, SSCD
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
MAR 3- 1939
OFFICE OF
AIR AND RADIATION
MEMORANDUM
SUBJECT: Guidance for Utilization of Method 9 Data in Enforcement
Activities
FROM: John S. Seitz, Directo:
Stationary Source Corp:
Office of Air Quality Pianning
TO: Roger p. Pfaff, Chief
Air Compliance Branch
Air, Pesticides and Toxics Management Division
In a July 28 letter to Region IV, North Carolina's Division of
Environmental Management requested resolution of an apparent contradiction
between the preamble for Method 9 that states "the accuracy of the method must
be taken into account when determining possible violations of applicable
opacity standards" and EPA's stated policy of not allowing or accreting an
error allowance when documenting opacity violations. This request was
forwarded to SSCD attached to an October 27, 1988 Region IV memorandum that
provided three alternative options to EPA's present policy on error allowance.
In further discussions between our staffs, we were informed that this request
stems from an enforcement action where a nonmetallic mineral processing plant,
during its performance test, exceeded the opacity standard established by the
NSPS Subpart 000. Further investigation of the elevated levels of opacity
identified problems with the plant's sprayer system, which required corrective
action.
A number of different issues are raised by this case and need to be
addressed one by one. First, the NSPS standards are carefully developed from
a comprehensive program of research, source testing study, and analysis.
Establishing the opacity standard for Subpart 000 sources was typical of this
process. OAQPS conducted a comprehensive study at nonraetallic mineral
processing plants to determine the range of opacity readings during maximum
operation using BDT. The opacity levels at the tested plants were very low
and the resulting Subpart 000 opacity standard adequately takes into account
the observed variation in opacity readings. Thus, even a marginal exceedance
of the standard is a strong indication of a control equipment, operation, or
maintenance problem which may require an enforcement remedy. It should be
noted that opacity standards are separately enforceable requirements and any
exceedance of the standard can be the sole basis for an enforcement action.
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. ; 20460
JAN ! 4 1992
OFFICE OF
AIR AND RADIATION
Mr. Craig S. Mann
Environmental Quality Management,
3109 University Drive - Suite B
Durham, North Carolina 27707
Inc.
Re: Applicability of NSPS Subpart OOO to Rip-Rap Plants
located on properties containing Nonmetallic Mineral
Processing Plants subject to NSPS Subpart OOO
Dear Mr. Mann:
This letter is in response to your October 29, 1991 request
for guidance on the applicability of Subpart OOO. Ellen Rattigan
of my staff discussed and resolved these issues with you on
November 14, 1991. Specifically, you requested a determination as
to whether a rip-rap plant, which does not include a crushing or
grinding operation, is subject to Subpart OOO in the event it is
located on a property containing a separate crushing/grinding
operation.
The facts you present in your letter indicate that the rip-
rap plant sizes and separates large rock fragments. The rip-rap
plant does not crush or grind nonmetallic minerals, nor does it
have any crushing or grinding equipment. Also, the material
processed at the rip-rap plant neither comes from nor goes to any
crushing or grinding operation located on the same property.
Based on this general description, the rip-rap plant would
not be a part of "any combination of equipment that i-s used to
crush or grind any nonmetallic mineral," and thus does not fall
within the definition of "nonmetallic mineral processing plant" at
40 CFR § 60.71. Such a rip-rap plant would not therefore be
subject to NSPS Subpart OOO despite its location on a property
containing a Subpart OOQ plant. If, however, the rip-rap plant
acted as the screening operation for a nonmetallic mineral
processing operation, then it may potentially qualify as an
affepted facility.
Printed on Recycled Paper
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If you have any questions regarding this letter, please
contact Ellen Rattigan of my staff at (703)308-8531.
Sincerely,
John B. Rasnic, Director
Stationary Source Compliance Division
Office of Air Quality Planning and Standards
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September 19, 1988
Mr. N. Ogden Gerald, Chief
Air Quality Branch
Division of Environmental Management
North Carolina Department of Natural
Resources and Community Development
P.O. Box 27687
Raleigh, North Carolina 27611
Dear Mr. Gerald:
As requested in your letter of July 8,1988, we have determined the applicability of 40 CFR Part
60, Subpart 000 to the J.M. Huber Corporation's Kings Mountain Mica plant in Kings
Mountain, North Carolina. Mr. Jerry Hoyle of your Asheville Regional office was contacted
in order to clarify some minor points. He stated that the Kings Mountain Mica Plant is an
entirely new production line comprised of new equipment.
We have determined that each individual piece of equipment listed on Table 1 (attached) at the
Kings Mountain Mica Plant is considered an affected facility as defined in 40 CFR Part 60,
Subpart 000. This plant is considered a mica processing plant and, therefore, none of the
exemptions in 40 CFR 60.670 apply.
The only piece of equipment not considered an affected facility is the centrifuge that receives
the crude mica feed.
J.M. Huber Corporation contended that the Kings Mountain Mica Plant is not subject to 40 CFR
Part 60, Subpart 000 because the high moisture content of the feed material precludes particulate
emissions. Although particulate emissions may not be generated from some of the affected
facilities at this plant, Subpart 000 is applicable because each individual piece of equipment was
constructed after August 31, 1983, the effective date of Subpart 000. In addition, the possibility
exists that particulate emissions could be generated from the affected facilities if the feed
material became dry or if the affected facilities were relocated at another site and were to
process dry feed material.
Your letter stated that Mr. Jay Hutto of the J.M. Huber Corporation requested that the
performance testing time requirement of 40 CFR 60.8 be waived until a final determination
regarding applicability is made. There are no provisions in 40 CFR 60.8 which allow the time
requirement to be waived and, therefore, performance testing must be conducted within 180 days
of startup or 60 days after achieving the maximum production rate.
We recommend that the performance testing of the affected facilities be conducted as indicated
in Table 2 (attached). Please note that a reduced testing frequency has been suggested in some
cases because of the high moisture content of the feed material.
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If you have any questions regarding this letter, please contact Mr. Paul Reinermann at
404/347-2904.
Sincerely yours,
Roger O. Pfaff, Chief
Air Compliance Branch
Air, Pesticides and Toxics
Management Division
Attachments
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July 27 1988
Mr. N. Ogden Gerald, Chief
Air Quality Section
Division of Environmental Management
North Carolina Department of Natural Resources & Community
Development P.O. Box 27687
Raleigh, North Carolina 27611
Dear Mr. Gerald:
As requested in your letter of July 12, 1988, we have determined the applicability of 40 CFR
Part 60, Subpart 000 to the Barmac crusher, conveyors and wash screen at the Central Rock
Company in Greensboro, North Carolina. In addition, you requested that we perform an
inspection of the facility before we determine the applicability of Subpart 000. We do not
believe that an inspection is warranted since Jim Critopoulos of my staff conducted an inspection
of this facility on May 19, 1988.
The Barmac crusher and associated conveyors are subject to Subpart 000 because the Barmac
crusher has a rated capacity greater than 150 tons per hour. Although Central Rock claims
that, because of the size of the feed material and product, the Barmac crusher can not process
more than 150 tons per hour, Subpart 000 is based on the actual rated capacity of the
affected facility which is 260 tons per hour for this Barmac crusher according to the
manufacturer.
In addition, the Barmac crusher is a secondary crusher and, as indicated in Mr. James T.
Wilburn's letter of June 14, 1988, the Barmac crusher would be considered an affected facility
regardless of its rated capacity. The exemption to applicability of Subpart 000 at 40 CFR
60.670(b)(2) applies only to portable plants that have initial or primary crushing capacity of 150
tons per hour or less. The wash screen at Central Rock is a screening operation as defined in
Subpart 000 and is subject to Subpart 000. We realize that paniculate emissions from the wash
screen will below, however, EPA did intend to regulate all screening
operations regardless of the moisture content of the feed material.
If you have any questions regarding this letter, please contact Mr. Paul Reinermann at
404/347-2904.
Sincerely yours,
Roger O. Pfaff, Chief
Air Compliance Branch
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June 8 1987
Mr. Paul J. Bontrager, Director
Air Pollution Control Division
Metropolitan Health Department, Nashville-Davidson County
311 23rd Avenue, North
Nashville, Tennessee 37203
Dear Mr. Bontrager:
This is in response to your letter of April 10, 1987, to Mr. Bruce P. Miller regarding the
applicability of 40 CFR Part 60, Subpart OOO, Standards of Performance for Non-Metallic
Mineral Processing Plants. Your question has been quoted and is followed by our response.
Question: If an existing 400 ton per hour limestone rock processing plant (quarry) is replaced
by a 1600 ton per hour processing plant comprised of various crushers, screens and conveyors
that were in existence prior to August 31, 1983, is the 1600 ton per hour plant subject to the
above Federal New Source Performance Standard, provided that the affected facilities (crushers,
screens and conveyor belts, etc.) have not been modified or reconstructed?
Response: An affected facility in 40 CFR Part 60, Subpart OOO is defined as the individual
components of the plant (crusher, grinding mill, screening operation, bucket elevator, belt
conveyor, bagging operation, storage bin, enclosed truck or railcar loading station) that
commences construction, reconstruction or modification after August 31, 1983. Therefore,
because each component of the 1600 ton per hour was in existence prior to the August 31, 1983,
effective date and had not been reconstructed or modified, the components of the 1600 ton per
hour plant would not be subject to 40 CFR Part 60 Subpart OOO. According to 40 CFR 60.1
(e)(6), relocation or change of ownership shall not be considered a modification. The definition
of an affected facility being the components of the plant instead of the entire plant being the
affected facility will allow individual existing components from different plants to be combined
to form a new plant and yet have the components not be subject to 40 CFR Part 60, Subpart
OOO.
This is different than combining components of existing nitric acid plants to form a new nitric
acid plant. An affected facility under 40 CFR Part 60, Subpart G, is defined as the production
line or plant, not the components. Therefore, combining existing components from two or more
existing plants to form a new nitric acid plant, would make the new nitric acid plant subject to
40 CFR Part 60, Subpart G. If you have any questions or comments regarding this letter, please
contact Paul Reinermann at 404/347-2904.
Sincerely yours,
James T. Wilburn, Chief
Air Compliance Branch, Air, Pesticides, and Toxics, Management Division
be: Jim Manning
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October 3, 1986
Mr. Carl Vogt
Wayne County Health Department
Air Pollution Control Division
2211 East Jefferson Street
Detroit, MI 48207
Dear Mr. Vogt:
This letter is pursuant to your request as to the applicability of 40 CFR Part 60, Subpart OOO:
Standards of Performance for Non-Metallic Mineral Processing Plants. Subpart OOO, Section
60.670(a) defines the applicability and designation of affected facilities. Except as provided in
paragraphs (b), (c) and (d) of this Section the provisions of this subpart are applicable to the
following affected facilities in fixed or portable non-metallic mineral processing plants: each
crusher, grinding mill, screening operation, bucket elevator, belt conveyor, bagging operation
storage bin, enclosed truck or railcar loading station.
The regulation goes on to define each of the above terms. Specifically, non-metallic mineral
processing plant is defined as "any combination of equipment that is used to crush or grind any
non- metallic mineral wherever located, including lime plants, power plants, steel mills, asphalt
concrete plants, portland cement plants, or any other facility processing non-metallic minerals
except as provided in Sections 60.670(b) and (c)". The complete process at hand involves
pneumatically conveying crushed lime into lime storage silos and exhausting the displaced air
through a small baghouse. In addition, there is no equipment or combination of equipment used
to crush or grind any non-metallic mineral at this plant. Therefore, it can be determined that
the plant is not classified as a non-metallic mineral processing plant and consequently, 40 CFR
Part 60, Subpart OOO is not applicable to this lime storage silo facility.
Sincerely,
Larry F. Kertcher, Chief
Air Compliance Branch (5AC-26), Region V2
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June 19, 1987
Terry A. Sweitzer, PE
Manager, Permit Section
Division of Air Pollution Control
ILEPA
2200 Churchill Rd
Springfield, IL 62706
Dear Mr. Sweitzer:
This letter is in response to your letter of May 4, 1987, regarding an interpretation of New
Source Performance Standard (NSPS) 40 CFR 60, Subpart OOO. United States Environmental
Protection Agency's interpretation is that when two smaller crushers are replaced with one larger
crusher the new crusher becomes an affected facility subject to NSPS. The fact that the larger
crusher has the same capacity as the sum of the two smaller crushers does not exempt it from
the NSPS. 40 CFR 60.670(d) does provide for an exemption when a crusher is replaced by
another crusher of the same capacity. However, this exemption applies only for crusher for
crusher replacement, not crusher for crushers. Should you have further questions, on this
matter, please contact Chae Pak of my staff at (312) 886-6797.
Sincerely yours,
Larry F. Kertcher, Chief
Air Compliance Branch (5AC-26), Region V
bcc: Kee
Czemiak
Spyropoulos
Paisie
Penson
Pak
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August 5, 1987
John Doss, Chief
Plan Review and Permit Section
Office of Air Management
Indiana Department of Environmental Management
105 South Meridian Street
PO Box 6015
Indianapolis, IN 46206-6015
RE: Marengo Quarry Plant
Dear Mr. Doss:
This letter is in response to your question regarding the New Source Performance Standards
(NSPS) 40 CFR 60 Subpart OOO, Section 60.672, as it applies to the limestone crusher and dust
collection system at Marengo Quarry Plant. Specifically, your question was, can the dust
collection system at the plant be considered a "wet scrubbing control device" and thus have the
crusher be exempt from the opacity limitation requirement set forth in 40 CFR 60.672(a)(2).
i
Discussed in page 39569 of the Federal Register dated August 31, 1983, (enclosed), are two
methods used to reduce particulate emissions from affected facilities (crushers included). They
are wet dust suppression system and dry and wet collection system. In a wet dust suppression
system, water (with or without surfactant) is sprayed on the material at critical dust producing
points in the process flow. In both wet and dry collection systems, particulate matter emissions
generated during process operations are controlled by capturing the emissions and passing them
through a collection device. "Collection devices" include fabric filters, internal cyclones and
wet scrubbers.
The system described for Marengo Quarry Plant constitutes a wet dust suppression system, not
a wet scrubbing control device. As such, Marengo Quarry Plant is subject to the opacity
limitation requirement of 40 CFR 60.672(a)(2). If you should have further inquiries regarding
this determination, please contact Mr. Chae Pak of my staff at (312) 866-6797.
Sincerely yours,
[signed]
Larry F. Kertcher, Chief, Air Compliance Branch (5AC-26)
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January 12 1988
Judith A. Slater
Regulatory Compliance Section
Division of Air Quality
Minnesota Pollution Control Agency
520 Lafayette Road
St. Paul, Minnesota 55155
Dear Ms. Slater:
This letter is in response to your question regarding the New Source Performance Standard
(NSPS) 40 CFR 60 Subpart 000 - Standard of Performance for Nonmetallic Mineral Processing
Plants. Specifically, you've asked the following questions: l.Several plants have bought used
equipment (manufactured before August 31, 1983) and have installed these equipment after
August 31,1983. Is a piece of equipment subject to the requirements based upon the date it was
manufactured or the date it was installed?
2.One plant owns several portable conveyors. Some of these conveyors were manufactured
before August 31, 1983. These conveyors are added and removed from the plant as deemed
necessary. Sometimes an existing conveyor is replaced by another conveyor of equal or smaller
size. Sometimes a conveyor is added as a new piece of equipment. Is each conveyor subject
to the requirements based upon the date it was manufactured?
S.One plant replaced a 30 inch conveyor (approximate speed of400 feet/minute) with a 42 inch
conveyor (approximate speed of 250 feet/minute). Both conveyors were manufactured before
ugust 31, 1983. The operator states that the capacity of both conveyors is equal. Is the
conveyor subject to the requirements based upon the date it was manufactured? If not, what
documentation should the operator provide to meet the "same size" exemption of part
60.670(d)(l)?
With regards to question 1, a telephone conversation between yourself and Chae Pak of my staff
has clarified that the word "equipment" should read "affected facility," as it is defined in Section
60.670(a). Any affected facility, in fixed or portable nonmetallic mineral processing plants, is
exempt from the requirement of Subpart 000 if it is manufactured (constructed) prior to August
3l, 1983, and provided that it has not been modified or reconstructed after August 31, 1983.
It does not matter whether the modification or reconstruction occurred at its current plant-site
or elsewhere.
Modification means any physical change in, or change in the method of operation of, an existing
facility (constructed before August 31, 1983, for facilities subject to Subpart 000) which
increases the amount of any air pollutant (to which a standard applies) emitted into the
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atmosphere by that facility or which results in the emission of any air pollutant (to which a
standard applies) into the atmosphere not previously emitted. Reconstruction means the
replacement of components of an existing facility to such an extent that: 1) the fixed capital cost
of the new components exceeds 50 percent of the fixed capital cost that would be required to
construct a comparable entirely new facility (except as provided in Section 60.673), and 2) it
is technology and economically feasible to meet the applicable standards set forth in 40 CFR Part
60.
With regard to question 2, belt conveyors, as defined in Section 60.671, constructed prior to
August 31,1983, are not subject to the requirements of Subpart 000. Belt conveyors constructed
after August 31, 1983, are subject to the requirements of Subpart 000, unless they are replacing
other belt conveyors (on one for one basis) that are of equal or larger size. For belt conveyors,
size is determined by the width of the conveyor belt.
With regards to question 3, both belt conveyors were constructed prior to August 31,1983. As
such, neither are subject to Subpart 000. Should you have further questions regarding this
determination, please forward them to Mr. Chae Pak of my staff at (312) 886-6797.
Sincerely yours,
(signed)
Larry F. Kertcher, Chief, Air Compliance Branch
March 01 1988
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January 30 1989
Terry Sweitzer, P.E.
Manager, Permit Section
Division of Air Pollution Control
Illinois Environmental Protection Agency
P.O. Box 19276
Springfield, Illinois 62794-9276
Re: New Source Performance Standards Subpart 000
Recycled Concrete or Asphalt Concrete
Dear Mr. Sweitzer:
This is in response to your request dated January 13, 1989, asking United States Environmental
Protection Agency (U.S. EPA), Region V, to confirm that operations such as the crushing of
concrete and asphalt paving for reuse are subject to the New Source Performance Standards for
Nonmetallic Mineral Processing Plants, 40 C.F.R. Subpart 000. The requirements of Subpart
000 are applicable to the affected facilities (listed in Section 60.670(a)) in fixed or portable
nonmetallic mineral processing plants. "Nonmetallic mineral" means any of the minerals or any
mixture of which the majority is any of the minerals listed in Section 60.671(a) to (r). Generally
both concrete and asphaltic concrete are composed mostly of minerals covered in Section
60.671(a) to (r).
As such, U.S. EPA has concluded that concrete and asphalt paving crushing operations are
subject to Subpart 000 on the basis that concrete and asphaltic concrete reasonably fits the
definition of nonmetallic mineral as a mixture of which the majority is any of the 18 minerals
listed, provided the operations fit into the size, or other constraints of the applicability section
of the standard.
Should you have further questions regarding this matter please call Spiros Bourgikos of my staff
at (312) 886-6862.
Sincerely yours,
(signed)
Larry F. Kertcher, Chief
Air Compliance Branch (5AC-26)
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