[Code of Federal Regulations]
[Title 40, Volume 12]
[Revised as of July 1, 2006]
From the U.S. Government Printing Office via GPO Access
[CITE: 40CFR63.1450]
[Page 34-38]
TITLE 40--PROTECTION OF ENVIRONMENT
CHAPTER I--ENVIRONMENTAL PROTECTION AGENCY (CONTINUED)
PART 63_NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS FOR
SOURCE CATEGORIES--Table of Contents
Subpart QQQ_National Emission Standards for Hazardous Air Pollutants for
Primary Copper Smelting
Sec. 63.1450 What test methods and other procedures must I use to
demonstrate initial compliance with the emission limitations?
(a) Total particulate matter emission limits. You must conduct each
performance test to determine compliance with the total particulate
matter emission limits in Sec. 63.1444 or Sec. 63.1446 that apply to
you according to the requirements for representative test conditions
specified in Sec. 63.7(e)(1) and using the test methods and procedures
in paragraphs (a)(1) through (5) of this section.
(1) Determine the concentration of total particulate matter
according to the test methods in appendix A to part 60 of this chapter
as specified in paragraphs (a)(1)(i) through (iii) of this section.
(i) Method 1 to select sampling port locations and the number of
traverse points. Sampling ports must be located at the outlet of the
control device and prior to any releases to the atmosphere.
(ii) Method 2, 2F, or 2G to determine the volumetric flow rate of
the stack gas.
(iii) Method 3, 3A, or 3B to determine the dry molecular weight of
the stack gas.
(iv) Method 4 to determine the moisture content of the stack gas.
(v) Method 5, 5D, or 17, as applicable, to determine the
concentration of total particulate matter. You can also use ASTM D4536-
96 incorporated by reference in Sec. 63.14 as an alternative to the
sampling equipment and operating procedures in Method 5 or 17 when
testing a positive pressure baghouse, but you must use the sample
traverse location and number of sampling points described in Method 5D.
(2) As an alternative to using the applicable method specified in
paragraph (a)(1)(v) of this section, you may determine total particulate
matter emissions from the control device using Method 29 in appendix A
of part 60 of this chapter provided that you follow the procedures and
precautions prescribed in Method 29. If the control device is a positive
pressure baghouse, you must also follow the measurement procedure
specified in sections 4.1 through 4.3 of Method 5D.
(3) You must conduct three separate test runs for each performance
test. Each test run must have a minimum sampling time of 60 minutes and
a minimum sampling volume of 0.85 dscm. For the purpose of determining
compliance with the applicable total particulate matter emission limit,
the arithmetic mean of the results for the three separate test runs is
used.
(4) For a venturi wet scrubber applied to emissions from an affected
source and subject to operating limits in Sec. 63.1444(g) or Sec.
63.1446(d) for pressure drop and scrubber water flow rate, you must
establish site-specific operating limits according to the procedures in
paragraph (a)(4)(i) and (ii) of this section.
(i) Using the continuous parameter monitoring system (CPMS) required
in Sec. 63.1452, measure and record the pressure drop and scrubber
water flow rate during each run of the particulate matter performance
test.
(ii) Compute and record the hourly average pressure drop and
scrubber water flow rate for each individual test run. Your operating
limits are the lowest average pressure drop and scrubber water flow rate
value in any of the three runs that meet the applicable emission limit.
(5) For a control device other than a baghouse or venturi wet
scrubber applied to emissions from an affected source and subject to
site-specific operating limit(s) in Sec. 63.1444(h) or Sec. 63.1446(e)
for appropriate, site-specific operating parameters that are
representative and reliable indicators of the control device
performance, you must establish a site-specific operating limit(s)
according to the procedures in paragraph (a)(5)(i) through (iv) of this
section.
(i) Select one or more operating parameters, as appropriate for the
control device design, that can be used as representative and reliable
indicators of the control device operation.
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(ii) Using the CPMS required in Sec. 63.1452, measure and record
the selected operating parameters for the control device during each run
of the total particulate matter performance test.
(iii) Compute and record the hourly average value for each of the
selected operating parameters for each individual test run. Your
operating limits are the lowest value or the highest value, as
appropriate for the selected operating parameter, measured in any of the
three runs that meet the applicable emission limit.
(iv) You must prepare written documentation to support your
selection of the operating parameters used for the control device. This
documentation must include a description of each selected parameter, a
rationale for why you chose the parameter, a description of the method
used to monitor the parameter, and the data recorded during the
performance test and used to set the operating limit(s).
(b) Nonsulfuric acid particulate matter emission limits. You must
conduct each performance test to determine compliance with the
nonsulfuric acid particulate matter emission limits in Sec. 63.1444
that apply to you according to the requirements for representative test
conditions specified in Sec. 63.7(e)(1) and using the test methods and
procedures in paragraphs (b)(1) and (2) of this section.
(1) Determine the concentration of nonsulfuric acid particulate
matter according to the test methods in appendix A to part 60 of this
chapter as specified in paragraphs (b)(1)(i) through (v) of this
section.
(i) Method 1 to select sampling port locations and the number of
traverse points. Sampling ports must be located at the outlet of the
control device and prior to any releases to the atmosphere.
(ii) Method 2, 2F, or 2G to determine the volumetric flow rate of
the stack gas.
(iii) Method 3, 3A, or 3B to determine the dry molecular weight of
the stack gas.
(iv) Method 4 to determine the moisture content of the stack gas.
(v) Method 5B to determine the nonsulfuric acid particulate matter
emissions.
(2) You must conduct three separate test runs for each performance
test. Each test run must have a minimum sampling time of 240 minutes and
a minimum sampling volume of 3.4 dscm. For the purpose of determining
compliance with the nonsulfuric acid particulate matter emission limit,
the arithmetic mean of the results for the three separate test runs is
used.
(c) Copper converter department capture system opacity limit. You
must conduct each performance test to determine compliance with the
opacity limit in Sec. 63.1444 using the test methods and procedures in
paragraphs (c)(1) through (9) of this section.
(1) You must conduct the performance test during the period when the
primary copper smelter is operating under conditions representative of
the smelter's normal blister copper production rate. You may not conduct
a performance test during periods of startup, shutdown, or malfunction.
Before conducting the performance test, you must prepare a written test
plan specifying the copper production conditions to be maintained
throughout the opacity observation period and including a copy of the
written documentation you have prepared according to paragraph (a)(3) of
this section to support the established operating limits for the copper
converter department capture system. You must submit a copy of the test
plan for review and approval by the Administrator or delegated
authority. During the observation period, you must collect appropriate
process information and copper converter department capture system
operating information to prepare documentation sufficient to verify that
all opacity observations were made during the copper production and
capture system operating conditions specified in the approved test plan.
(2) You must notify the Administrator or delegated authority before
conducting the opacity observations to allow the Administrator or
delegated authority the opportunity to have authorized representatives
attend the test. Written notification of the location and scheduled date
for conducting
[[Page 36]]
the opacity observations must be received by the Administrator on or
before 30 calendar days before this scheduled date.
(3) You must gather the data needed for determining compliance with
the opacity limit using qualified visible emission observers and process
monitors as described in paragraphs (c)(3)(i) and (ii) of this section.
(i) Opacity observations must be performed by a sufficient number of
qualified visible emission observers to obtain two complete concurrent
sets of opacity readings for the required observation period. Each
visible emission observer must be certified as a qualified observer by
the procedure specified in section 3 of Method 9 in appendix A of part
60 of this chapter. The entire set of readings during the required
observation period does not need to be made by the same two observers.
More than two observers may be used to allow for substitutions and
provide for observer rest breaks. The owner or operator must obtain
proof of current visible emission reading certification for each
observer.
(ii) A person (or persons) familiar with the copper production
operations conducted at the smelter must serve as the indoor process
monitor. The indoor process monitor is stationed at a location inside
the building housing the batch copper converters such that he or she can
visually observe and record operations that occur in the batch copper
converter aisle during the times that the visible emission observers are
making opacity readings. More than one indoor process monitor may be
used to allow for substitutions and provide for rest breaks.
(4) You must make all opacity observations using Method 9 in
appendix A to part 60 of this chapter and following the procedures
described in paragraphs (c)(4)(i) and (ii) of this section.
(i) Each visible emission observer must make his or her readings at
a position from the outside of the building that houses the copper
converter department such that the observer's line-of-sight is
approximately perpendicular to the longer axis of the converter
building, and the observer has an unobstructed view of the building roof
monitor sections or roof exhaust fan outlets that are positioned over
each of the batch copper converters inside the building. Opacity
readings can only be made during those times when the observer's
position meets the sun orientation and other conditions specified in
section 2.1 of Method 9.
(ii) At 15-second intervals, each visible emission observer views
the building roof monitor sections or roof exhaust fan outlets that are
positioned over each of the batch copper converters inside the building
and reads the opacity of the visible plumes. If no plume is visible, the
observer records zero as the opacity value for the 15-second interval.
In situations when it is possible for an observer to distinguish two or
more visible emission plumes from the building roof monitor sections or
roof exhaust fan outlets, the observer must identify, to the extent
feasible, the plume having the highest opacity and record his or her
opacity reading for that plume as the opacity value for the 15-second
interval.
(5) You must make opacity observations for a period of sufficient
duration to obtain a minimum of 120 1-minute intervals during which at
least one copper converter is blowing and no interferences have occurred
from other copper production events, as specified in paragraph (c)(7) of
this section, which generate visible emissions inside the building that
potentially can interfere with the visible emissions from the converter
capture systems as seen by the outside observers. To obtain the required
number of 1-minute intervals, the observation period may be divided into
two or more segments performed on the same day or on different days if
conditions prevent the required number of opacity readings from being
obtained during one continuous time period. Examples of these conditions
include, but are not limited to, changes in the sun's orientation
relative to visible emission observers' positions such that the Method 9
conditions are no longer met or an unexpected thunder storm. If the
total observation period is divided into two or more segments, all
opacity observations must be made during the same set of copper
production conditions described in your approved test plan as required
by paragraph (c)(1) of this section.
[[Page 37]]
(6) You must gather indoor process information during all times that
the visible emission observers are making opacity readings outside the
building housing the copper converter department. The indoor process
monitor must continually observe the operations occurring in the copper
converter department and prepare a written record of his or her
observations using the procedure specified in paragraphs (c)(6)(i)
through (iv) of this section.
(i) At the beginning of each observation period or segment, the
clock time setting on the watch or clock to be used by the indoor
process monitor must be synchronized with the clock time settings for
the timepieces to be used by the outdoor opacity observers.
(ii) During each period or segment when opacity readings are being
made by the visible emission observers, the indoor process monitor must
continuously observe the operations occurring in the copper converter
department and record his or her observations in a log book, on data
sheets, or other type of permanent written format.
(iii) When a batch copper converter is blowing, a record must be
prepared for the converter that includes, but is not limited to, the
clock times for when blowing begins and when blowing ends and the
converter blowing rate. This information may be recorded by the indoor
process monitor or by a separate, automated computer data system.
(iv) The process monitor must record each event other than converter
blowing that occurs in or nearby the converter aisle that he or she
observes to generate visible emissions inside the building. The recorded
entry for each event must include, but is not limited to, a description
of the event and the clock times when the event begins and when the
event ends.
(7) You must prepare a summary of the data for the entire
observation period using the information recorded during the observation
period by the outdoor visible emission observers and the indoor process
monitor and the procedure specified in paragraphs (c)(7)(i) through (iv)
of this section.
(i) Using the field data sheets, identify the 1-minute clock times
for which a total of eight opacity readings were made and recorded by
both observers at 15-second intervals according to the test procedures
(i.e., a total of four opacity values have been recorded for the 1-
minute interval by each of the two observers). Calculate the average of
the eight 15-second interval readings recorded on the field data sheets
by the two observers during the clock time minute interval (add the four
consecutive 15-second interval opacity readings made by Observer A
during the specified clock time minute, plus the four consecutive 15-
second interval opacity readings made by Observer B during the same
clock time minute, and divide the resulting total by eight). Record the
clock time and the opacity average for the 1-minute interval on a data
summary sheet. Figure 1 of this subpart shows an example of the format
for the data summary sheet you may use, but are not required to use.
(ii) Using the data summary sheets prepared according to paragraph
(c)(7)(i) of this section and the process information recorded according
to paragraph (c)(6)(iii) of this section, identify those 1-minute
intervals for which at least one of the batch copper converters was
blowing.
(iii) Using the data summary sheets prepared according to paragraph
(c)(7)(ii) of this section and the process information recorded
according to paragraph (c)(6)(iv) of this section, identify the 1-minute
intervals during which at least one copper converter was blowing but
none of the interference events listed in paragraphs (c)(7)(iii)(A)
through (F) of this section occurred. Other ancillary activities not
listed but conducted in or adjacent to the converter aisle during the
opacity observations are not considered to be interference events (e.g.,
converter aisle cleaning, placement of smoking ladles or skulls on the
converter aisle floor).
(A) Charging of copper matte, reverts, or other materials to a batch
copper converter;
(B) Skimming slag or other molten materials from a batch copper
converter;
(C) Pouring of blister copper or other molten materials from a batch
copper converter;
[[Page 38]]
(D) Return of slag or other molten materials to the flash smelting
furnace or slag cleaning vessel;
(E) Roll-out or roll-in of the batch copper converter; or
(F) Smoke and fumes generated inside the converter building by
operation of the smelting furnace, the slag cleaning vessel (if used),
anode refining and casting processes that drift into the copper
converter department.
(iv) Using the data summary sheets prepared according to paragraph
(c)(7)(iii) of this section, up to five 1-minute intervals following an
interference event may be eliminated from data used for the compliance
determination calculation specified in paragraph (c)(8) of this section
by applying a time delay factor. The time delay factor must be a
constant number of minutes not to exceed 5 minutes that is added to the
clock time recorded when cessation of the interference event occurs. The
same time delay factor must be used for all interference events (i.e., a
constant time delay factor for the smelter of 1 minute, 2 minutes, 3
minutes, 4 minutes, or 5 minutes). The number of minutes to be used for
the time delay factor is determined based on the site-specific equipment
and converter building configuration. An explanation of the rationale
for selecting the value used for the time delay factor must be prepared
and included in the test report.
(8) You must use the data summary prepared in paragraph (c)(7) of
this section to calculate the average opacity value for a minimum of 120
1-minute intervals during which at least one copper converter was
blowing with no interference events as determined according to
paragraphs (c)(7)(iii) and (iv) of this section. Average opacity is
calculated using Equation 1 of this section:
[GRAPHIC] [TIFF OMITTED] TR12JN02.026
Where
VEave = Average opacity to be used for compliance
determination (percent);
n = Total number of 1-minute intervals during which at least one copper
converter was blowing with no interference events as determined
according to paragraphs (c)(7)(iii) and (iv) of this section (at least
120 1-minute intervals);
i = 1-minute interval ``i'' during which at least one copper converter
was blowing with no interference events as determined according to
paragraphs (c)(7)(iii) and (iv) of this section; and
VEi = Average opacity value calculated for the eight opacity
readings recorded during 1-minute interval ``i'' (percent).
(9) You must certify that the copper converter department capture
system operated during the performance test at the operating limits
established in your capture system operation and maintenance plan using
the procedure specified in paragraphs (c)(9)(i) through (iv) of this
section.
(i) Concurrent with all opacity observations, measure and record
values for each of the operating limit parameters in your capture system
operation and maintenance plan according to the monitoring requirements
specified in Sec. 63.1452(a).
(ii) For any dampers that are manually set and remain in the same
position at all times the capture system is operating, the damper
position must be visually checked and recorded at the beginning and end
of each opacity observation period segment.
(iii) Review the recorded monitoring data. Identify and explain any
times during batch copper converter blowing when the capture system
operated outside the applicable operating limits.
(iv) Certify in your performance test report that during all
observation period segments, the copper converter department capture
system was operating at the values or settings established in your
capture system operation and maintenance plan.