tp NESHAP PortlandCement

Information about tp NESHAP PortlandCement

Published on February 13, 2008

Author: Candelora

Source: authorstream.com

Content

NESHAP Implementation National Cement Company Ragland, Alabama Air &Waste Management Association Southern Section Meeting September 16, 2002 Orange Beach, AL:  NESHAP Implementation National Cement Company Ragland, Alabama Air &Waste Management Association Southern Section Meeting September 16, 2002 Orange Beach, AL Bob Gunn, National Cement Company of Alabama Judy O’Neill, P.E., Trinity Consultants Dan Willis, Trinity Consultants Overview:  What is NESHAP? Common requirements New steps to implement Maintaining compliance Questions/Comments Overview What is NESHAP (1 of 2)?:  What is NESHAP (1 of 2)? National Emission Standards for Hazardous Air Pollutants Section 112 of 1970 CAA required EPA to establish NESHAPs Developed on pollutant basis (e.g., mercury, beryllium) “Part 61 NESHAP” What is NESHAP (2 of 2)?:  What is NESHAP (2 of 2)? Overhaul of Section 112 in CAAA of 1990 Developed on source basis (e.g., portland cement, aerospace, HON) Codified in 40 CFR 63 and referred to as maximum achievable control technology (MACT) MACT = “Part 63 NESHAP” NESHAP Commonalities:  NESHAP Commonalities What industries subject to a NESHAP have in common Emission and Operating Limits Monitoring Testing Recordkeeping Notifications and Reporting Subpart A, General Provisions of NESHAP Portland Cement Affected Sources:  Portland Cement Affected Sources Stock Pile Conveyor Raw Mill Pyroprocessing System (Kiln, Clinker Cooler) Finish Mill Loadout Packhouse Start at raw material storage withdrawal system End with bulk load-out and/or bagging of portland cement New Limits, New Monitoring:  New Limits, New Monitoring Emission/Operating Limits Particulate matter and opacity (as surrogates for inorganic HAP) Dioxin/furan emissions Temperature (as surrogate for dioxin/furan) Monitoring Continuous opacity (was in place for most sites) Continuous temperature Daily and monthly visible emission checks Monthly checks cover typically 50-150 sources New Source Testing :  New Source Testing Develop and Approve Test Plan Area vs. Major Source Status Testing required by PC MACT particulate matter (EPA Method 5) opacity (EPA Method 9 and COMS) dioxin/furan (EPA Method 23) New Records:  New Records Startup, Shutdown, Malfunction events Corrective action Visible emission readings (Method 22 and Method 9) CMS data (COMS, thermocouples) Manual and electronic tracking – resources available to program/tag system units Subpart A – Notifications and Reports (1 of 4):  Subpart A – Notifications and Reports (1 of 4) Subpart A – applies to sources subject to a specific NESHAP Initial notification of applicability - 120 days after effective date of standard CMS performance evaluation notify 60 days prior to evaluation continuous monitors (e.g., COMS, thermocouples) Performance testing notify 60 days prior to test source testing (e.g., PM, dioxin/furan, opacity) Subpart A – Notifications and Reports (2 of 4):  Subpart A – Notifications and Reports (2 of 4) COMS performance evaluation report due 15 days before a performance test Initial notification of compliance status due 60 days after performance test and includes CMS performance evaluation results (e.g., thermocouple) due 30 days after test if visible emissions only (e.g., transfer points) Quarterly Excess Emission Reports Subpart A – Notifications and Reports (3 of 4):  Subpart A – Notifications and Reports (3 of 4) Semi-annual Reports (July and January) Startup, Shutdown, Malfunction events Summary of CMS performance, excess emissions PC MACT-specific data Exceeded a temperature limit Failures to calibrate thermocouples Results of any combustion system inspections Failures to comply with the operations and maintenance plan Subpart A – Notifications and Reports (4 of 4):  Subpart A – Notifications and Reports (4 of 4) Immediate Reporting (2 day/7 day) Required if source does not follow their SSMP and exceeds a relevant emission standard April 5, 2002 amendments to Subpart A (40 CFR 63.6) New Documents:  New Documents Plans SSMP – Startup, Shutdown, Malfunction Plan OMP – Operation and Maintenance Plan CMSP – Continuous Monitoring System Plan Procedures SOPs – Standard Operating Procedures PMs – Preventative Maintenance SSMP Requirements:  SSMP Requirements Required of ALL sources subject to NESHAP (Subpart A, General Provisions) Develop & implement written procedures: Operating & maintaining the source during periods of SSM events “in a manner consistent with safety and good air pollution control practices” Corrective action for malfunctioning process, monitoring & air pollution control equipment “as soon as practicable after their occurrence” Review & Update :  Review & Update Annually review OMPs & SSMPs Periodically review SOPs, PMs, CMSP Review for adequacy and applicability, and as necessary, modify to address “new” or altered responses to malfunctions or alternate startup and shutdown sequences PC MACT Implementation Schedule:  PC MACT Implementation Schedule Rule Finalized June 14, 1999 Draft OMPs, SSMPs , SOPs, PMPs March 2002 Compliance Date June 14, 2002 Implement Compliance Plans & Procedures June 2002 Conduct Compliance Tests & Finalize Plans & Procedures & Initiate Training Program June 2002 Conduct Area/Major Source Tests May 2002 Initial Notification October 1999 Initiate Monitoring Program & Develop Test Plans April 2002 Training:  Training Supervisors, Managers, Operators Overview of Regulation Plans and Procedures to Follow Records to Keep (shift logs) Visible Emission Monitoring to Perform (M22/M9) Steps for Corrective Actions Continuous Monitoring Equipment Maintain Example 1 of 2: Recordkeeping Training:  Example 1 of 2: Recordkeeping Training Startup, Shutdown, Malfunction Sign-Off Log This form must be completed for every shift All deviations from SOPs for startup or shutdown must be documented on form All malfunctions must be documented on form These are legal records and should be treated as such Example 2 of 2: VE Training:  Example 2 of 2: VE Training Visible Emission Observations Equipment must be operating All observations must be documented on forms Follow VE flowcharts Timing will be critical! Documentation Must complete checklist to indicate you’re following procedures Must write down steps you took if unable to follow these procedures Prior to Compliance Date:  Prior to Compliance Date Perform a “trial run” to go through possible scenarios Conduct an internal audit to identify gaps Maintaining Compliance:  Maintaining Compliance Constant attention to monitoring and records Meeting deadlines within a specific regulation for the PC MACT, initiate corrective action within 1 hour of noting visible emissions from finish mills Subpart A reporting (SSM events) Routine internal audits Improving the System:  Improving the System Database to house emission sources, monitoring requirements, pictures of units More electronic tracking (e.g., JD Edwards system) Operating Permits:  Operating Permits Consider other requirements such as Title V permits How to streamline MACT and operating permit requirements (monitoring and recordkeeping) Summary:  Summary NESHAP implemented at Portland Cement plants in the US Requires more recordkeeping, reporting, documentation Room for continual improvement to process Need to incorporate NESHAP into Title V QUESTION/COMMENTS:  QUESTION/COMMENTS

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