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EPA Air Toxics Standards for Boilers <br />and Process Heaters<br />James A. Westbrook<br />March 15, 2011<br />
Agenda<br />Rule Introduction – Standards for Boilers and Process Heaters<br />NOT cover Incinerators<br />Applicability (...
About BlueScape<br />20 years experience, air quality compliance <br />Permits, air modeling, compliance for boilers and h...
Introduction to the Boiler Air Toxics Rules   <br />40 CFR 63 Subpart DDDDD, NESHAP<br />Finalized February 21, 2011<br />...
Applicability<br />Major or area source?<br />Major Source = 10 tpy or more of any single HAP or 25 tpy or more of any com...
Not Applicable, Major Sources<br />Electric utility steam generating unit<br />Recovery boiler or furnace under Subpart MM...
Major Source RequirementsLarge Boilers & Heaters  (>= 10 MMBtu/hr)<br />7<br />
Major Source RequirementsSmall Boilers & Heaters  (< 10 MMBtu/hr)<br />8<br />
Area Source RequirementsLarge Boilers & Heaters  (>= 10 MMBtu/hr)<br />9<br />
Area Source RequirementsSmall Boilers & Heaters  (< 10 MMBtu/hr)<br />10<br />
Tune-Up Program, Major Sources<br />Inspect burner, clean replace components<br />Inspect flame pattern, adjust<br />Inspe...
12<br />Emission Limits, Major Sources<br />Reference: USEPA<br />
13<br />Emission Limits, Area Sources<br />Reference: USEPA<br />
Emission Limit Comparisons<br />14<br />CO, ppm<br />PM, lb/MMBtu<br />
Startup, Shutdown & Malfunctions<br />Applies to both boiler and process heaters at major sources and boilers at area sour...
Notification, Recordkeeping & Reporting<br />Semiannual compliance reports<br />Notification of compliance status report<b...
Compliance Schedule<br />Boilers and process heaters, major sources<br />	- New, comply 60 days from rule date, or startup...
Case Study: Refinery<br /><ul><li>3 boilers and 10 process heaters, existing
Major Source of HAPs
Combust refinery gas, Gas 1 Subcategory
One affected facility, all 13 units
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BlueScape EPA Air Toxics Standards for Boilers and Process Heaters 03-15-11

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This webinar by James A Westbrook at BlueScape describes requirements of 40 CFR 63 Subpart DDDDD to boilers and process heaters located at industrial facilities, including major and area sources of hazardous air pollutants. Mr. Westbrook can be reached at 858-774-2009 for more information. Also see www.bluescapeinc.com.

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BlueScape EPA Air Toxics Standards for Boilers and Process Heaters 03-15-11

  1. 1. EPA Air Toxics Standards for Boilers <br />and Process Heaters<br />James A. Westbrook<br />March 15, 2011<br />
  2. 2. Agenda<br />Rule Introduction – Standards for Boilers and Process Heaters<br />NOT cover Incinerators<br />Applicability (and not applicable)<br />Major and Area Sources<br />Affected and Non-Affected, New & Existing Units<br />Large and small units, by unit and fuel type<br />Requirements – notification, limits, work practice requirements, testing, records and reporting<br />Case Studies – Refinery and Biomass Plant<br />
  3. 3. About BlueScape<br />20 years experience, air quality compliance <br />Permits, air modeling, compliance for boilers and heaters, various fuels<br />National Experience<br />Solve tough air quality compliance issues:<br />- Determining rule applicability<br />- Assess how to reduce impacts, change status<br />- Develop monitoring, recordkeeping and reporting protocols<br />- Agency negotiations <br />
  4. 4. Introduction to the Boiler Air Toxics Rules <br />40 CFR 63 Subpart DDDDD, NESHAP<br />Finalized February 21, 2011<br />Effective 60 days from publish in Federal Register<br />New and existing industrial, commercial and institutional boilers and process heaters<br />Regulate HCl, Hg, PM, dioxins/furans, and CO<br />Major Source Rule, 15 unit-based subcategories<br />Area Source Rule, 4 general subcategories<br />Parts will be reconsidered<br />
  5. 5. Applicability<br />Major or area source?<br />Major Source = 10 tpy or more of any single HAP or 25 tpy or more of any combination of HAP<br />Only boilers at area sources, not process heaters<br />Affected source, New or Existing<br />Collection of boilers and heaters at a source within a subcategory<br />New or reconstructed, commence construction or reconstruction after June 4, 2010<br />Existing affected source, June 4, 2010<br />Fuel subcategory?<br />Major source, 10% rule to determine source category and emission limits<br />Area source, 15% rule to determine source category and emission limits<br />
  6. 6. Not Applicable, Major Sources<br />Electric utility steam generating unit<br />Recovery boiler or furnace under Subpart MM<br />Boiler or heater for research and development<br />Hot water heater<br />Refining kettle under Subpart X<br />Ethylene cracking furnace<br />Blast furnace stoves<br />Boiler or process heater part of the affected source subject to another NESHAP<br />Boiler of process heater used as a control device<br />Temporary boilers<br />Blast furnace gas fuel-fired boilers and process heaters<br />Clean Air Act Section 129 and Solid Waste Disposal Act boilers<br />
  7. 7. Major Source RequirementsLarge Boilers & Heaters (>= 10 MMBtu/hr)<br />7<br />
  8. 8. Major Source RequirementsSmall Boilers & Heaters (< 10 MMBtu/hr)<br />8<br />
  9. 9. Area Source RequirementsLarge Boilers & Heaters (>= 10 MMBtu/hr)<br />9<br />
  10. 10. Area Source RequirementsSmall Boilers & Heaters (< 10 MMBtu/hr)<br />10<br />
  11. 11. Tune-Up Program, Major Sources<br />Inspect burner, clean replace components<br />Inspect flame pattern, adjust<br />Inspect system controlling air-to-fuel ratio, calibrate<br />Optimize CO emissions per manufacturer<br />Measure CO before and after adjustments<br />Submit annual reports, CO ppm and fuel data<br />
  12. 12. 12<br />Emission Limits, Major Sources<br />Reference: USEPA<br />
  13. 13. 13<br />Emission Limits, Area Sources<br />Reference: USEPA<br />
  14. 14. Emission Limit Comparisons<br />14<br />CO, ppm<br />PM, lb/MMBtu<br />
  15. 15. Startup, Shutdown & Malfunctions<br />Applies to both boiler and process heaters at major sources and boilers at area sources<br />Work practice standards<br />Manufacturer’s recommended procedures<br />Minimize emissions and prevent future malfunctions<br />
  16. 16. Notification, Recordkeeping & Reporting<br />Semiannual compliance reports<br />Notification of compliance status report<br />Records of compliance and tune-ups<br />Records of continuously monitored data<br />Electronic Reporting Tool (ERT) - Submission of test results <br />
  17. 17. Compliance Schedule<br />Boilers and process heaters, major sources<br /> - New, comply 60 days from rule date, or startup<br /> - Existing, 3 years from rule date <br />Boilers located at an area source<br /> - New, comply 60 days from rule date, or startup<br /> - Existing, tune-up compliance no later than 1 year from rule date<br /> - Existing, emission limits no later than 3 years after rule date<br />
  18. 18. Case Study: Refinery<br /><ul><li>3 boilers and 10 process heaters, existing
  19. 19. Major Source of HAPs
  20. 20. Combust refinery gas, Gas 1 Subcategory
  21. 21. One affected facility, all 13 units
  22. 22. Analysis:</li></ul>- Annual Tune-Up, 1-Time Energy Assessment (more extensive)<br />- Minimizing Periods of Startup and Shutdown<br />- Minimize and Correct Malfunctions<br /><ul><li>Recordkeeping and Reporting</li></li></ul><li>Case Study: Biomass Power Plant<br /><ul><li>250 MMBtu/hr FBC boiler
  23. 23. Built 1984, lignite Coal / biomass / tires
  24. 24. Idled 10 years
  25. 25. New Source Review permit in 2011, biomass only
  26. 26. Major source of HCL
  27. 27. Analysis:
  28. 28. New affected major source, new subcategory
  29. 29. Emission limits for 5 compounds apply, energy assessment
  30. 30. Startup, shutdown, malfunction requirements
  31. 31. Notification, testing/monitoring, records & reports
  32. 32. Option to control HCL, become area source</li></li></ul><li>Summary<br />Clean Gas boilers and heaters – mainly tune-up requirements, or not applicable<br />Extensive requirements for solid fuel process gas and oil boilers at major sources<br />Consider for new projects:<br />Emission controls to get area source status<br />Clean gas fuel to avoid emission limits<br />Time for existing boilers for compliance<br />Stay tuned to reconsideration details<br />
  33. 33. Contact with Questions<br />James A. Westbrook, President<br />BlueScape, Inc.<br />858-774-2009 (cell)<br />jwestbrook@bluescapeinc.com<br />www.bluescapeinc.com<br />The Webinar presentation will be posted on <br />Slideshare and Scribd (search for BlueScape)<br />

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