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

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EPA Air Toxics Standards for Boilersand Process Heaters

James A. WestbrookMarch 15, 2011



Agenda

� Rule Introduction ± Standards for Boilers andProcess Heaters� NOT cover Incinerators� Applicability (and not applicable)

± Major and Area Sources± Affected and Non-Affected, New & Existing

Units± Large and small units, by unit and fuel type

� Requirements ± notification, limits, work practicerequirements, testing, records and reporting

� Case Studies ± Refinery and Biomass Plant



About BlueScape

� 20 years experience, air quality compliance� Permits, air modeling, compliance for boilers

and heaters, various fuels

� National Experience� Solve tough air quality compliance issues:- Determining rule applicability- Assess how to reduce impacts, change status- Develop monitoring, recordkeeping and reporting

protocols- Agency negotiations



Introduction to the Boiler Air Toxics Rules

� 40 CFR 63 Subpart DDDDD, NESHAP� Finalized February 21, 2011� Effective 60 days from publish in Federal Register � New and existing industrial, commercial and

institutional boilers and process heaters� Regulate HCl, Hg, PM, dioxins/furans, and CO� Major Source Rule, 15 unit-based subcategories

� Area Source Rule, 4 general subcategories� Parts will be reconsidered



Applicability� Major or area source?

± Major Source = 10 tpy or more of any single HAP or 25 tpyor more of any combination of HAP

± Only boilers at area sources, not process heaters

� Affected source, New or Existing± Collection of boilers and heaters at a source within a

subcategory± New or reconstructed, commence construction or

reconstruction after June 4, 2010± Existing affected source, June 4, 2010

� Fuel subcategory?± Major source, 10% rule to determine source category andemission limits

± Area source, 15% rule to determine source category andemission limits



Not Applicable, Major SourcesElectric utility steam generating unit

� Recovery boiler or furnace under Subpart MM� Boiler or heater for research and development

Hot water heater � Refining kettle under Subpart X� Ethylene cracking furnace� Blast furnace stoves� Boiler or process heater part of the affected source subject to

another NESHAP� Boiler of process heater used as a control device

Temporary boilers� Blast furnace gas fuel-fired boilers and process heatersClean Air Act Section 129 and Solid Waste Disposal Act boilers



Major Source RequirementsLarge Boilers & Heaters

(>= 10 MMBtu/hr)Type Existing New

Clean Gas - Annual Tune-Up

- No Numeric Limits- One Time EnergyAssessment

- Annual Tune-Up

- No Numeric Limits

Solid Fuel, Oil,Process Gas

- Emission Limits for Hg,Dioxin, PM, HCL, CO

- One Time EnergyAssessment

- Emission Limits for Hg,Dioxin, PM, HCL, CO

Limited Use - Tune-Up Every Other Year - No Numeric Limits- One Time Energy

Assessment

- Tune-Up Every Other Year - No Numeric Limits

7



Major Source RequirementsSmall Boilers & Heaters

(< 10 MMBtu/hr)

Type Existing New

Gas, Solid Fuel,Oil, or LimitedUse

- Tune-Up Every Other Year - No Numeric Limits- One Time Energy

Assessment


8



Area Source RequirementsLarge Boilers & Heaters

(>= 10 MMBtu/hr)Type Existing New

Gas (all types) None None

Coal -Emission Limits for Hg, CO- One Time Energy

Assessment

- Emission Limits for Hg,PM, CO

Biomass, Oil - Tune-Up Every Other Year - No Numeric Limits

- One Time EnergyAssessment

- Emission Limit for PM- Tune-Up Every Other Year

9



Area Source RequirementsSmall Boilers & Heaters

(< 10 MMBtu/hr)

Type Existing New

Gas (all types) None None

Coal, Biomass,Oil



10



Tune-Up Program, Major Sources

� Inspect burner, clean replace components� Inspect flame pattern, adjust� Inspect system controlling air-to-fuel ratio,

calibrate� Optimize CO emissions per manufacturer � Measure CO before and after adjustments

� Submit annual reports, CO ppm and fuel data



12

Subca tegory Fin al l imits, lb/MMB tu u n less noted

Hg, lb/TBtu HCl PM CO, ppm D/F, ng/dscm

New coal stoker 3.5

Solid fuelsubcat.

0.0022

Solid fuelsubcat.

0.0011

Solid fuelsubcat.

6 0.003

New coal fluid. bed 18 0.002

New coal PC 12 0.003

New biomass stoker 160 0.005

New biomass fuel cell 470 0.003

New biomass fluid. bed 260 0.02

New biomass dutch oven 470 0.2

New biomass susp./grate 1,500 0.2

New liquid 0.21 0.00032 0.0013 3 0.002

New gas 2 7.9 0.0017 0.0067 3 0.08

New non-cont. liquid 0.78 0.00032 0.0013 51 0.002

Exist. coal stoker 4.6

Solid fuelsubcat.

0.035

Solid fuelsubcat.

0.039

Solid fuelsubcat.

270 0.003

Exist. coal fluid. Bed 82 0.002

Exist. coal PC 160 0.004

Exist. biomass stoker 490 0.005Exist. biomass fuel cell 690 4

Exist. biomass fluid. bed 430 0.02

Exist. biomass dutch oven 470 0.2

Exist. biomass sus./grate 3,500 0.2

Exist. liquid 3.4 0.00032 0.0075 10 4

Exist. gas 2 13 0.0017 0.043 9.0 0.08

Exist. non-cont. liquid 0.78 0.00032 0.0075 160 4

Emission Limits, Major Sources

Reference: USEPA



13

Subca tegory Fin al Emission LimitsHg, lb/TBtu CO, ppm PM, lb/MMBtu

New Coal 4.8 400 0.03 (> 30MMBtu/h)

0.42 ( 10 to 30MMBtu/h)

New Biomass - - 0.03 (> 30MMBtu/h)

0.07 ( 10 to 30MMBtu/h)

New Oil - - 0.03

Existing Coal 4.8 400 -

ExistingBiomass

- - -

Existing Oil - - -

Emission Limits, Area Sources

Reference: USEPA



Emission Limit Comparisons

Type Maj or S o u r c e Are a S o u r c e

New Coal Stoker 6 400

Existing Coal Stoker 270 400

New Biomass FBC 260 --

Existing Biomass FBC 430 --

14

CO, ppm

Type Maj or S o u r c e Are a S o u r c e

New Coal Stoker 0.0011 0.03 (> 30 MMBtu/hr)Existing Coal 0.039 --

New Biomass 0.0011 0.03 (> 30 MMBtu/hr)

Existing Biomass 0.039 --

PM, lb/MMBtu



Startup, Shutdown & Malfunctions

� Applies to both boiler and process heaters atmajor sources and boilers at area sources

� Work practice standards� Manufacturer¶s recommended procedures� Minimize emissions and prevent future

malfunctions



Notification, Recordkeeping &Reporting

� Semiannual compliance reports� Notification of compliance status report� Records of compliance and tune-ups� Records of continuously monitored data� Electronic Reporting Tool (ERT) -

Submission of test results



Compliance Schedule

� Boilers and process heaters, major sources- New, comply 60 days from rule date, or startup- Existing, 3 years from rule date

� Boilers located at an area source- New, comply 60 days from rule date, or startup- Existing, tune-up compliance no later than 1 year from rule date- Existing, emission limits no later than 3 years after rule date



Case Study: Refinery

� 3 boilers and 10 process heaters, existing� Major Source of HAPs� Combust refinery gas, Gas 1 Subcategory

� One affected facility, all 13 units� Analysis:- Annual Tune-Up, 1-Time Energy Assessment

(more extensive)

- Minimizing Periods of Startup and Shutdown- Minimize and Correct Malfunctions

� Recordkeeping and Reporting



Case Study: Biomass Power Plant

� 250 MMBtu/hr FBC boiler � Built 1984, lignite Coal / biomass / tires� Idled 10 years� New Source Review permit in 2011, biomass only

� Major source of HCL� Analysis:� New affected major source, new subcategory� Emission limits for 5 compounds apply, energy

assessment� Startup, shutdown, malfunction requirements� Notification, testing/monitoring, records & reports� Option to control HCL, become area source



Summary

� Clean Gas boilers and heaters ± mainly tune-up requirements, or not applicable

� Extensive requirements for solid fuel processgas and oil boilers at major sources

� Consider for new projects:± Emission controls to get area source status± Clean gas fuel to avoid emission limits

� Time for existing boilers for compliance� Stay tuned to reconsideration details



Contact with Questions

James A. Westbrook, PresidentBlueScape, Inc.

858-774-2009 (cell)[email protected]

www.bluescapeinc.com

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

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