p. 1 

OAR Box 1110 

Prepped by Ryan Dugan 

Document Number: 

10) lll-A-1 

Docket Number: 

A-82-39 

Printed 4/14/2008 1:23:55 PM Sheet 10 of 156 
w*" l 

P.2 

Wednesday 

April 23, 1986 

Part II 

Environmental 

Protection Agency 

40 CFR Part 60 

Standards of Performance for New 

Stationary Sources; Calciners and Dryers 

In Mineral Industries; Proposed Rule 
PJL 

•SNWOKICaEKITAL 

AGENCY 

§4are$ar$o ©tf Porfcmnanco tfos- Now 

Stationary Sous-coo; Catcinsro and 

Bryoro bi C38nsrcJ IraSustrteo 

0@GXGT. Environmental Protection 

Agency (EPA). 

aemots Proposed Rule and Notice of 

Public Hearing. 

CuacaAHV. The proposed standards 

roould limit emissions of particulate 

matter [PM] from new, modified, and 

reconstructed calciners and dryers at 

mineral processing plants. The proposed 

standards implement section 111 of the 

Clean Air Act and are based on the 

Administrator'o determination that 

emissions from the source categories 

that include mineral calciners and 

dryers, cause, or contribute significantly 

to. air pollution which may reasonably 

be anticipated to endanger public health 

or welfare. The intent is to require new. 

modified, and reconstructed mineral 

ealdnera and dryers to control 

emicoicaa to the level achievable by the 

fcsst demonstrated system of continuous 

emission reduction, considering costs, 

ssonair quality health, and 

environmental and energy impacts. 

A public hearing will be held, if 

requested, to provide interested parties 

on opportunity fo? oral presentations of 

data, view, o? arguments concerning 

the proposed standards. 

©ATES: Comments. Comments <jz& 

received on or before July 7,1988. 

Public Hearing. If anyone contacts 

EPA requesting ta cpsak at a public 

hearing by May 14.1988. s public 

hearing will be held on June 9.1988. 

beginning at IftCO a jn. Persons 

interested in attending the hearing 

ohould call Ms. Shelby Joumigan at (919) 

541-5578 to verify that a hearing will beheld. 

Request To Speak at Hearing. Persons 

wishing to present oral testimony must 

contact EPA by May 14.1988. 

AOOOESSES: Comments. Comments 

ohould be submitted (in duplicate if 

possible) to: Central Docket Section 

(LE-131). Attention Docket Number 

QAQPS-A-8Z-39. U.S. Environmental 

Protection Agency. 401 M Street SW.. 

Washington. DC 20460. 

Public Hearing. If anyone contacts 

EPA requesting a public hearing, it will 

be held at EPA's Office of 

Administration Auditorium. Research 

Triangle Park, North Carolina. Persons 

interested in attending the hearing or 

wishing to present oral testimony ohould 

notify Ms. Shelby Journigan, Standards 

Development Branch (MD-13). U.S. . 

Environmental Protection Agency, 

Research Triangle Park, North Carolina 

27711. telephone number (919) 541-5578. 

Background Information Document. 

The Background Information Document 

(BID) for the proposed standards may be 

obtained from the U.S. EPA Library 

(MD-35). Research Triangle Park, North 

Carolina 27711, telephone number (919) 

541-2777. Please refer to "Calciners and 

Dryers in Mineral Industries— ' 

Background Information for Proposed 

Standards" [EPA-*50/3-85-025a]. 

Docket. Docket No. A-82-39. 

containing supporting information used 

in developing the proposed standards, is 

available for public inspection and 

copying between 8:00 a.m. and 4.-00 p.m.. 

Monday through Friday, at EPA's 

Central Docket Section. West Tower 

Lobby. Gallery 1. Waterside Mali 401 M 

Street SW.. Washington. DC 20480. A 

reasonable fee may be charged for 

copying. 

FOfl FURTHER INFOHMATIOH COOT ACT: 

Mr. Doug Bell or Mr. David Painter (919) 

541-5824. Standards Development 

Branch, concerning regulatory decisions 

and the standard, or Mr. Kenneth 

Durkee (919) 541-5595. Industrial Studies 

Branch, conceming technical aspects of 

the industries and control technologies. 

The address for all parties is Emission 

Standards and Engineering Division 

(MD-13). U.S. Environmental Protection 

Agency, Research Triangle Park. North 

Carolina 27711. 

SUPSPLEtSEWTAHV IHFORMATIOM: 

L Introduction 

A. New Source Performance 

Standards—General 

New source performance standards ' 

(NSPS) implement Section 111 of the 

Clear Air Act. The NSPS are issued for 

categories of sources which cause, or 

contribute significantly to, air pollution 

which may reasonably be anticipated to 

endanger public healdi or welfare. They 

apply to new stationary sources of 

emissions, i.e., sources whose . 

construction, reconstruction, or 

modification begins after a standard for 

them is proposed. 

An NSPS requires these sources to 

control emissions to the level achievable 

by "best demonstrated technology," or 

"BDT." which Is defined in item B.3 

below. 

B. NSPS Decision Scheme 

An NSPS is the product of a series of 

decisions related to certain key 

elements for the source category being 

considered for regulation. The elements 

identified in this "decision scheme" are 

generally the following: 

1. Source category to be regulated. 

Usually an entire industry but can be a 

process or group of processes within an 

industry. 

2. Pollutant(s) to be regulated. The 

particular substance(s) emitted by the 

source that the standard will regulate. 

3. Best demonstrated technology. The 

technology on which the Agency will 

base the standards, Le., 

* ° * application of the best technological 

aystem of continuouo emission reduction 

which (taking into consideration the cost of 

achieving such emission reduction, and any 

nonair quality health and environmental 

impact and energy requirements) the 

Administrator determines has been 

adequately demonstrated. (Section 111(a)(1)]. 

For convenience, this will be referred to 

as "best demonstrated technology" or 

"BDT." 

4. Affected facility. The pieces or 

groups of equipment that comprise the 

sources to which the standards will 

~ apply. 

5. Emission points to be regulated. 

Within the affected facility, the specific 

physical location emitting pollutants 

(e.g., vents, stacks, and equipment 

<4eaks). 

8. Format for the standard. The form 

in which the standards are expressed, 

i.e.. as a percent reduction in emissions. 

as pollutant concentrations, or as 

equipment standards. 

7. Actual standards. Based on what 

BDT can achieve, the maximum 

permissible emissions. 

Note.—In general, standards do not require 

that a specific technology be used to achieve 

them. The oource owner/operator may select 

the method for achieving the pollution control 

required. 

8. Other possible considerations. In 

addition. NSPS often include: standards 

for visible emissions, modification/ 

reconstruction considerations, 

monitoring requirements, performance 

test methods, and reporting and 

recordkeeping requirements. 

C Overview of This Preamble 

This preamble will: 

1. Summarize the important features 

of the NSPS by discussing the 

conclusions reached with respect to 

each ofthe elements in the. decision 

scheme. 

2. Describe the environmental, energy, 

and economic impacts of the NSPS. 

3. Present a rationale for each of the 

decisions in the decision scheme. 

(^Discuss administrative 

eequirements relevant to this action. 
P.4 

Federal Register / Vol. 51, No. 78 / Wednesday, April 23, 1986 / Proposed Rules 15439 

II. Summary of the NSPS 

A. Source Category To Be Regulated 

The proposed standards would apply 

to new, modified, and reconstructed 

calciners and dryers at mineral 

processing plants. For the purpose of the 

proposed standards, a mineral 

processing plant is any facility that 

processes or produces any of the 

following minerals or their concentrates: 

alumina, ball clay, bentonite, diatomite. 

feldspar, fire clay, fuller's earth, gypsum, 

industrial sand, kaolin, lightweight 

aggregate (clay, shale, and slate), 

magnesium compounds, perlite. roofing 

granules, talc, titanium dioxide, and 

vermiculite. 

The affected facility for mineral 

processing plants in each of the 

industries listed above would be each 

calciner and each dryer. The types of 

dryers to which the proposed standards 

would apply include: rotary (direct), 

rotary (indirect), fluid bed, vibratinggrate, flash, and spray dryers. The types 

of calciners to which the proposed 

standards would apply include: rotary, 

flash, and kettle calciners: multiple 

hearth furnaces; and expansion 

furnaces. 

The following processes and process 

units used at mineral processing plants 

would hot be regulated under the NSPS: 

vertical shaft kilns in the magnesium 

compounds Industry, the chlorinationoxidation process in the titanium 

dioxide industry; coating kilns, mixers, 

and aerators in the roofing granules 

industry; and tunnel kilns, tunnel dryers, 

apron dryers, and grinding equipment 

that also dries the process material used 

in any of the 17 mineral industries. The 

reasons for their exclusion are discussed 

in Section IV_A. of this preamble. 

fl. Pollutant(s) To Be Regulated 

The proposed standards would limit 

emissions of PM from new. modified, 

and reconstructed mineral calciners and 

dryers. 

C. Best Demonstrated Technology 

The BDT ia the technology for 

emission reduction on which the 

proposed amission standards are based. 

The BDT for controlling emissions from 

calciners and dryers in this source 

category Is the use of a fabric filter, wet 

scrubber, or electrostatic precipitator 

(ESP), ln cases where either of two 

control devices can be used on the same 

type of process unit and both devices 

are cost effective, both control devices 

are considered BDT. 

Many of the control devices on 

existing calciner and dryer facilities are. 

or are capable ot achieving emission 

levels below the State implementation 

plan (SIP) level. This same control 

technology that is used at existing plants 

can also be used at new plants to 

achieve the NSPS. However, in most 

cases, facilities that become subject to 

the NSPS will only have to perform 

control device maintenance more 

frequently than is typical at existing 

plants, or modify control device 

operating parameters (i.e., increase the 

pressure drop on a wet scrubber) from 

those at existing fadlities to ensure 

compliance with the NSPS. By requiring 

better operation and maintenance 

procedures, the NSPS will preclude the 

deterioration in performance of new 

source control devices to the PM SIP 

levels or to the allowable State opacity 

limits. 

D. Affected Facility 

The affected facility in each mineral 

industry is the calciner or dryer process 

unit. Feed and product conveyors are 

not considered part of the affected 

facility. 

E. Format for the Standards 

The format selected for these 

standards would be the concentration of 

PM emissions per standard unit of gas 

flow, i.e., grams of particulate per dry 

standard cubic meter of gas (g/dscm) 

(grains per dry standard cubic foot of 

gas [gr/dscf]). 

F. Actual Standards 

The proposed standards would limit 

the concentration of PM at the outlet of 

a control device to 0.09 g/dscm (0.04 gr/ 

dscf) for calciners and for calciners and 

dryers installed in series and 0.057 g/ 

dscm (0.025 gr/dscf) for dryers. 

C. Standard for Visible Emissions 

Stack emissions would also be limited 

to 10 percent opacity for process units 

controlled with dry control devices. The 

visible emissions standard would not 

apply to afTected facilities that use wet 

scrubbers to control emissions. Instead, 

monitoring and reporting of the 

operating parameters of wet scrubbers 

(pressure drop and liquid flow rate) 

would be required to indicate that the 

control device is properly operated and 

maintained on a routine basis. 

H. Modification/Reconstruction 

Considerations 

According tolhe General Provisions 

(40 CFR 80.14). a modification is defined 

as certain physical or operational 

changes to an existing faciUty that 

would increase the PM emission rate to 

the atmosphere from that facihty. If a 

raw material or fuel change occurs for 

which the calciner or dryer-was 

originally designed, the change- is not 

considered a modification. However, if a 

change is made that allows a unit to 

bum a fuel or process a new material for 

which it was not originally designed and 

any increase in PM emissions occurs 

because of this change, the change is 

considered to be a modification. 

According to the General Provisions 

(40 CFR 80.15). reconstruction is defined 

as the replacement of the components of 

an existing facility to die extent that (1) 

the fixed capital cost of the new 

components exceeds 50 percent of the 

fixed capital cost required to construct a 

comparable new facihty and (2) it is 

technically and economically feasible 

for the facility to meet the applicable 

standards. Because replacement or 

refurbishing of equipment parts subject 

to high temperatures, abrasion, and 

impact (e.g., end seals, flights refractory 

lining) is performed on a regular basis, it 

is considered routine maintenance 

rather than reconstruction or 

modification. 

/. Compliance Testing 

Under the proposed standards, 

compliance tests for FM emissions 

would be required for all air pollution 

control devices on new, modified, and 

reconstructed calciners and dryers. The 

PM emissions would be measured using 

EPA Reference Mediod 5 to determine 

compUance with the stack emissions 

standards. Visible emissions from dry 

control devices would be measured 

using EPA Reference Method 3. 

/. Monitoring Requirements 

With the exception of die four process 

unit/control device combinations 

discussed below, the owner or operator 

of a calciner or dryer who uses a fabric 

filter or a dry ESP control device to 

comply with the mass emissions 

standards would be required to install. 

calibrate, maintain, and operate a 

continuous monitoring system to 

measure and record Uie opacity of 

emissions discharged into the 

atmosphere from the control device. In 

Ueu of a continuous opacity monitoring 

system, die owner or operator of a 

gypsum flash or kettle calciner or cf a 

perUte rotary dryer or expansion 

furnace who uses a dry control device 

could have a certified observer record 

diree 6-minute averages of die opacity of 

visible emissions from die control 

device, once per week of operation, in 

accordance widi EPA Reference Mediod 

9. . 

When a wet scrubber is used to 

comply widi die calciner or dryer mass 

emission standard, die owner or 

operator would be required to install, 

calibrate, maintain, and operate 
P.5 

15440 Federal Registe? / Vol. 51, No. 78 j Wednesday, April 23, 1986 f Propoaed Rules 

monitoring devices diat continuously 

measure and record die pressure loss of 

the gas stream through die scrubber and 

the scrubbing liquid flow rate to die 

scrubber. The pressure loss monitoring 

device must be certified by tha 

manufacturer to be accurate widiin ± 1 

inch of water column (in. w.c) gauge 

pressure and must be calibrated on a 

simiannual basis in accordance widi 

manufacturer's instructions. The liquid 

flow rate monitoring device must be 

certified by the manufacturer to be 

accurate widiin ±5 percent of design* 

scrubbing liquid flow rate and must be 

calibrated on a semiannual basis in 

accordance with the manufacturer's 

instructions. 

K. Reporting and Recordkeeping 

The proposed standards would 

require industry to provide the reports 

required under die General Provisions 

(40 CFR 60.7, 60.8 and 60.11). The . 

General Provisions require the owner or 

operator of an affected facility to notify 

the Administrator or his designated 

representative of die construction, 

anticipated startup, actual startup, and 

control system perfonnance test of an 

affected facility, including initial 

compliance testing for die visible 

emissions standards. 

During the most recent performance 

test, an average value of each wet 

scrubber operating parameter will be 

determined for the control device. 

Exceedances of this»value, defined as 

less than 90 percept or greater that 110 

percent of the average pressure drop, or 

less than 80 percent or greater man 120 

percent of the average liquid fiow rate, 

wiil be required to be reported to the 

Administrator semiannually. All 8-

minute periods during which the average 

opacity from dry devices is greater than 

10 percent will also be required to be 

reported semiannually. 

III. Impacts ofthe NSPS 

At present, 48 industry/process unit 

combinations are known to exist A 

total of 87 model facilities were 

developed to represent one to three 

production sizes for each industry/ 

process unit combination. As a result, no 

single "typical facility" exists that can 

be used as the basis for analyzing die 

impacts of the proposed standards. 

Instead, impacts were determined for 

model facilities representative of die 

typical-size process unit for each of the 

48 industry/process unit combinations. 

There are expected to be 198 affected 

facilities in the first 5 years after the '• 

NSPS would become applicable. Of die 

198 affected faculties. 94 wiU ba 

constructed to provide new production 

capacity and 104 will replace existing. 

facilities. Impacts to the NSPS were 

based on this projection. 

A. Air 

In die fifth year after the NSPS would 

become applicable (1930), nationwide 

emissions of PM would decrease by 

7,900 Mg (8,800 tons)'compared to 

emissions allowed under typical SIP's. 

This represents a 78 percent reduction in 

emissions. 

B. Water 

The standards would not produce 

adverse water pollution impacts. 

C. Solid Waste 

The nationwide increase in solid 

waste (as a sludge containing 70 percent 

moisture) in 1990 would be 7.500 Mg 

(8,300 tons), compared to the SIP level. 

D. Noise 

The noise introduced by air pollution 

control devices at new or modified 

facilities (e.g.. fan noise) would not 

significandy increase die noise levels 

beyond those already produced by 

processing equipment at the plant 

E. Radiation 

There will be no radiation impacts 

resulting from die proposed standards. 

F. Energy 

In the fifth yeaj after die NSPS would 

become appUcable, Uie maximum 

increase in energy' consumption for 

mineral calciner and dryer control 

devices nationwide would be 17,000 

megawatt-hours (MWh), compared to 

the SIP level for typical facilities. This 

incremental energy requirement due to 

the NSPS to operate control equipment 

would be less than 1 percent of Uie 

energy demands to operate die calciner 

and dryer process units. 

G. Control Costs 

1. Nationwide Costs. Based on 

industry growth projections, it ia 

estimated that 62 new calciners and 32 

new dryers will be installed in the first 5 

years Uiat the NSPS is in effect. In 

addition, during this same time period it 

is expected diat 60 calciners and 44 

dryers will be replaced at existing 

facilities at the end of dieir useful lives. 

The total nationwide incremental 

capital cost of poUution control 

equipment in 1990 would range from S2-2 

to $3.0 miUion under die proposed 

standards compared to die SIP level. 

The variation in costs is due to diose 

process units for.which either a fabric 

filter or a wet scrubber could be 

installed. If only wet scrubbers were 

installed, the capital cost of installation 

would be lower dian if only fabric filters 

were installed. 

The total nationwide incremental 

annualized cost of pollution control 

equipment in 1990 would range from S0.7 

to $1.0. million. If only wet scrubbers 

were installed where an option exists, 

the annuaUzed costs-would be higher 

than if only fabric filters were installed 

because of die additional energy costs 

associated widi operating a scrubber 

and die product recovery credits 

associated widi operating a fabric filter. 

At Uie 94 new facilities, capital 

control costs would be incurred for wet 

scrubbers and ESP*s where the control 

device design parameters (pressure 

drop, plate area) are upgraded to 

achieve an NSPS emission limit more 

stringent than Uie SIP emission limit. For 

these same facilities, annualized control 

costs would be incurred under the NSPS 

for fabric filters because of improved 

operation and maintenance and for wet 

scrubbers and ESP's because of Uie 

energy demand associated with 

upgraded design parameters. For the 104 

new process units Uiat are projected in 

die first 5 years of Uie NSPS to replace 

existing units at the end of their useful 

lives, capital control device costs would 

increase over baseline levels in 23 

percent of die cases as a result of 

upgrading the design of the control 

devices (e.g.. increased pressure drop for 

a wet scrubber). In 11 percent of Uie 

cases, the existing wet scrubber control 

devices are operated at pressure drops 

that achieve both Uie SIP and NSPS 

emission Umits, and. therefore, no. 

incremental capital costs would be 

incurred as a result of Uie NSPS. In 66 

percent of the cases, fabric filters 

installed to meet SEP emission Umits 

would achieve Uie NSPS emission limit 

with improved operation and 

maintenance. Therefore, there is no 

capital cost increase for fabric filter 

control devices. The annualized control 

device costs for these 104 projected 

process units would increase as a result 

of improved operation and maintenance 

of fabric filters (66 percent of the cases) 

or as a result of upgrading die design of 

a wet scrubber or ESP (23 percent of the 

cases). As vnth the capital costs, 

annualized control costs would not 

change in 11 percent of Uie cases where 

wet scrubbers achieve both die SIP and 

NSPS emission Umits. 

H. Economic Effects 

The projected growdi and profitability 

of the 17 mineral industries are not 

expected to be affected adversely by 

implementation of die NSPS. FOE 15 of 

the 17 industries included in Uie 

analysis, the product price increases 
P.6 

Federal Register / Vol. 51. No. 78 / Wednesday, April 23, 1986 / Proposed Rules 15441 

diat would be required as a result of 

implementation of die NSPS would 

typically be less than 0.5 percent. 

Typical-size facilities in the fire clay and 

lightweight aggregate industries could 

experience product price increases of 1 

and 1.75 percent respectively, as a 

result of implementation of the NSPS. 

Additional discussion about the 

economic effects on these two industries 

in presented in Section IV.G.5 of diis 

preamble. 

IV. Rational for Proposed Standards 

A. Selection of Source Category 

1. Threat to Public Health and 

Welfare Posed by Mineral Calciners 

and Dryers. The mineral industries 

being covered by the NSPS already have 

been shown to be major contributors to 

air pollution diat may reasonably be 

anticipated to endanger public healdi or 

welfare. There are 6 source categories 

currently listed on the NSPS priority Ust 

(44 FR 49225. August 21.1979, revised 

January 8. 1982) diat include 15 of die 17 

mineral industries being covered by the 

NSPS. Number 13 on the priority list is 

Nonmetallic Mineral Processing, which 

includes sand and gravel, clay (ball clay, 

bentonite. fuller's earth, kaolin), talc, 

feldspar, diatomite, and vermiculite. 

Number 14 on die priority Ust Metallic 

Mineral Processing, includes aluminum 

and titanium. The lightweight aggregate 

industry (clay, shale, and slate) is 

Number 32 on die NSPS priority list. 

Numbers 34.48, and 54 on the priority 

list are Gypsum, Brick and Related Clay 

Products (fire clay), and Perlite, 

respectively. For die Brick and Related 

Clay Products source category, only 

calcining and drying of raw materials 

prior to firing of Uie brick are included in 

diis source category. 

The two industries covered by die 

NSPS that are currently not included in 

the NonmetalUc Mineral Processing or 

Metallic Mineral Processing source 

categories listed on die priority Hst are 

roofing granules and magnesium 

compounds. The Agency is proposing to 

expand diese two source categories 

(Nos. 13 and 14) to include roofing 

granules and magnesium compounds. 

Roofing granules logicaUy belong in the 

Nonmetallic Mineral Processing source 

category and magnisum compounds 

belong in die Metallic Mineral 

Processing source category and are, 

therefore, being added. The calciner and 

dryer processing units in these two 

industries process materials that can be 

controUed widi similar effectiveness, 

costs, and control techniques as calciner 

and dryer units in the other industries 

being covered by the NSPS. 

2. Inclusions and Exclusions from the 

Source Category. The standards would 

apply to new, modified, and 

reconstructed calciners and dryers used 

in die 17 mineral industries discussed 

above. Drying in defined as the removal 

of uncombined (free) water from the 

mineral material dirough direct or 

indirect heating. Calcining is the 

removal of combined (chemically 

bound) water and/or gases from the 

mineral material dirough direct or 

indirect heating. Combined calciner/ 

dryer systems, which are common in the 

diatomite industry, would also be 

included and would be required to meet 

the emission limits established for 

calciners. 

The following processes or process 

units will not be regulated under the 

NSPS: barite and borate manufacturing, 

iron ore pelletizing, pumice and sodium 

sulfate manufacturing, chlorination/ 

oxidation processes in die titanium 

dioxide industry, apron and tunnel 

dryers, grinding mills diat dry process 

material, coating kilns in Uie roofing 

granules industry, vertical shaft kilns in 

die magnesium compounds industry, 

and coolers. The reasons for their 

exclusion are discussed .below. 

In 1981. aU mineral industries were 

reviewed to ascertain which industries 

had process equipment that could be 

considered dryers or calciners. The 

following 20 industries were selected for 

further analysis in the generic source 

category: alumina, ball clay, barite, 

bentonite, borates, diatomite, feldspar, 

fire day, fuller's earth, industrial sand, 

iron ore pelletizing. kaolin, magnesium 

compounds, magnesium metal, pumice, 

roofing granules, sodium sulfate, talc, 

titanium dioxide, and vermiculite. Five 

of these original 20 industries, barite. 

magnesium metal, pumice, sodium 

sulfate, and iron ore pelletizing were 

subsequendy dropped from 

consideration due to their limited 

growth potential. In addition, the 

Agency determined that chlorination/ 

oxidation processes in die titanium 

dioxide industry did not involve the use 

of calciners or dryers to remove water, 

and, therefore, these processes were 

also dropped from this generic source 

category. The borate industry was 

dropped from further consideration 

along with die following process units: 

apron dryers, tunnel dryers, coolers, 

grinders that also dry process material, 

coating kilns in die roofing granules 

industry, and vertical shaft kilns in die 

magnesium compounds industry. The 

borate industry was dropped from 

further consideration because the 

potential emission reduction below the 

baseline level in die fifth year would be 

less than 91 Mg (100 tons) for the entire 

industry. Apron dryers and tunnel 

dryers are used infrequently and are 

typically uncontrolled at existing 

facilities. Based on State compliance 

test data, apron and tunnel dryers have 

uncontrolled particulate emission levels 

lower than the proposed emission limit 

for other mineral dryers. All cooler types 

were also dropped from further 

consideration because of their lack of 

emission reduction potential. Grinding 

equipment that also dries the process 

material is currently regulated by the 

nonmetallic minerals NSPS for any of 

the industries covered by Uie NSPS. 

Two odier process units, coating kilns 

and vertical shaft kilns, were deleted 

because they did not fit the definition of 

a typical calciner. Coating kilns used in 

the roofing granules industry bake 

colored clay pigments onto already 

dried granules. Vertical shaft kilns are 

used in the magnesium compounds 

industry, and they sinter the raw 

material after it has been calcined in a 

multiple hearth furnace. 

fl. Pollutant(s) to be Regulated 

1. Particulate /na«e/-.'Particulate 

matter is the principal pollutant emitted 

to die atmosphere from mineral 

calciners and dryers. Nationwide PM 

emissions in 1990 from calciners and 

dryers in the 17 mineral industries 

would be approximately 10.200 Mg 

(11.300 tons) under existing SIP 

regulations. Continuous emission 

reduction systems are available Uiat 

would reduce emissions as much as 78 

percent below die SIP level. 

2. Other Pollutants Considered. Most 

calciners and dryers are fired with 

natural gas and generate oxides of 

nitrogen (NO,) and small quantities of 

sulfur dioxide (SO?) as combustion 

products. It is expected Uiat natural gas 

will continue to be die primary, fuel used 

to fire most of these units. Bentonite, fire 

clay, and lightweight aggregate are the 

only industries covered by the NSPS 

that routinely use coal for fuel. None of 

die data obtained from the 17 industries 

showed the usage of NO, or SO? control 

technology. 

The Agency tested one fire clay rotary 

calciner and four lightweight aggregate 

rotary kilns to obtain an SO? data base 

for future investigation of SO? 

emissions. The results of these five tests 

are presented in die BID for the NSPS. 

and they indicate that both fire clay and 

lightweight aggregate rotary calciners 

show a potential to be major sources of 

SO? emissions. This limited data base is 

insufficient however, to develop 

technology transfer for SO? control from 

other-source categories, such as 
P.7 

Fosbral Sagistsr / VoL 51, No. 78 / Wedneoday. April 23, 1S88 / Prepoead Rules 

industrial boilers, that use flue gas 

desulfurization systems for SO? control. 

Data for NO, emissions were obtained 

for five rotary calciners in the fire clay, 

lightweight aggregate, and titanium 

dioxide industries. These data show that 

both fire clay and lighweight aggregate 

rotary calciners are potential major 

sources of NO, emissions. However, 

control technology for NO, emissions 

has not been demonstrated on mineral 

calciners. 

Because SO? and NO, control 

technologies are not used in die 17 

mineral industries, and because the data 

base is insufficient at this time to 

develop technology transfer for SO, and 

NO? control, the Agency is not 

regulating SO? and NO, emissions from 

mineral calciners and dryers. 

C Selection of Best Demonstrated 

Technoiogy 

Section 111 of the Clean Air Act 

requires tf*at standards of performance 

reflect BDT, which is the technology that 

yields the greatest emission reduction 

without imposing unreasonable impacts. 

Essex Chemical Corp. v Ruckelshaus, 

486 F.2d 427. (D.C. Cir. 1973). 

1. Applicable Control Technologies. 

An effident PM coUection device used 

in the mineral industries is the fabric 

filter. Data gathered during emission 

tests on fabric filters used to control 

emissions from a variety of ealciners 

and dryers indicate that variations in 

die size distribution of PM and die 

mineral processed do not typically affect 

fabric filter performance. Other 

collection devices used in the mineral 

industries include dry ESPs and wet 

scrabbsrs. Dry ESP's are used only in 

die alumina, bentonite, gypsum, -

lightweight aggregate, and magnesium 

compounds industries. Bolh fabric filters 

and ESP's can achieve greater man 99 

percent PM collection efficiency for 

calciner aad dryer emissions is a variety 

of mineral industries. 

Tha effectiveness of wet scrubbers for 

the coatrol of ealdner and dryer PM 

emissions is directiy related to the 

pressure drop across Uie scrubber. The 

collection efficiency fer a given particle 

size distribution increases as pressure 

drop increases. Pressure drops for wet 

scrubber-controlled caldners and dryers 

range ferm 9.5 to 70 in. wx. For example. 

higher pressure drops are required for 

die smaller particle size distributions of 

titanium dioxide than are required for 

the larger particle size distributions of 

industrial sand to achieve the same 

emission Umit 

The cost of opera ting poUution control 

equipment for calciaexs and dryers 

increase s Wilh • nrm>m}aaA.ma\nte.nanri' 

and improved efficiency. Fabric fillers 

must be equipped with heat-resistant 

bag materials ouch as Teflon1 or 

Nomex0 to control PM entrained in 

heated gas s&eams from calciners and 

dryers. The cast of complying with an 

emission Umit increases as die emission 

limit decreases because more labor 

hours are required to maintain die fabric 

filter in its most efficient state. 

Maintenance of ESP's also must be 

performed more frequentiy to achieve 

greater emission reduction. In addition, 

the spedfic collection area of an ESP 

may need to be increased or multistage 

ESP's may need to be used to obtain a 

greater PM emission reduction. The cost 

of operating a wet scrubber increases 

with increasing pressure drop because 

of the additional energy required to 

achieve Uie higher pressure drop across 

the scrubber. 

m many instances, a particular 

caldner OT dryer could be controlled by 

either a dry control device (fabric filter 

or ESP) or a wet scrubber. For diese 

units, wet scrubbers would typically 

have lower capital costs and higher 

annualized costs than fabric filters or 

ESP's. 

2. Regulatory Alternatives '. 

Considered. The EPA considered the 

following regulatory alternatives as the 

means of achieving control of emissions: 

a. Regulatory Alternative 1 (RA I] is 

equivalent to no additional regulatory 

action beyond tiiat required by typical 

SIPs. i.e., baseline. Allowable PM 

emissjorrlrmits under SIFs vary widely 

as discussed below. 

Individual States Bse a variety of 

regulations and formulas to determine 

allorcab&s PM emissions from calciners 

and dryers used in mineral processing 

industries. For die determination of RA I 

levels for each process unit each 

mineral industry was surveyed, and Uie 

number and type of control devices used 

to control PM emissions from caldners 

and dryers were tabulated. Tbe moot 

commonly ucsd control device an each 

process unit was selected as hassling 

control technology fcr that type oi unit 

To determine die range of emissions 

allowed by Slates for o particular 

industry, concentration emission Umits 

equivalent to allowable emissions under 

die SIP's vyere calculated kt? each size 

and type o£ model prosess unit Typical 

size process uaitfl were titen used to 

develop a ciBgle, nariaoeride average 

SIP emission limit using a weighted 

average of total production by State. If 

the calculated baseline emission Umit 

was gTeeJen dian 0.45 gjdacsv (0.20 gr/ 

dscf) aad tho boeelisa control 

technology eras a faferic filter. U was 

assumed, basad upon EPA studies 

relating please opacities to wwi 

concentrations, of P£4 drat tha typical 

State opacity limits of 20 percent are 

more stringent tiian the corresponding 

SIP mass emission limits. For these 

cases, a baseline emission concentration 

that would approximate an exhaust gas 

opacity of 20 percent i.e.. 0.34 g/dscm 

(0.15 gr/dscf). was selected for 

evaluation. 

Data obtained from EPA-conducted 

tests or from State compliance tests 

approved by EPA show Uiat, in some 

instances, controlled emission levels 

from calciners and dryers at existing 

fadlittes ore significantly lower than the 

mass emission Umits stipulated by the 

appropriate SIP regulations. Therefore, 

die same control technology that is used 

at existing fadlities could also be used 

at affected faciUties to achieve the 

NSPS. However, in many cases. 

fadUties oabject to the NSPS would 

have to perform coatrol device 

maintenance more frequently dian is 

typical at existing plants or modify 

coatrol device operating parameters 

from diose at existing facilities to ensure 

compUance widi the NSPS. By requiring 

better operation and maintenance 

procedures, die NSPS would reduce Uie 

deterioration in performance of new 

source control devices to Uie SIP levels 

or to Uie allowable State opadty limits. 

b. Regulatory Alternative II (RA II) is' 

equivalent to an emission control level 

for bodi calciners and dryers of 0.09 g/ 

dscsi (0.04 gr/dscf). As discussed below. 

the results of emission tests and 

scrubber performance modeling indicate 

diat this level could be achieved by all 

affected faciUties in ail of Uie 17 mineral 

industries. 

c. Regulatory Alternative III (RA III) is 

equivalent te an emission control level 

for calciners of 0.09 g/dscm (0.04 gr/ 

dscf) and on emission control level for 

dryers of 0.057 g/dscra (0.025 gr/dscf). 

The emission test results indicate that a 

higher degree of emission control for 

dryers versus calciners is achievable. 

The additional emission reduction 

achievable by RA III over RA II requires 

only a small amount of additional 

maintena$£8 on the control devices for 

dryers. 

Emission test data from 52 source 

tests comprise die data base. Of the 52 

tests. 25 vaere conducted on dryers. 

These data show Uiat all ESP- and fabric 

filter-controlled dryers can achieve die 

emission level associated with RA III of 

0.057 g/deon £0.025 gr/dscf) during 

normal operation. Tests of 15 wet 

scrubber-controlled dryers in 7 

industries indicate Uiat for 10 of Uie 15 

dryers, relatively low-energy wet 

scrubbers (3- to 10-in. w.c pressure 

drop) were able to reduce emissions to 

less dian die lev-d of RA 111. The odier 
P.8 

Federal Register / Vol. 51. No. 78 / Wednesday, April 23, 1988 / Propoaed Rules 15443 

five dryers were unable to achieve Uie 

level of RA III widi a low-energy 

scrubber. The emissions for aU 15 dryers 

averaged 0.04 g/dscm (0.02 gr/dscf) and 

never exceeded 0.09 g/dscm (0.04 gr/ 

dscf). 

Of die 52 source tests comprising die 

data base, 27 tests were conducted on 

calciners. These data show that all ESPand fabric filter-controlled calciners can 

achieve die emission level associated 

with RA III of 0.09 g/dscm (0.04 gr/dscf) 

during normal operation. Of me 27 tests, 

9 tests were conducted on wet scrubbercontrolled calciners in 5 industries. Of 

the nine tests, six of the calciners had 

emissions at or below the level of RA III. 

The concentration of PM emissions from 

these units averaged 0.09 g/dscm (0.04 

gr/dscf) and never exceeded 0.17 g/ 

dscm (0.08 gr/dscf). 

Several dryers and calciners tested 

did not meet the emission limits of RA 

III using low-energy wet scrubbers as 

control equipment. To evaluate the 

performance of a higher energy scrubber 

on diese systems, an EPA computerized 

scrubber model, as described in EPA 

report No. EPA-600/7-78-026, was used. 

These analyses indicate diat dryers Uiat 

had emissions in excess of 0.057 g/dscm 

(0.025 gr/dscf) could be controlled below 

diat level by increasing scrubber 

pressure drops from 2 to 15 in. w.c. 

Calciners could be controlled to below 

0.09 g/dscm (0.04 gr/dscf) with 17- to 24-

in. w.c. pressure drop scrubbers in place 

of low-energy scrubbers (8 to 14 in. w.c.) 

now in use. Higher pressure drops (17 to 

43 in. w.c.) are required for industries 

such as titanium dioxide, whose calciner 

and dryer emissions are composed of 

smaller partides, than are required for 

industries such as fuller's earth (11 in. 

w.c), whose calciner and dryer 

emissions are composed of larger 

particles. 

Representatives of die lightweight 

aggregate industry commented at the 

National Air PoUution Control 

Techniques Advisory Committee 

meeting that it would be unreasonable 

to require tht pressure drop of wet 

scrubbers used to control rotary. 

calciners to be increased by 13 in. wx. 

to reduce emissions from oertais. tested 

fadlities. whidi had emissions ranging 

from 0.10 to 0.11 g/dscm (0.042 to 0.048 

gr/dscf). to die NSPS level of ooo trol. 

However, die 13 in. w.c. fs dia increase 

- in the pressure drop dial would he 

required to reduce emissions from die 

SIP level (0.20 g/dscm [0-09 gr/dacfy.to 

die NSPS lave! (0.09 g/dscm [0J0A gr/ 

dscf]) of control. Tne paesauct drop 

would have to be increaaad hy -only 3 to. 

5 in. w.c. to reduce emissions from the 

tested facilities to die NSPS level of 

control. 

Electrostatic precipitators are used 

primarily in the alumina, bentonite. and 

magnesium compounds industries. Test 

data for ESP-coatroded process units 

were obtained for a bentonite dryer, two 

alumina calciners, and two magnesium 

compounds calciners. Emissions from 

die dryer were 0.014 g/dscm (0.006 gr/ 

dscf), and emissions from die calciner 

ranged from 0.037 to 0JJ56 g/dscm (0.016 

to 0.025 gr/d3cf). 

There are 19 process unit 

combinations where no emission data 

were obtained. For these cases, one of 

two approaches was used to 

demonstrate whether die emission limit 

of RA 111 is achievable for Uiat process 

unit (1) Transfer of fabric filter 

technology from similar process units in 

other mineral industries whose PM 

emissions are more difficult to control 

than emissions from process units for 

which no data are available, or (2) tf-wet 

scrubbers were used oa existing process 

units of die type in question, then Uie 

scrubber performance model discussed 

earlier was used to determine Uie 

pressure drop required by a venturi 

scrubber to achieve die emission limit of 

RA III. For both of diese approaches, it 

was necessary to determine the process 

units that are most difficult to control. 

The Agency coUected grab samples of 

the product materials from all process 

units for which emission data were 

unavailable and performed sieve 

analyses on them to determine partide 

size distributions. Similar analyses were 

performed for grab samples of materials, 

collected during EPA-conducted 

emission tests. Analysis of the results of 

the sieve analyses indicates that the 

produds of heruonite rotary dryers (60 

percent less than 1.2 urn), fire clay 

rotary dryers (46 percent less than 1 

>im), and kaolin multiple hearth furnaces 

(62 percent Waa dian. 2 via), have die 

smaUest partide gize distribution* of all 

of die process units covered by tae 

NSPS. Emission testa were performed on 

process unita utilizing these three 

materials. The bentonite rotary dryer 

was.controlled by a fabric filter and had 

emission* oi 0-047 g/dscm (C*02 gr/aacf). 

The fire clay rotary dryer waa controlled 

by a 12-in. wx-presaure drop scrubber 

and had amiaaiona cf 0-Q88 g/dscm 

(0.038 gr/dacf). Tha kaolin SHdtipk 

hearth furnace waa also coatrodad by a 

12-in. w.c. pressure drop scrubber and 

had emiiiinna o£Gt047 g/dscm (Q0?0 gr/ 

dscf). 

In additioa (o taa tteva analyaas and 

outlet Boaas-amiaaioa data obtained, 

inlet PVC loading toth* control-device 

was measu rad aunac, tbt <TMi«ii^ teaU 

conducted by die Agency. The highest 

loading. 259 g/dscm (113 gr/dscf). was 

measured at Uie inlet ofa product 

recovery cyclone preceding a fabric 

filter controlling the bentonite rotary 

dryer. The inlet loading to the wet 

scrubber controlling the fire clay rotary 

dryer was 12 g/dscm (5 gr/dscf)- The 

kaolin multiple hearth furnace had an 

inlet loading concentration of 9 g/dscm 

(4 gr/dscf). 

These data are representative of the 

most difficult to control process unit 

combinations covered by the NSPS. 

Technology transfer analysis of the 

fabric filter-controlled bentonite dryer. 

with controlled emissions of 0.047 g/ 

dscm (0.02 gr/dscf). indicates thai other 

fabric filter-controlled calciners and 

dryers processing minerals with larger 

particle size distributions and lower 

inlet loading concentrations can achieve 

the emission limits of RA III. Similarly. 

wet scrubber-controlled calciners and 

dryers processing materials with a 

larger particle size distribution and 

lower inlet concentration than fire clay 

or kaolin can achieve the emission limits 

of RA III widi the appropriate pressure 

drop. 

The scrubber performan.ce model was 

used to determine the pressure drop 

required to achieve the emission limits 

of RA III for those units for which 

emission test data were unavailable and 

for those units controlled by low-energy 

wet scrubbers whose emissions 

exceeded the emission limits of RA III. 

For tiiose units for which emission test 

data were unavailable, input variables 

for the scrubber model were based on 

the smallest inlet particle size 

distribution and highest rnlet loading 

concentration obtained from emission 

test data for process units that had 

similar or smaller product material 

particle size distributions. Modeling of 

scrubber performance was performed on 

17 process units in 10 industries. The 

estimated pressure drop for larger 

materials such as industrial sand and 

roofing granules was approximately 3 in. 

wx. SraaUer-aused materials such as fire 

day. kaolin, and titanium dioxide would 

require scrubber pressure drops of 14 to 

43 in. w.c. to achieve the emission limits 

of RA III. For both fabric filter- and wet 

scrubber-controlled mineral calciners 

and dryers, the'data base supports Uie 

achievability of the emission limits of 

RA III by die most difficult to control 

procaas units. Emission test data for 

ESP-controlled calciners and dryers 

were all below du emission limits of RA 

QI aaa. Uurefore, ESP-controlled 

calciners and (fryers can also achieve 

the emiaaien bmUa of RA UI. 
P.9 

15444 Federal Register / Vol. 51. No. 78 / Wednesday, April 23, 1988 / Proposed Rules 

3. Environmental Impacts. The 

environmental impacts associated widi 

the NSPS include air. water, solid waste, 

and noise. The primary air poUution 

impact is from PM emissions. Regulatory 

Alternative I is equivalent to no 

additional regulatory action beyond that 

required by typical SIPs. i.e., baseline. 

As shown in Tables 1 and 2. die 

emission reduction attributable to RA II 

would be 3,550 Mg (3.920 tons) for dryers 

and 3,970 Mg (4,370 tons) for calciners in 

the fifth year (1990). The emission 

reduction attributable to RA III would 

be 4.000 Mg (4,420 tons) for dryers and 

3,970 Mg (4,370 tons) for calciners in the 

fifth year. The total annual PM emission 

reduction below baseline for all dryers 

and calciners in die fifth year for RA II 

would be 7,500 Mg (8,300 tons), or 73 

percent. The total annual PM emission 

reduction below baseline for all dryers 

and calciners in die fifth year for RA III 

is 7,900 Mg (8.800 tons), or 78 percent 

TABLE 1.—REGULATORY ALTERNATIVE IMPACTS 

ron ORYERS 

Regulatory 

altemaM 

conaaered 

• 

m 

Efnrasvjn 

reduction. 

Mg/yrxsso4 

4.000' 

Average 

eflecw 

neat 

versus 

besesne, 

*7Ug 

SSO 

770 

Average 

rawiwv 

•al oos 

srieome 

ness. $/ 

Ug* 

380 

310 

* Emrssion reduction range lor .-yc-cal see urvts. Reoucrjon 

credn was gjven io (he tabnc rlier wftere an action oasts. 

Breakdowns ara based on enaang percentages ol aacn 

devce. 

* iii leiiMimal cost vftectrveness*eddttronat oost ol nartmore-restnctiva control lecmqua. 

' Eraao n reduction attnbutabie to sv» SIP versus uncon. 

sceed dryar>> 337.300 Ug/yr. 

' Erraaon reduction below baiaina. 

TABLE 2.—REGULATORY ALTERNATIVE IMPACTS 

FOR CALCINERS 

Regulatory 

snemasve 

considered 

1 rhmMno) 

II and fli • 

Errvsson 

reduction, 

Ug/yrn 

1370' 

Average 

coat 

fjtlecrjven « 

varaue 

basevne. 

VUg 

410 

Average 

talcoat 

aneeoveness. 1/ 

Ug410 

' Ei rat ann raducam range lor typcal am una deduction 

credit was qrven to rne tabnc brier wnere an option exists. 

SreaMtowns are baaed on eason? percentages ol each 

oevice. 

" incremental oost arlectr»eneM» aortaanal coal ol nanmore-resrnc&ve control lecmgue. 

' Errasaon raduction annbutasie to ine SIP versus uncon-

><»ed c*ctners» 1SBSO0 Ug/yr. 

4

 The leva ol control lor caoners lor boot RA 11 and RA III 

Is 0 OS g/dscm. 

* Emaston reducaon below banana. 

Wet scrubbers are the only control 

devices on caldners and dryers in die 

mineral industries diat generate 

wastewater streams requiring treatment 

or disposal. Typically, a PMcontarninated water stream from a 

scrubber is pumped to a settling pond on 

die site and not discharged into 

navigable waterways. The solids settle 

in die pond, and the water is 

recirculated to die scrubber. When 

solids fill Uie pond. Uie pond can be 

dredged, and die solids can be 

landfilled. or a new pond can be 

constructed. Therefore, there would be 

no adverse water pollution impacts due 

to implementation of any of the 

regulatory alternatives. 

The material coUected by fabric filters 

and ESP's is typicaUy recycled back to 

die production process or is sold 

direcdy. Therefore, litde solid waste is 

generated by fabric filters and ESP's. 

The main source of solid waste would 

be Uie solids in die sludge produced by 

wet scrubbers. Typical dewatered 

sludge from a settling pond contains 

about 30 percent solids. The solids in the 

sludge are mainly the mineral processed 

by the dryers and calciners. The 

nationwide solid waste (as sludge 

containing 70 percent moisture) increase 

over baseline levels in 1990 would be 

7.000 Mg (7,700 tons) for RA II and 7,500 

Mg (8,300 tons) for RA DI. ln die case of 

Uie titanium dioxide industry, the sludge 

generated by wet scrubbers is recycled 

to the process, and, therefore, no solid 

waste is generated. Solid wastes from 

dryers and calciners in mineral 

industries presentiy are not classified as 

hazardous wastes under the Resource 

Conservation and Recovery Act. 

The noise introduced by air pollution 

control devices that would be required 

by either RA U or RA III will not 

significantly increase die noise levels 

beyond those already produced by 

processing equipment at die plant. 

4. Energy Impacts. Operation of fabric 

filters. ESP's, and wet scrubbers to 

control PM emissions requires electrical 

energy. For RA II and RA HI. die 

nationwide annual increase in energy 

demand of control devices over baseline 

levels would be 18.000 MWh and 17.000 

MWh. respectively. These values 

represent die highest incremental 

electric energy requirement between 

fabric filters and wet scrubbers where 

an option exists. The-addiuonal energy 

required to operate die control 

equipment under RA D and RA III 

compared to RA I is less than 1 percent 

of die energy demand to operate die 

dryer and calciner process units. 

Therefore, die application of additional 

emisson control above die baseline level 

will not significandy Increase die 

electrical energy demand of the mineral 

processing plants. 

5. Economic Impacts. To determine 

die economic impacts of the proposed 

NSPS on each of die 17 mineral 

industries, finandal analysis techniques 

were applied to die model fadlities to 

evaluate die affordability of the 

pollution controls. The principal 

technique employed is the calculation of 

the maximum percent product price 

increase. The annualized control costs 

of RA III were used in Uie analysis 

because diese costs are generally higher 

dian diose of RA II but are still 

considered to be reasonable. However, 

in a number of cases the annualized 

control costs for the two alternatives are 

the same and. in a few cases, the RA III 

costs are lower due to die product 

recovery credits resulting from fabric 

fiber use. a high product value, and die 

greater emission reduction achieved 

under RA Ql compared to RA II. 

The effect on product prices from 

implementation of die NSPS using Uie 

least costly control option for each of 

die model facilities in die 17 industries 

could range from a slight product price 

decrease for some industries to an 

increase of 1.75 percent for die 

lightweight aggregate industry. The 

product price increase for 15 of Uie 17 

Industries would typically be less than 

0.5 percent. For Uie fire clay industry, a 

typical-size vibrating-grate dryer by 

itself has a 0 percent product price 

increase. However, the combination of a 

typical-size rotary dryer (0.28 percent) 

and a typical-size rotary calciner'(0.95 

percent) to produce a single product 

could have a 1-2 percent product price 

increase. Aldiough the possible percent 

product price increases for fire clay and 

lightweight aggregate are higher than for 

die other 15 industries, these increases 

are not expected to have a significant 

effect on the output of either industry. 

8. Cost and Cost Effectiveness. The 

Agency is not requiring that any 

particular control device by used to 

meet die recommended standards. It is 

technically possible to meet Uie 

emission levels assodated with RA III 

with any of the control technologies . 

currently in use in each respective 

industry. For every industry, there is at 

least one control technology that is cost 

effective. It is die improved operation 

and maintenance of these devices Uiat 

enables die same control device to 

achieve a lower emission level under 

RA U or RA ni dian under RA I (e.g., Uie 

same scrubber would be operated at a 

higher pressure drop or fabric filter bags 

are replaced more frequentiy). 

The cost-effectiveness (C/E) values 

for die model sizes of each process unit 

would range from a net credit of $1,000/ 

Mg (S910/ton) to a cost of S5.500/Mg 

(S5.000/ton) for RA II versus baseline. 

AU but one process unit, however, 

would have C/E values of less than or 

equal to $1.700/Mg ($1.500/ton) for RA II 

versus baseline. As shown in Tables 1 

- and 2, die average C/E for die least 
P.10 

Federal Register / Vol. 51, No. 78 / Wednesday. April 23, 1988 / Proposed Rules 15445 

costly control option for all model sizes 

of calciners and dryers used in die 17 -

industries would be $410/Mg f$370/ton) 

and $380/Mg ($350/ton), respectively, 

for RA Q versus baseline. The C/E of die 

perlite rotary dryer controlled by a 

fabric filter is $S,500-Mg ($5,00CAonf. 

This unit has a high C/E because die 

emission reduction potential is small 

while the cost of achieving mis small 

amount of emission reduction is 

relatively high. However, the additional 

emission reduction that would be 

achieved under RA Ql would decrease 

the C/E to $2.200/Mg (52.000/ton), which 

is reasonable. 

For RA QI versus baseline, (he C/E 

would range from a net credit of $1,000/ 

Mg ($940/ton) to $Z200/Mg ($2,O00/tcm). 

As shown in Tables 1 and 2. the average 

industry-wide C/E for calciners' and 

dryers would be $4M/Mg (S370/ton) and 

$270/Mg ($250/ton), respectively. 

For RA III versus RA U. the C/E 

values for die model sizes of dryers 

would range from a net credit of $1,300/ 

Mg (SUOO/ton) to $1,900/Mg (W.700/ 

ton). The average incremental C/E for 

dryers for RA UI versus RA II i»$310/ 

Mg ($280/ton). Because the emission 

levels of RA U and RA IU are the same 

for calciners. diere is no average 

incremental C/E value. 

The C/E valuea are highly dependent 

on die product recovery credits for dry ' 

control devices. The product values 

used to calculate product recovery 

credits ranged from $8.00/Mg ($8.00/ton) 

for gypsum to $1.430/Mg ($1,300/ tan} for 

titanium dioxide. The high dollar value 

of mineral material* such as titanium 

dioxide results in large product recovery 

credits, and. therefore, negativa C/E 

values for some dry coatrol devicas. Far -

this same reason, if only wet scrubbers 

are used where an option exiats, the C/E 

is typically higher dian & wfnsidbe if 

only fabric filters are used. . 

7. Rationale for selecting Regulatory 

Alternative 111. Comparison of tite 

regulatory alternatives iiniirjtfrxi thai RA 

QI would result in a significant seduction 

in PM emissions widi minim*! adverse 

water poUution. salid waata. aad noise 

impacts. For RA QL Ihe inrrpigp- in 

energy comsumptkxi compared to 

baseline levels would aat be sig»ificant 

and the coats and erannnir iipacts 

would be teisnnnhrp.-SeLtclaan ei RA QI 

results in tha maximum eaaiaaian 

reduction below baselinelevela-al a 

reasonable cost for thia source category. 

The data base inalcates tsai dryers can 

achieve a lower eaiission Umit than 

calciners can achieve, across all 17 

industries, without a significant 

additional coat compajed tothe 

addStfonatemiaaiaa reduction oftf ained. 

Therefore. RA Ql waa selected'as tne 

recommended emission Umit for 

regulation of calciner and dryer 

emissions. -

D. Selection of Affected Facility 

1. General Principles. The choice of 

die affeded facility is based on the 

Agency's interpretation of Section 111 of 

the Clean Air Act and on the judicial 

construction of its meaning. See 

ASARCO. Inc. v. EPA. 578 F. 2d 319 

(D.C. Cir. 1978). Under this sedion, 

standards of performance must apply to 

new stationary sources of pollution, i.e.. 

sources that begin construction, 

reconstruction, or modification after 

EPA proposes the standards. 

"Source" is defined as "any building, 

structure. facUity. or installation which 

emits or may emit any air pollutant" 

[Section 111(a)(3)]. Most industrial 

plants, however, consist of numerous 

pieces or groups of equipment that emit 

air poUutants and that may be viewed 

as "sources." The EPA Uierefore uses 

the term "affected facility" to designate 

the equipment, within a particular kind 

of plant. Uiat is chosen at the "source" 

covered by a given standard. 

In designating die affected facUity. 

EPA determines which piece or group of 

equipment is die appropriate unit (thie 

source) for separate emission standards 

in the particular industrial context 

invoFved. The determination is made in 

Ught of die terms and purpose of sedion 

111. One major consideration in this 

decision is tiiat a narrow designation 

usually brings replacement equipment 

under standards of performance sooner. 

If. for example, an entire plant is 

designated as die affected facUity, die 

standards would cover no part of die 

plant unless the replacement causes tbe 

plant as a whole to be "modified" or 

"reconstructed." The plant as a whole is 

modified only if ita aggregate emissions 

are increased by the physical change in 

it, or by (he change in its method of. 

operating. Similarly, Uie plant is 

reconstructed only rf: (1) Its cost of 

replacement exceeds 50 percent ofthe 

fixed capital costs required to build a 

comparable new faciEtr and (2) meeting 

the applicable standards is 

technologically and-£C£uoamic*Uj 

feasible. 

QB the other hand, if each.piece oi 

equipment is deaignatad aa die aflactad 

facility, than as each piece is replaced, 

the new piece wilCbt a naw somce 

subject to tbe standard. Since aae 

purpose of section 101. is to tauiinrua 

emissions hy achieving emission; 

limitation reflection BOT at all new 

sources, a iiarraw designation of tha 

affectidiaciCty ia generally tiia 

appropriate choice-ILanaucea diat tbestandard wUl caver new pmioainn. 

sources within plants as they are 

installed. For diis reason. Uie proposed 

NSPS would designate each calciner 

and dryer as Uie affected facility 

because to do so would maximize the 

coverage of the standards without 

causing unreasonable costs or other 

unreasonable impacts. 

2. Other Affected Facilities. The , 

definition of an affected facility in each 

mineral processing industry is each 

calciner or dryer process unit. Selection 

of other affected faciUties for Uie NSPA » 

was not required because Uie equipment 

other dian caldners and dryers, i.e. 

crushers. grinding mills, screening 

operations, bucket elevators, belt • 

conveyors, bagging operations, storage 

bins, and enclosed truck or railcar 

loading stations, is already covered by 

the metallic and nonrnetallic minerals 

NSPS. 

3. Rational for Selecting Affected 

Facility. Designation of each calciner 

and each dryer as the affected facility 

will ensure the greatest emission 

reductions and will ensure that 

replacement calciners and dryers will be 

regulated by the NSPS. This designation 

will also maximize .die-coverage of the 

standards by the modification and 

reconstruction provisrons,.Therefore. 

each cafrineT and each dryer is 

designated as an affected facility. 

E. Selection of Emission Sources 

The emission sources to be regulated 

are calciners and dryers. Particulate 

matter emissions from calciners and 

dryers are typically controlled by a 

fabric filter, wet scrubber, or an ESP. To 

ensure that all PM emissions from 

affected facilities are regulated by the 

proposed standards, it is necessary to 

have an emission limit. A visible 

emission standard would also be 

enforced far dry control devices. 

F Selection of Format for Standards. 

1. Alternative Formats Considered. 

Two different formats could be selected 

to limit stack emissions from calciners 

and dryers at mineral processing plants. 

These are-. (1) A mass standard, limiting 

emissions in terms of mass emissions 

per unit of production, and (2) a 

concentration standard, limiting the 

concentration ol PM in the effluent 

gases. 

2. Rational of Format Selection. A 

mass standard may appear more 

meaningful than other formats because 

it relates directiy to Uie quantity of 

emissions discharged to the atmosphere. 

Honvevar. a major disadvantage of a 

mass standard ior calciners and dryers 

is that typically, die production or feed 

rate af a procaas operation is not 
P.11 

Federal Register / Vol. 51, No. 78 / Wednesday, April 23, 1988 / Proposed Rules 

measured over die "short term. Thus, an 

accurate determination of the weight of 

material processed dirough an affected 

facility during compUance testing would 

not be possible under typical plant 

operating conditions. 

A concentration format (g/dscm [gr/ 

dscf]) was selected for the 

recommended emission limits of Uie 

NSPS because of its ease of enforcement 

across 17 different mineral industries 

and because it adequately reflects best 

demonstrated technology. Monitoring of 

thie production process is not necessary 

to determine compliance with Uie PM 

emission limits. However, die process 

unit must be operated at its maximum 

production rate during compliance 

testing. A concentration-based standard 

could be circumvented by adding 

dilution air to die gas stream. However, 

diis is unlikely to occur at mineral 

calciner and dryer facilities because Uie 

size and operating costs of fans and 

motors increases witii increasing gas 

volume to be moved. Also, the General 

Provisions contain adequate language to 

allow enforcement agencies to prevent 

such attempts to circumvent Uie 

standards. 

To help ensure diat air pollution 

control systems are properly installed, 

operated, and maintained, a visible 

emissions standard also is being 

proposed for all facilities controlled by 

fabric filters and dry ESP's. As 

discussed later in this preamble, a 

visible emissions standard for scrubbers 

would not be a meaningful indication of 

scrubber performance at mineral 

processing plants. However, die 

monitoring of operating parameters of 

wet scrubbers (pressure drop across die 

unit and scrubber liquid flow rate) 

would be required by die proposed 

standards. 

G. Selection of Actual Siandards 

1. Rationale for Standards Selected. 

Section 111 of die Clean Air Act allows 

the Agency to distinguish among 

classes, types, and sizes within 

categories of new sources for die 

purpose of establishing standards. In Uie 

NSPS, based upon an analysis of Uie 

available test data, it was necessary to 

establish a separate standard for 

calciners, dryers, and calciners and 

dryers installed in series. The standards 

selected represent the levels of control 

achievable with the best system of 

continuous emission reduction. 

2. Need for Multiple Standards. As 

discussed earlier, fabric filters, wet 

ccrubbers, and ESP's are used to control 

PM emisoions from caldners and dryers 

ot mineral processing plants. 

Results of emission tests approved by 

EPA were obtained-for 25 dryerain-12 

industries for all dryer types. All test 

results were less dian O057 g/dscm 

(0.025 gr/dscf) except for four dryers 

controlled by low-energy wet scrubbers 

and one dryer controUed by a fabric 

filter. The scrubber modeling analysis 

indicated diat die four dryers controlled 

by low-energy wet scrubbers could 

achieve an emission level of 0.057 g/ 

dscm (0.025 gr/dscf) widi a high-energy 

wet scrubber. One dryer controlled by a 

fabric filter had an emission 

concentration of 0.059 g/dscm (0.026 gr/ 

dscf). The test report for this dryer 

states Uiat most of Uie emissions were 

caused by leakage dirough a closed 

bypass damper. The fabric filter should 

have been able to achieve an emission 

Umit of 0.09 g/dscm (0.025 gr/dscf) if no 

leakage had occurred. . 

Results of emission tests conducted or 

approved by EPA also were obtained for 

26 calciners in 9 industries for all 

calciner types. All test results were less 

dian 0.09 g/dscm (0.04 gr/dscf) except 

for diree calciners controlled by lowenergy wet scrubbers. Again, die 

scrubber modeling analysis indicated 

diat these three calciners achieve an 

emission level of 0.09 g/dscfm (0.04 gr/ 

dscf) with a high-energy scrubber. 

Therefore, an emission level of 0.057 g/ 

dscm (0.025 gr/dscf) was selected for 

dryers, and an emission level of 0.09 g/ 

dscm (0.04 gr/dscf) was selected for 

calciners. 

The available data for calciners and 

dryers operated in series indicate Uiat 

die proposed PM emission concentration 

of 0.04 gr/dscf for calciners can be 

achieved. Because die data did not 

indicate diat die more stringent PM 

concentration of 0.057 g/dscm (0.025 gr/ 

dscf) proposed for dryers can be 

achieved, Uie Agency is proposing Uiat 

die NSPS for calciners and dryers 

operated in series be established at Uie 

less stringent concentration of 0.09 g/ 

dscm (0.04 gr/dscf) and requests Uiat 

interested individuals provide 

additional comments on diis proposal 

during the public comment period. 

H. Visible Emission Standards 

Section 302(1) of the Act defines 

"standard of performance" to include 

"any requirement relating to the 

operation or maintenance of a source to 

assure continuous emission reduction." 

1. Reason for Including Visible 

Emission Standards. A 10 percent 

opacity Umit (based on 6-minute 

averages) is proposed for dryers and 

calciners in all 17 mineral industries 

Using dry control devices (fabric filters 

and dry ESP's) to control emissions. A 

visible emission standard is included in 

die NSPS to ensure Uiat dry control 

:

 devices are properly operated and 

maintained. This visible emission 

otandard wiU also serve as a tool for 

' enforcement personnel in determining 

. whedier^a faciUty should be tested for 

compliance widi the mass standard. 

2. Rationale for These Provisions. The 

opacity of visible emissions from a dry 

control device on an affected facility 

would be limited to 10 percent This 

visible emission Umit is based on 513 6-

minute averages obtained during tests 

conducted on fabric filters used to 

control emissions from 6 calciners and 3 

dryers in 5 industries and on 3 data 

points obtained during 1 test on a dry 

ESP used to control emissions frpm a 

flash calciner. The highest average 

opacity reading observed at any of the 

fabric filters was 8.3 percent, and the 

highest individual reading was 10 

percent The 8.3 percent 6-minute 

average opacity was measured at Uie 

oudet of a bentonite rotary dryer. 

Bentonite rotary dryer product material 

has die smallest sieve analysis particle 

oize distribution of aU of Uie mineral 

materials being covered by Uie NSPS. 

Process units for which both outiet mass 

and visible emission data are 

unavailable have lasger producTparticle 

size distributions dian diose for which 

data are available and, therefore«.*vould 

be expected to have lower opacities. In 

addition, die bentonite rotary dryer, 

widi mass emissions of 0.05 g/dscm 

(0.02 gr/dscf), was in compliance with, 

the proposed mass emission limit of 

0.057 g/dscm (0.025 gr/dscf). The 

minerals widi the largest percentage of 

smaU particles ( = 50 percent less dian 

2.5 fim) in die oudet gas stream have 

maximum average opacities of less than 

1 percent AU of these units also comply 

widi die proposed mass emission limits. 

From diese data, it can be concluded 

that process units for which both mass 

and visible emission data are 

unavailable would be less difficult to 

control than diose for which data are 

available and could, therefore, achieve 

the proposed mass emission limits and a 

10 percent visible emission standard 

under normal operating conditions. 

The highest average opacity reading 

observed-at the outiet of Uie flash 

calciner ESP was 6.7 percent, and Uie 

highest individual reading was 10 

percent. The flash caldner had mass 

emissions df 0.057 g/dscm (0.025 gr/dscf) 

and, mere fore, bad mass emissions 

below die level of die proposed mass 

standard. When die opacity data from 

die ESP were normalized to Uie largest 

stack diameter known to exist on an 

ESP in die mineral industries. Uie 

average opadty at the normalized stack 

diameter was 7.1 percent. Therefore, all 

' ESP's on caldners and dryers in Uie 
P.12 

Federal Register / Vol. 51. N a 78 / Wednesday. April 23, 1986 / Proposed Rules 15447 

mineral industries should be capable of 

meeting a visible emission limit of 10 

percent under normal operating 

conditions. 

Based on tile results of the visible 

emission tests, a 10 percent opacity limit 

is being proposed to ensure the proper 

operation and maintenance of dry air 

pollution control devices on calciners 

and dryers. This standard, as shown by 

the data presented above and in the 

BOD. is achievable in all cases through 

die application of properly designed, 

operated, and maintained fabric filters 

and dry ESP's. Facilities controlled with 

wet scrubbers would be exempt from 

the proposed visible emission standard 

as discussed below. 

3. Other Considerations. The visible 

emissions standard for stack emissions 

would be applicable in all cases unless 

EPA were to approve establishment of a 

special or adjusted visible emission 

standard under the provisions of 40 CFR 

60.11(e). The provisions allow an owner 

or operator to apply to EPA for 

establishment of an adjusted visible 

emission standard for any source that 

meets Uie applicable concentration 

standard (demonstrated dirough 

performance tests under conditions 

established by EPA) but is unable to 

meet the visible emission standard, 

despite operating and maintaining the 

control equipment so as io minimize 

opacity. An adjusted visible emission 

standard might be established, for 

example, where an unusually large 

diameter stack precludes compliance 

with the proposed opacity limit. 

Wet scrubber control devices 

frequently have a steam plume exiting 

from dieir exhaust stacks. Under these 

conditions. EPA Reference Method 9 

specifies that Uie opacity of emissions 

be determined at a point after the steam 

plume has dissipated. Thus, opadty of 

emissions is determined at some 

variable distance from the stack outlet 

at a point where the emissions have 

been diluted. This distance and the / 

amount of dilution vary widi gas 

moisture content and meteorological 

conditions. Therefore, on a nationwide 

basis, an opacity limit for scrubbercontrolled mineral calciners and dryers 

is not as demonstrative of proper 

operation and maintenance as die 

monitoring of pressure drop and liquid 

flow rate. Monitoring of wet scrubber 

parameters is discussed in Section IV.) 

of this preamble. 

/. Modification/Reconstruction 

Considerations 

A modification is defined as certain 

physical or operational changes to an 

existing facility Uiat result in an " 

increased emission rate of any pollutant 

to which die standards apply (40 CFR 

60.14). Upon modification, an existing 

facility becomes an affected facility and. 

therefore, becomes subject to die NSPS. 

Routine maintenance procedures such 

as replacement or repair of calciner or 

dryer components subject to high 

temperatures and impact (e.g.. end seals, 

flights, refractory lining) would not 

constitute a modification (40 CFR 

60.14(e)(1)). Additional activities 

considered routine maintenance for 

calciners and dryers in mineral 

industries are described in Chapter 5 of 

die BE) for the NSPS. referenced in die 

ADORESSES section of this preamble. 

When expansions at existing plants 

take place, usually a completely new 

calciner or dryer is added. Such an 

increase in production would not be 

considered a modification but ratiier a 

new source. Calcining and drying 

operations usually operate below 100 

percent of capacity and are capable of 

handling increased throughput without 

additional equipment. If a new raw feed 

material is used or a fuel change occurs 

for which the calciner or dryer was 

originally designed, die change is not 

considered a modification. However, if a 

conversion is made allowing a unit to 

bum a fuel or to process a new material 

for which it was not originally designed, 

and an increase in emissions occurs 

because of diis change, die change is 

considered to be a modification (40 CFR 

60.14(e)(4)). 

An existing facility may become 

subject to an NSPS if it is reconstructed. 

Reconstruction is defined in 40 CFR 

60.15 as die replacement of die 

components of an existing facility to Uie 

extent diat: (1) The fixed capital cost of 

die new components exceeds 50 percent 

of the fixed capital cost required to 

construct a comparable new facility and 

(2) it is technically and economically 

feasible for die facility to meet die 

applicable standards. Because EPA 

considers reconstructed fadlities to 

constitute new construction ratiier than 

modification, reconstruction. 

determinations are made irrespective of 

changes in emission rates. 

If an owner or operator of an existing 

facility is planning to replace 

components and the fixed capital cost of 

die new components exceeds 50 percent 

of the fixed cost of a comparable new 

facility, die owner or operator must 

notify die appropriate EPA regional 

office 60 days before die construction of 

die replacement commences, as required 

under 40 CFR 60.15(d). 

These modification and reconstruction 

provisions should not cause many 

calciners and dryers in die 17 mineral 

industries to become affected facilities 

because most of the physical and 

operational changes made to existing 

calciners and dryers are considered 

routine maintenance. Calciners and 

dryers at existing plants are more likely 

to become affected facilities when they 

are replaced by new process units at the 

end of their useful lives. Owners and 

operators of modified, reconstucted. or 

replaced facilities controlled by wet 

scrubbers of ESP's will probably incur 

retrofit costs if the design operating 

parameters of the existing wet scrubber 

or ESP must be increased to achieve the 

emission limit of die proposed NSPS. 

However, the cost of retrofitting wet 

scrubbers or ESP's would be similarto 

the cost of installing wet scrubbers or 

ESP's on new facilities because sitespecific factors Uiat might normally 

increase retrofit costs (e.g.. availability ' 

of land and configuration of equipment) 

typically are not limiting factors at 

mineral processing plants. If site-specific 

factors are limiting at a plant, the capital 

cost of retrofiting wet scrubbers or ESP's 

may be greater than the capital cost of 

wet scrubbers and ESP's installed on 

new facilities (e.g., more ductwork). 

However, the annualized costs of 

retrofitting wet scrubbers or ESP's 

would not differ significantly from the 

annualized cost of wet scrubbers and 

ESP's installed on new facilities. 

Owners and operators of modified. 

reconstructed, or replaced facilities 

controlled by fabric filters should not 

incur retrofit costs because the emission 

limits of the proposed NSPS can be 

achieved by increasing the operation 

and maintenance of fabric filters. 

/. Monitoring Requirements 

Section 302(1) of the Act defines 

"standards of performance" to include 

"any requirement relating to the 

operation or maintenance of a source to 

assure continuous emission reduction." 

Section 114(a) authorizes EPA to require 

sources to monitor, test, keep records. 

and make reports. 

With Uie exception of the four process 

unit/control device combinations 

discussed below, Uie owner or operator 

of a calciner or dryer who uses a dry 

control device to comply with the mass 

emission standard will be required to 

install and operate a continuous 

monitoring system to measure the 

opacity of emissions discharged into the 

atmosphere from Uie control device. In 

lieu ofa continuous opacity monitoring 

system. Uie owner or operator of a 

gypsum flash or kettle calciner or of a 

perlite rotary dryer or expansion 

furnace who uses a dry control device 

could have a certified observer make 

three 6-minute observations of the 

opacity of visible emissions from the 
P.13 

control device, once per week of 

operation using EPA Reference Method 

9. 

When a wet scrubber control device is 

used to comply widi die caldner or 

dryer mass emission standard, the 

owner or bperator would be required to 

install and operate a monitoring device 

to continuously measure and record die 

pressure loss of die gas stream through 

die scrubber and die scrubbing Uquid 

flow rate to the scrubber. 

1. Rationale for Including Monitoring 

Requirements. Visible emission limits 

will help ensure mat proper fabric filter 

and ESP operation and maintenance 

procedures are performed and 

monitored. This monitoring can indicate 

when fabric filter bags are torn or loose 

and when ESP electrodes ore damaged 

or malfunctioning. SimUarly, monitoring 

of scrubber pressure loss and Uquid flow 

rate can indicate malfunctions in die 

water pumping equipment blockage of 

pipes, and die need to adjust die 

variable throat opening (if applicable). 

Monitoring of visible emissions from 

dry control devices and recording of 

exceedances of the 10 percent oparity 

limit by a certified observer or a 

continuous monitoring system wiU alert 

industry and enforcement personnel of 

potential violations of tile mass 

emission standard. Continuous opadty 

monitoring using a transmissometer is 

an effective means of ensuring die 

proper operation and maintenance of 

particulate control equipment. As a 

result operation of a transmissometer is 

an integral part of Use improved control 

device operation and maintenance 

practices Uiat account for me emission 

reduction below baseline Levels 

associated widi RA QL 

The absence of an opacity limit in the 

NSPS for wet scrubber emissions 

requires diat an alternative mediod be 

used to ensure proper operation and 

maintenance of diese devices. 

Therefore, to monitor Uie potential 

degradation in die performance of wet 

scrubbers over time, the proposed 

standards would require Uie owner or 

operator of wet scrubbers to measure 

and record selected control device 

operating parameters. These recorded 

values would then be available to 

enforcement and industry personnel for 

comparison against the range of values 

of each operating parameter recorded 

during the performance test when the 

mass emission limit was being met. 

Under Section 60.7(d) of die General 

Provisions, me owner or operator (s 

required to maintain the monitoring 

records at the source for a minimum of 2 

years and to make these records 

available for inspection, upon request. 

by Agency personnel or their 

representatives. 

The Agency beHeveo that changes in 

the values of operating parameters from 

those measured during a performance 

test are good indicators for an owner or 

operator and an enforcement agency to 

use to verify proper operation and 

maintenance of a control device. Not 

maintaining die operating parameters at 

levels widiin die range recorded during 

die performance test could indicate a 

violation of die requirements to properly 

operate and maintain die control 

equipment, as stated in Section 60.11(d) 

of me General Provisions. 

Aldiough periods of excursions from, 

or reductions in. die various operating 

parameters would not of themselves, 

constitute a violation cff die numerical 

emission limit diey may indicate to an 

enforcement agency die need to conduct 

a performance test. The results of die 

performance test would be used to 

determine compliance with die 

numerical emission Umit in accordance 

with Section 60.11(a) of die General 

Provisions. 

To evaluate die cost of continuous 

opadty monitoring systema under RA 

QI, die annual operating coot of die 

transmissometer was added to die 

annual operating cost of UievPM control 

device, end the C/E of control was 

calculated. With the exception of die 

four process anil/control device 

combinations discussed below, all of the 

C/E values were less than or equal to 

S3.000/Mg ($2,7C0/ton). The C/E was 

§4.5S0/Mg (S4,170/ton) for die gypsum 

flash calciner. S3.030/Mg (S2,7B0/ton) for 

the gypsum ketde calciner, $3,670/Mg 

(S3,340/ton) for the perlite rotary dryer, 

and S7,530/Mg (S8,840/ton) for Uie 

perlite expansion furnace. 

For die gypsum flash and ketde 

calciners and die perlite rotary dryer 

and expansion furnace, a less cosdy 

monitoring method could be used. The 

C/E of control, induding a certified 

observer to obtain three 6-minute 

averages of die opadty of visible 

emissions once per week of operation of 

these fadlities in accordance with EPA 

Reference Metiiod 9, would range from 

S1.740 Mg (S1.580/ton) to $2,7B0/Mg 

(S2,510/ton). 

K. Performtaias Tost Methods 

1. Method Selected. Under the 

proposed standards, performance tests 

for PM emiosions would be required fdr 

aii air pollution control devices on 

caldners and dryers. Particulate matter 

would be measured by Reference 

Methods l, 2. 3, 4, and 5 to determine 

compUance with the stack emission 

standards. Compliance wife the visible 

emissions standard would be 

determined using Reference Method 9 to 

measure stack opadty as 6-minute 

averages. 

2. Applicability of Method 5 to 

Standard. Reference Method 5 provides 

the concentration of PM in die stack 

exhaust gas stream as g/dscm (gr/dscf). 

The NSPS requires diat calciners 

achieve a level of 0.09 g/dscm [OM gr/ 

dscf) and mat dryers achieve a level of 

0.057 g/dscnr(0.025 gr/dscf). Mediod 5, 

dierefore, provides an accurate 

determination of compliance directiy, 

without requiring any additional 

monitoring of tile production process 

(e.g., production rate). 

L Reporting and Recordkeeping 

Requirements 

Section 302(1) of die Act defines 

"standard of performance" to include 

"any requirement relating to die 

operation or maintenance of a source to 

assure continuous emission reduction." 

Section 114(a) authorizes EPA to require 

sources to monitor, test keep records, 

and make reports. 

The owner or operator of a dry control 

device controlling PM emissions from an 

affected calciner dir dryes» facility wiU be 

required to record visible emissions 

using a continuous monitoring system, 

or to have a certified observer record 

three 6-minute averages (24 consecutive 

readings each) of die opadty of visible 

emiooioBO from the control device, once 

per week of operation, in accordance 

widi EPA Reference Method 9. as 

described in Section IV.). of this 

preamble. 

When o wet ocrubber io need to 

control particulate emissions from an 

affected calciner or dryer facility, die 

owner or operator wiU be required to 

record both the pressure loss of the gas 

stream dirough die scrubber and die 

scrubbing Uquid flow rate to die 

ocrubber once per day of normal < 

operation. 

Each owner or operator will be 

required to submit written reports 

semiannually of exceedances of Uie 10 

percent visible emission limit and any 

exceedances of the wet scrubber 

operating parameters discussed above. 

For the parpose of diese reports, an 

exceedance of wet scrubber operating 

parameters is defined as less than 90 

percent or greater than 110 percent of 

the average pressure drop, or less than 

80 percent or greater dian 120 percent of 

die average liquid flow rate determined 

during Uie most recent performance test 

ouccessfuUy passed to demonstrate 

compliance widi die mass emission 

Umit. The owner or operator will be 

required to submit written 

documentation of semiannual 
P.M 

Federal Register / Vol. 51. No. 78 / Wednesday, April 23. 1986 / Proposed Rules 15449 

calibrations of monitoring devices as 

part of die semiannual reports. 

Records of the measurements 

discussed in this section must be 

retained for at least 2 years. The 

requirements of mis section remain in 

force until and unless the Agency, in 

delegating enforcement authority to a 

State under Section 111(c) of die Act 

approves reporting requirements or an 

alternative means of compliance 

surveillance adopted by such State. In 

diat event, affected facilities within the 

State will be relieved of the obligation to 

comply with diis section provided that 

they comply widi die requirements 

estabUshed by die State. [Section 114 of 

die Clean Air Act as amended (42 

U.S.C. 7414)]. 

V. Administrative Requirements 

A. Public Hearing 

A public hearing will be held, if 

requested, to discuss the proposed 

standards in accordance widi Sedion 

307(d)(5) of die Clean Air Act. Persons 

wishing to make oral presentations 

should contact EPA at the address given 

in the ADDRESSES section of this 

preamble. Oral presentations will be 

limited to 15 minutes each. Any member 

of die public may file a written 

statement widi EPA before, during, or 

widiin 30 days after the hearing. Written 

statements should be addressed to the 

Central Docket Section address given in 

the ADDRESSES section of diis preamble. 

A verbatim transcript of die hearing 

and written statements will be available 

for public inspection and copying during 

normal working hours at EPA's Central 

Docket Section in Washington, D.C. (see 

ADDRESSES section of this preamble). 

B. Docket 

The docket is an organized and 

complete file of all die information 

submitted to or otherwise considered by 

EPA in die development of this proposed 

rulemaking. The principal purposes of 

the docket are: (1) to allow interested 

parties to identify and locate documents 

so that they can effectively participate 

in the rulemaking process and (2) to 

serve as die record in case of judicial 

review (except for interagency review 

materials [Section 307(d)(7)(A)]). 

C. Clean Air Act Procedural 

Requirements 

1. Administrator Listing—Section 111. 

As prescribed in Section 111 of the 

Clean Air Act as amended, 

establishment of standards of 

perfonnance for calciners and dryers in 

mineral industries was preceded by the 

Administrator's determination (40 CFR 

60.16 44 FR 48322. dated August 21.1979 

and 40 CFR 60.16 47 FR 950. dated 

January 8,1982) that diese sources 

contribute significandy to air pollution 

which may reasonably be anticipated to 

endanger public health or welfare. 

2. Periodic Review—Section 111. This 

regulation will be reviewed 4 years from 

die date of promulgation as required by 

die Clean Air Act. This review will 

include an assessment of such factors as 

the need for integration with other 

programs, the existence of alternative 

mediods. enforceabUity, improvements 

in emission control technology, and 

reporting requirements. 

3. Extemal Participation—Section 

117. In accordance widi Section 117 of 

die Act. publication of this proposal was 

preceded by consultation with 

appropriate advisory committees, 

independent experts, and Federal 

departments and agencies. In addition, 

numerous meetings were held with 

industry representatives and trade 

associations during development of die 

proposed standards. The Administrator 

will welcome comments on-all aspects 

ofthe proposed regulation, including 

economic and technological issues. 

Comments are also specifically 

invited on the achievability of the 

standard with regard to calciners and 

dryers combined in series. Any 

comments submitted to the 

Administrator on this issue should 

contain specific information and data 

pertinent to an evaluation of the 

magnitude and severity of its impact 

and suggested alternative courses of 

action that could avoid diis impact. 

4. Economic Impact Assessment— 

Section 317. Section 317 of the Clean Air 

Act requires the Administration to 

prepare an economic impact assessment 

for any new source standard of 

performance promulgated under Section 

111(b) of the Act. An economic impact 

assessment was prepared for die 

proposed regulations and for other 

regulatory alternatives. All aspects of 

the assessment were considered in the 

formulation of the proposed standards 

to ensure mat the proposed standards 

would represent the best system of 

emission reduction considering costs. 

The economic impact assessment is 

included in the BID. 

D. Office of Management and Budget 

Reviews 

1. Paperwork Reduction Act. The 

information collection requiements in 

diis proposed rule have been submitted 

for approval to the Office of 

Management and Budget (OMB) under 

die Paperwork Reduction Act of 1960. 44 

U.S.C. 3501 et sea. Comments on diese 

requirements should be submitted to the 

Office of Infonnation and Regulatory 

Affairs of OMB, marked "Attention: 

Desk Officer for EPA." as well as to 

EPA. The final rule will respond to any 

OMB or public comments on the 

information collection requirements. 

2. Executive Order 12291 Review. 

Under Executive Order 12291. EPA must 

judge whether a regulation is "major" 

and therefore subject to the requirement • 

of a Regulatory Impact Analysis. This 

proposed regulation is not major 

because it would result in none of the 

adverse economic effects set forth in 

Section 1 of the Order as grounds for 

finding a regulation to be major. The 

total nationwide incremental annualized 

costs in Uie fifth year after the standards 

would go into effect would range from 

$0.7 to $1.0 million, less than the S100 

million established as the first criterion 

for a major regulation in the Order. The 

maximum estimated price increase of 

1.75 percent associated with the 

proposed standards would not be 

considered a "major increase in costs or 

prices" specified as the second criterion 

in the Order. The economic analysis of 

the proposed standards' effect on the 

industry did not indicate any significant 

adverse effects on competition. 

investment, productivity, employment. 

innovation, or the ability of.U.S. firms to 

compete with foreign firms (the third 

criterion in the Order). 

This regulation was submitted to 

OMB for review as required by. 

Executive Order 12291. All written 

communications between EPA and OMB 

are in the docket. 

E. Regulatory Flexibility Act 

Compliance 

The Regulatory Flexibility Act of 1980 

requires die identification of potentially 

adverse impacts of Federal regulations 

upon small business entities. The Act 

specifically requires die completion of a 

Regulatory Flexibility Analysis in those 

instances where small business impacts 

are possible. The EPA definition of 

significant effect involves four tests: (1) 

Prices for small entities rise 5 percent or 

more, assuming costs are passed on to 

consumers: or (2) annualized investment 

costs for pollution control are greater 

than 20 percent of total capital spending. 

or (3) control costs as a percentage of 

sales for small entities are 10 percent 

greater dian control costs as a 

percentage of sales for large entities: or 

(4) the requirements of die regulation are 

likely to result in closures of small 

entities. 

The Act's definition of "small 

business" is based on definitions 

developed by die Small Business 

Administration (SBA). The SBA's 

definitions are listed in 13 CFR Part 121 
P.15 

3*450 Federal Eegjater / Vol. 5L No. 78 / Wedngaday, April 23. 1986 / Proposed Aules 

by Standard Industrial Classification 

(SIC) categories. For most of fte mineral 

dryer and calciner industries, the SBA 

defines a smaU business oa oos with 500 

or fewer employees (the 2 exceptions 

are gypsum aad ti tarn am dioxide, each 

of which is 1.000 employee*). As part of 

the development of this propoaed 

standard a considerable amount of 

effort has been devoted to die task of 

identifying small businesses m die 17 

industries. Steps that have b*en taken to 

identify smaU businesses indude an 

extensive review of standard finandal 

reference sources sudi as Moody's and 

Standard & Poor's, a mailing of Section 

114 information requests, and an 

electronic data base search. Most of die 

mineral dryer and calciner industries do 

indude smaU businesses according to 

die SBA definition. Because die 

standard under consideration here is an 

NSPS, the standard would apply to all 

businesses (bodi small and Large) in the 

17 industries, and as a result die test of 

a substantial number of small 

businesses is met 

Aldiough diere are a substantial 

number of small businesses, die 

measure of significant effects is not 

Ukely to be met. As described eariier, 

die absolute level of die percent product 

price increases is quite small for most of 

die industries, typically about 05 

percent or less. Thus, die first test is 

never triggered. Neidier are tbe second 

or fourth tests triggered. Tbe third test is 

occasionaUy triggered, but die absolute 

sizes of the numbers are so small as to 

make diis test inappHcable. For 

example, in die diatomite industry, a 

small flash dryer (4 Mg/h) has control 

costs as a percentage of sales diat are 23 

percent higher man the corresponding 

percentage for a larger flash dryer (11 

Mg/h). But die absolute levels of these 

two percentages ara 0.16 percent and 

0.13 percent and the 23 percent 

difference between them is virtually 

meaningless. Thus, because die absolute 

level of die percent product price 

increases is quite small for most of die 

industries, and because the tests are 

presented as guidelines, an 

interpretation of die spirit and purpose 

of the Act indicates that die industries 

do not exceed the Act's tests. Because 

diese standards impose no adverse 

economic impacts, a Regulatory 

Flexibility Analysis has not been 

conducted. 

Pursuant to the provisions of 5 ILS.C. 

605(b). I hereby certify that tins rule, if 

promulgated. wiU net have a signififant 

economic impad on a substantial 

number of smaU business entities. 

Ust of Sdbjocts ia 49 CTS Pitt 90 

Air poButron control. Reporting and 

recordkeeping requirements, 

Incorporation by reference. 

Intergovernmental relations. Metallic 

minerals, and Nonmetallic minerals. 

Dated: April 12,1886. 

LM M. Thoma*, 

AaLwanntmior. 

PART 60—(AMENDED) 

H is proposed that 40 CFR Part 80 be 

amended as follows: 

1. The authority dtation for Part 60 

continues to read as follows: 

Authority: Sees. 101.111.114. 301(a). Clean 

Air Act as amended (42 USX. 7401.7411. 

7414. 7601). 

2. By adding a new Subpart UUU 

consisting of j} 60.730 dirough 6CL736 as 

follows: 

Subpart UW—Standard*- of Pmtommncm 

for CSarClfMrs snd Dryers in MifMfv 

nKfUStlirMSec. 

60.730 Applicability and designation of 

afTected facility. 

60.731 Definitions. 

60.732 Standarda for particulate matter. 

60.733 RecoastnicUon. 

60.734 Monitoring of emissions asd 

operations. * 

80.735 Recordkeeping and reporting 

requirements. 

60.736 Test methods and procedures. 

Subpart UUU—Standards of 

Performance for Calciners and Dryers 

In Mineral Industrie* 

JS0.730 ApofleabHtty and daarfgnsrlsoM of 

aff acted facUity. 

(a) The affected faciUty to which die 

provisions of tiiis subpart apply ia each 

calciner and dryer at mineral processing 

plants. Feed aad product conveyors are 

not considered part of die affected 

facility. 

(b) An affected faciUty that is subject 

to the provisions of Subpart LL, metallic 

mineral processing plants, is not subject 

to die provisions of diis subpart 

(c) The owner or operator of any 

facility under paragraph (a) of diis 

section that commences construction, 

modification, or reconstruction after 

April 23.1986. is subject to the 

requirements of diis subpart 

{60.731 OafinMtoos. 

As used ia diis subpart aU terms not 

defined herein shaU have the meaning 

given diem in the Clean Air Act and in 

Subpart A of this part 

"Calciner" means tite equipment uaed 

to remove combined (caemicaUy bound) 

watar and/or gases from mineral 

material through direct or indirect 

heating. This definition includes 

expansion furnaces and multiple hearth 

furnaces. 

"Control device" means the air 

pollution control equipment used to 

reduce particulate matter emissions 

released to die atmosphere from one or 

more affected fadlities. 

"Dryer" means the equipment used to 

remove anccmbined (free) water from 

mineral material dirough direct or 

indirect heating. 

"InstaUed in series" means a calciner 

and dryer instaUed such that the 

exhaust gases from one flow dirough die 

other and then die combined exhaust 

gases are discharged to die atmosphere. 

"Mineral processing plant" means any 

facility that processes or produces any 

of the following minerals or tiieir 

concentrates: alumina, baU day, 

bentonite, diatomite. feldspar, fire clay, 

fuller's earth, gypsum, industrial sand, 

kaolin, Eghtweight aggregate, 

magnesium compounds, perlite, roofing 

granules, talc, titanium dioxide, and 

vermicalite. The foUowing processes 

and process units used at mineral 

processing plants would not be 

regulated under dia NSE& Vertical shaft 

kirns in me magnesium compounds 

industry: the chlorination-oxidation 

process in die titanium dioxide industry; 

coating kilns, mixers, and aerators in the 

roofing granules industry, and tunnel 

kilns, tunnel dryers, apron dryers, and 

grinding equipment diat also dries die 

process material used in any of die 17 

mineral industries. 

§60.732 Standards for partJctsate matter. 

Each owner or operator of any 

affected facility which is subject to die 

requirements of diis subpart shaU 

comply widi the emission limitations set 

forth in this secton on and after die date 

on which the initial performance test 

required by I 60.8 is completed, but not 

later than 180 days after die initial 

startup, whichever date comes first No 

emissions shaU be discharged into die 

atmosphere from any affected facility 

diat: 

(a) Contain particulate matter in 

excess of 0.09 gram per dry standard 

cubic meter (g/dscm) (0.04 grain per dry 

standard cubic foot (gr/dscf)) for 

calciners and for calciners and dryers 

installed in series and in excess of 0.057 

g/dscm (0.025 gr/dscf) for dryers: and 

fb) Exhibit greater dian 10 percent 

opacity, unless die emissions are 

discharged from an afTected facility 

using a wet scrubbing control device. 

160.733 Racoostructlon. 

The cost of replacement of equipment 

subject to high temperatures and 
P.16 

Federal Register / Vol. 51, No. 78 / Wednesday, April 23, 1986 / Proposed Rules 15451 

abrasion 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 i 60.15. 

Calciner and dryer equipment subject to 

high temperatures and abrasion are: end 

seals, flights, and refractory lining. 

§ 60.734 Monitoring of amissions and 

operations. 

(a) With the exception of the process 

units described in paragraph (b) of this 

section, die owner or operator of an 

affected facility subject to the provisions 

of this subpart who uses a dry control 

device to comply with the mass 

emission standard shall install, 

calibrate, maintain, and operate a 

continuous monitoring system to 

measure and record the opacity of 

emissions discharged into the 

atmosphere from the control device. 

Each owner or operator who uses a 

continuous monitoring device to comply 

with the requirements of this paragraph 

shall recalibrate the device 

semiannually in accordance with 

procedures under § 60.13. 

(b) In lieu of a continuous opacity 

monitoring system required in paragraph 

(a) of this section, the owner of operator 

of a gypsum flash or kettle calciner or of 

a perlite rotary dryer or expansion 

furnace who uses a dry control device 

may have a certified visible emissions 

observer measure and record three 6-

minute averages of the opacity of visible 

emissions to die atmosphere once per 

week of operation in accordance widi 

EPA Reference Method 9. 

(c) The owner or operator of an 

affected facility subject to the provisions 

of this subpart who uses a wet scrubber 

to comply with the mass emission 

standard for any affected facility .shall 

install, calibrate, maintain, and operate 

monitoring systems diat continuously 

measure and record die pressure loss of 

die gas stream through the scrubber and 

the scrubbing liquid flow rate to the 

scrubber. The pressure loss monitoring 

device must be certified by the 

manufacturer to be accurate within ±1 

inch of water column gauge pressure. 

The liquid flow rate monitoring device 

must be certified by the manufacturer to 

be accurate widiin ±5 percent of design 

scrubbing liquid fiow rate. All 

monitoring devices required under this 

paragraph are to be recalibrated 

semiannually in accordance with 

manufacturer's instructions. 

§ 60.735 Recordkeeping and reporting 

requirements. 

(a) Records of the measurements 

required in | 60.734 of this subpart must 

be retained for at least 2 years. 

(b) Each owner or operator shall 

submit written reports semiannually of 

exceedances of control device operating 

parameters required to be monitored by 

§ 60.734 of this subpart. Each owner or 

operator also shall submit written 

reports semiannually that document 

corrective maintenance required as a 

result of semiannual calibrations of die 

monitoring device diat is required in 

S 60.734. For this purpose of these 

reports, exceedances are defined as all 

6-minute periods during which the 

average opacity from dry control 

devices is greater dian 10 percent, or 

any wet scrubber pressure drop diat is 

less than 90 percent or greater than 110 

percent or each wet scrubber liquid 

flow rate that is less dian 30 percent or 

greater than 120 percent of Uie average 

value recorded according to Section 

60.736(c) during the most recent 

performance test that demonstrated 

compliance.with the particulate matter 

standard. 

(c) The requirements of this section 

rtmain in force until and unless the 

Agency, in delegating enforcement 

authority to a State under Section 111(c) 

of Uie Clean Air Act. approves reporting 

requirements or an alternative means of 

compliance surveillance adopted by

 ] 

such State. In that event, affected 

facilities within the State will be 

relieved of die obligation to comply with 

diis section provided that they comply 

with die requirements established by the 

State. 

5 60.736 Test methods and procedures. 

(a) Reference methods in Appendix A 

of mis part, except as provided under 

5 60.8(b), shall be used to determine 

compliance with the standards 

prescribed under § 60.732 as follows: 

(1) Method 1 for sample and velocity 

traverses: 

(2) Method 2 for stack gas velocity 

and volumetric flow rate: 

(3) Mediod 3 for stack gas dry 

molecular weight; 

(4) Mediod 4 for stack gas moisture 

content: .- •.' '" 

(5) Mediod 5 fdr the measurement of 

particulate emissions: and. 

(6) Method 9 for the opacity of visible 

emissions. 

(b) The sampling time for each test 

run shall be at least 2 hours and the 

minimum volume of gas sampled shall 

be 1.7 dscm (60 dscf). 

(c) During the initial performance test 

of a wet scrubber, the owner or operator 

shall measure and record an arithmetic 

average of botii die change in pressure 

of die gas stream across the scrubber 

and Uie scrubbing liquid flow rate. 

(FR Ooe 86-8342 Filed 4-22-86; 8:45 am| 

StLUMQ COOE S560-40-M