### 1 MEMORANDUM

TO: Jim Eddinger, U.S. Environmental Protection Agency, OAQPS

FROM: Eastern Research Group, Inc.

DATE: August 2012

SUBJECT: Revision ( August 2012 ) of Alternate Equivalent Output

- Based Emission Limi ts for Boilers and Process Heaters Located at Major Source Facilities

1.0 INTRODUCTION

The purpose of this memorandum is to discuss the changes in the methodology used to calculate alternate output

- based emission limits from the analysis conducted for t he final reconsideration of the NESHAP for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters (76 FR 80598). The methodology used to calculate alternate

output

- based emission limits for the proposed reconsideration of th e rule is discussed in

another memorandum. 1 

### This memorandum focuses only on the changes in methodology since the previous analysis. This memorandum is organized as follows:

1.0 Introduction

2.0 Changes since the Proposed Reconsideration Analysis

3 .0 References Appendix A: Output

- Based Emission Limits for Existing Boilers and Process Heaters Appendix B: Output

- Based Emission Limits for New Boilers and Process Heaters

### 2 2.0 CHANGES SINCE THE PROPOSED RECONSIDERATION ANALYSIS

This section details the changes in the methodology and results of the alternate output

based emission limit analysis since the analysis conducted for the proposed reconsideration of the rule. The methodology used is identical to the methodology described in the memorandum

for th e December 2011 rule analysis, unless otherwise noted. 1 

### The revised output

- based emission limits for existing and new sources are provided in Appendices A and B, respectively.

2.1 Revised Conversion Factors for Existing Sources The boilers and process hea ters comprising the top performers for each pollutant and subcategory have changed since the proposed reconsideration of the rule. Thus, the sources for which boiler output data were used to estimate conversion factors for the proposed rule analysis were updated for this analysis. This resulted in the conversion factors changing for a few subcategories. There were also two new subcategories added since the proposed rule which did not have a previously estimated conversion factor. Table 1 shows the subca tegories

for which the conversion factors have changed since the previous analysis. If a subcategory is not shown in the table, then its conversion factor did not change.

Table 1

– Changes in Conversion Factors for Existing Source s since the Previous Analysis

Fuel Category Combustor Design Conversion Factors (Steam Btu Out/Fuel Btu In) Notes Proposed Reconsideration Analysis Revised Analysis All Coal/Fossil Solid N/A N/A 0.96 New subcategory

Coal/Fossil Solid FB

- HE N/A 0.96 New subcategory; no output data, assumed same as Coal FB
Liquid N/A 0.80 0.83 One unit with output data has permanently shut down

Light Liquid N/A 0.77 0.83 Only one unit had output data, but has since permanently shut down; no remaining output data, assumed same as Heavy Liquid

### 3 2.2 Revised Conversion Factors for New Sources For some pollutants and subcategories, the top performer has changed since the previous analysis. Thus, the conversion factor for new sources for these subcategories has also changed. Table 2 shows the subcategories for which the conversion factors have changed since the previous analysis. If a subcategory is not shown in the table, then its conversion factor did not change.

Table 2

– Changes in Conve rsion Factors for New Sources since the Previous Analysis

Subcategory Top Performer Conversion Factors (Steam Btu Out/Fuel Btu In) Notes Facility ID Unit ID Proposed Reconsideration Analysis Revised Analysis

TSM Coal ILPolyOne B1 N/A 0.86 Coal PM/TSM no longer parsed by combustor design TSM Heavy Liquid MNGPDuluth EU33 Boiler #3 N/A 0.92 There was no TSM alternative limit for liquid units in the proposed rule TSM Light

Liquid No output data, assume same as TSM Heavy Liquid N/A 0.92

TSM NC

- Liquid No output data, assume same as TSM Heavy Liquid N/A 0.92

PM Biomass Dutch Oven/Pile

Burner WAWeyerhae

user_Raymond Hog Fuel Boiler EU1 0.66 0.75

PM Biomass

Fuel Cell ARWeyerhaeu

serDierksMill SN

- 45 0.37 0.67

PM Coal IAArchersDani

elsMidlandDe

sMoines Asea Boiler #1 N/A 1.00 Coal PM/TSM no longer parsed by combustor design PM Light

Liquid No output data, assume same as PM Heavy Liquid 0.77 0.92

CO Biomass Dutch Oven/Pile

Burner WAWeyerhae

user_Raymond Hog Fuel Boiler EU1 0.67 0.75

CO Biomass

Fuel Cell ARWeyerhaeu

serDierksMill SN

- 45 0.57 0.67

### 4 CO Coal FB IAADMCornPr

ocessingCR EU

- 530 0.98 1.00

CO Coal FB

- HE No output data, assume same as CO Coal FB N/A 1.00 New subcategory

CO Coal PC IAUofNorther

nIowa Boiler #3 1.02 0.99

CO Light Liquid No output data, assume same as CO Heavy Liquid 0.77 0.73

### 5 3 .0 REFERENCES

1. Eddinger, Jim, U.S. EPA OAQPS. Revision of Alternate Equivalent Output

- Based Emission Limits for Boilers and Process Heaters Located at Major Source Facilities. November 2011.

### 6 Appendix A

Output

- Based Emission Limits for Existing Boilers and Process Heaters

### 7 Appendix A

– Summary of Calculated Output

- based (MACT Floor) Emission Limits for Existing Boilers and Process Heaters at Major Sources (Units with Heat Input Capacity of 10 Million Btu per Hour or Greater)

Subcategory Pollutant MACT (heat input

based) proposed emission limits Output

- based emission limits ( lb per MMBtu of steam output) Output

- based emission limits

( lb per Mwh)

1. Units in all subcategories designed to burn solid fuel a. Hydrogen Chloride 2. 2 E

- 02 lb per MMBtu of heat input. 0.025 0.27

b. Mercury 5.7E

- 06 lb per MMBtu of heat input. 6.4E

- 06 7.3E

- 05

2. Units design to burn coal/solid fossil fuel b. Filterable Particulate Matter (or Total Selected Metals) 4.0 E

- 02 lb per MMBtu of heat input; or (5.3E

- 05 lb per MMBtu of heat input). 0.04 2 ; or (5.6E

05) 0.4 9 ; or (6.5E

04)

3. Pulverized coal boilers designed to burn coal/solid fossil fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.11 1.4

4. Stokers designed to burn coal/solid fossil fuel a. CO 160 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.14 1.7

5. Fluidized bed units designed to burn coal/ solid fossil fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.12 1.4

6. Fluidized bed units with an integrated heat exchanger designed to burn coal/solid fossil fuel a. CO 140 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.13 1.5

7. Stokers/sloped grate/others designed to burn wet biomass fuel a. CO 1,500 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 1.4 17

### 8 b. Filterable Particulate Matter (or Total Selected Metals) 3. 7 E

- 02 lb per MMBtu of heat input; or (2.4E

- 04 lb per MMBtu of heat input). 0.04 3 ; or (2.8E

04) 0. 52 ; or (0.0034)

8. Stokers/sloped grate/others designed to burn kiln

- dried biomass fuel a. CO 460 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.42 5.1

b. Filterable Particulate Matter (or Total Selected Metals) 3.2E

- 01 lb per MMBtu of heat input; or (4.0E

- 03 lb per MMBtu of heat input). 0.37 ; or (0.0046) 4.5 ; or (0.056)

9. Fluidized bed units designed to burn biomass/bio

- based solid a. CO 470 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.46 5.2

b. Filterable Particulate Matter (or Total Selected Metals) 1.1E

- 01 lb per MMBtu of heat input; or (1.2E

- 03 lb per MMBtu of heat input). 0.14 ; or (0.0015) 1.6 ; or (0.017)

10. Suspension burners designed to burn biomass/bio

- based solid a. CO 2,400 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 1.9 27

b. Filterable Particulate Matter (or Total Selected Metals) 5.1E

- 02 lb per MMBtu of heat input; or (6.5E

- 03 lb per MMBtu of heat input). 0.052 ; or (0.0066) 0.71 ; or (0.091)

11. Dutch Ovens/Pile burners designed to burn biomass/bio

- based solid a. CO 770 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.84 8.4

b. Filterable Particulate Matter (or Total Selected Metals) 2 .8E

- 01 lb per MMBtu of heat input; or (2.0E

- 03 lb per MMBtu of heat input). 0. 39 ; or (0.0028) 3.9 ; or (0.028)

### 9 12. Fuel cell units designed to burn biomass/ bio

- based solid a. CO 1,100 ppm by volume on a dry basis corrected to 3 percent oxygen. 2.4 12

b. Filterable Particulate Matter (or Total Selected Metals) 2.0E

- 02 lb per MMBtu of heat input; or (5.8E

- 03 lb per MMBtu of heat input). 0.055 ; or (0.016) 0.28 ; or (0.081)

13. Hybrid suspension grate units designed to burn biomass/ bio

based solid a. CO 2,800 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 2.8 31

b. Filterable Particulate Matter (or Total Selected Metals) 4.4E

- 01 lb per MMBtu of heat input; or (4.5E

- 04 lb per MMBtu of heat input). 0.55 ; or (5.7E

04) 6.2 ; or (0.0063)

14. Units designed to burn liquid fuel a. Hydroge n Chloride 1.1E

- 03 lb per MMBtu of heat input. 0.0014 0.016

b. Mercury 2.0E

- 06 lb per MMBtu of heat input. 2.5E

- 06 2.8E

- 05

15. Units designed to burn heavy liquid fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.13 1.4

b. Filterable Particulate Matter (or Total Selected Metals) 6.2E

- 02 lb per MMBtu of heat input; or (2.0E

- 04 lb per MMBtu of heat input). 0.075 ; or (2.5E

04) 0.86 ; or (0.0028)

16. Units designed to burn light liquid fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.13 1.4

b. Filterable Particulate Matter (or Total Selected Metals) 7.9E

- 03 lb per MMBtu of heat input; or (6.2E

- 05 lb per MMBtu of heat input). 0.0096 ; or (7.5E

- 05) 0.11 ; or (8.6E

04)

### 10 17. Un its designed to burn liquid fuel that is a

non

- continental unit a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.13 1.4

b. Filterable Particulate Matter (or Total Selected Metals) 2.7E

- 01 lb per MMBtu of heat input; or (8.6E

- 04 lb per MMBtu of heat input). 0.33 ; or (0.0011) 3.8 ; or (0.012)

18. Units designed to burn gas 2 (other) gases a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.16 1.0

b. Hydrogen Chloride 1.7E

- 03 lb per MMBtu of heat input. 0.0029 0.018

c. Mercury 7.9E

- 06 lb per MMBtu of heat input. 1.4E

- 05 8.3E

- 05

d. Filterable Particulate Matter (or Total Selected Metals). 6.7E

- 03 lb per MMBtu of heat input or (2.1E

- 04 lb per MMBtu of heat input). 0.012 ; or (3.5E

04) 0.070 ; or (0.0022)

### 11 Appendix B

Output

- Based Emission Limits for New Boilers and Process Heaters

### 12 Appendix B

– Summary of Calculated Output

- based (MACT Floor) Emission Limits for New Boilers and Process Heaters at Major Sources (Units with Heat Input Capacity of 10 Million Btu per Hour or Greater)

Subcategory Pollutant MACT Floor Input

based Emission Limit Output

- based Emission Limit ( lb per MMBtu of steam output) Output

- based E mission Limit ( lb per Mwh)

1. Units in all subcategories designed to burn solid fuel a. Hydrogen Chloride 2. 2 E

- 02 lb per MMBtu of heat input. 0.02 5 A 0.2 8

b. Mercury 8.0E

- 07 lb per MMBtu of heat input. 8.7E

- 07 1.1E

- 05

2. Units design to burn coal/solid fossil fuel b. Filterable Particulate Matter (or Total Selected Metals) 1. 1 E

- 03 lb per MMBtu of heat input; or (2.3E

- 05 lb per MMBtu of heat input). 0.001 1 ; or (2.7E

- 05) 0.0 14 ; or (2.9E

04)

3. Pulverized coal boilers designed to burn coal/solid fossil fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.11 1.4

4. Stokers designed to burn coal/solid fossil fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.12 1.4

5. Fluidized bed units designed to burn coal/ solid fossil fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.11 1.4

6. Fluidized bed units with an integrated heat exchanger designed to burn coal/solid fossil fuel a. CO 140 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.12 1.5

7. Stokers/sloped grate/others designed to burn wet biomass fuel a. CO 620 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.58 6.8

### 13 b. Filterable Particulate Matter (or Total Selected Metals) 3. 0 E

- 02 lb per MMBtu of heat input; or (2.6E

- 05 lb per MMBtu of heat input). 0.0 35 ; or (2.7E

05) 0.4 2 ; or (3.7E

04)

8. Stokers/sloped grate/others designed to burn kiln

- dried biomass fuel a. CO 460 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.42 A 5.1

b. Filterable Particulate Matter (or Total Selected Metals) 3.0E

- 02 lb per MMBtu of heat input; or (4.0E

- 03 lb per MMBtu of heat input). 0.035 ; or (0.0042) 0.42 ; or (0.056)

9. Fluidized bed units designed to burn biomass/bio

- based solid a. CO 230 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.22 2.6

b. Filterable Particulate Matter (or Total Selected Metals) 9.8E

- 03 lb per MMBtu of heat input; or (8.3E

- 05 lb per MMBtu of heat input). 0.01 2 ; or (1.1E

04) 0.14 ; or (0.0012)

10. Suspension burners designed to burn biomass/bio

- based solid a. CO 2,400 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run avera ge. 1.9 27

b. Filterable Particulate Matter (or Total Selected Metals) 3.0 E

- 02 lb per MMBtu of heat input; or (6.5E

- 03 lb per MMBtu of heat input). 0.0 31 ; or (0.0066) 0. 42 ; or (0.091)

11. Dutch Ovens/Pile burners designed to burn biomass/bio

- based solid a. CO 330 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.35 3.6

b. Filterable Particulate Matter (or Total Selected Metals) 3. 2 E

- 03 lb per MMBtu of heat input; or (3.9E

- 05 lb per MMBtu of heat input). 0.004 3 ; or (5.2E

- 05) 0.04 5 ; or (5.5E

04)

### 14 12. Fuel cell units designed to burn biomass/ bio

- based solid a. CO 910 ppm by volume on a dry basis corrected to 3 percent oxygen. 1.1 10

b. Filterable Particulate Matter (or Total Selected Metals) 2.0E

- 02 lb per MMBtu of heat input; or (2.9E

- 05 lb per MMBtu of heat input). 0.030 ; or (5.1E

05) 0.28 ; or (4.1E

04)

13. Hybrid suspension grate units designed to burn biomass/ bio

based solid a. CO 1,100 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 1.4 12

b. Filterable Particulate Matter (or Total Selected Metals) 2.6E

- 02 lb per MMBtu of heat input; or (4.4E

- 04 lb per MMBtu of heat input). 0.033 ; or (5.5E

04) 0.37 ; or (0.0062)

14. Units designed to burn liquid fuel a. Hydrogen Chloride 4.4E

- 04 lb per MMBtu of heat input. 4.8E

- 04 0.0061

b. Mercury 4.8E

- 07 lb per MMBtu of heat input. 5.3E

- 07 6.7E

- 06

15. Units designed to burn heavy liquid fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.13 A 1.4 A

b. Filterable Particulate Matter (or Total Selected Metals) 1.3E

- 02 lb per MMBtu of heat input; or (7.5E

- 05 lb per MMBtu of heat input). 0.015 ; or (8.2E

05) 0.18 ; or (0.0011)

16. Units designed to burn light liquid fuel a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.13 A 1.4 A

b. Filterable Particulate Matter (or Total Selected Metals) 1.1E

- 03 lb per MMBtu of heat input; or (2.9E

- 05 lb per MMBtu of heat input). 0.0012 ; or (3.2E

- 05) 0.016 ; or (4.0E

04)

### 15 17. Units designed to burn liquid fuel that is a

non

- continental unit a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen, 3

- run average. 0.13 A 1.4 A

b. Filterable Particulate Matter (or Total Selected Metals) 2.3E

- 02 lb per MMBtu of heat i nput; or (8.6E

- 04 lb per MMBtu of heat input). 0.025 ; or (9.4E

04) 0.32 ; or (0.012)

18. Units designed to burn gas 2 (other) gases a. CO 130 ppm by volume on a dry basis corrected to 3 percent oxygen. 0.16 A 1.0 A

b. Hydrogen Chloride 1.7E

- 03 lb per MMBtu of heat input. 0.0029 0.018

c. Mercury 7.9E

- 06 lb per MMBtu of heat input. 1.4E

- 05 8.3E

- 05

d. Filterable Particulate Matter (or Total Selected Metals). 6.7E

- 03 lb per MMBtu of heat input; or (2.1E

- 04 lb per MMBtu of heat input). 0.012 ; or (3.5E

04) 0.070 ; or (0.0022)

A The calculated output

- based limit for new sources was less stringent than the output

- based limit for existing sources for the same subcategory. The new source output

- based limit was defaulted to the existing source limit.