CFR Subpart KK

in effect

40 C.F.R. § 60.370 Applicability and designation of affected facility.

(a) The provisions of this subpart are applicable to the affected facilities listed in paragraph (b) of this section at any lead-acid battery manufacturing plant that produces or has the design capacity to produce in one day (24 hours) batteries containing an amount of lead equal to or greater than 5.9 Mg (6.5 tons). (b) The provisions of this subpart are applicable to the following affected facilities used in the manufacture of lead-acid storage batteries: (1) Grid casting facility. (2) Paste mixing facility. (3) Three-process operation facility. (4) Lead oxide manufacturing facility. (5) Lead reclamation facility. (6) Other lead-emitting operations. (c) Any facility under paragraph (b) of this section the construction or modification of which is commenced after January 14, 1980, and on or before February 23, 2022, is subject to the requirements of this subpart.

40 C.F.R. § 60.371 Definitions.

As used in this subpart, all terms not defined herein shall have the meaning given them in the Act and in subpart A of this part. (a) Grid casting facility means the facility which includes all lead melting pots and machines used for casting the grid used in battery manufacturing. (b) Lead-acid battery manufacturing plant means any plant that produces a storage battery using lead and lead compounds for the plates and sulfuric acid for the electrolyte. (c) Lead oxide manufacturing facility means a facility that produces lead oxide from lead, including product recovery. (d) Lead reclamation facility means the facility that remelts lead scrap and casts it into lead ingots for use in the battery manufacturing process, and which is not a furnace affected under subpart L of this part. (e) Other lead-emitting operation means any lead-acid battery manufacturing plant operation from which lead emissions are collected and ducted to the atmosphere and which is not part of a grid casting, lead oxide manufacturing, lead reclamation, paste mixing, or three-process operation facility, or a furnace affected under subpart L of this part. (f) Paste mixing facility means the facility including lead oxide storage, conveying, weighing, metering, and charging operations; paste blending, handling, and cooling operations; and plate pasting, takeoff, cooling, and drying operations. (g) Three-process operation facility means the facility including those processes involved with plate stacking, burning or strap casting, and assembly of elements into the battery case.

40 C.F.R. § 60.372 Standards for lead.

(a) On and after the date on which the performance test required to be conducted by § 60.8 is completed, no owner or operator subject to the provisions of this subpart shall cause to be discharged into the atmosphere: (1) From any grid casting facility any gases that contain lead in excess of 0.40 milligram of lead per dry standard cubic meter of exhaust (0.000175 gr/dscf). (2) From any paste mixing facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf). (3) From any three-process operation facility any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf). (4) From any lead oxide manufacturing facility any gases that contain in excess of 5.0 milligrams of lead per kilogram of lead feed (0.010 lb/ton). (5) From any lead reclamation facility any gases that contain in excess of 4.50 milligrams of lead per dry standard cubic meter of exhaust (0.00197 gr/dscf). (6) From any other lead-emitting operation any gases that contain in excess of 1.00 milligram of lead per dry standard cubic meter of exhaust (0.000437 gr/dscf). (7) From any affected facility other than a lead reclamation facility any gases with greater than 0 percent opacity (measured according to Method 9 and rounded to the nearest whole percentage). (8) From any lead reclamation facility any gases with greater than 5 percent opacity (measured according to Method 9 and rounded to the nearest whole percentage). (b) When two or more facilities at the same plant (except the lead oxide manufacturing facility) are ducted to a common control device, an equivalent standard for the total exhaust from the commonly controlled facilities shall be determined as follows: Where: Se = is the equivalent standard for the total exhaust stream. Sa = is the actual standard for each exhaust stream ducted to the control device. N = is the total number of exhaust streams ducted to the control device. Qsda = is the dry standard volumetric flow rate of the effluent gas stream from each facility ducted to the control device. QsdT = is the total dry standard volumetric flow rate of all effluent gas streams ducted to the control device.

40 C.F.R. § 60.373 Monitoring of emissions and operations.

The owner or operator of any lead-acid battery manufacturing facility subject to the provisions of this subpart and controlled by a scrubbing system(s) shall install, calibrate, maintain, and operate a monitoring device(s) that measures and records the pressure drop across the scrubbing system(s) at least once every 15 minutes. The monitoring device shall have an accuracy of ±5 percent over its operating range.

40 C.F.R. § 60.374 Test methods and procedures.

(a) In conducting the performance tests required in § 60.8, the owner or operator shall use as reference methods and procedures the test methods in appendix A of this part or other methods and procedures as specified in this section, except as provided in § 60.8(b). (b) The owner or operator shall determine compliance with the lead standards in § 60.372, except § 60.372(a)(4), as follows: (1) Method 12 or Method 29 shall be used to determine the lead concentration (CPb) and, if applicable, the volumetric flow rate (Qsda) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30 dscf). (2) When different operations in a three-process operation facility are ducted to separate control devices, the lead emission concentration (C) from the facility shall be determined as follows: (3) Method 9 and the procedures in § 60.11 shall be used to determine opacity. The opacity numbers shall be rounded off to the nearest whole percentage. (c) The owner or operator shall determine compliance with the lead standard in § 60.372(a)(4) as follows: (1) The emission rate (E) from lead oxide manufacturing facility shall be computed for each run using the following equation: (2) Method 12 or Method 29 shall be used to determine the lead concentration (CPb) and the volumetric flow rate (Qsd) of the effluent gas. The sampling time and sample volume for each run shall be at least 60 minutes and 0.85 dscm (30 dscf). (3) The average lead feed rate (P) shall be determined for each run using the following equation: Where: C = concentration of lead emissions for the entire facility, mg/dscm (gr/dscf). Ca = concentration of lead emissions from facility “a”, mg/dscm (gr/dscf). Qsda = volumetric flow rate of effluent gas from facility “a”, dscm/hr (dscf/hr). N = total number of control devices to which separate operations in the facility are ducted. where: E = emission rate of lead, mg/kg (lb/ton) of lead charged. CPbi = concentration of lead from emission point “i,” mg/dscm (gr/dscf). Qsdi = volumetric flow rate of effluent gas from emission point “i,” dscm/hr (sdcf/hr). M = number of emission points in the affected facility. P = lead feed rate to the facility, kg/hr (ton/hr). K = conversion factor, 1.0 mg/mg (7000 gr/lb). where: N = number of lead pigs (ingots) charged. W = average mass of a pig, kg (ton). Θ = duration of run, hr.