NDEQ NESHAP Training Subpart ZZZZ - Engines

transcript

Melissa EllisFebruary 24, 2011

Overview Objectives Industry Overview Rule Background Applicability Requirements Tips Tools & Resources

Acronyms

HP = horsepower CI = compression ignition SI = spark ignition 4S = four stroke 2S = two stroke LB = lean burn RB = rich burn

Objectives

Become familiar with industry

Understand rule requirements

Be aware of tools & resources to

help do your job more effectively

Industry Overview

Stationary Internal Combustion Engines

1. Point of use for 12 months OR 3-12 months for seasonal

2. Not used to propel motor vehicle

3. Not a non-road engine

Industry Overview

Engines manufactured the same, used differently

Electrical generators & powering emission units

Compression Ignition Spark Ignition

Compression Ignition Engines Diesel or dual fuel Heat from compression auto-ignites

fuel & air mixture Two-stroke & four-stroke Diesel trucks

Compression Ignition

Spark Ignition Engines

Gasoline or natural gas Spark plug ignites fuel/air mixture Motor vehicle Two-stroke or Four-stroke Lean burn or rich burn

Rich Burn Excess fuel in combustion chamber

during combustion Mfg. recommends operating air/fuel

ratio divided by stoichiometric at full load = < 1.1

Existing with no mfg. recommendations if O2 in exhaust at full load < 2%

Lean Burn Excess air in combustion chamber O2 rich exhaust Not rich burn

Spark Ignition

Nebraska Sources

LOTS? 96+ facilities have notified

Multiple engines on-site Many more that don’t need to notify

Mostly municipal power plants & asphalt/concrete

Most compression ignition

Rule Background

NESHAP Subpart ZZZZ 40 CFR Part 63 – 63.6580 Title 129, Chapter 28 001.88 (not

current rules)

Initial final rule = 6/15/04 (effective 8/16/04)

Rule Background 4 significant rule actions

Original: June 15, 2004 Revision: January 18, 2008 (effective 3/18/08) Revision: March 3, 2010 (effective 5/3/10) Revision: August 20, 2010 (effective 10/19/10)

Applicability

Stationary sources Major & area sources of HAP New & existing sources

Need to know: Manufacture date, installation date, startup date,

fuel, engine type, horsepower, displacement, black start, emergency or non-emergency

Applicability

Not subject Not engines tested @ test cell/stand RICE for national security

Request exemption 40 CFR Part 1068, Subpart C

Existing emergency residential, commercial, or institutional at area source

Some existing > 500 HP at major source

Applicability

Residential, commercial, institutional Homes & apartments Office, hotel, stores, restaurants, banks,

etc. Hospitals, schools, police station, fire, etc.

Farming – not exempt Most smaller engines

See Air Toxics Notebook for list

Emergency Engines

Emergency & required testing & maintenance

Not peak shaving for your facility or the grid

Does not have interruptible service contract with power utility

Emergency Engines

Can be used up to 15 hours/yr as part of demand response

Can supply emergency power as part of financial agreement

100 hours/yr – testing & maintenance 50 hours/yr for non-emergency Includes 15 hours for demand response

Reconsideration

12/7/10 15 hours for demand response

Emergency conditions could lead to potential blackout (unusually low frequency, equipment overload, capacity or energy deficiency, or unacceptable voltage level)

Black Start & Limited Use

Black Start Used to start combustion turbines Different terminology than industry

Limited Use Operate < 100 hours/yr

Requirements

Source Classification

Area SourceExisting = Before 6/12/06

Change in ownership doesn’t make new

New = On or after 6/12/06

Source Classification

Major Source Existing

> 500 HP = Before 12/19/02 < 500 HP = Before 6/12/06

New > 500 HP = On or after 12/19/02 < 500 HP = On or after 6/12/06

Typical Controls

Oxidation Catalyst Spark ignition lean burn & compression

ignition Selective Catalytic Reduction (SCR)

Spark ignition lean burn & compression ignition

Non-selective Catalytic Reduction (NSCR) Spark ignition rich burn

Catalysts

Causes chemical reactions without being changed or consumed

Steel housing contains a metal or ceramic structure which acts as a catalyst support or substrate.

No moving parts, interior surfaces coated with base or precious catalytic metals

Chemical reaction differs depending on lean, rich, or stoichiometric

Oxidation Catalyst

Flow through honeycomb coated with platinum metals

Small parallel channels = high catalytic contact area to exhaust

Completes combustion & mixed with free O2 in exhaust

Pollutants oxidized into CO2 & H2O vapor Doesn’t reduce NOx

May need to be combined with SCR

Diesel Oxidation Catalyst

Selective Catalytic Reduction Converts NOx with aid of catalyst

into N2 and H2O Anhydrous ammonia, aqueous

ammonia or urea added to exhaust & absorbed onto catalyst CO2 is a reaction product when urea is

Selective Catalytic Reduction (SCR)

Diesel SCR

Non-selective Catalytic Reduction (NSCR) Also Three-Way Catalysts

(stoichiometric) Causes CO to react with NOx in

presence of catalyst Creates N2 and H2O vapor

Area Sources

Compression Ignition (SI)Spark Ignition (SI)

No Requirements

Existing Emergency residential,

commercial, & institutional at area

No NESHAP Requirements May Be Subject to NSPS

New area sources

Existing CI @ Area

Work practice Emergency (hour meter) Black start Non-emergency < 300 HP

Numerical standards Non-emergency > 300 HP

Work Practice Standards

Engine Type & Requirement

Oil Change& Filter replaced

Inspect Air Cleaner

Inspect Hoses & Belts

Emergency & Black Start

500 hours or annually

1,000 hours or annually

Non-emergency < 300 HP

RecordsMalfunctionsMaintenanceEmergency – hours of operation

No reports or notifications required

Non-emergency > 300 HP

CO limits Initial Testing Closed crankcase Sulfur fuel requirements <

30 l/cyl

Meet all from previous slide and Periodic testing

Every three years or 8,760 hours Limited use = Every five years or 8,760

hours Continuous monitoring

CPMS CEMS

Initial notification 8/31/10

Performance test60 days prior to test

Compliance StatusWithin 60 days after test

ReportsSemiannual

Malfunctions & deviationsEven if noneDue 30 days after calendar half or

according to Title V scheduleAnnual if limited use

RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data (> 500 HP)

All Existing CI @ Area

Startup requirementsMinimize idle time to < 30

min. Compliance date 5/3/13

Existing SI @ Area 8/20/10 rules Work practice

Emergency (hour meter installed) Black Start Non-emergency

4SLB & 4SRB > 500 HP operates < 24 hr/yr 4SLB & 4SRB < 500 HP 2SLB Landfill/digester gas

Inspect Spark Plugs

Emergency & Black Start

Non-emergency Landfill/Digester

Inspect Spark Plugs

Non-Emergency 2SLB

Non-emergency 4SLB & 4SRB < 500 HP

Inspect Spark Plugs

Non-Emergency 4SLB & 4SRB > 500 HP operate < 24 hrs/yr

4SLB & 4SRB > 500 HP operates > 24 hr/yr Numerical standards

CO (4SLB) or Formaldehyde (4SRB) limits May need controls & operational

parameters CPMS or CEMS

Initial & periodic testing Every three years or 8,760 hours Limited use = Every five years or 8,760 hours

4SLB & 4SRB > 500 HP operates > 24 hr/yr

Performance Test60 days prior to test

Compliance StatusWithin 60 days of test

ReportsSemiannual

RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data

All Existing SI @ Area

All have startup requirementsMinimize idle time to < 30 min.

Compliance date 10/19/13

Major Sources

Existing CIExisting SI < 500 HP

New SI 4SLBOther > 500 HP

No Requirements Existing @ major

Limited use & emergency > 500 HP Spark ignition 4SLB & 2SLB > 500 HP Landfill/Digester > 500 HP

New @ major Constructed between 6/12/06 –

1/1/08 spark ignition 4SLB > 250 HP < 500 HP

No NESHAP Requirements May Be Subject to NSPS

New sources @ major source < 500 HP

Emergency and limited use Non-emergency compression ignition Spark ignition 4SLB < 250 HP Spark ignition 2SLB & 4SRB Landfill/digester

Limited NESHAP Requirements May Be Subject to NSPS (@ major) Initial notification only

New emergency and limited use > 500 HP Monitoring & recordkeeping

New landfill/digester > 500 HP Hour meter installed

New, emergency manufactured after 1/1/08 spark ignition 4SLB > 250 < 500 HP

Existing CI @ Major

3/3/10 rules Work practice

Emergency (hour meter) < 500 HP Black start < 500 HP Non-emergency < 100 HP

Numerical standards Non-emergency > 100 HP

Inspect Air Cleaner

Emergency & Black Start < 500 HP

Records Malfunctions Maintenance Emergency – hours of operation

Non-emergency >100 HP

CO limits Initial testing > 300 HP

Closed crankcaseFuel requirements < 30 l/cyl

Non-emergency > 500 HP Meet all from previous slide and Periodic testing

Every three years or 8,760 hours Limited use = Every five years or

8,760 hours Continuous monitoring

CPMS CEMS

Performance test60 days prior to test

ReportsSemiannual

RecordsNotifications & reportsMalfunctionsTest dataCPMS or CEMS data (> 500

All Existing CI @ Major

Startup requirementsMinimize idle time to < 30 min.

Existing SI @ Major < 500 HP

8/20/10 rules Work practice

Emergency (hour meter installed) & Black Start < 500 HP

Numerical standards Non-emergency > 100 < 500 HP

Inspect Spark Plugs

Emergency & Black Start < 500 HP

Non-emergency < 100 HP (not 2SLB)

Inspect Spark Plugs

Non-emergency 2SLB < 100 HP

Existing SI @ Major >100 < 500 HP

CO or Formaldehyde Limit

May need controls Initial testing

Compliance StatusWithin 60 days of test

ReportsSemiannual

RecordsNotifications & reportsMalfunctionsTest data

All Existing SI @ Major < 500 HP All have startup requirements

Minimize idle time to < 30 min.

New SI 4SLB @ Major > 250 < 500 HP

1/18/08 rules Manufactured after 1/1/08 > 250 and < 500 HP Numerical standards

Formaldehyde or CO limit

Initial testing Periodic testing

Semiannual if no CEMS & reducing CO Semiannual if reducing formaldehyde Can reduce to annual

Continuous monitoring CPMS CEMS

Initial Notification 7/16/08 120 days after startup (startup after 3/18/08)

Performance Test 60 days prior to test

Compliance Status Within 60 days after test

ReportsSemiannual

Records Notifications & reports Malfunctions Test data CPMS & CEMS data

Compliance 1/18/08 or startup

Major sources > 500 HP

6/15/04 Rules Existing

SI 4SRB New

SI 4SRB, 4SLB, 2SLBCI

Numerical standards for formaldehyde or CO

Initial testing

Periodic testing Semiannual if no CEMS & reducing CO Semiannual if reducing formaldehyde Can reduce to annual

Continuous monitoring CPMS CEMS

Initial Notification 12/13/04 (existing) 120 days after startup (new - startup after

8/16/04) Performance Test

60 days prior to test Compliance Status

Within 60 days after test

ReportsSemiannual

RecordsNotifications & reportsMalfunctionsTest dataCPMS & CEMS data

Compliance 6/15/07 (existing) and 8/16/04 or startup (new)

Testing

Option for 2SLB, 4SLB, & CI to use portable CO/O2 Analyzer

Not an option for 4SRB or reducing formaldehyde

May reduce costs of testing Might be able to use previous

test – 2 years from rule

Requirements Summary

No NESHAP Requirements

Existing Area – Emergency residential,

commercial, institutional Major

Limited use & emergency > 500 HP SI 4SLB & 2SLB > 500 HP Landfill/digester > 500 HP

No NESHAP - NSPS

New SourcesAll areaMajor < 500 HP

Limited NESHAP – Maybe NSPS New, major

> 500 HP Emergency & Limited Use (notify) Landfill/digester (monitoring &

recordkeeping) < 500 HP

Emergency 4SLB > 250 HP mfg. after 1/1/08 (hour meter)

Work Practice

Existing Area Emergency & Black Start CI & SI Non-emergency

CI < 300 HP SI Landfill/digester SI 2SLB SI 4SLB & 4SRB < 500 HP SI 4SLB & 4SRB > 500 HP < 24 hrs/yr

Work Practice

Existing Major Emergency & Black Start – CI & SI

< 500 HP Non-emergency CI & SI < 100 HP

Numerical Standards

Existing Area Non-emergency CI > 300 HP SI > 500 HP > 24 hrs/yr

Existing Major Non-emergency CI > 100 HP SI > 100 HP < 500 HP SI 4SRB > 500 HP

Numerical Standards

New Major Non-Emergency SI 4SLB > 250 HP < 500 HP mfg.

after 1/1/08 SI 4SRB > 500 HP SI 4SLB > 500 HP SI 2SLB > 500 HP CI > 500 HP

Compliance Date Summary 10/19/13

Existing SI @ area and major (< 500 HP) 5/3/13

Existing CI @ area and major 1/18/08

New 4SLB > 250 HP < 500 HP @ major 6/15/07

Majors > 500 HP

Initial Notification Summary (not work practice) Due 2/16/11

Existing SI @ area and major (< 500 HP) Due 8/31/10

Existing CI @ area and major Due 7/16/08

New 4SLB > 250 HP < 500 HP @ major Due 12/13/04

Majors > 500 HP

Other Notifications

Reports Summary

Only subject to numerical standards

Semiannual Malfunctions & deviations Even if none Due 30 days after calendar half or

according to Title V schedule Annual if limited use

Records Summary

Notifications & reports Malfunctions Maintenance (work practice) Hours operated (emergency) Test data (numerical) CPMS & CEMS data (some

numerical) Landfill/digester

Tips, Tools, & Resources

Many small municipalities affected Cost of compliance ~$100,000 Many have agreements with NPPD,

NMPP, etc. Dedicating some to emergency & some

non- Reconsideration of demand response

may help

Permitting Tips

Engine Identification Nonroad or stationary? Emergency, non-, fuel, HP, LB/RB,

4S/2S etc. Mostly power plants, concrete,

& asphalt plants

Inspection Tips

May not inspect many area sources Area Source Implementation Strategy

Following work practice – probably not inspecting Some may be permitted

Mostly power plants

Emergency operation Check contracts If operate not following emergency –

automatically non-emergency & must comply

Tools & Resources

Air Toxics Notebook Citations guidance (just updated) EPA guidance – just updated LOTS of info!

Part of National Workgroup Will share all tools/resources

developed or obtained by that group

Questions/Comments?

Look for the feedback survey in your email!!

NDEQ NESHAP Training Subpart ZZZZ - Engines

Documents