Current through Register Vol. 50, No. 9, March 1, 2024
RELATES TO:
KRS
224.20-100,
224.20-110,
224.20-120
NECESSITY, FUNCTION, AND CONFORMITY:
KRS
224.10-100 requires the Environmental and
Public Protection Cabinet to prescribe administrative regulations for the
prevention, abatement, and control of air pollution. This administrative
regulation provides for the control of emissions from existing primary aluminum
reduction plants.
Section 1.
Applicability.
(1) The provisions of this
administrative regulation shall apply to each affected facility which means
each potroom group within a primary aluminum reduction plant commenced before
the classification date defined below.
(2) A physical change in, or change in the
method of operation of, each potroom group within a primary aluminum reduction
plant in conformance with the change from this administrative regulation, as
effective November 5, 1981, to this administrative regulation, as effective
October 1, 1984, shall not be a modification; provided, that the potroom group
within a primary aluminum reduction plant was an affected facility at the time
of the physical or operational change.
Section 2. Definitions. As used in this
administrative regulation, all terms not defined herein shall have the meaning
given them in
401 KAR
50:010.
(1) "Primary
aluminum reduction plant" means any source manufacturing aluminum by
electrolytic reduction.
(2)
"Potroom" means a building unit which houses a group of electrolytic cells in
which aluminum is produced.
(3)
"Potroom group" means an uncontrolled potroom, a potroom which is controlled
individually, or a group of potrooms or potroom segments ducted to a common
control system.
(4) "Roof monitor"
means that portion of the roof of a potroom where gases not captured at the
cell exit from the potroom.
(5)
"Total fluorides" and "gaseous fluorides" means elemental fluorine and all
fluoride compounds, as measured and distinguished by reference methods
specified in Section 7 or equivalent or alternative methods.
(6) "Primary control system" means an air
pollution control system designed to remove gaseous and particulate fluorides
from exhaust gases which are captured at the cell.
(7) "Classification date" means October 23,
1974.
(8) "Dry scrubbing plant"
means each primary aluminum reduction plant with a primary control system which
operates in a manner whereby potroom group gases flow through a reaction bed
consisting of alumina prior to being treated by dry removal methods for
particulate emissions control. The resulting reaction bed products are then
used as feed to the potroom group electrolytic reduction cells.
(9) "Start-up cell" means an electrolytic
reduction cell which is initially devoid of any materials other than carbon
cathodes and anodes. Such a cell undergoes a prebake period by passing
electrical current through anodes resting on the cathode floor, then has the
necessary electrolyte and aluminum added, such that it will produce
aluminum.
(10) "Sick cell" means an
electrolytic reduction cell which has lost its proper heat balance, cannot
maintain a solid crust, and must be removed from the primary control system to
receive corrective attention.
(11)
"Normal potroom operations" means any potroom activity and includes uncaptured
cell gases resulting from start-up cells, cell tapping, anode changing, ore
additions, or any other potroom operation but does not include operations due
to sick cells.
(12) "State
Implementation Plan" means the most recently prepared plan or revision thereof
required by Section 110 of the Clean Air Act which has been approved by the
U.S. EPA.
Section 3.
Standard for Visible Emissions. On and after the date on which the performance
test required to be conducted by
401 KAR 61:005
is completed, no owner or operator subject to the provisions of this
administrative regulation shall cause to be discharged into the atmosphere:
(1) From any potroom roof monitor any gases
which exhibit ten (10) percent opacity or greater during normal potroom
operation except start-up cells;
(2) From any potroom roof monitor section
directly above sick cells or start-up cells any gases which exhibit forty (40)
percent opacity or greater;
(3)
From any dry scrubbing plant primary control system any gases which exhibit ten
(10) percent opacity or greater; or
(4) From any primary aluminum reduction plant
other than a dry scrubbing plant primary control system any gases which exhibit
twenty-five (25) percent opacity or greater.
Section 4. Standard for Fluorides.
(1) On and after the date on which the
performance test required to be conducted by
401 KAR 61:005
is completed, the owner or operator subject to the provisions of this
administrative regulation shall:
(a) For a dry
scrubbing plant cause to be discharged into the atmosphere no gases which
contain total fluorides in excess of one and nine-tenths (1.9) lb/ton of
aluminum produced except that emissions between one and nine-tenths (1.9)
lb/ton and two and five-tenths (2.5) lb/ton will be considered in compliance if
the owner or operator demonstrates to the cabinet's satisfaction that exemplary
operation and maintenance procedures were used with respect to the emission
control system and that proper control equipment was operating at the affected
facility during the performance test.
(b) For any primary aluminum reduction plant
other than a dry scrubbing plant cause to be discharged into the atmosphere
through each potroom roof monitor no gases which contain gaseous fluorides in
excess of 3.25 lb/hr.
(c) For a
primary aluminum reduction plant other than a dry scrubbing plant cause to be
discharged into the atmosphere from any primary control system no gases which
contain gaseous fluorides in excess of one (1.0) lbs/ton of aluminum produced
except that any such plant may cause to be discharged into the atmosphere gases
which contain gaseous fluorides not exceeding 290 lb/hr providing that a State
Implementation Plan allowing such emissions has been approved by the U.S. EPA.
The minimum stack height for the primary control system shall be 400
feet.
(2) In the event of
a recorded violation of the fluoride standard prescribed in
401 KAR
53:010, the cabinet shall require that remedial
measures be initiated from the source(s) responsible for causing said
violation.
Section 5.
Standard for Particulate Emissions. On and after the date on which the
performance test required to be conducted by
401 KAR 61:005
is completed, no owner or operator subject to the provisions of this
administrative regulation shall cause to be discharged into the atmosphere from
any primary aluminum reduction plant other than a dry scrubbing plant primary
control system any gases which contain particulate emissions in excess of 0.010
gr/scf. Addition of dilution air shall not constitute compliance.
Section 6. Monitoring of Operations.
(1) The owner or operator of any primary
aluminum reduction plant other than a dry scrubbing plant subject to the
provisions of this administrative regulation shall install, calibrate,
maintain, and operate monitoring devices which can be used to determine daily
the weight of the aluminum produced. The weighing devices shall have an
accuracy of plus or minus five (5) percent over their operating
range.
(2) The owner or operator of
any primary aluminum reduction plant other than a dry scrubbing plant shall
maintain a record of daily production rates of aluminum, raw material feed
rates, and cell or potline voltages.
(3) The owner or operator of any affected
facility shall install, use, and maintain ambient air monitoring equipment in
accordance with such methods as the cabinet shall prescribe; establish and
maintain records of same; and make periodic emission reports at intervals
prescribed by the cabinet.
Section
7. Test Methods and Procedures.
(1) Reference methods as defined in Appendix
A of 40 CFR 60 or as otherwise specified, filed by reference in
401 KAR
50:015, except as provided for in
401 KAR 50:045,
shall be used to determine compliance with the standards prescribed in Section
3, 4 and 5 as follows:
(a) For sampling
emissions from stacks:
1. Reference Method
13A or 13B for the concentration of total fluoride and the associated moisture
content;
2. Reference Method 1 for
sample and velocity traverses;
3.
Reference Method 2 for velocity and volumetric flow rate;
4. Reference Method 3 for gas analysis;
and
5. Reference Method 5 for
particulate emissions.
(b) For sampling emissions from roof monitors
not employing stacks or pollutant collection systems:
1. Reference Method 14 and Kentucky Method
130 for the concentration of gaseous fluorides and associated moisture
content;
2. Reference Method 1 for
sample and velocity traverses;
3.
Reference Method 2 and Reference Method 14 for velocity and volumetric flow
rate; and
4. Reference Method 3 for
gas analysis.
(c) For
opacity determination: Reference Method 9.
(2) For Reference Method 13A or 13B, 14, and
Kentucky Method 130, the sampling time for each run shall be at least eight (8)
hours for any potroom sample, and the minimum sample volume shall be six and
eight-tenths (6.8) dscm (240 dscf) for any potroom sample except that shorter
sampling times or smaller volumes, when necessitated by process variables or
other factors, may be approved by the cabinet.
(3) The air pollution control system for each
affected facility shall be constructed so that volumetric flow rates and total
fluoride emissions can be accurately determined using applicable methods
specified under subsection (1) of this section.
(4) The rate of aluminum production is
determined by dividing 720 hours into the weight of aluminum tapped from the
affected facility during a period of thirty (30) days prior to and including
the final run of a performance test.
(5) For each run for any plant with an
emission limitation expressed in lbs/ton of aluminum produced, potroom group
emissions expressed in kg/metric ton of aluminum produced shall be determined
using the equation in Appendix A of this administrative regulation.
(6) For any sampling harness which does not
comply with Reference Method 14 in Appendix A to 40 CFR 60, as amended on June
30, 1980, the cabinet shall prescribe such sampling procedures as it deems
appropriate.
Section 8.
Compliance Timetable.
(1) The owner or
operator of an affected facility shall be required with respect to start-up
cell and sick cell emissions to achieve compliance with this administrative
regulation no later than February 1, 1982, except as provided for under Section
9 of this administrative regulation.
(2) The owner or operator of an affected
facility shall be required with respect to the primary removal system to
achieve final compliance no later than February 1, 1981.
Section 9. Variance. To allow for
technological and economic circumstances unique to a source, variation from the
visible emission standard for sick or start-up cells specified in Section 3(2)
of this administrative regulation shall be granted by the cabinet when
supported by adequate technical and economic documentation reasonably
acceptable to the cabinet.
Section
10. Appendix A. Equation for Potroom Group Emissions.
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Where:
Ep = Primary control system emissions of
gaseous fluorides in kg/metric ton of aluminum produced at any plant other than
a dry scrubbing plant.
= Potroom group emissions of total fluorides in kg/metric ton
of aluminum produced at dry scrubbing plants.
C = For dry scrubbing plants, concentration of total fluorides
in mg/dscm as determined by Reference Method 13A or 13B, or Reference Method 14
as applicable.
= For plants other than dry scrubbing plants, concentration of
gaseous fluorides as determined by Kentucky Method 130.
Q = Volumetric flow rate of the effluent gas stream in
dscm/hour as determined by Reference Method 2 and/or Reference Method 14, as
applicable.
10-6 = Conversion factor for mg to
kg.
M = Rate of aluminum production in metric ton/hour as
determined by Section 7(4).
(CQ)1 = Product of C and Q for
measurements of primary control system effluent gas streams.
(CQ)2 = Product of C and Q for
measurements of roof monitor effluent gas stream at dry scrubbing plants.
(CQ)2 shall be equal to zero for any plant other than a
dry scrubbing plant.
STATUTORY AUTHORITY:
KRS
224.10-100