Current through August 26, 2024
(1) SUMMARY. On and
after the compliance date established by s.
NR 463.115, the owner or operator of a new or existing
affected source or emission unit shall monitor all control equipment and
processes according to the requirements in this section. Monitoring
requirements for each type of affected source and emission unit are summarized
in the following table.
Table 3
Summary of Monitoring Requirements for New and Existing
Affected Sources and Emission Units
Affected Source and Emission
Unit
|
Monitor Type, Operation,
Process
|
Monitoring Requirements
|
All affected sources and emission units with an
add-on air pollution control device
|
Emission capture and collection system
|
Annual inspection of all emission capture,
collection, and transport systems to ensure that systems continue to operate in
accordance with Industrial Ventilation: A Manual of Recommended Practice,
incorporated by reference in s.
NR 484.11(2)
(d).
|
All affected sources and emission units subject
to production-based, lb/ton of feed or charge, emission limits.
a
|
Feed charge weight
|
Record weight of each feed or charge, weight
measurements device of other procedure accuracy of
±1%b-; calibrate according to manufacturers
specifications, or at least once every 6 months
|
Group 1 furnace, group 2 furnace inline fluxer,
scrap dryer, delacquering kiln or decoating kiln
|
Labeling
|
Check monthly to confirm that labels are intact
and legible
|
Aluminum scrap shredder with fabric filter
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance."c; Record
voltage output from bag leak detector.
|
Continuous opacity monitor or
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63 ; determine and
record 6-minute block averages.
|
Visual emissions
|
Conduct and record results of 30-minute daily
test in accordance with Method 9 in Appendix A to 40 CFR part 60, incorporated
by reference in s.
NR 484.04(13).
|
Thermal Chip dryer with afterburner
|
Afterburner operating temperature
|
Continuous measurement device to meet
specifications in s. NR 463.15(7) (a); record average temperature for each
15-minute block; determine and record 3-hr block averages.
|
Afterburner operation
|
Annual inspection of afterburner internal parts;
complete repairs in accordance with the OM&Md
plan.
|
Feed or charge material
|
Record identity of each feed or charge; certify
feed or charge materials ever 6 months
|
Scrap dryer, delacquering kiln or decoating kiln
with afterburner and lime injected fabric filter
|
Afterburner operating temperature
|
Continuous measurement device to meet
specifications in s. NR 463.15(7) (a); record temperature for each 15-minute
block; determine and record 3-hr block averages.
|
Afterburner operation
|
Annual inspection of afterburner internal parts;
complete repairs in accordance with the OM&Md
plan.
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance"c; record voltage
output from bag leak detector.
|
Continuous opacity monitor
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63; determine and
record 6-minute block averages.
|
Lime injection rate
|
For continuous injection systems; inspect each
feed hopper or silo every 8 hr to verify that lime is free-flowing; record
results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
return to 8-hr inspections if corrective action results in no further blockage
during the 3-day period; record feeder setting daily.
|
Fabric filter inlet temperature
|
Continuous measurement device to meet
specifications in s. NR 463.15(8) (b); record temperatures in 15-minute block
averages; determine and record 3-hr blockage averages.
|
Sweat furnace with after burner
|
Afterburner operating temperature
|
Continuous measurement device to meet
specifications in s. NR 463.15(8) (a); record temperature in 15-minute block
averages; determine and record 3-hr block average.
|
Afterburner operation
|
Annual inspection of afterburner internal parts;
complete repairs in accordance with the OM&Md
plan.
|
Dross-only furnace with fabric filter
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance"c; record output
voltage from bag leak detector.
|
Continuous opacity monitor
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63; determine and
record 6-minute block averages.
|
Feed or charge material
|
Record identify of each feed or charge; certify
charge materials every 6 months.
|
Rotary dross cooler with fabric filter
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance"c; record output
voltage from bag leak detector.
|
Continuous opacity monitor
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63; determine and
record 6-minute block averages.
|
In-Line fluxer with lime-injected fabric
filter
|
Flux materials
|
Record flux material; certify every 6 months for
no reactive flux.
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance"c; record output
voltage from bag leak detector.
|
Continuous opacity monitor
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63; determine and
record 6-minute block averages.
|
Reactive flux injection rate
|
Weight measurement device accuracy of ±1%;
calibrate according to manufacturers specifications or at least once every 6
months; record time, weight and type of reactive flux added or injected for
each 15-minute block period while reactive fluxing occurs; calculate and record
total reactive flux injection rate for each operating cycle or time period used
in performance test; or
Alternative flux injection rate determination
procedure per s. NR 463.15(10) (e).
|
Lime injection rate
|
For continuous injection systems; inspect each
feed hopper or silo every 8 hr to verify that lime is free-flowing; record
results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
return to 8-hr inspections if corrective action results in no further blockage
during the 3-day period.e
|
In-line fluxer using no reactive flux
|
Flux materials
|
Record flux materials; certify every 6 months for
no reactive flux.
|
Group 1 furnace with lime injected fabric
filter
|
Bag leak detector or
|
Install and operate in accordance with "Fabric
Filter Bag Leak Detection Guidance"c; record output
voltage from bag leak detector.
|
Continuous opacity monitor
|
Design and install in accordance with PS-1;
collect data in accordance with subpart A of 40 CFR part 63; determine and
record 6-minute block averages.
|
Lime injection rate
|
For continuous injection systems; inspect each
feed hopper or silo every 8 hr to verify that lime is free-flowing; record
results of each inspection. If blockage occurs, inspect every 4 hr for 3 days;
return to 8-hr inspections if corrective action results in no further blockage
during the 3-day period; record feeder setting daily.
|
Reactive flux injection rate
|
Weight measurement device accuracy of
±1%b, calibrate every 3 months; record weight
and type of reactive flux added or injected for each 15-minute block period
while reactive fluxing occurs; calculate and record total reactive flux
injection rate for each operating cycle or time period used in performance
test; or Alternative flux rate injection rate determination procedure per s. NR 463.15(10) (e).
|
Group 1 furnace with lime injected fabric filter
(Continued)
|
Fabric filter inlet temperature
|
Continuous measurement device to meet
specifications in s. NR 463.15(8) (b); record temperatures in 15-minute block
averages; determine and record 3-hour block averages
|
Maintain molten aluminum level in sidewell
furnace
|
Maintain aluminum level operating log; certify
every 6 months.
|
Group 1 furnace without add-on controls
|
Fluxing molten aluminum level in sidewell
furnace
|
Maintain flux addition operating log; certify
every 6 months.
|
Reactive flux injection rate
|
Weight measurement device accuracy of ±1%;
calibrate according to manufacturers specifications or at least once every 6
months; record time, weight and type of reactive flux added or injected for
each 15-minute block period while reactive fluxing occurs; calculate and record
total reactive flux injection rate for each operating cycle or time period used
in performance test.
|
OM&Md plan
approved by the department
|
Demonstration of site-specific monitoring
procedures to provide data and show correlation of emissions across the range
of charge and flux materials and furnace operating parameters.
|
Feed material - melting and holding
furnace
|
Record type of permissible feed or charge
material; certify charge materials every 6 months.
|
Clean group 2 furnace
|
Charge and flux materials
|
Record charge and flux materials; certify every 6
months for clean charge and no reactive flux.
|
a Thermal chip dryers, scrap dryers, delacquering kilns,
dross-only furnaces, in-line fluxers and group 1 furnaces or melting and
holding furnaces
b The department may approve measurement devices of
alternative accuracy, for example in cases where flux rates are very low and
costs of meters of specified accuracy are prohibitive; or where feed or charge
weighing devices of specified accuracy are not practicable due to equipment
layout or charging practices.
c Non-turboelectric bag leak detectors shall be installed
and operated in accordance with manufacturers' specifications.
d OM&M plan- Operation, maintenance, and monitoring
plan.
e The department may approve of other alternatives
including load cells for lime hopper weight, sensors for carrier gas pressure,
or HCl monitoring devices of fabric filter outlet.
(2) OPERATION, MAINTENANCE, AND MONITORING
PLAN. The owner or operator shall prepare and implement for each new or
existing affected source and emission unit, a written operation, maintenance
and monitoring (OM&M) plan. The owner or operator of an existing affected
source shall submit the OM&M plan to the department no later than the
compliance date established by s.
NR 463.115(1). The owner or operator of
any new MACT source subject to this subchapter shall submit the OM&M plan
to the department within 90 days after a successful initial performance test
under s.
NR 463.16(2) or within 90 days after the
compliance date established by s.
NR 463.115(2) if no initial performance
test is required. The plan shall be accompanied by a written certification by
the owner or operator that the OM&M plan satisfies all requirements of this
section and is otherwise consistent with the requirements of this subchapter.
The owner or operator shall comply with all of the provisions of the OM&M
plan as submitted to the department, unless and until the plan is revised in
accordance with the following procedures. If the department determines at any
time after receipt of the OM&M plan that any revisions of the plan are
necessary to satisfy the requirements of this subchapter, the owner or operator
shall promptly make all necessary revisions and resubmit the revised plan. If
the owner or operator determines that any other revisions of the OM&M plan
are necessary, the revisions may not become effective until the owner or
operator submits a description of the changes and a revised plan incorporating
them to the department. Each plan shall contain all of the following
information:
(a) Process and control device
parameters to be monitored to determine compliance, along with established
operating levels or ranges, as applicable, for each process and control
device.
(b) A monitoring schedule
for each affected source and emission unit.
(c) Procedures for the proper operation and
maintenance of each process unit and add-on control device used to meet the
applicable emission limits or standards in s.
NR 463.13.
(d) Procedures for the proper operation and
maintenance of monitoring devices or systems used to determine compliance,
including the following:
1. Calibration and
certification of accuracy of each monitoring device, at least once every 6
months, according to the manufacturer's instructions.
2. Procedures for the quality control and
quality assurance of continuous emission or opacity monitoring systems as
required by the general provisions in ch. NR 460.
(e) Procedures for monitoring process and
control device parameters, including procedures for annual inspections of
afterburners, and if applicable, the procedure to be used for determining
charge or feed or throughput weight if a measurement device is not
used.
(f) Corrective actions to be
taken when process or operating parameters or add-on control device parameters
deviate from the value or range established in par. (a), including the
following:
1. Procedures to determine and
record the cause of a deviation or excursion, and the time the deviation or
excursion began and ended.
2.
Procedures for recording the corrective action taken, the time corrective
action was initiated, and the time and date corrective action was
completed.
(g) A
maintenance schedule for each process and control device that is consistent
with the manufacturer's instructions and recommendations for routine and
long-term maintenance.
(h)
Documentation of the work practice and pollution prevention measures used to
achieve compliance with the applicable emission limits and a site-specific
monitoring plan as required in sub. (15) for each group 1 furnace not equipped
with an add-on air pollution control device.
(3) LABELING. The owner or operator shall
inspect the labels for each group 1 furnace, group 2 furnace, in-line fluxer,
scrap dryer, delacquering kiln and decoating kiln at least once per calendar
month to confirm that posted labels as required by the operational standard in
s.
NR 463.14(2) are intact and
legible.
(4) CAPTURE AND COLLECTION
SYSTEM. The owner or operator shall do both of the following:
(a) Install, operate and maintain a capture
and collection system for each affected source and emission unit equipped with
an add-on air pollution control device.
(b) Inspect each capture and collection and
closed vent system at least once each calendar year to ensure that each system
is operating in accordance with the operating requirements in s.
NR 463.14(3) and record the results of
each inspection.
(5)
FEED OR CHARGE WEIGHT. The owner or operator of an affected source or emission
unit subject to an emission limit in kg/Mg (lb/ton) or mg/Mg (gr/ton) of feed
or charge shall install, calibrate, operate and maintain a device to measure
and record the total weight of feed or charge to, or the aluminum production
from, the affected source or emission unit over the same operating cycle or
time period used in the performance test. Feed or charge or aluminum production
within SAPUs shall be measured and recorded on an emission unit-by-emission
unit basis. As an alternative to a measurement device, the owner or operator
may use a procedure acceptable to the department to determine the total weight
of feed or charge or aluminum production to the affected source or emission
unit.
(a) The weight measurement device or
procedure shall have an accuracy of ± 1% of the weight being measured.
The owner or operator may apply to the department for approval to use a device
of alternative accuracy if the required accuracy cannot be achieved as a result
of equipment layout or charging practices. A device of alternative accuracy may
not be approved unless the owner or operator provides assurance through data
and information that the affected source will meet the relevant emission
standard.
(b) The owner or operator
shall verify the calibration of the weight measurement device in accordance
with the schedule specified by the manufacturer, or if no calibration schedule
is specified, at least once every 6 months.
(6) FABRIC FILTERS AND LIME-INJECTED FABRIC
FILTERS. The owner or operator of an affected source or emission unit using a
fabric filter or lime-injected fabric filter to comply with the requirements of
this subchapter shall install, calibrate, maintain and continuously operate a
bag leak detection system as required in par. (a) or a continuous opacity
monitoring system as required in par. (b). The owner or operator of an aluminum
scrap shredder shall install and operate a bag leak detection system as
required in par. (a), install and operate a continuous opacity monitoring
system as required in par. (b), or conduct visible emission observations as
required in par. (c).
(a) The requirements of
this paragraph apply to the owner or operator of a new or existing affected
source or existing emission unit using a bag leak detection system.
1. The owner or operator shall install and
operate a bag leak detection system for each exhaust stack of a fabric
filter.
2. Each triboelectric bag
leak detection system shall be installed, calibrated, operated and maintained
according to the Fabric Filter Bag Leak Detection Guidance, EPA, OAQPS,
September 1997, incorporated by reference in s.
NR 484.05(10). Other bag leak detection
systems shall be installed, operated, calibrated, and maintained in a manner
consistent with the manufacturer's written specifications and
recommendations.
3. The bag leak
detection system shall be certified by the manufacturer to be capable of
detecting PM emissions at concentrations of 10 milligrams per actual cubic
meter (0.0044 grains per actual cubic foot) or less.
4. The bag leak detection system sensor shall
provide output of relative or absolute PM loadings.
5. The bag leak detection system shall be
equipped with a device to continuously record the output signal from the
sensor.
6. The bag leak detection
system shall be equipped with an alarm system that shall sound automatically
when an increase in relative PM emissions over a preset level is detected. The
alarm shall be located where it is easily heard by plant operating
personnel.
7. For positive pressure
fabric filter systems, a bag leak detection system shall be installed in each
baghouse compartment or cell. For negative pressure or induced air fabric
filters, the bag leak detector shall be installed downstream of the fabric
filter.
8. Where multiple detectors
are required, the system's instrumentation and alarm may be shared among
detectors.
9. The baseline output
shall be established by adjusting the range and the averaging period of the
device and establishing the alarm set points and the alarm delay
time.
10. Following initial
adjustment of the system, the owner or operator may not adjust the sensitivity
or range, averaging period, alarm set points, or alarm delay time except as
detailed in the OM&M plan. In no case may the sensitivity be increased by
more than 100% or decreased more than 50% over a 365-day period unless the
adjustment follows a complete fabric filter inspection which demonstrates that
the fabric filter is in good operating condition.
(b) The requirements of this paragraph apply
to the owner or operator of a new or existing affected source or an existing
emission unit using a continuous opacity monitoring system.
1. The owner or operator shall install,
calibrate, maintain and operate a continuous opacity monitoring system to
measure and record the opacity of emissions exiting each exhaust
stack.
2. Each continuous opacity
monitoring system shall meet the design and installation requirements of
Performance Specification 1 in Appendix B to 40 CFR part 60, incorporated by
reference in s.
NR 484.04(21).
(c) The requirements of this paragraph apply
to the owner or operator of a new or existing aluminum scrap shredder who
conducts visible emission observations. The owner or operator shall do both of
the following:
1. Perform a visible emissions
test for each aluminum scrap shredder using a certified observer at least once
a day according to the requirements of Method 9 in Appendix A to 40 CFR part
60, incorporated by reference in s.
NR 484.04(13). Each Method 9 test shall
consist of 5 6-minute observations in a 30-minute period.
2. Record the results of each test required
under subd. 1.
(7) AFTERBURNER. The requirements of this
subsection apply to the owner or operator of an affected source using an
afterburner to comply with the requirements of this subchapter.
(a) The owner or operator shall install,
calibrate, maintain, and operate a device to continuously monitor and record
the operating temperature of the afterburner consistent with the requirements
for continuous monitoring systems in s.
NR 460.07(3).
(b) The temperature monitoring device shall
meet each of the following performance and equipment specifications:
1. The temperature monitoring device shall be
installed at the exit of the combustion zone of each afterburner.
2. The monitoring system shall record the
temperature in 15-minute block averages and determine and record the average
temperature for each 3-hour block period.
3. The recorder response range shall include
zero and 1.5 times the average temperature established according to the
requirements in s.
NR 463.163(13).
4. The reference method shall be a National
Institute of Standards and Technology calibrated reference
thermocouple-potentiometer system or alternate reference, subject to approval
by the department.
(c)
The owner or operator shall conduct an inspection of each afterburner at least
once a year and record the results. At a minimum, an inspection and resulting
steps shall include all of the following:
1.
Inspection of all burners, pilot assemblies, and pilot sensing devices for
proper operation and clean pilot sensor.
2. Inspection for proper adjustment of
combustion air.
3. Inspection of
internal structures, such as baffles, to ensure structural integrity.
4. Inspection of dampers, fans, and blowers
for proper operation.
5. Inspection
for proper sealing.
6. Inspection
of motors for proper operation.
7.
Inspection of combustion chamber refractory lining and cleaning and replacement
of lining as necessary.
8.
Inspection of afterburner shell for corrosion and hot spots.
9. Documentation, for the burn cycle that
follows the inspection, that the afterburner is operating properly and any
necessary adjustments have been made.
10. Verification that the equipment is
maintained in good operating condition.
11. Following an equipment inspection,
completion of all necessary repairs in accordance with the requirements of the
OM&M plan.
(8) FABRIC FILTER INLET TEMPERATURE. The
requirements of this subsection apply to the owner or operator of a scrap
dryer, delacquering kiln or decoating kiln or a group 1 furnace using a
lime-injected fabric filter to comply with the requirements of this subchapter.
(a) The owner or operator shall install,
calibrate, maintain and operate a device to continuously monitor and record the
temperature of the fabric filter inlet gases consistent with the requirements
for continuous monitoring systems in s.
NR 460.07(3).
(b) The temperature monitoring device shall
meet each of the following performance and equipment specifications:
1. The monitoring system shall record the
temperature in 15-minute block averages and calculate and record the average
temperature for each 3-hour block period.
2. The recorder response range shall include
zero and 1.5 times the average temperature established according to the
requirements in s.
NR 463.163(14).
3. The reference method shall be a National
Institute of Standards and Technology calibrated reference
thermocouple-potentiometer system or alternate reference, subject to approval
by the department.
(9) LIME INJECTION. The requirements of this
subsection apply to the owner or operator of an affected source or emission
unit using a lime-injected fabric filter to comply with the requirements of
this subchapter.
(a) The owner or operator of
a continuous lime injection system shall verify that lime is always
free-flowing by one of the following methods:
1. Inspecting each feed hopper or silo at
least once each 8-hour period and recording the results of each inspection. If
lime is found not to be free-flowing during any of the 8-hour periods, the
owner or operator shall increase the frequency of inspections to at least once
every 4-hour period for the next 3 days. The owner or operator may return to
inspections at least once every 8-hour period if corrective action results in
no further blockages of lime during the 3-day period.
2. Subject to the approval of the department,
installing, operating and maintaining a load cell, carrier gas or lime flow
indicator, carrier gas pressure drop measurement system or other system to
confirm that lime is free-flowing. If lime is found not to be free-flowing, the
owner or operator shall promptly initiate and complete corrective
action.
3. Subject to the approval
of the department, installing, operating and maintaining a device to monitor
the concentration of HCl at the outlet of the fabric filter. If an increase in
the concentration of HCl indicates that the lime is not free-flowing, the owner
or operator shall promptly initiate and complete corrective action.
(b) The owner or operator of a
continuous lime injection system shall record the lime feeder setting once each
day of operation.
(c) An owner or
operator who intermittently adds lime to a lime coated fabric filter shall
obtain approval from the department for a lime addition monitoring procedure.
The department may not approve a monitoring procedure unless data and
information are submitted establishing that the procedure is adequate to ensure
that relevant emission standards will be met on a continuous basis.
(10) TOTAL REACTIVE FLUX INJECTION
RATE. The requirements of this subsection apply to the owner or operator of a
group 1 furnace or in-line fluxer. The owner or operator shall meet pars. (a)
to (d) or apply for approval of an alternate method under par. (e):
(a) Install, calibrate, operate and maintain
a device to continuously measure and record the weight of gaseous or liquid
reactive flux injected to each affected source or emission unit.
1. The monitoring system shall record the
weight for each 15-minute block period, during which reactive fluxing occurs,
over the same operating cycle or time period used in the performance
test.
2. The weight measurement
device shall be accurate to ± 1% of the weight of the reactive component
of the flux being measured. The owner or operator may apply to the department
for permission to use a weight measurement device of alternative accuracy in
cases where the reactive flux flow rates are so low as to make the use of a
weight measurement device of ±1% impracticable. A device of alternative
accuracy may not be approved unless the owner or operator provides assurance
through data and information that the affected source will meet the relevant
emission standards.
3. The owner or
operator shall verify the calibration of the weight measurement device in
accordance with the schedule specified by the manufacturer, or if no
calibration schedule is specified, at least once every 6 months.
(b) Calculate and record the
gaseous or liquid reactive flux injection rate (kg/Mg or lb/ton) for each
operating cycle or time period used in the performance test using the procedure
in s.
NR 463.163(15).
(c) Record, for each 15-minute block period
during each operating cycle or time period used in the performance test during
which reactive fluxing occurs, the time, weight and type of flux for each
addition of the following:
1. Gaseous or
liquid reactive flux other than chlorine.
2. Solid reactive flux.
(d) Calculate and record the total reactive
flux injection rate for each operating cycle or time period used in the
performance test using the procedure in s.
NR 463.163(15).
(e) At their discretion, apply to the
department for approval of an alternative method for monitoring and recording
the total reactive flux addition rate based on monitoring the weight or
quantity of reactive flux per ton of feed or charge for each operating cycle or
time period used in the performance test. An alternative monitoring method may
not be approved unless the owner or operator provides assurance through data
and information that the affected source will meet the relevant emission
standards on a continuous basis.
(11) THERMAL CHIP DRYER. The requirements of
this subsection apply to the owner or operator of a thermal chip dryer with
emissions controlled by an afterburner. The owner or operator shall do both of
the following:
(a) Record the type of
materials charged to the unit for each operating cycle or time period used in
the performance test.
(b) Submit a
certification of compliance with the applicable operational standard for charge
materials in s.
NR 463.14(6)
(c) for each 6-month reporting period. Each
certification shall contain the information in s.
NR 463.18(2) (b) 1.
(12) DROSS-ONLY FURNACE. The
requirements of this subsection apply to the owner or operator of a dross-only
furnace. The owner or operator shall do both of the following:
(a) Record the materials charged to each unit
for each operating cycle or time period used in the performance test.
(b) Submit a certification of compliance with
the applicable operational standard for charge materials in s.
NR 463.14(9)
(c) for each 6-month reporting period. Each
certification shall contain the information in s.
NR 463.18(2) (b) 2.
(13) IN-LINE FLUXERS USING NO
REACTIVE FLUX. The owner or operator of an in-line fluxer that uses no reactive
flux materials shall submit a certification of compliance with the operational
standard for no reactive flux materials in s.
NR 463.14(12) for each 6-month reporting
period. Each certification shall contain the information in s.
NR 463.18(2) (b) 6.
(14) SIDEWELL GROUP 1 FURNACE WITH ADD-ON AIR
POLLUTION CONTROL DEVICES. The requirements of this subsection apply to the
owner or operator of a sidewell group 1 furnace using add-on air pollution
control devices. The owner or operator shall do both of the following:
(a) Record in an operating log for each
charge of a sidewell furnace that the level of molten metal was above the top
of the passage between the sidewell and hearth during reactive flux injection,
unless the furnace hearth was also equipped with an add-on control
device.
(b) Submit a certification
of compliance with the operational standards in s.
NR 463.14(13)
(f) for each 6-month reporting period. Each
certification shall contain the information in s.
NR 463.18(2) (b) 3.
(15) GROUP 1 FURNACE WITHOUT
ADD-ON AIR POLLUTION CONTROL DEVICES.
(a) The
requirements of this paragraph apply to the owner or operator of a group 1
furnace that is not equipped with an add-on air pollution control device.
1. The owner or operator shall develop, in
consultation with the department, a written site-specific monitoring plan. The
site-specific monitoring plan shall be submitted to the department as part of
the OM&M plan. The site-specific monitoring plan shall contain sufficient
procedures to ensure continuing compliance with all applicable emission limits
and shall demonstrate, based on documented test results, the relationship
between emissions of PM, HCl and D&F and the proposed monitoring parameters
for each pollutant. Test data shall establish the highest level of PM, HCl and
D&F that will be emitted from the furnace. This emission level may be
determined by conducting performance tests and monitoring operating parameters
while charging the furnace with feed or charge materials containing the highest
anticipated levels of oils and coatings and fluxing at the highest anticipated
rate. If the department determines that any revisions of the site-specific
monitoring plan are necessary to meet the requirements of this subchapter, the
owner or operator shall promptly make all necessary revisions and resubmit the
revised plan to the department.
2.
The site-specific monitoring plan shall contain all of the following as
applicable:
a. Each site-specific monitoring
plan shall document each work practice, equipment and design practice,
pollution prevention practice or other measure used to meet the applicable
emission standards.
b. Each
site-specific monitoring plan shall include provisions for unit labeling as
required in sub. (3), feed or charge weight measurement, or production weight
measurement, as required in sub. (5) and flux weight measurement as required in
sub. (10).
c. Each site-specific
monitoring plan for a melting and holding furnace subject to the clean charge
emission standard in s.
NR 463.13(9) (c) shall include
requirements that the owner or operator record the type of feed or charge, such
as ingot, thermally dried chips, dried scrap, or other, for each operating
cycle or time period used in the performance test, and that the owner or
operator submit a certification of compliance with the applicable operational
standard for clean charge materials in s.
NR 463.14(14)
(c) for each 6-month reporting period. Each
certification shall contain the information in s.
NR 463.18(2) (b) 4.
d. If a continuous emission monitoring system
is included in a site-specific monitoring plan, the plan shall include
provisions for the installation, operation and maintenance of the system to
provide quality-assured measurements in accordance with all applicable
requirements of the general provisions of ch. NR 460.
e. If a continuous opacity monitoring system
is included in a site-specific monitoring plan, the plan shall include
provisions for the installation, operation and maintenance of the system to
provide quality-assured measurements in accordance with all applicable
requirements of this subchapter.
f.
If a site-specific monitoring plan includes a scrap inspection program for
monitoring the scrap contaminant level of furnace feed or charge materials, the
plan shall include provisions for the demonstration and implementation of the
program in accordance with all applicable requirements in sub. (16).
g. If a site-specific monitoring plan
includes a calculation method for monitoring the scrap contaminant level of
furnace feed or charge materials, the plan shall include provisions for the
demonstration and implementation of the program in accordance with all
applicable requirements in sub. (17).
3. The owner or operator of an existing
affected source shall submit the site-specific monitoring plan to the
department for review at least 6 months prior to the compliance date.
(b) The department shall review
and approve or disapprove a proposed site-specific monitoring plan, or request
changes to a plan, based on whether the plan contains sufficient provisions to
ensure continuing compliance with applicable emission limits and demonstrates,
based on documented test results, the relationship between emissions of PM, HCl
and D&F and the proposed monitoring parameters for each pollutant. Test
data shall establish the highest level of PM, HCl and D&F that will be
emitted from the furnace. Subject to department approval of the OM&M plan,
this may be determined by conducting performance tests and monitoring operating
parameters while charging the furnace with feed or charge materials containing
the highest anticipated levels of oils and coatings and fluxing at the highest
anticipated rate.
(16)
SCRAP INSPECTION PROGRAM FOR GROUP 1 FURNACE WITHOUT ADD-ON AIR POLLUTION
CONTROL DEVICES. A scrap inspection program shall include all of the following:
(a) A proven method for collecting
representative samples and measuring the oil and coatings content of scrap
samples.
(b) A scrap inspector
training program.
(c) An
established correlation between visual inspection and physical measurement of
oil and coatings content of scrap samples.
(d) Periodic physical measurements of oil and
coatings content of randomly-selected scrap samples and comparison with visual
inspection results.
(e) A system
for assuring that only acceptable scrap is charged to an affected group 1
furnace.
(f) Recordkeeping
requirements to document conformance with plan requirements.
(17) MONITORING OF SCRAP
CONTAMINATION LEVEL BY CALCULATION METHOD FOR GROUP 1 FURNACE WITHOUT ADD-ON
AIR POLLUTION CONTROL DEVICES. The owner or operator of a group 1 furnace
dedicated to processing a distinct type of furnace feed or charge composed of
scrap with a uniform composition, such as rejected product from a manufacturing
process for which the coating-to-scrap ratio can be documented, may include a
program in the site-specific monitoring plan for determining, monitoring and
certifying the scrap contaminant level using a calculation method rather than a
scrap inspection program. A scrap contaminant monitoring program using a
calculation method shall include all of the following:
(a) Procedures for the characterization and
documentation of the contaminant level of the scrap prior to the performance
test.
(b) Limitations on the scrap
in the furnace feed or charge to scrap of the same composition as that used in
the performance test. If the performance test was conducted with a mixture of
scrap and clean charge, limitations on the proportion of scrap in the furnace
feed or charge to no greater than the proportion used during the performance
test.
(c) Operating, monitoring,
recordkeeping and reporting requirements to ensure that no scrap with a
contaminant level higher than that used in the performance test is charged to
the furnace.
(18) GROUP
2 FURNACE. The requirements of this subsection apply to the owner or operator
of a new or existing group 2 furnace. The owner or operator shall do both of
the following:
(a) Record a description of
the materials charged to each furnace, including any nonreactive,
non-HAP-containing, non-HAP-generating fluxing materials or agents.
(b) Submit a certification of compliance with
the applicable operational standard for charge materials in s.
NR 463.14(15) for each 6-month reporting
period. Each certification shall contain the information in s.
NR 463.18(2) (b) 5.
(19) SITE-SPECIFIC REQUIREMENTS
FOR SECONDARY ALUMINUM PROCESSING UNITS.
(a)
An owner or operator of a secondary aluminum processing unit at a facility
shall include, within the OM&M plan prepared in accordance with sub. (2),
all of the following information:
1. The
identification of each emission unit in the secondary aluminum processing
unit.
2. The specific control
technology or pollution prevention measure to be used for each emission unit in
the secondary aluminum processing unit and the date of its installation or
application.
3. The emission limit
calculated for each secondary aluminum processing unit and performance test
results with supporting calculations demonstrating initial compliance with each
applicable emission limit.
4.
Information and data demonstrating compliance for each emission unit with all
applicable design, equipment, work practice or operational standards of this
subchapter.
5. The monitoring
requirements applicable to each emission unit in a secondary aluminum
processing unit and the monitoring procedures for daily calculation of the
3-day, 24-hour rolling average using the procedure in sub. (20).
(b) The SAPU compliance procedures
within the OM&M plan may not contain any of the following provisions:
1. Any averaging among emissions of differing
pollutants.
2. The inclusion of any
affected sources other than emission units in a secondary aluminum processing
unit.
3. The inclusion of any
emission unit while it is shut down.
4. The inclusion of any periods of startup,
shutdown or malfunction in emission calculations.
(c) To revise the SAPU compliance provisions
within the OM&M plan prior to the end of the permit term, the owner or
operator shall submit a request to the department containing the information
required by par. (a) and obtain approval of the department prior to
implementing any revisions.
(20) SECONDARY ALUMINUM PROCESSING UNIT.
Except as provided in sub. (21), the owner or operator shall calculate and
record the 3-day, 24-hour rolling average emissions of PM, HCl and D&F for
each secondary aluminum processing unit on a daily basis. To calculate the
3-day, 24-hour rolling average, the owner or operator shall do all of the
following:
(a) Calculate and record the total
weight of material charged to each emission unit in the secondary aluminum
processing unit for each 24-hour day of operation using the feed or charge
weight information required in sub. (5). If the owner or operator chooses to
comply on the basis of weight of aluminum produced by the emission unit, rather
than weight of material charged to the emission unit, all performance test
emissions results and all calculations shall be conducted on the aluminum
production weight basis.
(b)
Multiply the total feed or charge weight to the emission unit, or the weight of
aluminum produced by the emission unit, for each emission unit for the 24-hour
period by the emission rate, in lb/ton of feed or charge, for that emission
unit, as determined during the performance test, to provide emissions for each
emission unit for the 24-hour period, in pounds.
(c) Divide the total emissions for each SAPU
for the 24-hour period by the total material charged to the SAPU, or the weight
of aluminum produced by the SAPU over the 24-hour period, to provide the daily
emission rate for the SAPU.
(d)
Compute the 24-hour daily emission rate using Equation 4:
See
Image
where:
Eday is the daily PM, HCl, or
D&F emission rate for the secondary aluminum processing unit for the
24-hour period
Ti is the total amount of feed, or
aluminum produced, for emission unit i for the 24-hour period (tons or
Mg)
ER i is the measured emission rate
for emission unit i as determined in the performance test (lb/ton or mg/Mg of
feed or charge)
n is the number of emission units in the secondary aluminum
processing unit
(e)
Calculate and record the 3-day, 24-hour rolling average for each pollutant each
day by summing the daily emission rates for each pollutant over the 3 most
recent consecutive days and dividing by 3.
(21) SECONDARY ALUMINUM PROCESSING UNIT
COMPLIANCE BY INDIVIDUAL EMISSION UNIT DEMONSTRATION. As an alternative to the
procedures of sub. (20), an owner or operator may demonstrate, through
performance tests, that each individual emission unit within the secondary
aluminum production unit is in compliance with the applicable emission limits
for the emission unit.
(22)
ALTERNATIVE MONITORING METHOD FOR LIME ADDITION. The owner or operator of a
lime-coated fabric filter that employs intermittent or noncontinuous lime
addition may apply to the department for approval of an alternative method for
monitoring the lime addition schedule and rate based on monitoring the weight
of lime added per ton of feed or charge for each operating cycle or time period
used in the performance test. An alternative monitoring method may not be
approved unless the owner or operator provides assurance through data and
information that the affected source will meet the relevant emission standards
on a continuous basis.
(23)
ALTERNATIVE MONITORING METHODS. If an owner or operator wishes to use an
alternative monitoring method to demonstrate compliance with any emission
standard in this subchapter, other than those alternative monitoring methods
which may be authorized pursuant to subs. (10) (e) and (22), the owner or
operator may submit an application to the department. Any application shall be
processed according to the criteria and procedures in pars. (a) to (f).
(a) The department may not approve averaging
periods other than those specified in this section.
(b) The owner or operator shall continue to
use the original monitoring requirement until necessary data are submitted and
approval is received to use another monitoring procedure.
(c) The owner or operator shall submit the
application for approval of alternate monitoring methods no later than the
notification of the performance test. The application shall contain all the
information specified in subds. 1. to 3.:
1.
Data or information justifying the request, such as the technical or economic
infeasibility, or the impracticality of using the required approach.
2. A description of the proposed alternative
monitoring requirements, including the operating parameters to be monitored,
the monitoring approach and technique, and how the limit is to be
calculated.
3. Data and information
documenting that the alternative monitoring requirements would provide
equivalent or better assurance of compliance with the relevant emission
standards.
(d) The
department may not approve an alternate monitoring application unless it would
provide equivalent or better assurance of compliance with the relevant emission
standards. Before disapproving any alternate monitoring application, the
department shall provide both of the following:
1. Notice of the information and findings
upon which the intended disapproval is based.
2. Notice of opportunity for the owner or
operator to present additional supporting information before final action is
taken on the application. This notice shall specify how much additional time is
allowed for the owner or operator to provide additional supporting
information.
(e) The
owner or operator is responsible for submitting any supporting information in a
timely manner to enable the department to consider the application prior to the
performance test. Neither submittal of an application nor the department's
failure to approve or disapprove the application relieves the owner or operator
of the responsibility to comply with any provisions of this
subchapter.
(f) The department may
decide at any time, on a case-by-case basis, that additional or alternative
operating limits, or alternative approaches to establishing operating limits,
are necessary to demonstrate compliance with the emission standards of this
subchapter.