Wisconsin Legislature: NR 257.03(13)

Subchapter VI — The Drawing With Emulsions or Soaps Subcategory

NR 257.60 Applicability; description of the drawing with emulsions or soaps subcategory.

NR 257.61 Specialized definitions.

NR 257.62 Effluent limitations representing the degree of effluent reduction attainable by application of the best practicable control technology currently available.

NR 257.63 Effluent limitations representing the degree of effluent reduction attainable by the application of best available technology economically achievable.

NR 257.64 New source performance standards.

NR 257.65 Pretreatment standards for existing sources.

NR 257.66 Pretreatment standards for new sources.

NR 257.01 NR 257.01 Purpose. The purpose of this chapter is to establish effluent limitations, performance standards, and pretreatment standards for the discharge of process wastes from the aluminum forming point source category and its subcategories.

NR 257.01 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.02 NR 257.02 Applicability.

NR 257.02(1) (1) This chapter applies to any aluminum forming facility which discharges or may discharge pollutants to waters of the state or which introduces or may introduce pollutants into a publicly owned treatment works.

NR 257.02(2) (2) This chapter applies to chemical or electrochemical treatments applied to the surface of the aluminum when these surface treatments are performed at [the] aluminum forming site. When these surface treatments are not performed at the aluminum forming site, regulations for electroplating, ch. NR 260, or metal finishing, ch. NR 261, apply.

NR 257.02(3) (3) This chapter applies to aluminum casting when the casting is performed as an integral part of aluminum forming and is located at the aluminum forming site. When aluminum forming is performed on the same site as primary aluminum reduction, this chapter applies if the aluminum cools prior to casting. If the aluminum does not cool prior to casting, the regulations for nonferrous metals manufacturing, ch. NR 274, apply.

NR 257.02 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.03 NR 257.03 General definitions. In addition to the definitions set forth in ss. NR 205.03, 205.04, and 211.03, the following definitions apply to the terms used in this chapter:

NR 257.03(1) (1) “Aluminum forming” means a set of manufacturing operations in which aluminum and aluminum alloys are made into semifinished products by hot or cold working, such as rolling, drawing, extruding, and forging, and related operations such as heat treatment and casting.

NR 257.03(2) (2) “Ancillary operation” means a manufacturing operation that has a large flow, discharges significant amounts of pollutants, and may not be present at every plant in a subcategory but when present is an integral part of the aluminum forming process.

NR 257.03(3) (3) “Cleaning or etching operation” means a chemical solution bath and rinse or series of rinses designed to produce a desired surface finish on the workpiece, including conversion coating and anodizing when performed as an integral part of the aluminum forming operations, and the air pollution scrubbers used to control fumes from the chemical solution baths.

NR 257.03(4) (4) “Contact cooling water” means any wastewater which contacts the aluminum workpiece or the raw materials used in aluminum forming.

NR 257.03(5) (5) “Continuous casting” means the production of sheet, rod, or other long shapes by solidifying the metal while it is being poured through an open ended mold using little or no contact cooling water.

NR 257.03(6) (6) “Degassing” means the removal of dissolved hydrogen from the molten aluminum prior to casting by adding chemicals and bubbling gases through the molten aluminum.

NR 257.03(7) (7) “Direct chill casting” means an operation in which molten aluminum is poured into a water cooled mold, contact cooling water is sprayed onto the aluminum as the aluminum is dropped into the mold, and the aluminum ingot falls into a water bath at the end of the process.

NR 257.03(8) (8) “Drawing” means the process of pulling metal through a die or succession of dies to reduce the metal's diameter or alter its shape, using either neat oils, emulsions, or soap solutions as a lubricant.

NR 257.03(9) (9) “Emulsion” means a stable dispersion of 2 immiscible liquids, usually oil and water.

NR 257.03(10) (10) “Existing source” means any point source from which pollutants may be discharged either directly into the waters of the state or into a POTW, except a new source as defined in sub. (18).

NR 257.03(11) (11) “Extrusion” means the application of pressure to a billet of aluminum to force the aluminum to flow through a die orifice.

NR 257.03(12) (12) “Forging” means the exertion of pressure on dies or rolls surrounding heated aluminum stock to force the stock to change shape and, when dies are used, to take the shape of the die.

NR 257.03(13) (13) “Heat treatment” means the application of heat of specified temperature and duration to change the physical properties of the metal.

NR 257.03(14) (14) “Hot water seal” means a water bath heated to approximately 180° F used to seal the surface coating on formed aluminum which has been anodized and coated.

NR 257.03(15) (15) “lb/million off-lbs” means pounds of pollutant introduced into the wastestream per million pounds of aluminum or aluminum alloy removed from a forming or ancillary operation at the end of a process cycle for transfer to a different machine or process.

NR 257.03(16) (16) “mg/off-kg” means milligrams of pollutant introduced into the wastestream per kilogram of aluminum or aluminum alloy removed from a forming or ancillary operation at the end of a process cycle for transfer to a different machine or process.

NR 257.03(17) (17) “Neat oil” means an oil used as a lubricant with few or no added impurities.

NR 257.03(18) (18) “New source” means any point source for which construction commenced after November 22, 1982 and from which pollutants may be discharged either directly into waters of the state or into a publicly owned treatment works.

NR 257.03(19) (19) “Rolling” means the reduction in thickness or diameter of a workpiece by passing it between rollers lubricated with either neat oils or emulsions.

NR 257.03(20) (20) “Stationary casting” means the pouring of molten aluminum into molds and allowing the metal to air cool.

NR 257.03(21) (21) “TTO” means the sum of the masses or concentrations of each of the following toxic organic compounds which is found in the discharge at a concentration greater than 0.010 mg/l: - See PDF for table

NR 257.03(22) (22) “Wet scrubber” means an air pollution control device used to remove particulates and fumes from air by entraining the pollutants in a water spray.

NR 257.03 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.04 NR 257.04 Monitoring and reporting requirements. The following special monitoring and reporting requirements apply to all facilities subject to this chapter:

NR 257.04(1) (1) Analyses for cyanide are not required when both of the following conditions are met:

NR 257.04(1)(a) (a) The first wastewater sample of the calendar year has been analyzed and found to contain less than 0.07 mg/1.

NR 257.04(1)(b) (b) The owner or operator of the aluminum forming facility certifies in writing to the department or control authority that cyanide is not and will not be used in the aluminum forming process.

NR 257.04(2) (2) As an alternative pretreatment monitoring procedure, the POTW user may measure and limit oil and grease to the levels shown in the pretreatment standards in lieu of measuring and regulating TTO.

NR 257.04(3) (3) Compliance with the maximum monthly average effluent limitations and pretreatment standards is required regardless of the number of samples analyzed and averaged. The maximum monthly average effluent limitations and pretreatment standards shall be the basis for monthly average discharge limits in direct discharge permits and for pretreatment standards.

NR 257.04 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.05 NR 257.05 Compliance dates.

NR 257.05(1) (1) Any existing source subject to this chapter which discharges to waters of the state shall achieve;

NR 257.05(1)(a) (a) The effluent limitations representing BPT by July 1, 1977; and

NR 257.05(1)(b) (b) The effluent limitations representing BAT by July 1, 1984.

NR 257.05(2) (2) Any new source subject to this chapter which discharges to waters of the state shall achieve NSPS at the commencement of discharge.

NR 257.05(3) (3) Any existing source subject to this chapter which discharges process wastewater pollutants to a POTW shall achieve PSES by October 24, 1986.

NR 257.05(4) (4) Any new source subject to this chapter which discharges process wastewater pollutants to a POTW shall achieve PSNS at the commencement of discharge.

NR 257.05 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.06 NR 257.06 Removal allowances for pretreatment standards. Removal allowances for pretreatment standards pursuant to s. NR 211.13 may be granted for the toxic metals limited by this chapter when the toxic metals are used as indicator pollutants.

NR 257.06 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

subch. I of ch. NR 257 Subchapter I — Rolling With Neat Oils Subcategory

NR 257.10 NR 257.10 Applicability; description of the rolling with neat oils subcategory. This subchapter applies to the discharge of pollutants to waters of the state and the introduction of pollutants into POTWs from core and ancillary rolling with neat oils operations.

NR 257.10 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.11 NR 257.11 Specialized definitions. In addition to the definitions set forth in s. NR 257.03, the following definitions apply to the terms used in this subchapter:

NR 257.11(1) (1) “Ancillary operation” means any operation which is not a core operation but which is performed on-site following or preceding the rolling operation, such as continuous rod casting, continuous sheet casting, solution heat treatment, and cleaning or etching.

NR 257.11(2) (2) “Core operation” means rolling using neat oils, roll grinding, sawing, annealing, stationary casting, homogenizing, artificial aging, degreasing, and stamping.

NR 257.11 History History: Cr. Register, November, 1989, No. 407, eff. 12-1-89.

NR 257.12 NR 257.12 Effluent limitations representing the degree of effluent reduction attainable by application of the best practicable control technology currently available. Except as provided in 40 CFR 125.30 to 125.32, any existing point source subject to this subchapter shall achieve the following effluent limitations representing the degree of effluent reduction attainable by the application of BPT: - See PDF for table