NR 463.15(7)(c)3.
3. Inspection of internal structures, such as baffles, to ensure structural integrity.
NR 463.15(7)(c)7.
7. Inspection of combustion chamber refractory lining and cleaning and replacement of lining as necessary.
NR 463.15(7)(c)9.
9. Documentation, for the burn cycle that follows the inspection, that the afterburner is operating properly and any necessary adjustments have been made.
NR 463.15(7)(c)10.
10. Verification that the equipment is maintained in good operating condition.
NR 463.15(7)(c)11.
11. Following an equipment inspection, completion of all necessary repairs in accordance with the requirements of the OM&M plan.
NR 463.15(8)
(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.
NR 463.15(8)(a)
(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).
NR 463.15(8)(b)
(b) The temperature monitoring device shall meet each of the following performance and equipment specifications:
NR 463.15(8)(b)1.
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.
NR 463.15(8)(b)2.
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).
NR 463.15(8)(b)3.
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.
NR 463.15(9)
(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.
NR 463.15(9)(a)
(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:
NR 463.15(9)(a)1.
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.
NR 463.15(9)(a)2.
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.
NR 463.15(9)(a)3.
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.
NR 463.15(9)(b)
(b) The owner or operator of a continuous lime injection system shall record the lime feeder setting once each day of operation.
NR 463.15(9)(c)
(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.
NR 463.15(10)
(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):
NR 463.15(10)(a)
(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.
NR 463.15(10)(a)1.
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.
NR 463.15(10)(a)2.
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.
NR 463.15(10)(a)3.
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.
NR 463.15(10)(b)
(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).
NR 463.15(10)(c)
(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:
NR 463.15(10)(d)
(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).
NR 463.15(10)(e)
(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.
NR 463.15(11)
(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:
NR 463.15(11)(a)
(a) Record the type of materials charged to the unit for each operating cycle or time period used in the performance test.
NR 463.15(12)
(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:
NR 463.15(12)(a)
(a) Record the materials charged to each unit for each operating cycle or time period used in the performance test.
NR 463.15(13)
(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.
NR 463.15(14)
(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:
NR 463.15(14)(a)
(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.
NR 463.15(15)
(15) Group 1 furnace without add-on air pollution control devices. NR 463.15(15)(a)(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.
NR 463.15(15)(a)1.
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.
NR 463.15(15)(a)2.
2. The site-specific monitoring plan shall contain all of the following as applicable:
NR 463.15(15)(a)2.a.
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.
NR 463.15(15)(a)2.b.
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).
NR 463.15(15)(a)2.c.
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.
NR 463.15(15)(a)2.d.
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.
NR 463.15(15)(a)2.e.
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.
NR 463.15(15)(a)2.f.
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).
NR 463.15(15)(a)2.g.
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).
NR 463.15(15)(a)3.
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.
NR 463.15(15)(b)
(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.
NR 463.15(16)
(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:
NR 463.15(16)(a)
(a) A proven method for collecting representative samples and measuring the oil and coatings content of scrap samples.
NR 463.15(16)(c)
(c) An established correlation between visual inspection and physical measurement of oil and coatings content of scrap samples.
NR 463.15(16)(d)
(d) Periodic physical measurements of oil and coatings content of randomly-selected scrap samples and comparison with visual inspection results.
NR 463.15(16)(e)
(e) A system for assuring that only acceptable scrap is charged to an affected group 1 furnace.
NR 463.15(16)(f)
(f) Recordkeeping requirements to document conformance with plan requirements.
NR 463.15(17)
(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:
NR 463.15(17)(a)
(a) Procedures for the characterization and documentation of the contaminant level of the scrap prior to the performance test.
NR 463.15(17)(b)
(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.
NR 463.15(17)(c)
(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.
NR 463.15(18)
(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:
NR 463.15(18)(a)
(a) Record a description of the materials charged to each furnace, including any nonreactive, non-HAP-containing, non-HAP-generating fluxing materials or agents.
NR 463.15(18)(b)
(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.
NR 463.15(19)
(19) Site-specific requirements for secondary aluminum processing units. NR 463.15(19)(a)(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:
NR 463.15(19)(a)1.
1. The identification of each emission unit in the secondary aluminum processing unit.
NR 463.15(19)(a)2.
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.
NR 463.15(19)(a)3.
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.
NR 463.15(19)(a)4.
4. Information and data demonstrating compliance for each emission unit with all applicable design, equipment, work practice or operational standards of this subchapter.
NR 463.15(19)(a)5.
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).
NR 463.15(19)(b)
(b) The SAPU compliance procedures within the OM&M plan may not contain any of the following provisions:
NR 463.15(19)(b)2.
2. The inclusion of any affected sources other than emission units in a secondary aluminum processing unit.
NR 463.15(19)(b)4.
4. The inclusion of any periods of startup, shutdown or malfunction in emission calculations.
NR 463.15(19)(c)
(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.
NR 463.15(20)
(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:
NR 463.15(20)(a)
(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.
NR 463.15(20)(b)
(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.
NR 463.15(20)(c)
(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.
