NR 463.16(6)(6) Testing of representative emission units. With the prior approval of the department, an owner or operator may utilize emission rates obtained by testing a particular type of group 1 furnace which is not controlled by any add-on control device, or by testing an in-line flux box which is not controlled by any add-on control device, to determine the emission rate for other units of the same type at the same facility. Emission test results may only be considered to be representative of other units if all of the following criteria are satisfied: NR 463.16(6)(a)(a) The tested emission unit uses feed materials and charge rates which are comparable to the emission units that it represents. NR 463.16(6)(b)(b) The tested emission unit uses the same type of flux materials in the same proportions as the emission units it represents. NR 463.16(6)(c)(c) The tested emission unit is operated utilizing the same work practices as the emission units that it represents. NR 463.16(6)(d)(d) The tested emission unit is of the same design as the emission units that it represents. NR 463.16(6)(e)(e) The tested emission unit is tested under the highest load or capacity reasonably expected to occur for any of the emission units that it represents. NR 463.16(7)(7) Establishment of monitoring and operating parameter values. The owner or operator of new or existing affected sources and emission units shall establish a minimum or maximum operating parameter value, or an operating parameter range, for each parameter to be monitored as required by s. NR 463.15 that ensures compliance with the applicable emission limit or standard. To establish the minimum or maximum value or range, the owner or operator shall use the appropriate procedures in this section and submit the information required by s. NR 463.17 (2) (d) in the notification of compliance status report. The owner or operator may use existing data in addition to the results of performance tests to establish operating parameter values for compliance monitoring provided each of the following conditions are met to the satisfaction of the department: NR 463.16(7)(a)(a) The complete emission test report used as the basis of the parameter or parameters is submitted. NR 463.16(7)(b)(b) The same test methods and procedures as required by this subchapter were used in the test. NR 463.16(7)(c)(c) The owner or operator certifies that no design or work practice changes have been made to the source, process or emission control equipment since the time of the report. NR 463.16(7)(d)(d) All process and control equipment operating parameters required to be monitored were monitored as required in this subchapter and documented in the test report. NR 463.16(8)(8) Testing of commonly-ducted units within a secondary aluminum processing unit. When group 1 furnaces and in-line fluxers are included in a single existing SAPU or new SAPU, and the emissions from more than one emission unit within that existing SAPU or new SAPU are manifolded to a single control device, compliance for all units within the SAPU is demonstrated if the total measured emissions from all controlled and uncontrolled units in the SAPU do not exceed the emission limits calculated for that SAPU based on the applicable equation in s. NR 463.13 (11). NR 463.16(9)(9) Testing of commonly-ducted units not within a secondary aluminum processing unit. With the prior approval of the department, an owner or operator may do combined performance testing of 2 or more individual affected sources or emission units which are not included in a single existing SAPU or new SAPU, but whose emissions are manifolded to a single control device. Any performance testing of commonly-ducted units shall satisfy all the following basic requirements: NR 463.16(9)(a)(a) All testing shall be designed to verify that each affected source or emission unit individually satisfies all emission requirements applicable to that affected source or emission unit. NR 463.16(9)(b)(b) All emissions of pollutants subject to a standard shall be tested at the outlet from each individual affected source or emission unit while operating under the highest load or capacity reasonably expected to occur, and prior to the point that the emissions are manifolded together with emissions from other affected sources or emission units. NR 463.16(9)(c)(c) The combined emissions from all affected sources and emission units which are manifolded to a single emission control device shall be tested at the outlet of the emission control device. NR 463.16(9)(d)(d) All tests at the outlet of the emission control device shall be conducted with all affected sources and emission units whose emissions are manifolded to the control device operating simultaneously under the highest load or capacity reasonably expected to occur. NR 463.16(9)(e)(e) For purposes of demonstrating compliance of a commonly-ducted unit with any emission limit for a particular type of pollutant, the emissions of that pollutant by the individual unit shall be presumed to be controlled by the same percentage as total emissions of that pollutant from all commonly-ducted units are controlled at the outlet of the emission control device. NR 463.16 HistoryHistory: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; correction in (2) (a) made under s. 13.92 (4) (b) 7., Stats., Register December 2008 No. 636. NR 463.163NR 463.163 Performance test and compliance demonstration requirements and procedures. NR 463.163(1)(1) Aluminum scrap shredder. The owner or operator shall conduct performance tests to measure PM emissions at the outlet of the control system. If visible emission observations is the selected monitoring option, the owner or operator shall record visible emission observations from each exhaust stack for all consecutive 6-minute periods during the PM emission test according to the requirements of Method 9 in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04 (13). NR 463.163(2)(2) Thermal chip dryer. The owner or operator shall conduct a performance test to measure THC and D&F emissions at the outlet of the control device while the unit processes only unpainted aluminum chips. NR 463.163(3)(3) Scrap dryer, delacquering kiln and decoating kiln. NR 463.163(3)(a)(a) The owner or operator shall conduct performance tests to measure emissions of THC, D&F, HCl and PM at the outlet of the control device. NR 463.163(3)(b)(b) If the scrap dryer, delacquering kiln or decoating kiln is subject to the alternative emission limits in s. NR 463.13 (5), the average afterburner operating temperature in each 3-hour block period shall be maintained at or above 760°C (1400°F) for the test. NR 463.163(3)(c)(c) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln subject to the alternative limits in s. NR 463.13 (5) shall submit a written certification in the notification of compliance status report containing the information required by s. NR 463.17 (2) (g). NR 463.163(4)(4) Group 1 furnace with add-on air pollution control devices. NR 463.163(4)(a)(a) The owner or operator of a group 1 furnace that processes scrap other than clean charge materials with emissions controlled by a lime-injected fabric filter shall conduct performance tests to measure emissions of PM and D&F at the outlet of the control device and emissions of HCl at the outlet, for the emission limit, or the inlet and the outlet, for the percent reduction standard. NR 463.163(4)(b)(b) The owner or operator of a group 1 furnace that processes only clean charge materials with emissions controlled by a lime-injected fabric filter shall conduct performance tests to measure emissions of PM at the outlet of the control device and emissions of HCl at the outlet, for the emission limit, or the inlet and the outlet, for the percent reduction standard. NR 463.163(4)(c)(c) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux added to the group 1 furnace is emitted. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl. NR 463.163(4)(d)(d) The owner or operator of a sidewell group 1 furnace that conducts reactive fluxing, except for cover flux, in the hearth, or that conducts reactive fluxing in the sidewell at times when the level of molten metal falls below the top of the passage between the sidewell and the hearth, shall conduct the performance tests required by par. (a) or (b), to measure emissions from both the sidewell and the hearth. NR 463.163(5)(5) Group 1 furnace, including melting and holding furnaces, without add-on air pollution control devices. NR 463.163(5)(a)(a) In the site-specific monitoring plan required by s. NR 463.15 (15), the owner or operator of a group 1 furnace, including a melting and holding furnace, without add-on air pollution control devices shall include data and information demonstrating compliance with the applicable emission limits. NR 463.163(5)(b)(b) If the group 1 furnace processes material other than clean charge, the owner or operator shall conduct emission tests to measure emissions of PM, HCl and D&F at the furnace exhaust outlet. NR 463.163(5)(c)(c) If the group 1 furnace processes only clean charge, the owner or operator shall conduct emission tests to simultaneously measure emissions of PM and HCl at the furnace exhaust outlet. A D&F test is not required. Each test shall be conducted while the group 1 furnace, including a melting and holding furnace, processes only clean charge. NR 463.163(5)(d)(d) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux added to the group 1 furnace is emitted. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl. NR 463.163(6)(6) Sweat furnace. The owner or operator shall measure emissions of D&F from each sweat furnace at the outlet of the control device except that the owner or operator is not required to conduct a performance test to demonstrate compliance with the emission standard of s. NR 463.13 (6), provided that, on and after the compliance date established by s. NR 463.115, the owner or operator operates and maintains an afterburner with a design residence time of 0.8 seconds or greater and an operating temperature of 1600°F or greater. NR 463.163(7)(7) Dross-only furnace. The owner or operator shall conduct a performance test to measure emissions of PM from each dross-only furnace at the outlet of each control device while the unit processes only dross and salt flux as the sole feedstock. NR 463.163(8)(a)(a) The owner or operator of an in-line fluxer that uses reactive flux materials shall conduct a performance test to measure emissions of HCl and PM or otherwise demonstrate compliance in accordance with par. (b). If the in-line fluxer is equipped with an add-on control device, the emissions shall be measured at the outlet of the control device. NR 463.163(8)(b)(b) The owner or operator may choose to limit the rate at which reactive chlorine flux is added to an in-line fluxer and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all chlorine in the reactive flux added to the in-line fluxer is emitted as HCl. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl. If the owner or operator of any in-line flux box which has no ventilation ductwork manifolded to any outlet or emission control device chooses to demonstrate compliance with the emission limit for HCl by limiting use of reactive chlorine flux and assuming that all chlorine in the flux is emitted as HCl, compliance with the HCl limit shall also constitute compliance with the emission limit for PM, and no separate emission test for PM is required. In this case, the owner or operator of the unvented in-line flux box shall utilize the maximum permissible PM emission rate for the in-line flux boxes when determining the total emissions for any SAPU which includes the flux box. NR 463.163(9)(9) Rotary dross cooler. The owner or operator shall conduct a performance test to measure PM emissions from a rotary dross cooler at the outlet of the control device. NR 463.163(10)(10) Secondary aluminum processing unit. The owner or operator shall conduct performance tests as described in pars. (a) to (c). The results of the performance tests shall be used to establish emission rates in lb/ton of feed or charge for PM and HCl and mg TEQ/Mg of feed or charge for D&F emissions from each emission unit. These emission rates shall be used for compliance monitoring in the calculation of the 3-day, 24-hour rolling average emission rates using the equation in s. NR 463.15 (20). A performance test is required for: NR 463.163(10)(a)(a) Each group 1 furnace processing only clean charge to measure emissions of PM and either of the following: NR 463.163(10)(a)2.2. The mass flow rate of HCl at the inlet to and outlet from the control device, for the percent reduction standard. NR 463.163(10)(b)(b) Each group 1 furnace that processes scrap other than clean charge to measure emissions of PM and D&F and either of the following: NR 463.163(10)(b)2.2. The mass flow rate of HCl at the inlet to and outlet from the control device, for the percent reduction standard. NR 463.163(11)(11) Feed or charge weight measurement. During the emission tests conducted to determine compliance with emission limits in a kg/Mg (lb/ton) format, the owner or operator of an affected source or emission unit, subject to an emission limit in a kg/Mg (lb/ton) of feed or charge format, shall measure, or otherwise determine, and record the total weight of feed or charge to the affected source or emission unit for each of the 3 test runs and calculate and record the total weight. An owner or operator that chooses to demonstrate compliance on the basis of the aluminum production weight shall measure the weight of aluminum produced by the emission unit or affected source instead of the feed or charge weight. NR 463.163(12)(12) Continuous opacity monitoring system. The owner or operator of an affected source or emission unit using a continuous opacity monitoring system shall conduct a performance evaluation to demonstrate compliance with Performance Specification 1 in Appendix B to 40 CFR part 60, incorporated by reference in s. NR 484.04 (21). Following the performance evaluation, the owner or operator shall measure and record the opacity of emissions from each exhaust stack for all consecutive 6-minute periods during the PM emission test. NR 463.163(13)(13) Afterburner. The owner or operator of an affected source using an afterburner to comply with the requirements of this subchapter shall do both of the following: NR 463.163(13)(a)(a) Prior to the initial performance test, the owner or operator shall conduct a performance evaluation for the temperature monitoring device according to the requirements of s. NR 460.07. NR 463.163(13)(b)(b) The owner or operator shall use the following procedures to establish an operating parameter value or range for the afterburner operating temperature: NR 463.163(13)(b)1.1. Continuously measure and record the operating temperature of each afterburner every 15 minutes during the THC and D&F performance tests. NR 463.163(13)(b)2.2. Determine and record the 15-minute block average temperatures for the 3 test runs. NR 463.163(13)(b)3.3. Determine and record the 3-hour block average temperature measurements for the 3 test runs. NR 463.163(14)(14) Inlet gas temperature. The owner or operator of a scrap dryer, delacquering kiln or decoating kiln or a group 1 furnace using a lime-injected fabric filter shall use the following procedures to establish an operating parameter value or range for the inlet gas temperature: NR 463.163(14)(a)(a) Continuously measure and record the temperature at the inlet to the lime-injected fabric filter every 15 minutes during the HCl and D&F performance tests. NR 463.163(14)(b)(b) Determine and record the 15-minute block average temperatures for the 3 test runs. NR 463.163(14)(c)(c) Determine and record the 3-hour block average of the recorded temperature measurements for the 3 test runs. NR 463.163(15)(15) Flux injection rate. The owner or operator shall use the following procedures to establish an operating parameter value or range for the total reactive chlorine flux injection rate: NR 463.163(15)(a)(a) Continuously measure and record the weight of gaseous or liquid reactive flux injected for each 15-minute period during the HCl and D&F tests, determine and record the 15-minute block average weights, and calculate and record the total weight of the gaseous or liquid reactive flux for the 3 test runs. NR 463.163(15)(b)(b) Record the identity, composition and total weight of each addition of solid reactive flux for the 3 test runs. NR 463.163(15)(c)(c) Determine the total reactive chlorine flux injection rate by adding the recorded measurement of the total weight of chlorine in the gaseous or liquid reactive flux injected and the total weight of chlorine in the solid reactive flux using Equation 5: where:
Wt is the total chlorine usage, by weight
F1 is the faction of gaseous or liquid flux that is chlorine
W1 is the weight of reactive flux gas injected
F2 is the fraction of solid reactive chloride flux that is chlorine
NR 463.163 NoteNote: For example, F2 is equal to 0.75 for magnesium chloride
W2 is the weight of solid reactive flux
NR 463.163(15)(d)(d) Divide the weight of total chlorine usage (Wt) for the 3 test runs by the recorded measurement of the total weight of feed for the 3 test runs. NR 463.163(15)(e)(e) If a solid reactive flux other than magnesium chloride is used, the owner or operator shall derive the appropriate proportion factor subject to approval by the department. NR 463.163(16)(16) Lime injection. The owner or operator of an affected source or emission unit using a lime-injected fabric filter system shall use the following procedures during the HCl and D&F tests to establish an operating parameter value for the feeder setting for each operating cycle or time period used in the performance test: NR 463.163(16)(a)(a) For continuous lime injection systems, ensure that lime in the feed hopper or silo is free-flowing at all times. NR 463.163(16)(b)(b) Record the feeder setting for the 3 test runs. If the feed rate setting varies during the runs, determine and record the average feed rate from the 3 runs. NR 463.163(17)(17) Bag leak detection system. The owner or operator of an affected source or emission unit using a bag leak detection system shall submit the information described in s. NR 463.17 (2) (f) as part of the notification of compliance status report to document conformance with the specifications and requirements in s. NR 463.15 (6). NR 463.163(18)(18) Labeling. The owner or operator of each scrap dryer, delacquering kiln or decoating kiln, group 1 furnace, group 2 furnace and in-line fluxer shall submit the information described in s. NR 463.17 (2) (c) as part of the notification of compliance status report to document conformance with the operational standard in s. NR 463.14 (2). NR 463.163(19)(19) Capture and collection system. The owner or operator of a new or existing affected source or emission unit with an add-on control device shall submit the information described in s. NR 463.17 (2) (b) as part of the notification of compliance status report to document conformance with the operational standard in s. NR 463.14 (3). NR 463.163 HistoryHistory: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09. NR 463.166NR 463.166 Equations for determining compliance. NR 463.166(1)(1) THC emission limit. The owner or operator of an emission unit subject to a THC emission limit shall use Equation 6 to determine compliance with the THC emission limit in s. NR 463.13: where:
E is the emission rate of measured pollutant, kg/Mg (lb/ton) of feed
C is the measured volume fraction of pollutant, ppmv
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