Chapter NR 463

NR 463.166(3) (3) HCL percent reduction standard. The owner or operator of an emission unit subject to the HCl percent reduction standard shall use Equation 8 to determine compliance with the HCl percent reduction standard in s. NR 463.13:

´

(Equation 8)

where:

%R is the percent reduction of the control device

Li is the inlet loading of pollutant, kg/Mg (lb/ton)

Lo is the outlet loading of pollutant, kg/Mg (lb/ton)

NR 463.166(4) (4) Conversion of D&F measurements to TEQ units. To convert D&F measurements to TEQ units, the owner or operator shall use the procedures and equations in Interim Procedures for Estimating Risks Associated with Exposures to Mixtures of Chlorinated Dibenzo-p-Dioxins and -Dibenzofurans (CDDs and CDFs) and 1989 Update (EPA-625/3-89-016), incorporated by reference in s. NR 484.05 (12).

NR 463.166(5) (5) Secondary aluminum processing unit. The owner or operator of a secondary aluminum processing unit shall use the procedures in pars. (a) to (c) or the procedure in par. (d) to determine compliance with emission limits in s. NR 463.13 for a secondary aluminum processing unit.

NR 463.166(5)(a) (a) Use Equation 9 to compute the mass-weighted PM emissions for a secondary aluminum processing unit. Compliance is achieved if the mass-weighted emissions for the secondary aluminum processing unit (EcPM) is less than or equal to the emission limit for the secondary aluminum processing unit (LcPM calculated using Equation 1 in s. NR 463.13 (11)).

å

å

´

(Equation 9)

where:

is the mass-weighted PM emissions for the secondary aluminum processing unit

is the measured PM emissions for individual emission unit i

is the average feed rate for individual emission unit i during the operating cycle or performance test period

n is the number of emission units in the secondary aluminum processing unit

NR 463.166(5)(b) (b) Use Equation 10 to compute the aluminum mass-weighted HCl emissions for the secondary aluminum processing unit. Compliance is achieved if the mass-weighted emissions for the secondary aluminum processing unit (EcHCl) is less than or equal to the emission limit for the secondary aluminum processing unit (LcHCl) calculated using Equation 2 in s. NR 463.13 (11).

å

å

´

(Equation 10)

where:

is the mass-weighted HCl emissions for the secondary aluminum processing unit

is the measured HCl emissions for individual emission unit i

NR 463.166(5)(c) (c) Use Equation 11 to compute the aluminum mass-weighted D&F emissions for the secondary aluminum processing unit. Compliance is achieved if the mass-weighted emissions for the secondary aluminum processing unit is less than or equal to the emission limit for the secondary aluminum processing unit. The emission limit for the secondary aluminum processing unit (LcD&F) is calculated using Equation 3 in s. NR 463.13 (11).

å

å

´

(Equation 11)

where:

is the mass-weighted D&F emissions for the secondary aluminum processing unit

is the measured D&F emissions for individual emission unit i

NR 463.166(5)(d) (d) As an alternative to using the equations in pars. (a) to (c), the owner or operator may demonstrate compliance for a secondary aluminum processing unit by demonstrating that each existing group 1 furnace is in compliance with the emission limits for a new group 1 furnace in s. NR 463.13 (9) and that each existing in-line fluxer is in compliance with the emission limits for a new in-line fluxer in s. NR 463.13 (10).

NR 463.166 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09.

NR 463.17 NR 463.17 Notifications.

NR 463.17(1) (1) Initial notifications. The owner or operator shall submit initial notifications to the department as described in pars. (a) to (g).

NR 463.17(1)(a) (a) As required by s. NR 460.08 (2) (a), the owner or operator shall provide notification for an area source that subsequently increases its emissions such that the source is a major source subject to the standard.

NR 463.17(1)(b) (b) The owner or operator of a new or reconstructed affected source, or a source that has been reconstructed such that it is an affected source, that has an initial startup after September 24, 2002 and for which an application for approval of construction or reconstruction is not required under ch. NR 406, shall provide notification that the source is subject to the standard.

NR 463.17(1)(c) (c) As required by s. NR 460.08 (2) (d), the owner or operator of a new or reconstructed major affected source that has an initial startup after September 24, 2002 and for which an application for approval of construction or reconstruction is required by ch. NR 406 shall provide all the following notifications:

NR 463.17(1)(c)1. 1. Intention to construct a new major affected source, reconstruct a major source or reconstruct a major source such that the source becomes a major affected source.

NR 463.17(1)(c)2. 2. Date when construction or reconstruction was commenced, submitted simultaneously with the application for approval of construction or reconstruction if construction or reconstruction was commenced before September 24, 2002, or no later than 30 days after the date construction or reconstruction commenced if construction or reconstruction commenced after September 24, 2002.

NR 463.17(1)(c)3. 3. Anticipated date of startup.

NR 463.17(1)(c)4. 4. Actual date of startup.

NR 463.17(1)(d) (d) As required by s. NR 460.08 (2) (d), after September 24, 2002, an owner or operator who intends to construct a new affected source or reconstruct an affected source subject to this subchapter, or reconstruct a source such that it becomes an affected source subject to this subchapter, shall provide notification of the intended construction or reconstruction. The notification shall include all the information required for an application for approval of construction or reconstruction as required by ch. NR 406. For major sources, the application for approval of construction or reconstruction may be used to fulfill these requirements. The application shall be submitted according to one of the following, as applicable:

NR 463.17(1)(d)1. 1. The application shall be submitted as soon as practicable before the construction or reconstruction is planned to commence, but no sooner than September 24, 2002, if the construction or reconstruction commences after September 24, 2002.

NR 463.17(1)(d)2. 2. The application shall be submitted as soon as practicable before startup but no later than 90 days after September 24, 2002 if the construction or reconstruction had commenced and initial startup had not occurred before September 24, 2002.

NR 463.17(1)(e) (e) As required by s. NR 460.08 (4), the owner or operator shall provide notification of any special compliance obligations for a new source.

NR 463.17(1)(f) (f) As required by s. NR 460.08 (5) and (6), the owner or operator shall provide notification of the anticipated date for conducting performance tests and visible emission observations. The owner or operator shall notify the department of the intent to conduct a performance test at least 60 days before the performance test is scheduled; notification of opacity or visible emission observations for a performance test shall be provided at least 30 days before the observations are scheduled to take place.

NR 463.17(1)(g) (g) As required by s. NR 460.08 (7), the owner or operator shall provide additional notifications for sources with continuous emission monitoring systems or continuous opacity monitoring systems.

NR 463.17(2) (2) Notification of compliance status report. Each owner or operator of an existing affected source shall submit a notification of compliance status report within 60 days after the compliance date established by s. NR 463.115 (1). Each owner or operator of a new affected source shall submit a notification of compliance status report within 90 days after conducting the initial performance test required by 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 notification shall be signed by the responsible official who shall certify its accuracy. A notification of compliance status report shall include the information specified in pars. (a) to (j). The required information may be submitted in an operation permit application, in an amendment to an operation permit application, in a separate submittal, or in any combination. If an owner or operator submits the information specified in this section at different times or in different submittals, later submittals may refer to earlier submittals instead of duplicating and resubmitting the information previously submitted. A notification of compliance status report shall include:

NR 463.17(2)(a) (a) All information required in s. NR 460.08 (8). The owner or operator shall provide a complete performance test report for each affected source and emission unit for which a performance test is required. A complete performance test report includes all data, associated measurements, and calculations, including visible emission and opacity tests.

NR 463.17(2)(b) (b) The approved site-specific test plan and performance evaluation test results for each continuous monitoring system, including a continuous emission or opacity monitoring system.

NR 463.17(2)(c) (c) Unit labeling as described in s. NR 463.14 (2), including process type or furnace classification and operating requirements.

NR 463.17(2)(d) (d) The compliant operating parameter value or range established for each affected source or emission unit with supporting documentation and a description of the procedure used to establish the value, such as lime injection rate, total reactive chlorine flux injection rate, afterburner operating temperature, fabric filter inlet temperature, including the operating cycle or time period used in the performance test.

NR 463.17(2)(e) (e) Design information and analysis, with supporting documentation, demonstrating conformance with the requirements for capture and collection systems in s. NR 463.14 (3).

NR 463.17(2)(f) (f) If applicable, analysis and supporting documentation demonstrating conformance with EPA guidance and specifications for bag leak detection systems in s. NR 463.15 (6).

NR 463.17(2)(g) (g) Manufacturer’s specification or analysis documenting the design residence time of no less than one second for each afterburner used to control emissions from a scrap dryer, delacquering kiln or decoating kiln subject to alternative emission standards in s. NR 463.13 (5).

NR 463.17(2)(h) (h) Manufacturer’s specification or analysis documenting the design residence time of no less than 0.8 seconds and design operating temperature of no less than 1,600°F for each afterburner used to control emissions from a sweat furnace that is not subject to a performance test.

NR 463.17(2)(i) (i) The operation, maintenance and monitoring (OM&M) plan, including site-specific monitoring plan for each group 1 furnace with no add-on air pollution control device.

NR 463.17(2)(j) (j) Startup, shutdown and malfunction plan, with revisions.

NR 463.17 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; correction in (1) (b) made under s. 13.92 (4) (b) 7., Stats., Register December 2008 No. 636.

NR 463.18 NR 463.18 Reports.

NR 463.18(1) (1) Startup, shutdown and malfunction plan and reports. The owner or operator shall develop a written plan as described in s. NR 460.05 (4) (c) that contains specific procedures to be followed for operating and maintaining the source during periods of startup, shutdown and malfunction, and a program of corrective action for malfunctioning process and air pollution control equipment used to comply with the standard. The owner or operator shall also keep records of each event as required by s. NR 460.09 (2) and record and report if an action taken during a startup, shutdown or malfunction is not consistent with the procedures in the plan as described in s. NR 460.05 (4) (c). In addition to the information required in s. NR 460.05 (4) (c), the plan shall include both of the following:

NR 463.18(1)(a) (a) Procedures to determine and record the cause of the malfunction and the time the malfunction began and ended.

NR 463.18(1)(b) (b) Corrective actions to be taken in the event of a malfunction of a process or control device, including procedures for recording the actions taken to correct the malfunction or minimize emissions.

NR 463.18(2) (2) Excess emissions and summary report. The owner or operator shall submit semiannual reports according to the requirements in s. NR 460.09 (5) (c), except that the semiannual reports shall be submitted within 60 days after the end of each 6-month period instead of within 30 days after the calendar half as specified in s. NR 460.09 (5) (c) 5. When no deviations of parameters have occurred, the owner or operator shall submit a report stating that no excess emissions occurred during the reporting period. Reports shall be submitted in accordance with all of the following:

NR 463.18(2)(a) (a) A report shall be submitted if any of the following conditions occur during a 6-month reporting period:

NR 463.18(2)(a)1. 1. The corrective action specified in the operation, maintenance and monitoring (OM&M) plan for a bag leak detection system alarm was not initiated within one hour.

NR 463.18(2)(a)2. 2. The corrective action specified in the OM&M plan for a continuous opacity monitoring deviation was not initiated within one hour.

NR 463.18(2)(a)3. 3. The corrective action specified in the OM&M plan for visible emissions from an aluminum scrap shredder was not initiated within one hour.

NR 463.18(2)(a)4. 4. An excursion of a compliant process or operating parameter value or range, including lime injection rate or screw feeder setting, total reactive chlorine flux injection rate, afterburner operating temperature, fabric filter inlet temperature, definition of acceptable scrap or other approved operating parameter.

NR 463.18(2)(a)5. 5. An action taken during a startup, shutdown or malfunction was not consistent with the procedures in the plan as described in s. NR 460.05 (4) (c).

NR 463.18(2)(a)6. 6. An affected source, including an emission unit in a secondary aluminum processing unit, was not operated according to the requirements of this subchapter.

NR 463.18(2)(a)7. 7. A deviation from the 3-day, 24-hour rolling average emission limit for a secondary aluminum processing unit.

NR 463.18(2)(b) (b) Each report shall include each of these certifications, as applicable:

NR 463.18(2)(b)1. 1. For each thermal chip dryer: “Only unpainted aluminum chips were used as feedstock in any thermal chip dryer during this reporting period.”

NR 463.18(2)(b)2. 2. For each dross-only furnace: “Only dross and salt flux were used as the charge material in any dross-only furnace during this reporting period.”

NR 463.18(2)(b)3. 3. For each sidewell group 1 furnace with add-on air pollution control devices: “Each furnace was operated such that the level of molten metal remained above the top of the passage between the sidewell and hearth during reactive fluxing, and reactive flux, except for cover flux, was added only to the sidewell or to a furnace hearth equipped with an add-on air pollution control device for PM, HCl, and D&F emissions during this reporting period.”

NR 463.18(2)(b)4. 4. For each group 1 melting and holding furnace without add-on air pollution control devices and using pollution prevention measures that processes only clean charge material: “Each group 1 furnace without add-on air pollution control devices subject to emission limits in s. NR 463.13 (9) (b) processed only clean charge during this reporting period.”

NR 463.18(2)(b)5. 5. For each group 2 furnace: “Only clean charge materials were processed in any group 2 furnace during this reporting period, and no fluxing was performed or all fluxing performed was conducted using only nonreactive, non-HAP-containing and non-HAP-generating fluxing gases or agents, except for cover fluxes, during this reporting period.”

NR 463.18(2)(b)6. 6. For each in-line fluxer using no reactive flux: “Only nonreactive, non-HAP-containing, non-HAP-generating flux gases, agents, or materials were used at any time during this reporting period.”

NR 463.18(2)(c) (c) The owner or operator shall submit the results of any performance test conducted during the reporting period, including one complete report documenting test methods and procedures, process operation and monitoring parameter ranges or values for each test method used for a particular type of emission point tested.

NR 463.18(3) (3) Annual compliance certifications. For the purpose of annual certifications of compliance required by s. NR 439.03 (1) (c), the owner or operator shall certify continuing compliance based upon, but not limited to, both of the following conditions:

NR 463.18(3)(a) (a) Any and all periods of excess emissions, as defined in sub. (2) (a), that occurred during the year were reported.

NR 463.18(3)(b) (b) All monitoring, recordkeeping and reporting requirements were met during the year.

NR 463.18 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09.

NR 463.19 NR 463.19 Records.

NR 463.19(1) (1) 

NR 463.19(1)(a) (a) The owner or operator shall maintain files of all information, including all reports and notifications, required by s. NR 460.09 (2) and this subchapter.

NR 463.19(1)(b) (b) The owner or operator shall retain each record for at least 5 years following the date of each occurrence, measurement, maintenance, corrective action, report or record. The most recent 2 years of records shall be retained at the facility. The remaining 3 years of records may be retained off site.

NR 463.19(1)(c) (c) The owner or operator may retain records on microfilm, computer disks, magnetic tape or microfiche.

NR 463.19(1)(d) (d) The owner or operator may report required information on paper or on a labeled computer disk using commonly available and department compatible computer software.

NR 463.19(2) (2) In addition to the general records required by s. NR 460.09 (2), the owner or operator of a new or existing affected source, including an emission unit in a secondary aluminum processing unit, shall maintain records of all of the following:

NR 463.19(2)(a) (a) For each affected source and emission unit with emissions controlled by a fabric filter or a lime-injected fabric filter each of the following as applicable:

NR 463.19(2)(a)1. 1. If a bag leak detection system is used, the number of total operating hours for the affected source or emission unit during each 6-month reporting period, records of each alarm, the time of the alarm, the time corrective action was initiated and completed and a brief description of the cause of the alarm and the corrective actions taken.

NR 463.19(2)(a)2. 2. If a continuous opacity monitoring system is used, records of opacity measurement data, including records where the average opacity of any 6-minute period exceeds 5%, with a brief explanation of the cause of the emissions, the time the emissions occurred, the time corrective action was initiated and completed and the corrective action taken.