NR 463.22(1)
(1) “Automated conveyor and pallet cooling line" means any dedicated conveyor line or area used for cooling molds received from pouring stations.
NR 463.22(2)
(2) “Automated shakeout line" means any mechanical process unit designed for and dedicated to separating a casting from a mold. These mechanical processes include shaker decks, rotary separators and high-frequency vibration units. Automated shakeout lines do not include manual processes for separating a casting from a mold, such as personnel using a hammer, chisel, pick ax, sledge hammer or jackhammer.
NR 463.22(3)
(3) “Bag leak detection system" means a system that is capable of continuously monitoring relative particulate matter loadings in the exhaust of a baghouse to detect bag leaks and other upset conditions. A bag leak detection system includes an instrument that operates on triboelectric, electrodynamic, light scattering, light transmittance or other effect to continuously monitor relative particulate matter loadings.
NR 463.22(4)
(4) “Binder chemical" means a component of a system of chemicals used to bind sand together into molds, mold sections and cores through chemical reaction as opposed to pressure.
NR 463.22(5)
(5) “Capture system" means the collection of components used to capture gases and fumes released from one or more emissions points and then convey the captured gas stream to a control device or to the atmosphere. A capture system may include the following components as applicable to a given capture system design: duct intake devices, hoods, enclosures, ductwork, dampers, manifolds, plenums and fans.
NR 463.22(6)
(6) “Cold box mold or core making line" means a mold or core making line in which the formed aggregate is hardened by catalysis with a gas.
NR 463.22(7)
(7) “Combustion device" means an afterburner, thermal incinerator or scrap preheater.
NR 463.22(8)
(8) “Conveyance" means the system of equipment that is designed to capture pollutants at the source, convey them through ductwork and exhaust them using forced ventilation. A conveyance may include control equipment designed to reduce emissions of the pollutants. Emissions that are released through windows, vents or other general building ventilation or exhaust systems are not considered to be discharged through a conveyance.
NR 463.22(9)
(9) “Cooling" means the process of molten metal solidification within the mold and subsequent temperature reduction prior to shakeout.
NR 463.22(10)
(10) “Cupola" means a vertical cylindrical shaft furnace that uses coke and forms of iron and steel such as scrap and foundry returns as the primary charge components and melts the iron and steel through combustion of the coke by a forced upward flow of heated air.
NR 463.22(11)
(11) “Deviation" means any instance in which an affected source or an owner or operator of an affected source fails to meet any of the following:
NR 463.22(11)(a)
(a) Any requirement or obligation established by this subchapter, including any emission limitation, operating limit, work practice standard or operation and maintenance requirement.
NR 463.22(11)(b)
(b) Any term or condition that is adopted to implement an applicable requirement in this subchapter and that is included in the operating permit for any iron and steel foundry required to obtain an operating permit.
NR 463.22(11)(c)
(c) Any emission limitation, operating limit or work practice standard in this subchapter during startup, shutdown or malfunction, regardless of whether or not the failure is permitted by this subchapter.
NR 463.22(12)
(12) “Electric arc furnace" means a vessel in which forms of iron and steel, such as scrap and foundry returns, are melted through resistance heating by an electric current flowing through the arcs formed between the electrodes and the surface of the metal and also flowing through the metal between the arc paths.
NR 463.22(13)
(13) “Electric induction furnace" means a vessel in which forms of iron and steel, such as scrap and foundry returns, are melted though resistance heating by an electric current that is induced in the metal by passing an alternating current through a coil surrounding the metal charge or surrounding a pool of molten metal at the bottom of the vessel.
NR 463.22(14)
(14) “Emissions limitation" has the meaning given in s.
285.01 (16), Stats., and includes any operating limit specified in this subchapter.
NR 463.22(15)
(15) “Exhaust stream" means gases emitted from a process through a conveyance, as defined in
sub. (8).
NR 463.22(16)
(16) “Free organic liquids" means material that fails the paint filter test by Method 9095A, “Paint Filter Liquids Test", Revision 1, December 1996, as published in EPA Publication SW–846 “Test Methods for Evaluating Solid Waste, Physical/Chemical Methods", incorporated by reference in
s. NR 484.06 (4) (e). If any portion of the material passes through and drops from the filter within the 5-minute test period, the material contains free liquids.
NR 463.22(17)
(17) “Fresh acid solution" means a sulfuric acid solution used for the control of triethylamine emissions that has a pH of 2.0 or less.
NR 463.22(18)
(18) “Fugitive emissions" means any pollutant released to the atmosphere that is not discharged through a conveyance, as defined in
sub. (8).
NR 463.22(19)
(19) “Furan warm box mold or core making line" means a mold or core making line in which the binder chemical system used is that system commonly designated as a furan warm box system by the foundry industry.
NR 463.22(20)
(20) “Iron and steel foundry" means a facility or portion of a facility that melts one or more of the following: scrap, ingot or other forms of iron and steel, and pours the resulting molten metal into molds to produce final or near final shape products for introduction into commerce. Research and development facilities and operations that only produce non-commercial castings are not included in this definition.
NR 463.22(21)
(21) “Metal melting furnace" means a cupola, electric arc furnace or electric induction furnace that converts one or more of the following: scrap, foundry returns and other solid forms of iron and steel to a liquid state. Metal melting furnace does not include a holding furnace, an argon oxygen decarburization vessel or ladle that receives molten metal from a metal melting furnace, and to which metal ingots or other material may be added to adjust the metal chemistry.
NR 463.22(22)
(22) “Mold or core making line" means the collection of equipment that is used to mix an aggregate of sand and binder chemicals, form the aggregate into final shape and harden the formed aggregate. A mold or core making line does not include a line for making green sand molds or cores.
NR 463.22(23)
(23) “Mold vent" means an intentional opening in a mold through which gases containing pyrolysis products of organic mold and core constituents produced by contact with or proximity to molten metal normally escape the mold during and after metal pouring.
NR 463.22(24)
(24) “Monitoring malfunction" means any sudden, infrequent, not reasonably preventable failure of the monitoring system to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions.
NR 463.22(25)
(25) “Pouring area" means an area, generally associated with floor and pit molding operations, in which molten metal is brought to each individual mold. Pouring areas include all pouring operations that are not a pouring station.
NR 463.22(26)
(26) “Pouring station" means the fixed location to which molds are brought in a continuous or semi-continuous manner to receive molten metal, after which the molds are moved to a cooling area.
NR 463.22(28)
(28) “Scrap preheater" means a vessel or other piece of equipment in which metal scrap that is to be used as melting furnace feed is heated to a temperature high enough to eliminate moisture and other volatile impurities or tramp materials by direct flame heating or similar means of heating.
NR 463.22(29)
(29) “Scrubber blowdown" means liquor or slurry discharged from a wet scrubber that is either removed as a waste stream or processed to remove impurities or adjust its composition or pH before being returned to the scrubber.
NR 463.22(30)
(30) “Work practice standard" means any design, equipment, work practice, operational standard or combination thereof, that is promulgated pursuant to section 112 (h) of the Clean Air Act (
42 USC 7412 (h)).
NR 463.22(31)
(31) “You" or “your" means the owner or operator of an iron and steel foundry.
NR 463.22 History
History: CR 06-110: cr.
Register July 2007 No. 619, eff. 8-1-07.
NR 463.23
NR 463.23 Emissions limitations, work practice standards and operation and maintenance requirements. NR 463.23(1)(a)(a) You shall meet each of the following emission limits or standards that applies to you:
NR 463.23(1)(a)1.
1. For each electric arc metal melting furnace, electric induction metal melting furnace or scrap preheater at an existing iron and steel foundry, as described in
s. NR 463.21 (3) (c), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for particulate matter (PM) in
subd. 1. a. or the limit for total metal HAP in
subd. 1. b.:
NR 463.23(1)(a)2.
2. For each cupola metal melting furnace at an existing iron and steel foundry, as described in
s. NR 463.21 (3) (c), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in
subd. 2. a. or the limit for total metal HAP in
subd. 2. b.:
NR 463.23(1)(a)3.
3. For each cupola metal melting furnace or electric arc metal melting furnace at a new iron and steel foundry, as described in
s. NR 463.21 (3) (d), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in
subd. 3. a. or, alternatively, the limit for total metal HAP in
subd. 3. b.:
NR 463.23(1)(a)4.
4. For each electric induction metal melting furnace or scrap preheater at a new iron and steel foundry, as described in
s. NR 463.21 (3) (d), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in
subd. 4. a. or, alternatively, the limit for total metal HAP in
subd. 4. b.:
NR 463.23(1)(a)5.
5. For each pouring station at an existing iron and steel foundry, as described in
s. NR 463.21 (3) (c), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in
subd. 5. a. or, alternatively, the limit for total metal HAP in
subd. 5. b.:
NR 463.23(1)(a)6.
6. For each pouring area or pouring station at a new iron and steel foundry, as described in
s. NR 463.21 (3) (d), you may not discharge emissions through a conveyance to the atmosphere that exceed either the limit for PM in
subd. 6. a. or, alternatively, the limit for total metal HAP in
subd. 6. b.:
NR 463.23(1)(a)7.
7. For each building or structure housing any emissions source at the iron and steel foundry, you may not discharge any fugitive emissions to the atmosphere that exhibit opacity greater than 20% averaged over 6 minutes except for one 6-minute average per hour that does not exceed 27% opacity.
NR 463.23(1)(a)8.
8. For each cupola metal melting furnace at a new or existing iron and steel foundry, you may not discharge emissions of volatile organic hazardous air pollutants (VOHAP) through a conveyance to the atmosphere that exceed 20 parts per million by volume (ppmv) corrected to 10% oxygen.
NR 463.23(1)(a)9.
9. As an alternative to the work practice standard in
sub. (2) (e) for a scrap preheater at an existing iron and steel foundry or in
sub. (2) (f) for a scrap preheater at a new iron and steel foundry, as described in
s. NR 463.21 (3) (d), you may not discharge emissions of VOHAP through a conveyance to the atmosphere that exceed 20 ppmv.
NR 463.23(1)(a)10.
10. For one or more automated conveyor and pallet cooling lines that use a sand mold system, or one or more automated shakeout lines that use a sand mold system, at a new iron and steel foundry, as described in
s. NR 463.21 (3) (d), you may not discharge emissions of VOHAP through a conveyance to the atmosphere that exceed a flow-weighted average of 20 ppmv.
NR 463.23(1)(a)11.
11. For each triethylamine (TEA) cold box mold or core making line at a new or existing iron and steel foundry, you shall meet either the emission limit in
subd. 11. a. or the emission standard in
subd. 11. b.:
NR 463.23(1)(a)11.a.
a. You may not discharge emissions of TEA through a conveyance to the atmosphere that exceed 1 ppmv, as determined when scrubbing with fresh acid solution.
NR 463.23(1)(a)11.b.
b. You shall reduce emissions of TEA from each TEA cold box mold or core making line by at least 99%, as determined when scrubbing with fresh acid solution.
NR 463.23(1)(b)
(b) You shall meet each of the following operating limits that applies to you:
NR 463.23(1)(b)1.
1. You shall install, operate and maintain a capture and collection system for all emission sources subject to an emission limit or standard for VOHAP or TEA in
par. (a) 8. to
11. in accordance with both of the following:
NR 463.23(1)(b)1.a.
a. Each capture and collection system shall meet accepted engineering standards, such as those published by the American Conference of Governmental Industrial Hygienists.
NR 463.23 Note
Note: Publications of the American Conference of Governmental Industrial Hygienists may be obtained at:
NR 463.23 Note
American Conference of Governmental Industrial Hygienists
1330 Kemper Meadow Drive
Cincinnati, Ohio 45240
(513) 742-2020
mail@acgih.orgwww.acgih.org NR 463.23(1)(b)1.b.
b. You shall operate each capture system at or above the lowest value or settings established as operating limits in your operation and maintenance plan.
NR 463.23(1)(b)2.
2. You shall operate each wet scrubber applied to emissions from a metal melting furnace, scrap preheater, pouring area or pouring station subject to an emission limit for PM or total metal HAP in
par. (a) 1. to
6. to insure that the 3-hour average pressure drop and scrubber water flow rate does not fall below the minimum levels established during the initial or subsequent performance test.
NR 463.23(1)(b)3.
3. You shall operate each combustion device applied to emissions from a cupola metal melting furnace subject to the emission limit for VOHAP in
par. (a) 8. to insure that the 15-minute average combustion zone temperature does not fall below 1,300ºF. Periods when the cupola is off blast and for 15 minutes after going on blast from an off blast condition are not included in the 15-minute average.
NR 463.23(1)(b)4.
4. You shall operate each combustion device applied to emissions from a scrap preheater subject to the emission limit for VOHAP in
par. (a) 9. or from a TEA cold box mold or core making line subject to the emission limit for TEA in
par. (a) 11. to insure that the 3-hour average combustion zone temperature does not fall below the minimum level established during the initial or subsequent performance test.
NR 463.23(1)(b)5.
5. You shall operate each wet acid scrubber applied to emissions from a TEA cold box mold or core making line subject to the emission limit for TEA in
par. (a) 11. to insure both of the following:
NR 463.23(1)(b)5.a.
a. The 3-hour average scrubbing liquid flow rate does not fall below the minimum level established during the initial or subsequent performance test.
NR 463.23(1)(b)5.b.
b. The 3-hour average pH of the scrubber blowdown, as measured by a continuous parameter monitoring system (CPMS), does not exceed 4.5 or the pH of the scrubber blowdown, as measured once every 8 hours during process operations, does not exceed 4.5.
NR 463.23(1)(c)
(c) If you use a control device other than a baghouse, wet scrubber, wet acid scrubber or combustion device, you shall prepare and submit a monitoring plan. The monitoring plan is subject to approval by the department and shall contain all of the following:
NR 463.23(1)(c)2.
2. Test results collected in accordance with
s. NR 463.25 (3) verifying the performance of the device for reducing emissions of PM, total metal HAP, VOHAP or TEA to the levels required by this subchapter.
NR 463.23(1)(c)4.
4. A list of appropriate operating parameters that will be monitored to maintain continuous compliance with the applicable emissions limitations.
NR 463.23(1)(c)5.
5. Operating parameter limits based on monitoring data collected during the performance test.
NR 463.23(2)(a)(a) For each segregated scrap storage area, bin or pile, you shall either comply with the certification requirements in
par. (b) or prepare and implement a plan for the selection and inspection of scrap according to the requirements in
par. (c). You may have certain scrap subject to
par. (b) and other scrap subject to
par. (c) at your facility, provided the scrap remains segregated until being aggregated to make up the charge for the furnace.
NR 463.23(2)(b)
(b) If you elect to meet this paragraph as allowed under
par. (a), you shall prepare, and operate at all times according to, a written certification that the foundry purchases and uses only metal ingots, pig iron, slitter or other materials that do not include post-consumer automotive body scrap, post-consumer engine blocks, post-consumer oil filters, oily turnings, lead components, mercury switches, plastics or free organic liquids, as defined in
s. NR 463.22 (16). Any post-consumer engine blocks, post-consumer oil filters or oily turnings that are processed and cleaned, to the extent practicable, such that the materials do not include lead components, mercury switches, plastics or free organic liquids may be included in this certification.
NR 463.23(2)(c)
(c) If you elect to meet this paragraph as allowed under
par. (a), you shall prepare and operate at all times according to a written plan for the selection and inspection of iron and steel scrap to minimize, to the extent practicable, the amount of organics and HAP metals in the charge materials used by the iron and steel foundry. This scrap selection and inspection plan is subject to approval by the department. You shall keep a copy of the plan onsite and readily available to all plant personnel with materials acquisition or inspection duties. You shall provide a copy of the material specifications to each of your scrap vendors. Each plan shall include all of the following information:
NR 463.23(2)(c)1.
1. A materials acquisition program to limit organic contaminants according to the following requirements as applicable:
NR 463.23(2)(c)1.a.
a. For scrap charged to a scrap preheater, electric arc metal melting furnace or electric induction metal melting furnaces, specifications for scrap materials to be depleted, to the extent practicable, of the presence of used oil filters, plastic parts and organic liquids, and a program to ensure the scrap materials are drained of free liquids.
NR 463.23(2)(c)1.b.
b. For scrap charged to a cupola metal melting furnace, specifications for scrap materials to be depleted, to the extent practicable, of the presence of plastic, and a program to ensure the scrap materials are drained of free liquids.
NR 463.23(2)(c)2.
2. A materials acquisition program specifying that the scrap supplier remove accessible mercury switches from the trunks and hoods of any automotive bodies contained in the scrap and remove accessible lead components such as batteries and wheel weights. You shall obtain and maintain onsite a copy of the procedures used by the scrap supplier for either removing accessible mercury switches or for purchasing automobile bodies that have had mercury switches removed, as applicable.
