NR 463.25(3)
(3) What test methods and other procedures must I use to demonstrate initial compliance with the emission limitations? You shall conduct each performance test that applies to your iron and steel foundry according to the requirements in
s. NR 460.06 (4) (a) and the following conditions, as applicable:
NR 463.25(3)(a)
(a)
Particulate matter. To determine compliance with the applicable emission limit for PM in
s. NR 463.23 (1) (a) 1. to
6. for a metal melting furnace, scrap preheater, pouring station or pouring area, you shall use the following test methods and procedures:
NR 463.25(3)(a)1.a.
a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emission source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(a)1.b.
b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas.
NR 463.25(3)(a)1.c.
c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas.
NR 463.25(3)(a)1.e.
e. Method 5, 5B, 5D, 5F or 5I, as applicable, to determine the PM concentration. The PM concentration is determined using only the front-half, probe rinse and filter, of the PM catch.
NR 463.25(3)(a)2.
2. Collect a minimum sample volume of 60 dscf of gas during each PM sampling run. A minimum of 3 valid test runs are needed to comprise a performance test.
NR 463.25(3)(a)3.
3. For cupola metal melting furnaces, sample only during times when the cupola is on blast.
NR 463.25(3)(a)4.
4. For electric arc and electric induction metal melting furnaces, sample only when metal is being melted.
NR 463.25(3)(a)5.
5. For scrap preheaters, sample only when scrap is being preheated.
NR 463.25(3)(b)
(b)
Total metal HAP. To determine compliance with the applicable emission limit for total metal HAP in
s. NR 463.23 (1) (a) 1. to
6. for a metal melting furnace, scrap preheater, pouring station, or pouring area, you shall use the following test methods and procedures:
NR 463.25(3)(b)1.a.
a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(b)1.b.
b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas.
NR 463.25(3)(b)1.c.
c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas.
NR 463.25(3)(b)2.
2. Collect a minimum sample volume of 60 dscf of gas during each total metal HAP sampling run. A minimum of 3 valid test runs are needed to comprise a performance test.
NR 463.25(3)(b)3.
3. For cupola metal melting furnaces, sample only during times when the cupola is on blast.
NR 463.25(3)(b)4.
4. For electric arc and electric induction metal melting furnaces, sample only when metal is being melted.
NR 463.25(3)(b)5.
5. For scrap preheaters, sample only when scrap is being preheated.
NR 463.25(3)(c)
(c)
Fugitive emissions. To determine compliance with the opacity limit in
s. NR 463.23 (1) (a) 7. for fugitive emissions from buildings or structures housing any emissions source at the iron and steel foundry, you shall use the following test method and procedures:
NR 463.25(3)(c)2.
2. Conduct each test such that the opacity observations overlap with the PM performance tests.
NR 463.25(3)(d)
(d)
Volatile organic HAP emissions from cupola furnaces and scrap preheaters. To determine compliance with the applicable VOHAP emissions limit in
s. NR 463.23 (1) (a) 8. for a cupola metal melting furnace or in
s. NR 463.23 (1) (a) 9. for a scrap preheater, you shall use the following test methods and procedures:
NR 463.25(3)(d)1.a.
a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(d)1.b.
b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas.
NR 463.25(3)(d)1.c.
c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas.
NR 463.25(3)(d)1.e.
e. Method 18 to determine the VOHAP concentration. Alternatively, you may use Method 25 to determine the concentration of total gaseous nonmethane organics (TGNMO) or Method 25A to determine the concentration of total organic compounds (TOC), using hexane as the calibration gas.
NR 463.25(3)(d)2.
2. Determine the average VOHAP, TGNMO or TOC concentration using a minimum of 3 valid test runs. Each test run shall include a minimum of 60 continuous operating minutes.
NR 463.25(3)(d)3.
3. For a cupola metal melting furnace, correct the measured concentration of VOHAP, TGNMO or TOC for oxygen content in the gas stream using Equation 1:
where:
C
VOHAP is the concentration of VOHAP in ppmv as measured by Method 18 in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (16) or the concentration of TGNMO or TOC in ppmv as hexane as measured by Method 25 or 25A in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (19) or (20)
%O2 is the oxygen concentration in gas stream, percent by volume (dry basis)
NR 463.25(3)(d)4.
4. For a cupola metal melting furnace, measure the combustion zone temperature of the combustion device with the CPMS required in
s. NR 463.26 (1) (d) during each sampling run in 15-minute intervals. Determine and record the 15-minute average of the 3 runs.
NR 463.25(3)(e)
(e)
Volatile organic HAP emissions from automated pallet cooling lines or automated shakeout lines. To determine compliance with the VOHAP emissions limit in
s. NR 463.23 (1) (a) 10. for automated pallet cooling lines or automated shakeout lines you shall use either the procedures in
subds. 1. and
3. or
subds. 2. and
3.
NR 463.25(3)(e)1.
1. To demonstrate compliance by direct measurement of total hydrocarbons, a surrogate for VOHAP, use all of the following procedures:
NR 463.25(3)(e)1.a.
a. Using the VOC CEMS required in
s. NR 463.26 (1) (g), measure and record the concentration of total hydrocarbons, as hexane, for 180 continuous operating minutes. You shall measure emissions at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(e)2.
2. To demonstrate compliance by establishing a site-specific TOC emissions limit that is correlated to the VOHAP emissions limit, use the following procedures:
NR 463.25(3)(e)2.a.
a. Determine the VOHAP concentration for each test run according to the test methods in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (13), that are specified in this subdivision.
1) Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
2) Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas.
3) Method 3, 3A or 3B to determine the dry molecular weight of the stack gas.
4) Method 4 to determine the moisture content of the stack gas.
5) Method 18 to determine the VOHAP concentration. Alternatively, you may use Method 25 to determine the concentration of TGNMO using hexane as the calibration gas.
NR 463.25(3)(e)2.b.
b. Using the CEMS required in
s. NR 463.26 (1) (g), measure and record the concentration of total hydrocarbons, as hexane, during each of the Method 18 or Method 25 sampling runs. You shall measure emissions at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(e)2.c.
c. Calculate the average VOHAP or TGNMO concentration for the source test as the arithmetic average of the concentrations measured for the individual test runs and determine the average concentration of total hydrocarbon, as hexane, as measured by the CEMS during all test runs.
where:
C
VOHAP,avg is the average concentration of VOHAP for the source test in ppmv as measured by Method 18 in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (16), or the average concentration of TGNMO for the source test in ppmv as hexane as measured by Method 25 in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (19)
CCEM is the average concentration of total hydrocarbons in ppmv as hexane as measured using the CEMS during the source test
NR 463.25(3)(e)3.
3. For 2 or more exhaust streams from one or more automated conveyor and pallet cooling lines or automated shakeout lines, compute the flow-weighted average concentration of VOHAP emissions for each combination of exhaust streams using Equation 3:
where:
CW is the flow-weighted concentration of VOHAP or VOC, ppmv, as hexane
Ci is the concentration of VOHAP or VOC from exhaust stream i, ppmv, as hexane
n is the number of exhaust streams sampled
Qi is the volumetric flow rate of effluent gas from exhaust stream i in dscfm
NR 463.25(3)(f)
(f)
Triethylamine emissions. To determine compliance with the emissions limit or standard in
s. NR 463.23 (1) (a) 11. for a TEA cold box mold or core making line, you shall use the following test methods and procedures:
NR 463.25(3)(f)1.a.
a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. If you elect to meet the 99% reduction standard, sampling sites shall be located both at the inlet to the control device and at the outlet of the control device prior to any releases to the atmosphere. If you elect to meet the concentration limit, the sampling site shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere.
NR 463.25(3)(f)1.b.
b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas.
NR 463.25(3)(f)1.c.
c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas.
NR 463.25(3)(f)1.e.
e. Method 18 to determine the TEA concentration. The Method 18 sampling time shall be sufficiently long such that either the TEA concentration in the field sample is at least 5 times the limit of detection for the analytical method or the test results calculated using the laboratory's reported analytical detection limit for the specific field samples are less than 1/5 of the applicable emissions limit. The adsorbent tube approach, as described in Method 18, may be required to achieve the necessary analytical detection limits. The sampling time shall be at least one hour in all cases.
NR 463.25(3)(f)2.
2. Conduct the test as soon as practicable after adding fresh acid solution and the system has reached normal operating conditions.
NR 463.25(3)(f)3.
3. If you use a wet acid scrubber that is subject to the operating limit in
s. NR 463.23 (1) (b) 5. b. for pH level, determine the pH of the scrubber blowdown using one of the following procedures:
NR 463.25(3)(f)3.a.
a. Measure the pH of the scrubber blowdown with the CPMS required in
s. NR 463.26 (1) (f) 2. during each TEA sampling run in intervals of no more than 15 minutes. Determine and record the 3-hour average.
NR 463.25(3)(f)3.b.
b. Measure and record the pH level using the probe and meter required in
s. NR 463.26 (1) (f) 2. once each sampling run. Determine and record the average pH level for the 3 runs.
NR 463.25(3)(f)4.
4. If you are subject to the 99% reduction standard, calculate the mass emissions reduction using Equation 4:
where
Ei is the mass emissions rate of TEA at control device inlet, kg/hr
Eo is the mass emissions rate of TEA at control device outlet, kg/hr
NR 463.25(3)(g)
(g)
Combined emission sources. To determine compliance with the PM or total metal HAP emission limits in
s. NR 463.23 (1) (a) 1. to
6. when one or more regulated emissions sources are combined with either another regulated emissions source subject to a different emissions limit or other non-regulated emissions sources, you may demonstrate compliance using one of the following procedures:
NR 463.25(3)(g)1.
1. You shall meet the most stringent applicable emission limit for the regulated emission sources included in the combined emissions stream for the combined emissions stream.
NR 463.25(3)(g)2.a.
a. Determine the volumetric flow rate of the individual regulated streams for which emissions limits apply.
NR 463.25(3)(g)2.b.
b. Calculate the flow-weighted average emissions limit, considering only the regulated streams, using Equation 3 in
par. (e) 3., except C
w is the flow-weighted average emissions limit for PM or total metal HAP in the exhaust stream, gr/dscf; and C
i is the concentration of PM or total metal HAP in exhaust stream i, gr/dscf.
NR 463.25(3)(g)2.c.
c. Meet the calculated flow-weighted average emissions limit for the regulated emissions sources included in the combined emissions stream for the combined emissions stream.
