Chapter NR 463

NR 463.25(3)(f)1.d. d. Method 4 to determine the moisture content 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:

=

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. 2. You shall do all of the following:

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 Cw is the flow-weighted average emissions limit for PM or total metal HAP in the exhaust stream, gr/dscf; and Ci 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.

NR 463.25(3)(g)3. 3. You shall do all of the following:

NR 463.25(3)(g)3.a. a. Determine the PM or total metal HAP concentration of each of the regulated streams prior to the combination with other exhaust streams or control device.

NR 463.25(3)(g)3.b. b. Measure the flow rate and PM or total metal HAP concentration of the combined exhaust stream both before and after the control device and calculate the mass removal efficiency of the control device using Equation 4 in par. (f) 4., except Ei is the mass emissions rate of PM or total metal HAP at the control device inlet, lb/hr, and Eo is the mass emissions rate of PM or total metal HAP at the control device outlet, lb/hr.

NR 463.25(3)(g)3.c. c. Meet the applicable emissions limit based on the calculated PM or total metal HAP concentration for the regulated emissions source using Equation 5 of this section:

÷

ø

ö

ç

è

æ

-

=

Equation 5

where

Creleased is the calculated concentration of PM or total metal HAP predicted to be released to the atmosphere from the regulated emission source, in gr/dscf

Ci is the concentration of PM or total metal HAP in the uncontrolled regulated exhaust stream, in gr/dscf

NR 463.25(4) (4) What procedures must I use to establish operating limits?

NR 463.25(4)(a) (a) For each capture system subject to operating limits in s. NR 463.23 (1) (b) 1. b., you shall establish site-specific operating limits in your operation and maintenance plan according to all of the following procedures:

NR 463.25(4)(a)1. 1. Concurrent with applicable emissions and opacity tests, measure and record values for each of the operating limit parameters in your capture system operation and maintenance plan according to the monitoring requirements in s. NR 463.26 (1) (a).

NR 463.25(4)(a)2. 2. For any dampers that are manually set and remain at the same position at all times the capture system is operating, visually check and record the damper position at the beginning and end of each run.

NR 463.25(4)(a)3. 3. Review and record the monitoring data. Identify and explain any times the capture system operated outside the applicable operating limits.

NR 463.25(4)(b) (b) For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2. for pressure drop and scrubber water flow rate, you shall establish site-specific operating limits according to both of the following procedures:

NR 463.25(4)(b)1. 1. Using the CPMS required in s. NR 463.26 (1) (c), measure and record the pressure drop and scrubber water flow rate in intervals of no more than 15 minutes during each PM test run.

NR 463.25(4)(b)2. 2. Compute and record the 3-hour average pressure drop and average scrubber water flow rate for each sampling run in which the applicable emissions limit is met.

NR 463.25(4)(c) (c) For each combustion device applied to emissions from a scrap preheater or TEA cold box mold or core making line subject to the operating limit in s. NR 463.23 (1) (b) 4. for combustion zone temperature, you shall establish a site-specific operating limit according to both of the following procedures:

NR 463.25(4)(c)1. 1. Using the CPMS required in s. NR 463.26 (1) (e), measure and record the combustion zone temperature during each sampling run in intervals of no more than 15 minutes.

NR 463.25(4)(c)2. 2. Compute and record the 3-hour average combustion zone temperature for each sampling run in which the applicable emissions limit is met.

NR 463.25(4)(d) (d) For each acid wet scrubber subject to the operating limit in s. NR 463.23 (1) (b) 5., you shall establish a site-specific operating limit for scrubbing liquid flow rate according to both of the following procedures:

NR 463.25(4)(d)1. 1. Using the CPMS required in s. NR 463.26 (1) (f), measure and record the scrubbing liquid flow rate during each TEA sampling run in intervals of no more than 15 minutes.

NR 463.25(4)(d)2. 2. Compute and record the 3-hour average scrubbing liquid flow rate for each sampling run in which the applicable emissions limit is met.

NR 463.25(4)(e) (e) You may change the operating limits for a capture system, wet scrubber, acid wet scrubber or combustion device if you do all of the following:

NR 463.25(4)(e)1. 1. Submit a written notification to the department of your request to conduct a new performance test to revise the operating limit.

NR 463.25(4)(e)2. 2. Conduct a performance test to demonstrate compliance with the applicable emissions limitation in s. NR 463.23 (1).

NR 463.25(4)(e)3. 3. Establish revised operating limits according to the applicable procedures in pars. (a) to (d).

NR 463.25(4)(f) (f) You may use a previous performance test conducted since December 22, 2002 to establish an operating limit, provided the test meets the requirements of this subchapter.

NR 463.25(5) (5) How do I demonstrate initial compliance with the emission limitations that apply to me?

NR 463.25(5)(a) (a) You have demonstrated initial compliance with the emissions limits in s. NR 463.23 (1) (a) if you do the following, as applicable:

NR 463.25(5)(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 you demonstrate one of the following:

NR 463.25(5)(a)1.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.005 gr/dscf.

NR 463.25(5)(a)1.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0004 gr/dscf.

NR 463.25(5)(a)2. 2. For each cupola metal melting furnace at an existing iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)2.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.006 gr/dscf.

NR 463.25(5)(a)2.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0005 gr/dscf.

NR 463.25(5)(a)3. 3. For each cupola metal melting furnace or electric arc metal melting furnace at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)3.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.002 gr/dscf.

NR 463.25(5)(a)3.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0002 gr/dscf.

NR 463.25(5)(a)4. 4. For each electric induction metal melting furnace or scrap preheater at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)4.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.001 gr/dscf.

NR 463.25(5)(a)4.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.00008 gr/dscf.

NR 463.25(5)(a)5. 5. For each pouring station at an existing iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)5.a. a. The average PM concentration in the exhaust stream, measured according to the performance test procedures in sub. (3) (a), did not exceed 0.010 gr/dscf.

NR 463.25(5)(a)5.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0008 gr/dscf.

NR 463.25(5)(a)6. 6. For each pouring area or pouring station at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)6.a. a. The average PM concentration in the exhaust stream, measured according to the performance test procedures in sub. (3) (a), did not exceed 0.002 gr/dscf.

NR 463.25(5)(a)6.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0002 gr/dscf.

NR 463.25(5)(a)7. 7. For each building or structure housing any emission source at the iron and steel foundry, the opacity of fugitive emissions discharged to the atmosphere, determined according to the performance test procedures in sub. (3) (c), did not exceed 20% averaged over 6-minutes, except for one 6-minute average per hour that did not exceed 27% opacity.

NR 463.25(5)(a)8. 8. For each cupola metal melting furnace at a new or existing iron and steel foundry, the average VOHAP concentration, determined according to the performance test procedures in sub. (3) (d), did not exceed 20 ppmv corrected to 10% oxygen.

NR 463.25(5)(a)9. 9. For each scrap preheater at an existing iron and steel foundry that does not meet the work practice standards in s. NR 463.23 (2) (e) 1. or 2., and for each scrap preheater at a new iron and steel foundry that does not meet the work practice standard in s. NR 463.23 (2) (f), the average VOHAP concentration determined according to the performance test procedures in sub. (3) (d), did not exceed 20 ppmv.

NR 463.25(5)(a)10. 10. For one or more automated conveyor and pallet cooling lines that use a sand mold system or automated shakeout lines that use a sand mold system at a new foundry you demonstrate both of the following:

NR 463.25(5)(a)10.a. a. You have reduced the data from the CEMS to 3-hour averages according to the performance test procedures in sub. (3) (e).

NR 463.25(5)(a)10.b. b. The 3-hour flow-weighted average VOHAP concentration, measured according to the performance test procedures in sub. (3) (e), did not exceed 20 ppmv.

NR 463.25(5)(a)11. 11. For each TEA cold box mold or core making line in a new or existing iron and steel foundry, the average TEA concentration, determined according to the performance test procedures in sub. (3) (f) did not exceed 1 ppmv or was reduced by 99%.

NR 463.25(5)(b) (b) You have demonstrated initial compliance with the operating limits in s. NR 463.23 (1) (b) if you do the following, as applicable:

NR 463.25(5)(b)1. 1. For each capture system subject to the operating limit in s. NR 463.23 (1) (b) 1. a., you have established appropriate site-specific operating limits in your operation and maintenance plan according to the requirements in s. NR 463.23 (3) (b) and have a record of the operating parameter data measured during the performance test in accordance with sub. (4) (a).

NR 463.25(5)(b)2. 2. For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2. for pressure drop and scrubber water flow rate, you have established appropriate site-specific operating limits and have a record of the pressure drop and scrubber water flow rate measured during the performance test in accordance with sub. (4) (b).

NR 463.25(5)(b)3. 3. For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 3. for combustion zone temperature, you have a record of the combustion zone temperature measured during the performance test in accordance with sub. (3) (d) 4.

NR 463.25(5)(b)4. 4. For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 4. for combustion zone temperature, you have established appropriate site-specific operating limits and have a record of the combustion zone temperature measured during the performance test in accordance with sub. (4) (c).

NR 463.25(5)(b)5. 5. For each acid wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5. for scrubbing liquid flow rate and scrubber blowdown pH, you satisfy both of the following:

NR 463.25(5)(b)5.a. a. You have established appropriate site-specific operating limits for the scrubbing liquid flow rate and have a record of the scrubbing liquid flow rate measured during the performance test in accordance with sub. (4) (d).

NR 463.25(5)(b)5.b. b. You have a record of the pH of the scrubbing liquid blowdown measured during the performance test in accordance with sub. (3) (g) 3.

NR 463.25(6) (6) How do I demonstrate initial compliance with the work practice standards that apply to me?

NR 463.25(6)(a) (a) For each iron and steel foundry subject to the certification requirement in s. NR 463.23 (2) (b), you have demonstrated initial compliance if you have certified in your notification of compliance status that: “At all times, your foundry will purchase and use 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.”

NR 463.25(6)(b) (b) For each iron and steel foundry subject to the requirements in s. NR 463.23 (2) (c) for a scrap inspection and selection plan, you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status:

NR 463.25(6)(b)1. 1. That you have submitted a written plan to the department for approval according to the requirements in s. NR 463.23 (2) (c).

NR 463.25(6)(b)2. 2. That you will operate at all times according to the plan requirements.

NR 463.25(6)(c) (c) For each furan warm box mold or core making line in a new or existing foundry subject to the work practice standard in s. NR 463.23 (2) (d), you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status:

NR 463.25(6)(c)1. 1. That you will meet the no methanol requirement for the catalyst portion of each binder chemical formulation.

NR 463.25(6)(c)2. 2. That you have records documenting your certification of compliance, such as a material safety data sheet, provided that it contains appropriate information, a certified product data sheet or a manufacturer’s hazardous air pollutant data sheet, onsite and available for inspection.

NR 463.25(6)(d) (d) For each scrap preheater at an existing iron and steel foundry subject to the work practice standard in s. NR 463.23 (2) (e) 1. or 2., you have demonstrated initial compliance if you have certified one of the following in your notification of compliance status:

NR 463.25(6)(d)1. 1. That you have installed a gas-fired preheater where the flame directly contacts the scrap charged, you will operate and maintain each gas-fired scrap preheater so that the flame directly contacts the scrap charged and you have records documenting your certification of compliance that are onsite and available for inspection.