Chapter NR 463

Register December 2008 No. 636

Chapter NR 463

NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS
FOR METALS TREATING AND PROCESSING

Subchapter I — Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks

NR 463.01   Applicability and designation of sources; purpose.

NR 463.02   Definitions.

NR 463.03   Nomenclature, units and abbreviations.

NR 463.04   Emission limits.

NR 463.05   Operation and maintenance practices.

NR 463.06   Compliance provisions.

NR 463.07   Monitoring to demonstrate continuous compliance.

NR 463.08   Alternative control devices.

NR 463.09   Performance test requirements and test methods.

NR 463.10   Preconstruction review requirements for new and reconstructed sources.

NR 463.103   Recordkeeping requirements.

NR 463.106   Reporting requirements.

Subchapter II — Secondary Aluminum Production

NR 463.11   Applicability.

NR 463.115   Dates.

NR 463.12   Definitions.

NR 463.13   Emission standards for affected sources and emission units.

NR 463.14   Operating requirements.

NR 463.15   Monitoring requirements.

NR 463.16   Performance test and compliance demonstration general requirements.

NR 463.163   Performance test and compliance demonstration requirements and procedures.

NR 463.166   Equations for determining compliance.

NR 463.17   Notifications.

NR 463.18   Reports.

NR 463.19   Records.

NR 463.20   Applicability of general provisions.

Subchapter III — Iron and Steel Foundries

NR 463.21   What this subchapter covers.

NR 463.22   What definitions apply to this subchapter?

NR 463.23   Emissions limitations, work practice standards and operation and maintenance requirements.

NR 463.24   General compliance requirements.

NR 463.25   Initial compliance requirements.

NR 463.26   Continuous compliance requirements.

NR 463.27   Notifications, reports and records.

subch. I of ch. NR 463 Subchapter I — Chromium Emissions from Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks

NR 463.01 NR 463.01 Applicability and designation of sources; purpose.

NR 463.01(1) (1) Applicability. This subchapter applies to the owners and operators of hard chromium electroplating tanks, decorative chromium electroplating tanks and chromium anodizing tanks.

NR 463.01(1)(a) (a) The affected source to which this subchapter applies is each chromium electroplating or chromium anodizing tank at facilities performing hard chromium electroplating, decorative chromium electroplating or chromium anodizing.

NR 463.01(1)(b) (b) Owners or operators of affected sources subject to this subchapter are also subject to the requirements of ch. NR 460, according to the applicability of ch. NR 460 to these sources as identified in ch. NR 460 Appendix N.

NR 463.01(1)(c) (c) Process tanks associated with a chromium electroplating or chromium anodizing process, but in which neither chromium electroplating nor chromium anodizing takes place, are not subject to this subchapter. Examples of these tanks include, but are not limited to, rinse tanks, etching tanks and cleaning tanks. Likewise, tanks that contain a chromium solution, but in which no electrolytic process occurs, are not subject to this subchapter. An example of such a tank is a chrome conversion coating tank where no electrical current is applied.

NR 463.01(1)(d) (d) Affected sources in which research and laboratory operations are performed are exempt from this subchapter when these operations are taking place.

NR 463.01(1)(e) (e) An owner or operator of any affected source subject to this subchapter which is not exempt under s. NR 407.03 (1) (km) is subject to part 70 permit requirements under ch. NR 407.

NR 463.01(2) (2) Purpose. This subchapter is adopted under ss. 285.11, 285.13, 285.27 (2) and 285.65, Stats., to establish emission standards for hard chromium electroplating tanks, decorative chromium electroplating tanks, and chromium anodizing tanks in order to protect air quality.

NR 463.01 Note Note: This subchapter is based on the federal regulations contained in 40 CFR part 63 Subpart N, created January 25, 1995, as last revised on June 3, 1996.

NR 463.01 History History: Cr. Register, September, 1997, No. 501, eff. 10-1-97; CR 04-023: am. Register December 2008 No. 636, eff. 1-1-09; correction in (1) (b) made under s. 35.17, Stats., Register June 2015 No. 714.

NR 463.02 NR 463.02 Definitions. For terms not defined in this section, the definitions contained in chs. NR 400 and 460 apply to the terms used in this subchapter, with definitions in ch. NR 460 taking priority over definitions in ch. NR 400. In addition, the definitions in this section apply to the terms used in this subchapter. If this section defines a term which is also defined in ch. NR 400 or 460, the definition in this section applies in this subchapter rather than the definition in ch. NR 400 or 460. In this subchapter:

NR 463.02(1) (1) “Add-on air pollution control device” means equipment installed in the ventilation system of chromium electroplating and anodizing tanks for the purposes of collecting and containing chromium emissions from the tanks.

NR 463.02(2) (2) “Air pollution control technique” means any method, such as an add-on air pollution control device or a chemical fume suppressant, that is used to reduce chromium emissions from chromium electroplating and chromium anodizing tanks.

NR 463.02(3) (3) “Base metal” means the metal or metal alloy that comprises the workpiece.

NR 463.02(4) (4) “Bath component” means the trade, brand or chemical name of each component in trivalent chromium plating baths.

NR 463.02 Note Note: Since for trivalent chromium baths, the bath composition is proprietary in most cases, the trade or brand name for each component may be used. However, ss. NR 463.103 (2) (n) and 463.106 (9) (a) 3. require identification by chemical name of the wetting agent contained in that component.

NR 463.02(5) (5) “Chemical fume suppressant” means any chemical agent that reduces or suppresses fumes or mists at the surface of an electroplating or anodizing bath.

NR 463.02 Note Note: Another term for fume suppressant is mist suppressant.

NR 463.02(6) (6) “Chromic acid” means the common name for chromium anhydride (CrO3).

NR 463.02(7) (7) “Chromium anodizing” means the electrolytic process by which an oxide layer is produced on the surface of a base metal for functional purposes, such as corrosion resistance or electrical insulation, using a chromic acid solution. In chromium anodizing, the part to be anodized acts as the anode in the electrical circuit, and the chromic acid solution, with a concentration typically ranging from 50 to 100 grams per liter (g/L), serves as the electrolyte.

NR 463.02(8) (8) “Chromium anodizing tank” means the receptacle or container along with the following accompanying internal and external components needed for chromium anodizing: rectifiers fitted with controls to allow for voltage adjustments, heat exchanger equipment, circulation pumps and air agitation systems.

NR 463.02(8m) (8m) “Chromium electroplating tank” means the receptacle or container along with the following accompanying internal and external components needed for chromium electroplating: rectifiers, anodes, heat exchanger equipment, circulation pumps and air agitation systems.

NR 463.02(9) (9) “Composite mesh-pad system” means an add-on air pollution control device typically consisting of several mesh-pad stages. The purpose of the first stage is to remove large particles. Smaller particles are removed in the second stage, which consists of the composite mesh pad. A final stage may remove any reentrained particles not collected by the composite mesh pad.

NR 463.02(10) (10) “Decorative chromium electroplating” means the process by which a thin layer of chromium (typically 0.003 to 2.5 µm) is electrodeposited on a base metal, plastic or undercoating to provide a bright surface with wear and tarnish resistance. In this process, the part serves as the cathode in the electrolytic cell and the solution serves as the electrolyte. Typical current density applied during this process ranges from 540 to 2,400 amperes per square meter (A/m2) for total plating times ranging between 0.5 to 5 minutes.

NR 463.02(11) (11) “Electroplating or anodizing bath” means the electrolytic solution used as the conducting medium in which the flow of current is accompanied by movement of metal ions for the purposes of electroplating metal out of the solution onto a workpiece or for oxidizing the base material.

NR 463.02(12) (12) “Emission limitation” means the concentration of total chromium allowed to be emitted expressed in milligrams per dry standard cubic meter (mg/dscm), or the allowable surface tension expressed in dynes per centimeter (dynes/cm).

NR 463.02(12m) (12m) “Enclosed hard chromium electroplating tank” means a chromium electroplating tank that is equipped with an enclosing hood and ventilated at half the rate or less than that of an open surface tank of the same surface area.

NR 463.02(13) (13) “Existing” means any hard chromium electroplating tank, decorative chromium electroplating tank or chromium anodizing tank the construction or reconstruction of which was commenced on or before December 16, 1993.

NR 463.02(14) (14) “Facility” means the major or area source at which chromium electroplating or chromium anodizing is performed.

NR 463.02(15) (15) “Fiber-bed mist eliminator” means an add-on air pollution control device that removes contaminants from a gas stream through the mechanisms of inertial impaction and Brownian diffusion. These devices are typically installed downstream of another control device, which serves to prevent plugging, and consist of one or more fiber beds. Each bed consists of a hollow cylinder formed from 2 concentric screens; the fiber between the screens may be fabricated from glass, ceramic plastic or metal.

NR 463.02(16) (16) “Foam blanket” means the type of chemical fume suppressant that generates a layer of foam across the surface of a solution when current is applied to that solution.

NR 463.02(17) (17) “Fresh water” means water, such as tap water, that has not been previously used in a process operation or, if the water has been recycled from a process operation, it has been treated and meets the effluent guidelines for chromium wastewater.

NR 463.02(18) (18) “Hard chromium electroplating” or “industrial chromium electroplating” means a process by which a thick layer of chromium (typically 1.3 to 760 µm) is electrodeposited on a base material to provide a surface with functional properties such as wear resistance, a low coefficient of friction, hardness and corrosion resistance. In this process, the part serves as the cathode in the electrolytic cell and the solution serves as the electrolyte. The hard chromium electroplating process is performed at current densities typically ranging from 1,600 to 6,500 A/m2 for total plating times ranging from 20 minutes to 36 hours depending upon the desired plate thickness.

NR 463.02(19) (19) “Hexavalent chromium” means the form of chromium in a valence state of +6.

NR 463.02(20) (20) “Large, hard chromium electroplating facility” means a facility that performs hard chromium electroplating and has a maximum cumulative potential rectifier capacity greater than or equal to 60 million ampere-hours per year (A-hr/yr).

NR 463.02(21) (21) “Maximum cumulative potential rectifier capacity” means the summation of the total installed rectifier capacity associated with the hard chromium electroplating tanks at a facility, expressed in amperes, multiplied by the maximum potential operating schedule of 8,400 hours per year and 0.7, which assumes that electrodes are energized 70% of the total operating time. The maximum potential operating schedule is based on operating 24 hours per day, 7 days per week, 50 weeks per year.

NR 463.02(22) (22) “New source” or “new tank” means any hard chromium electroplating, decorative chromium electroplating or chromium anodizing source or tank the construction or reconstruction of which is commenced after December 16, 1993.

NR 463.02(22m) (22m) “Open surface hard chromium electroplating tank” means a chromium electroplating tank that is ventilated at a rate consistent with good ventilation practices for open tanks.

NR 463.02(23) (23) “Operating parameter value” means a minimum or maximum value established for a control device or process parameter which, if achieved by itself or in combination with one or more other operating parameter values, determines that an owner or operator is in continual compliance with the applicable emission limitation or standard.

NR 463.02(24) (24) “Packed-bed scrubber” means an add-on air pollution control device consisting of a single or double packed bed that contains packing media on which the chromic acid droplets impinge. The packed-bed section of the scrubber is followed by a mist eliminator to remove any water entrained from the packed-bed section.

NR 463.02(25) (25) “Research or laboratory operation” means an operation whose primary purpose is for research and development of new processes and products, that is conducted under the close supervision of technically trained personnel, and that is not involved in the manufacture of products for commercial sale, except in a de minimis manner.

NR 463.02(26) (26) “Small, hard chromium electroplating facility” means a facility that performs hard chromium electroplating and has a maximum cumulative potential rectifier capacity less than 60 million A-hr/yr.