NR 463.12(25)(25) “Melting and holding furnace” means a group 1 furnace that processes only clean charge, performs melting, holding, and fluxing functions, and does not transfer molten aluminum to or from another furnace except for the purposes of alloy changes, off-specification product drains or maintenance activities. NR 463.12(26)(26) “Operating cycle” means for a batch process, the period beginning when the feed material is first charged to the operation and ending when all feed material charged to the operation has been processed. For a batch melting and holding furnace process, operating cycle means the period including the charging and melting of scrap aluminum and the fluxing, refining, alloying and tapping of molten aluminum. NR 463.12(27)(27) “PM” means, for the purposes of this subchapter, emissions of particulate matter that serve as a measure of total particulate emissions and as a surrogate for metal HAPs contained in the particulates, including antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, mercury, nickel and selenium. NR 463.12(28)(28) “Pollution prevention” means source reduction as defined under the Pollution Prevention Act of 1990 (42 USC 13101 to 13109) including equipment or technology modifications, process or procedure modifications, reformulation or redesign of products, substitution of raw materials, and improvements in housekeeping, maintenance, training, or inventory control, and other practices that reduce or eliminate the creation of pollutants through increased efficiency in the use of raw materials, energy, water or other resources or protection of natural resources by conservation. NR 463.12(29)(29) “Reactive fluxing” means the use of any gas, liquid, or solid flux, other than cover flux, that results in a HAP emission. Argon and nitrogen are not reactive and do not produce HAPs. NR 463.12(30)(30) “Reconstruction” means the replacement of components of an affected source or emission unit such that the fixed capital cost of the new components exceeds 50% of the fixed capital cost that would be required to construct a comparable new affected source, and it is technologically and economically feasible for the reconstructed source to meet relevant standards established in this subchapter. Replacement of the refractory in a furnace is routine maintenance and is not a reconstruction. The repair and replacement of in-line fluxer components, such as rotors, shafts, burner tubes, refractory or warped steel, is considered to be routine maintenance and is not considered a reconstruction. In-line fluxers are typically removed to a maintenance or repair area and are replaced with repaired units. The replacement of an existing in-line fluxer with a repaired unit is not considered a reconstruction. NR 463.12(31)(31) “Residence time” means, for an afterburner, the duration of time required for gases to pass through the afterburner combustion zone. Residence time is calculated by dividing the afterburner combustion zone volume in cubic feet by the volumetric flow rate of the gas stream in actual cubic feet per second. NR 463.12(32)(32) “Rotary dross cooler” means a water-cooled rotary barrel device that accelerates cooling of dross. NR 463.12(33)(33) “Runaround scrap” means scrap materials generated on-site by aluminum casting, extruding, rolling, scalping, forging, forming, stamping, cutting and trimming operations and that do not contain paint or solid coatings. Uncoated and unpainted aluminum chips generated by turning, boring, milling and similar machining operations may be clean charge if they have been thermally dried or treated by a centrifugal cleaner, but are not considered to be runaround scrap. NR 463.12(34)(34) “Scrap dryer, delacquering kiln or decoating kiln” means a unit used primarily to remove various organic contaminants such as oil, paint, lacquer, ink, plastic or rubber from aluminum scrap, including used beverage containers, prior to melting. NR 463.12(35)(35) “Secondary aluminum processing unit” or “SAPU” means one of the following: NR 463.12(35)(a)(a) An existing SAPU means all existing group 1 furnaces and all existing in-line fluxers within a secondary aluminum production facility. Each existing group 1 furnace or existing in-line fluxer is considered an emission unit within a secondary aluminum processing unit. NR 463.12(35)(b)(b) A new SAPU means any combination of individual group 1 furnaces and in-line fluxers within a secondary aluminum processing facility which either were constructed or reconstructed after February 11, 1999, or have been permanently redesignated as new emission units pursuant to s. NR 463.13 (11). Each of the group 1 furnaces or in-line fluxers within a new SAPU is considered an emission unit within that secondary aluminum processing unit. NR 463.12(36)(36) “Secondary aluminum production facility” means any establishment using clean charge, aluminum scrap or dross from aluminum production as the raw material and performing one or more of the following processes: scrap shredding, scrap drying, delacquering or decoating, thermal chip drying, recovery of aluminum from dross, in-line fluxing, dross cooling or furnace operations such as melting, holding, sweating, refining, fluxing or alloying. A secondary aluminum production facility may be independent or part of a primary aluminum production facility. For purposes of this subchapter, aluminum die casting facilities, aluminum foundries and aluminum extrusion facilities are not considered to be secondary aluminum production facilities if the only materials they melt are clean charge, customer returns or internal scrap, and if they do not operate sweat furnaces, thermal chip dryers, scrap dryers, delacquering kilns or decoating kilns. The determination of whether a facility is a secondary aluminum production facility is only for purposes of this subchapter and any regulatory requirements which are derived from the applicability of this subchapter, and is separate from any determination which may be made under other environmental laws and regulations, including whether the same facility is a “secondary metal production facility” as that term is used in 42 USC 7479(1) or a “secondary metal production plant” as that term is used in s. NR 405.02 (22) (a) 1. NR 463.12(37)(37) “Sidewell” means an open well adjacent to the hearth of a furnace with connecting arches between the hearth and the open well through which molten aluminum is circulated between the hearth, where heat is applied by burners, and the open well, which is used for charging scrap and solid flux or salt to the furnace, injecting fluxing agents and skimming dross. NR 463.12(38)(38) “Sweat furnace” means a furnace used exclusively to reclaim aluminum from scrap that contains substantial quantities of iron by using heat to separate the low-melting point aluminum from the scrap while the higher melting-point iron remains in solid form. NR 463.12(39)(39) “TEQ” means the international method of expressing toxicity equivalents for dioxins and furans as defined 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 463.12(40)(40) “THC” means total hydrocarbon emissions that also serve as a surrogate for the emissions of organic HAP compounds. NR 463.12(41)(41) “Thermal chip dryer” means a device that uses heat to evaporate oil or oil and water mixtures from unpainted or uncoated aluminum chips. Pre-heating boxes or other dryers which are used solely to remove water from aluminum scrap are not considered to be thermal chip dryers. NR 463.12(42)(42) “Three-day, 24-hour rolling average” means daily calculations of the average 24-hour emission rate in lb/ton of feed or charge over the 3 most recent consecutive 24-hour periods, for a secondary aluminum processing unit. NR 463.12(43)(43) “Total reactive chlorine flux injection rate” means the sum of the total weight of chlorine in the gaseous or liquid reactive flux and the total weight of chlorine in the solid reactive chloride flux, divided by the total weight of feed or charge, as determined by the procedure in s. NR 463.163 (16) NR 463.12 HistoryHistory: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09. NR 463.13NR 463.13 Emission standards for affected sources and emission units. NR 463.13(1)(1) Summary. The owner or operator of a new or existing affected source shall comply with each applicable limit in this section. The following table summarizes the emission standards for each type of source: Table 1
Emission Standards for New and Existing Affected Sources
Table 1 (Continued)
Emission Standards for New and Existing Affected Sources
a D&F limit applies to a unit at a major or area source.
b Sweat furnaces equipped with afterburners meeting the specifications of s. NR 463.13 (6) are not required to conduct a performance test. c These limits are also used to calculate the limits applicable to secondary aluminum processing units.
d Equation definitions:
LiPM is the PM emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/ton) of feed]
Ti is the feed rate for individual emission unit i in the secondary aluminum processing unit
LtPM is the overall PM emission limit for the secondary aluminum processing unit [kg/Mg (lb/ton) of feed]
LiHCl is the HCl emission limit for individual emission unit i in the secondary aluminum processing unit [kg/Mg (lb/ton) of feed]
LtHCl is the overall HCl emission limit for the secondary aluminum processing unit [kg/Mg (lb/ton) of feed]
Li D&F is the D&F emission limit for individual emission unit i [mg TEQ/Mg (gr TEQ/ton) of feed]
Lt D&F is the overall D&F emission limit for the secondary aluminum processing unit [mg TEQ/Mg (gr TEQ/ton) of feed]
n is the number of units in the secondary aluminum processing unit
e In-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the PM limit.
f In-line fluxers using no reactive flux materials cannot be included in this calculation since they are not subject to the HCl limit.
g Clean charge furnaces cannot be included in this calculation since they are not subject to the D&F limit.
NR 463.13(2)(2) Aluminum scrap shredder. On and after the compliance date established by s. NR 463.115, the owner or operator of an aluminum scrap shredder at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere either of the following: NR 463.13(2)(a)(a) Emissions in excess of 0.023 grams of PM per dry standard cubic meter (0.010 grain of PM per dry standard cubic foot). NR 463.13(2)(b)(b) Visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a continuous opacity monitor (COM) or visible emissions monitoring is chosen as the monitoring option. NR 463.13(3)(3) Thermal chip dryer. On and after the compliance date established by s. NR 463.115, the owner or operator of a thermal chip dryer may not discharge or cause to be discharged to the atmosphere emissions in excess of either of the following: NR 463.13(3)(a)(a) 0.40 kilogram (kg) of THC, as propane, per megagram (Mg) (0.80 lb of THC, as propane, per ton) of feed or charge from a thermal chip dryer at a secondary aluminum production facility that is a major source. NR 463.13(3)(b)(b) 2.50 micrograms (mg) of D&F TEQ per Mg (3.5 x 10-5 gr per ton) of feed or charge from a thermal chip dryer at a secondary aluminum production facility that is a major or area source. NR 463.13(4)(4) Scrap dryer, delacquering kiln, decoating kiln. On and after the compliance date established by s. NR 463.115: NR 463.13(4)(a)(a) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln may not discharge or cause to be discharged to the atmosphere emissions in excess of any of the following: NR 463.13(4)(a)1.1. 0.03 kg of THC, as propane, per Mg (0.06 lb of THC, as propane, per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(4)(a)2.2. 0.04 kg of PM per Mg (0.08 lb per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(4)(a)3.3. 0.25 mg of D&F TEQ per Mg (3.5 x 10-6 gr of D&F TEQ per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major or area source. NR 463.13(4)(a)4.4. 0.40 kg of HCl per Mg (0.80 lb per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(4)(b)(b) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a COM is chosen as the monitoring option. NR 463.13(5)(5) Scrap dryer, delacquering kiln and decoating kiln: alternative limits. The owner or operator of a scrap dryer, delacquering kiln or decoating kiln may choose to comply with the emission limits in this subsection as an alternative to the limits in sub. (4) if the scrap dryer, delacquering kiln or decoating kiln is equipped with an afterburner having a design residence time of at least one second and the afterburner is operated at a temperature of at least 760 °C (1400 °F) at all times. On and after the compliance date established by s. NR 463.115: NR 463.13(5)(a)(a) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln may not discharge or cause to be discharged to the atmosphere emissions in excess of any of the following: NR 463.13(5)(a)1.1. 0.10 kg of THC, as propane, per Mg (0.20 lb of THC, as propane, per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(5)(a)2.2. 0.15 kg of PM per Mg (0.30 lb per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(5)(a)3.3. 5.0 mg of D&F TEQ per Mg (7.0 x 10-5 gr of D&F TEQ per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major or area source. NR 463.13(5)(a)4.4. 0.75 kg of HCl per Mg (1.50 lb per ton) of feed or charge from a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source. NR 463.13(5)(b)(b) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a COM is chosen as the monitoring option. NR 463.13(6)(6) Sweat furnace. On and after the compliance date established by s. NR 463.115, the owner or operator of a sweat furnace at a secondary aluminum production facility that is a major or area source may not discharge or cause to be discharged to the atmosphere emissions in excess of 0.80 nanogram (ng) of D&F TEQ per dscm (3.5 x 10-10 gr per dscf) at 11% oxygen. A performance test is not required under s. NR 463.163 (6) to demonstrate compliance with this emission standard provided that the owner or operator operates and maintains an afterburner with a design residence time of 0.8 seconds or greater and an operating temperature of 1600°F or greater. NR 463.13(7)(7) Dross-only furnace. On and after the compliance date established by s. NR 463.115, the owner or operator of a dross-only furnace at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere either of the following: NR 463.13(7)(a)(a) Emissions in excess of 0.15 kg of PM per Mg (0.30 lb of PM per ton) of feed or charge. NR 463.13(7)(b)(b) Visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a COM is chosen as the monitoring option. NR 463.13(8)(8) Rotary dross cooler. On and after the compliance date established by s. NR 463.115, the owner or operator of a rotary dross cooler at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere either of the following: NR 463.13(8)(a)(a) Emissions in excess of 0.09 g of PM per dscm (0.04 gr per dscf). NR 463.13(8)(b)(b) Visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a COM is chosen as the monitoring option. NR 463.13(9)(9) Group 1 furnace. The owner or operator of a group 1 furnace shall use the limits in this subsection to determine the emission standards for a SAPU under sub. (11). NR 463.13(9)(a)(a) 0.20 kg of PM per Mg (0.40 lb of PM per ton) of feed or charge from a group 1 furnace, that is not a melting and holding furnace processing only clean charge, at a secondary aluminum production facility that is a major source. NR 463.13(9)(b)(b) 0.40 kg of PM per Mg (0.80 lb of PM per ton) of feed or charge from a group 1 melting and holding furnace processing only clean charge at a secondary aluminum production facility that is a major source. NR 463.13(9)(c)(c) 15 mg of D&F TEQ per Mg (2.1 x 10-4 gr of D&F TEQ per ton) of feed or charge from a group 1 furnace at a secondary aluminum production facility that is a major or area source. This limit does not apply if the furnace processes only clean charge. NR 463.13(9)(d)(d) 0.20 kg of HCl per Mg (0.40 lb of HCl per ton) of feed or charge or, if the furnace is equipped with an add-on air pollution control device, 10% of the uncontrolled HCl emissions, by weight, for a group 1 furnace at a secondary aluminum production facility that is a major source. NR 463.13(9)(e)(e) The owner or operator of a group 1 furnace at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10% opacity from any PM add-on air pollution control device if a COM is chosen as the monitoring option. NR 463.13(9)(f)(f) The owner or operator may determine the emission standards for a SAPU by applying the group 1 furnace limits on the basis of the aluminum production weight in each group 1 furnace, rather than on the basis of feed or charge. NR 463.13(9)(g)(g) The owner or operator of a sidewell group 1 furnace that conducts reactive fluxing, except for cover flux, in the hearth, or that conducts reactive fluxing in the sidewell at times when the level of molten metal falls below the top of the passage between the sidewell and the hearth, shall comply with the emission limits of pars. (a) to (d) on the basis of the combined emissions from the sidewell and the hearth. NR 463.13(10)(10) In-line fluxer. Except as provided in par. (c) for an in-line fluxer using no reactive flux material, the owner or operator of an in-line fluxer shall use the limits in this subsection to determine the emission standards for a SAPU under sub. (11). NR 463.13(10)(a)(a) 0.02 kg of HCl per Mg (0.04 lb of HCl per ton) of feed or charge. NR 463.13(10)(b)(b) 0.005 kg of PM per Mg (0.01 lb of PM per ton) of feed or charge. NR 463.13(10)(c)(c) The emission limits in pars. (a) and (b) do not apply to an in-line fluxer that uses no reactive flux materials. NR 463.13(10)(d)(d) The owner or operator of an in-line fluxer at a secondary aluminum production facility that is a major source may not discharge or cause to be discharged to the atmosphere visible emissions in excess of 10% opacity from any PM add-on air pollution control device used to control emissions from the in-line fluxer, if a COM is chosen as the monitoring option. NR 463.13(10)(e)(e) The owner or operator may determine the emission standards for a SAPU by applying the in-line fluxer limits on the basis of the aluminum production weight in each in-line fluxer, rather than on the basis of feed or charge. NR 463.13(11)(11) Secondary aluminum processing unit. On and after the compliance date established by s. NR 463.115, the owner or operator shall comply with the emission limits calculated using the equations for PM and HCl in pars. (a) and (b) for each secondary aluminum processing unit at a secondary aluminum production facility that is a major source. The owner or operator shall comply with the emission limit calculated using the equation for D&F in par. (c) for each secondary aluminum processing unit at a secondary aluminum production facility that is a major or area source. NR 463.13(11)(a)(a) The owner or operator may not discharge or allow to be discharged to the atmosphere any 3-day, 24-hour rolling average emissions of PM in excess of: where:
is the PM emission limit for individual emission unit i in sub. (9) (a) and (b) for a group 1 furnace or in sub. (10) (b) for an in-line fluxer
