NR 463.15(15)(15) Group 1 furnace without add-on air pollution control devices. NR 463.15(15)(a)(a) The requirements of this paragraph apply to the owner or operator of a group 1 furnace that is not equipped with an add-on air pollution control device. NR 463.15(15)(a)1.1. The owner or operator shall develop, in consultation with the department, a written site-specific monitoring plan. The site-specific monitoring plan shall be submitted to the department as part of the OM&M plan. The site-specific monitoring plan shall contain sufficient procedures to ensure continuing compliance with all applicable emission limits and shall demonstrate, based on documented test results, the relationship between emissions of PM, HCl and D&F and the proposed monitoring parameters for each pollutant. Test data shall establish the highest level of PM, HCl and D&F that will be emitted from the furnace. This emission level may be determined by conducting performance tests and monitoring operating parameters while charging the furnace with feed or charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate. If the department determines that any revisions of the site-specific monitoring plan are necessary to meet the requirements of this subchapter, the owner or operator shall promptly make all necessary revisions and resubmit the revised plan to the department. NR 463.15(15)(a)2.2. The site-specific monitoring plan shall contain all of the following as applicable: NR 463.15(15)(a)2.a.a. Each site-specific monitoring plan shall document each work practice, equipment and design practice, pollution prevention practice or other measure used to meet the applicable emission standards. NR 463.15(15)(a)2.b.b. Each site-specific monitoring plan shall include provisions for unit labeling as required in sub. (3), feed or charge weight measurement, or production weight measurement, as required in sub. (5) and flux weight measurement as required in sub. (10). NR 463.15(15)(a)2.c.c. Each site-specific monitoring plan for a melting and holding furnace subject to the clean charge emission standard in s. NR 463.13 (9) (c) shall include requirements that the owner or operator record the type of feed or charge, such as ingot, thermally dried chips, dried scrap, or other, for each operating cycle or time period used in the performance test, and that the owner or operator submit a certification of compliance with the applicable operational standard for clean charge materials in s. NR 463.14 (14) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18 (2) (b) 4. NR 463.15(15)(a)2.d.d. If a continuous emission monitoring system is included in a site-specific monitoring plan, the plan shall include provisions for the installation, operation and maintenance of the system to provide quality-assured measurements in accordance with all applicable requirements of the general provisions of ch. NR 460. NR 463.15(15)(a)2.e.e. If a continuous opacity monitoring system is included in a site-specific monitoring plan, the plan shall include provisions for the installation, operation and maintenance of the system to provide quality-assured measurements in accordance with all applicable requirements of this subchapter. NR 463.15(15)(a)2.f.f. If a site-specific monitoring plan includes a scrap inspection program for monitoring the scrap contaminant level of furnace feed or charge materials, the plan shall include provisions for the demonstration and implementation of the program in accordance with all applicable requirements in sub. (16). NR 463.15(15)(a)2.g.g. If a site-specific monitoring plan includes a calculation method for monitoring the scrap contaminant level of furnace feed or charge materials, the plan shall include provisions for the demonstration and implementation of the program in accordance with all applicable requirements in sub. (17). NR 463.15(15)(a)3.3. The owner or operator of an existing affected source shall submit the site-specific monitoring plan to the department for review at least 6 months prior to the compliance date. NR 463.15(15)(b)(b) The department shall review and approve or disapprove a proposed site-specific monitoring plan, or request changes to a plan, based on whether the plan contains sufficient provisions to ensure continuing compliance with applicable emission limits and demonstrates, based on documented test results, the relationship between emissions of PM, HCl and D&F and the proposed monitoring parameters for each pollutant. Test data shall establish the highest level of PM, HCl and D&F that will be emitted from the furnace. Subject to department approval of the OM&M plan, this may be determined by conducting performance tests and monitoring operating parameters while charging the furnace with feed or charge materials containing the highest anticipated levels of oils and coatings and fluxing at the highest anticipated rate. NR 463.15(16)(16) Scrap inspection program for group 1 furnace without add-on air pollution control devices. A scrap inspection program shall include all of the following: NR 463.15(16)(a)(a) A proven method for collecting representative samples and measuring the oil and coatings content of scrap samples. NR 463.15(16)(c)(c) An established correlation between visual inspection and physical measurement of oil and coatings content of scrap samples. NR 463.15(16)(d)(d) Periodic physical measurements of oil and coatings content of randomly-selected scrap samples and comparison with visual inspection results. NR 463.15(16)(e)(e) A system for assuring that only acceptable scrap is charged to an affected group 1 furnace. NR 463.15(16)(f)(f) Recordkeeping requirements to document conformance with plan requirements. NR 463.15(17)(17) Monitoring of scrap contamination level by calculation method for group 1 furnace without add-on air pollution control devices. The owner or operator of a group 1 furnace dedicated to processing a distinct type of furnace feed or charge composed of scrap with a uniform composition, such as rejected product from a manufacturing process for which the coating-to-scrap ratio can be documented, may include a program in the site-specific monitoring plan for determining, monitoring and certifying the scrap contaminant level using a calculation method rather than a scrap inspection program. A scrap contaminant monitoring program using a calculation method shall include all of the following: NR 463.15(17)(a)(a) Procedures for the characterization and documentation of the contaminant level of the scrap prior to the performance test. NR 463.15(17)(b)(b) Limitations on the scrap in the furnace feed or charge to scrap of the same composition as that used in the performance test. If the performance test was conducted with a mixture of scrap and clean charge, limitations on the proportion of scrap in the furnace feed or charge to no greater than the proportion used during the performance test. NR 463.15(17)(c)(c) Operating, monitoring, recordkeeping and reporting requirements to ensure that no scrap with a contaminant level higher than that used in the performance test is charged to the furnace. NR 463.15(18)(18) Group 2 furnace. The requirements of this subsection apply to the owner or operator of a new or existing group 2 furnace. The owner or operator shall do both of the following: NR 463.15(18)(a)(a) Record a description of the materials charged to each furnace, including any nonreactive, non-HAP-containing, non-HAP-generating fluxing materials or agents. NR 463.15(18)(b)(b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14 (15) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18 (2) (b) 5. NR 463.15(19)(19) Site-specific requirements for secondary aluminum processing units. NR 463.15(19)(a)(a) An owner or operator of a secondary aluminum processing unit at a facility shall include, within the OM&M plan prepared in accordance with sub. (2), all of the following information: NR 463.15(19)(a)1.1. The identification of each emission unit in the secondary aluminum processing unit. NR 463.15(19)(a)2.2. The specific control technology or pollution prevention measure to be used for each emission unit in the secondary aluminum processing unit and the date of its installation or application. NR 463.15(19)(a)3.3. The emission limit calculated for each secondary aluminum processing unit and performance test results with supporting calculations demonstrating initial compliance with each applicable emission limit. NR 463.15(19)(a)4.4. Information and data demonstrating compliance for each emission unit with all applicable design, equipment, work practice or operational standards of this subchapter. NR 463.15(19)(a)5.5. The monitoring requirements applicable to each emission unit in a secondary aluminum processing unit and the monitoring procedures for daily calculation of the 3-day, 24-hour rolling average using the procedure in sub. (20). NR 463.15(19)(b)(b) The SAPU compliance procedures within the OM&M plan may not contain any of the following provisions: NR 463.15(19)(b)2.2. The inclusion of any affected sources other than emission units in a secondary aluminum processing unit. NR 463.15(19)(b)4.4. The inclusion of any periods of startup, shutdown or malfunction in emission calculations. NR 463.15(19)(c)(c) To revise the SAPU compliance provisions within the OM&M plan prior to the end of the permit term, the owner or operator shall submit a request to the department containing the information required by par. (a) and obtain approval of the department prior to implementing any revisions. NR 463.15(20)(20) Secondary aluminum processing unit. Except as provided in sub. (21), the owner or operator shall calculate and record the 3-day, 24-hour rolling average emissions of PM, HCl and D&F for each secondary aluminum processing unit on a daily basis. To calculate the 3-day, 24-hour rolling average, the owner or operator shall do all of the following: NR 463.15(20)(a)(a) Calculate and record the total weight of material charged to each emission unit in the secondary aluminum processing unit for each 24-hour day of operation using the feed or charge weight information required in sub. (5). If the owner or operator chooses to comply on the basis of weight of aluminum produced by the emission unit, rather than weight of material charged to the emission unit, all performance test emissions results and all calculations shall be conducted on the aluminum production weight basis. NR 463.15(20)(b)(b) Multiply the total feed or charge weight to the emission unit, or the weight of aluminum produced by the emission unit, for each emission unit for the 24-hour period by the emission rate, in lb/ton of feed or charge, for that emission unit, as determined during the performance test, to provide emissions for each emission unit for the 24-hour period, in pounds. NR 463.15(20)(c)(c) Divide the total emissions for each SAPU for the 24-hour period by the total material charged to the SAPU, or the weight of aluminum produced by the SAPU over the 24-hour period, to provide the daily emission rate for the SAPU. where:
Eday is the daily PM, HCl, or D&F emission rate for the secondary aluminum processing unit for the 24-hour period
Ti is the total amount of feed, or aluminum produced, for emission unit i for the 24-hour period (tons or Mg)
ER i is the measured emission rate for emission unit i as determined in the performance test (lb/ton or mg/Mg of feed or charge)
n is the number of emission units in the secondary aluminum processing unit
NR 463.15(20)(e)(e) Calculate and record the 3-day, 24-hour rolling average for each pollutant each day by summing the daily emission rates for each pollutant over the 3 most recent consecutive days and dividing by 3. NR 463.15(21)(21) Secondary aluminum processing unit compliance by individual emission unit demonstration. As an alternative to the procedures of sub. (20), an owner or operator may demonstrate, through performance tests, that each individual emission unit within the secondary aluminum production unit is in compliance with the applicable emission limits for the emission unit. NR 463.15(22)(22) Alternative monitoring method for lime addition. The owner or operator of a lime-coated fabric filter that employs intermittent or noncontinuous lime addition may apply to the department for approval of an alternative method for monitoring the lime addition schedule and rate based on monitoring the weight of lime added per ton of feed or charge for each operating cycle or time period used in the performance test. An alternative monitoring method may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis. NR 463.15(23)(23) Alternative monitoring methods. If an owner or operator wishes to use an alternative monitoring method to demonstrate compliance with any emission standard in this subchapter, other than those alternative monitoring methods which may be authorized pursuant to subs. (10) (e) and (22), the owner or operator may submit an application to the department. Any application shall be processed according to the criteria and procedures in pars. (a) to (f). NR 463.15(23)(a)(a) The department may not approve averaging periods other than those specified in this section. NR 463.15(23)(b)(b) The owner or operator shall continue to use the original monitoring requirement until necessary data are submitted and approval is received to use another monitoring procedure. NR 463.15(23)(c)(c) The owner or operator shall submit the application for approval of alternate monitoring methods no later than the notification of the performance test. The application shall contain all the information specified in subds. 1. to 3.: NR 463.15(23)(c)1.1. Data or information justifying the request, such as the technical or economic infeasibility, or the impracticality of using the required approach. NR 463.15(23)(c)2.2. A description of the proposed alternative monitoring requirements, including the operating parameters to be monitored, the monitoring approach and technique, and how the limit is to be calculated. NR 463.15(23)(c)3.3. Data and information documenting that the alternative monitoring requirements would provide equivalent or better assurance of compliance with the relevant emission standards. NR 463.15(23)(d)(d) The department may not approve an alternate monitoring application unless it would provide equivalent or better assurance of compliance with the relevant emission standards. Before disapproving any alternate monitoring application, the department shall provide both of the following: NR 463.15(23)(d)1.1. Notice of the information and findings upon which the intended disapproval is based. NR 463.15(23)(d)2.2. Notice of opportunity for the owner or operator to present additional supporting information before final action is taken on the application. This notice shall specify how much additional time is allowed for the owner or operator to provide additional supporting information. NR 463.15(23)(e)(e) The owner or operator is responsible for submitting any supporting information in a timely manner to enable the department to consider the application prior to the performance test. Neither submittal of an application nor the department’s failure to approve or disapprove the application relieves the owner or operator of the responsibility to comply with any provisions of this subchapter. NR 463.15(23)(f)(f) The department may decide at any time, on a case-by-case basis, that additional or alternative operating limits, or alternative approaches to establishing operating limits, are necessary to demonstrate compliance with the emission standards of this subchapter. NR 463.15 HistoryHistory: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; corrections in (11) (b), (14) (b) and (18) (b) made under s. 13.92 (4) (b) 7., Stats., Register December 2008 No. 636. NR 463.16NR 463.16 Performance test and compliance demonstration general requirements. NR 463.16(1)(1) Site-specific test plan. Prior to conducting any performance test required by this subchapter, the owner or operator shall prepare a site-specific test plan which satisfies all of the requirements of this section, and shall obtain review and evaluation of the plan by the department pursuant to the procedures in s. NR 460.06. NR 463.16(2)(a)(a) Following the review and evaluation of the site-specific test plan, the owner or operator shall demonstrate initial compliance with each applicable emission, equipment, work practice or operational standard for each affected source and emission unit, and report the results in the notification of compliance status report as described in s. NR 463.17 (2). The owner or operator of any existing affected source for which an initial performance test is required to demonstrate compliance shall conduct this initial performance test no later than the date for compliance established by s. NR 463.115 (1). The owner or operator of any new affected source for which an initial performance test is required shall conduct this initial performance test within 90 days after the date for compliance established by s. NR 463.115 (2). Except for the date by which the performance test shall be conducted, the owner or operator shall conduct each performance test in accordance with the requirements and procedures in s. NR 460.06 (2). Owners or operators of affected sources located at facilities which are area sources are subject only to those performance testing requirements pertaining to D&F. Owners or operators of sweat furnaces meeting the specifications of s. NR 463.13 (6) are not required to conduct a performance test. NR 463.16(2)(b)(b) The owner or operator shall conduct each test while the affected source or emission unit is operating at the highest production level with charge materials representative of the range of materials processed by the unit and, if applicable, at the highest reactive fluxing rate. NR 463.16(2)(c)(c) Each performance test for a continuous process shall consist of 3 separate runs; pollutant sampling for each run shall be conducted for the time period specified in the applicable method or, in the absence of a specific time period in the test method, for a minimum of 3 hours. NR 463.16(2)(d)(d) Each performance test for a batch process shall consist of 3 separate runs; pollutant sampling for each run shall be conducted over the entire process operating cycle. NR 463.16(2)(e)(e) Where multiple affected sources or emission units are exhausted through a common stack, pollutant sampling for each run shall be conducted over a period of time during which all affected sources or emission units complete at least one entire process operating cycle or for 24 hours, whichever is shorter. NR 463.16(2)(f)(f) Initial compliance with an applicable emission limit or standard is demonstrated if the average of 3 runs conducted during the performance test is less than or equal to the applicable emission limit or standard. NR 463.16(3)(3) Test methods. The owner or operator shall use the following methods in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04 (13), to determine compliance with the applicable emission limits or standards: NR 463.16(3)(i)(i) Method 26A for the concentration of HCl. Where a lime-injected fabric filter is used as the control device to comply with the 90% reduction standard, the owner or operator shall measure the fabric filter inlet concentration of HCl at a point before lime is introduced to the system. NR 463.16(4)(4) Alternative methods. The owner or operator may use an alternative test method, subject to approval by the department. NR 463.16(5)(5) Repeat tests. The owner or operator of new or existing affected sources and emission units located at secondary aluminum production facilities that are major sources shall conduct a performance test every 5 years following the initial performance test. NR 463.16(6)(6) Testing of representative emission units. With the prior approval of the department, an owner or operator may utilize emission rates obtained by testing a particular type of group 1 furnace which is not controlled by any add-on control device, or by testing an in-line flux box which is not controlled by any add-on control device, to determine the emission rate for other units of the same type at the same facility. Emission test results may only be considered to be representative of other units if all of the following criteria are satisfied:
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Chs. NR 400-499; Environmental Protection – Air Pollution Control
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