Chapter NR 463

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 History History: 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 463.16 NR 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) (2) initial performance test.

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)(a) (a) Method 1 for sample and velocity traverses.

NR 463.16(3)(b) (b) Method 2 for velocity and volumetric flow rate.

NR 463.16(3)(c) (c) Method 3 for gas analysis.

NR 463.16(3)(d) (d) Method 4 for moisture content of the stack gas.

NR 463.16(3)(e) (e) Method 5 for the concentration of PM.

NR 463.16(3)(f) (f) Method 9 for visible emission observations.

NR 463.16(3)(g) (g) Method 23 for the concentration of D&F.

NR 463.16(3)(h) (h) Method 25A for the concentration of THC, as propane.

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:

NR 463.16(6)(a) (a) The tested emission unit uses feed materials and charge rates which are comparable to the emission units that it represents.

NR 463.16(6)(b) (b) The tested emission unit uses the same type of flux materials in the same proportions as the emission units it represents.

NR 463.16(6)(c) (c) The tested emission unit is operated utilizing the same work practices as the emission units that it represents.

NR 463.16(6)(d) (d) The tested emission unit is of the same design as the emission units that it represents.

NR 463.16(6)(e) (e) The tested emission unit is tested under the highest load or capacity reasonably expected to occur for any of the emission units that it represents.

NR 463.16(7) (7) Establishment of monitoring and operating parameter values. The owner or operator of new or existing affected sources and emission units shall establish a minimum or maximum operating parameter value, or an operating parameter range, for each parameter to be monitored as required by s. NR 463.15 that ensures compliance with the applicable emission limit or standard. To establish the minimum or maximum value or range, the owner or operator shall use the appropriate procedures in this section and submit the information required by s. NR 463.17 (2) (d) in the notification of compliance status report. The owner or operator may use existing data in addition to the results of performance tests to establish operating parameter values for compliance monitoring provided each of the following conditions are met to the satisfaction of the department:

NR 463.16(7)(a) (a) The complete emission test report used as the basis of the parameter or parameters is submitted.

NR 463.16(7)(b) (b) The same test methods and procedures as required by this subchapter were used in the test.

NR 463.16(7)(c) (c) The owner or operator certifies that no design or work practice changes have been made to the source, process or emission control equipment since the time of the report.

NR 463.16(7)(d) (d) All process and control equipment operating parameters required to be monitored were monitored as required in this subchapter and documented in the test report.

NR 463.16(8) (8) Testing of commonly-ducted units within a secondary aluminum processing unit. When group 1 furnaces and in-line fluxers are included in a single existing SAPU or new SAPU, and the emissions from more than one emission unit within that existing SAPU or new SAPU are manifolded to a single control device, compliance for all units within the SAPU is demonstrated if the total measured emissions from all controlled and uncontrolled units in the SAPU do not exceed the emission limits calculated for that SAPU based on the applicable equation in s. NR 463.13 (11).

NR 463.16(9) (9) Testing of commonly-ducted units not within a secondary aluminum processing unit. With the prior approval of the department, an owner or operator may do combined performance testing of 2 or more individual affected sources or emission units which are not included in a single existing SAPU or new SAPU, but whose emissions are manifolded to a single control device. Any performance testing of commonly-ducted units shall satisfy all the following basic requirements:

NR 463.16(9)(a) (a) All testing shall be designed to verify that each affected source or emission unit individually satisfies all emission requirements applicable to that affected source or emission unit.

NR 463.16(9)(b) (b) All emissions of pollutants subject to a standard shall be tested at the outlet from each individual affected source or emission unit while operating under the highest load or capacity reasonably expected to occur, and prior to the point that the emissions are manifolded together with emissions from other affected sources or emission units.

NR 463.16(9)(c) (c) The combined emissions from all affected sources and emission units which are manifolded to a single emission control device shall be tested at the outlet of the emission control device.

NR 463.16(9)(d) (d) All tests at the outlet of the emission control device shall be conducted with all affected sources and emission units whose emissions are manifolded to the control device operating simultaneously under the highest load or capacity reasonably expected to occur.

NR 463.16(9)(e) (e) For purposes of demonstrating compliance of a commonly-ducted unit with any emission limit for a particular type of pollutant, the emissions of that pollutant by the individual unit shall be presumed to be controlled by the same percentage as total emissions of that pollutant from all commonly-ducted units are controlled at the outlet of the emission control device.

NR 463.16 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; correction in (2) (a) made under s. 13.92 (4) (b) 7., Stats., Register December 2008 No. 636.

NR 463.163 NR 463.163 Performance test and compliance demonstration requirements and procedures.

NR 463.163(1) (1) Aluminum scrap shredder. The owner or operator shall conduct performance tests to measure PM emissions at the outlet of the control system. If visible emission observations is the selected monitoring option, the owner or operator shall record visible emission observations from each exhaust stack for all consecutive 6-minute periods during the PM emission test according to the requirements of Method 9 in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04 (13).

NR 463.163(2) (2) Thermal chip dryer. The owner or operator shall conduct a performance test to measure THC and D&F emissions at the outlet of the control device while the unit processes only unpainted aluminum chips.

NR 463.163(3) (3) Scrap dryer, delacquering kiln and decoating kiln.

NR 463.163(3)(a) (a) The owner or operator shall conduct performance tests to measure emissions of THC, D&F, HCl and PM at the outlet of the control device.

NR 463.163(3)(b) (b) If the scrap dryer, delacquering kiln or decoating kiln is subject to the alternative emission limits in s. NR 463.13 (5), the average afterburner operating temperature in each 3-hour block period shall be maintained at or above 760°C (1400°F) for the test.

NR 463.163(3)(c) (c) The owner or operator of a scrap dryer, delacquering kiln or decoating kiln subject to the alternative limits in s. NR 463.13 (5) shall submit a written certification in the notification of compliance status report containing the information required by s. NR 463.17 (2) (g).

NR 463.163(4) (4) Group 1 furnace with add-on air pollution control devices.

NR 463.163(4)(a) (a) The owner or operator of a group 1 furnace that processes scrap other than clean charge materials with emissions controlled by a lime-injected fabric filter shall conduct performance tests to measure emissions of PM and D&F at the outlet of the control device and emissions of HCl at the outlet, for the emission limit, or the inlet and the outlet, for the percent reduction standard.

NR 463.163(4)(b) (b) The owner or operator of a group 1 furnace that processes only clean charge materials with emissions controlled by a lime-injected fabric filter shall conduct performance tests to measure emissions of PM at the outlet of the control device and emissions of HCl at the outlet, for the emission limit, or the inlet and the outlet, for the percent reduction standard.

NR 463.163(4)(c) (c) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux added to the group 1 furnace is emitted. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl.

NR 463.163(4)(d) (d) 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 conduct the performance tests required by par. (a) or (b), to measure emissions from both the sidewell and the hearth.

NR 463.163(5) (5) Group 1 furnace, including melting and holding furnaces, without add-on air pollution control devices.

NR 463.163(5)(a) (a) In the site-specific monitoring plan required by s. NR 463.15 (15), the owner or operator of a group 1 furnace, including a melting and holding furnace, without add-on air pollution control devices shall include data and information demonstrating compliance with the applicable emission limits.

NR 463.163(5)(b) (b) If the group 1 furnace processes material other than clean charge, the owner or operator shall conduct emission tests to measure emissions of PM, HCl and D&F at the furnace exhaust outlet.

NR 463.163(5)(c) (c) If the group 1 furnace processes only clean charge, the owner or operator shall conduct emission tests to simultaneously measure emissions of PM and HCl at the furnace exhaust outlet. A D&F test is not required. Each test shall be conducted while the group 1 furnace, including a melting and holding furnace, processes only clean charge.

NR 463.163(5)(d) (d) The owner or operator may choose to determine the rate of reactive flux addition to the group 1 furnace and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all reactive flux added to the group 1 furnace is emitted. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl.

NR 463.163(6) (6) Sweat furnace. The owner or operator shall measure emissions of D&F from each sweat furnace at the outlet of the control device except that the owner or operator is not required to conduct a performance test to demonstrate compliance with the emission standard of s. NR 463.13 (6), provided that, on and after the compliance date established by s. NR 463.115, 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 463.163(7) (7) Dross-only furnace. The owner or operator shall conduct a performance test to measure emissions of PM from each dross-only furnace at the outlet of each control device while the unit processes only dross and salt flux as the sole feedstock.

NR 463.163(8) (8) In-line fluxer.

NR 463.163(8)(a) (a) The owner or operator of an in-line fluxer that uses reactive flux materials shall conduct a performance test to measure emissions of HCl and PM or otherwise demonstrate compliance in accordance with par. (b). If the in-line fluxer is equipped with an add-on control device, the emissions shall be measured at the outlet of the control device.

NR 463.163(8)(b) (b) The owner or operator may choose to limit the rate at which reactive chlorine flux is added to an in-line fluxer and assume, for the purposes of demonstrating compliance with the SAPU emission limit, that all chlorine in the reactive flux added to the in-line fluxer is emitted as HCl. Under these circumstances, the owner or operator is not required to conduct an emission test for HCl. If the owner or operator of any in-line flux box which has no ventilation ductwork manifolded to any outlet or emission control device chooses to demonstrate compliance with the emission limit for HCl by limiting use of reactive chlorine flux and assuming that all chlorine in the flux is emitted as HCl, compliance with the HCl limit shall also constitute compliance with the emission limit for PM, and no separate emission test for PM is required. In this case, the owner or operator of the unvented in-line flux box shall utilize the maximum permissible PM emission rate for the in-line flux boxes when determining the total emissions for any SAPU which includes the flux box.

NR 463.163(9) (9) Rotary dross cooler. The owner or operator shall conduct a performance test to measure PM emissions from a rotary dross cooler at the outlet of the control device.

NR 463.163(10) (10) Secondary aluminum processing unit. The owner or operator shall conduct performance tests as described in pars. (a) to (c). The results of the performance tests shall be used to establish emission rates in lb/ton of feed or charge for PM and HCl and mg TEQ/Mg of feed or charge for D&F emissions from each emission unit. These emission rates shall be used for compliance monitoring in the calculation of the 3-day, 24-hour rolling average emission rates using the equation in s. NR 463.15 (20). A performance test is required for:

NR 463.163(10)(a) (a) Each group 1 furnace processing only clean charge to measure emissions of PM and either of the following:

NR 463.163(10)(a)1. 1. Emissions of HCl, for the emission limit.

NR 463.163(10)(a)2. 2. The mass flow rate of HCl at the inlet to and outlet from the control device, for the percent reduction standard.

NR 463.163(10)(b) (b) Each group 1 furnace that processes scrap other than clean charge to measure emissions of PM and D&F and either of the following:

NR 463.163(10)(b)1. 1. Emissions of HCl, for the emission limit.

NR 463.163(10)(b)2. 2. The mass flow rate of HCl at the inlet to and outlet from the control device, for the percent reduction standard.

NR 463.163(10)(c) (c) Each in-line fluxer to measure emissions of PM and HCl.

NR 463.163(11) (11) Feed or charge weight measurement. During the emission tests conducted to determine compliance with emission limits in a kg/Mg (lb/ton) format, the owner or operator of an affected source or emission unit, subject to an emission limit in a kg/Mg (lb/ton) of feed or charge format, shall measure, or otherwise determine, and record the total weight of feed or charge to the affected source or emission unit for each of the 3 test runs and calculate and record the total weight. An owner or operator that chooses to demonstrate compliance on the basis of the aluminum production weight shall measure the weight of aluminum produced by the emission unit or affected source instead of the feed or charge weight.

NR 463.163(12) (12) Continuous opacity monitoring system. The owner or operator of an affected source or emission unit using a continuous opacity monitoring system shall conduct a performance evaluation to demonstrate compliance with Performance Specification 1 in Appendix B to 40 CFR part 60, incorporated by reference in s. NR 484.04 (21). Following the performance evaluation, the owner or operator shall measure and record the opacity of emissions from each exhaust stack for all consecutive 6-minute periods during the PM emission test.

NR 463.163(13) (13) Afterburner. The owner or operator of an affected source using an afterburner to comply with the requirements of this subchapter shall do both of the following:

NR 463.163(13)(a) (a) Prior to the initial performance test, the owner or operator shall conduct a performance evaluation for the temperature monitoring device according to the requirements of s. NR 460.07.

NR 463.163(13)(b) (b) The owner or operator shall use the following procedures to establish an operating parameter value or range for the afterburner operating temperature:

NR 463.163(13)(b)1. 1. Continuously measure and record the operating temperature of each afterburner every 15 minutes during the THC and D&F performance tests.

NR 463.163(13)(b)2. 2. Determine and record the 15-minute block average temperatures for the 3 test runs.

NR 463.163(13)(b)3. 3. Determine and record the 3-hour block average temperature measurements for the 3 test runs.

NR 463.163(14) (14) Inlet gas temperature. The owner or operator of a scrap dryer, delacquering kiln or decoating kiln or a group 1 furnace using a lime-injected fabric filter shall use the following procedures to establish an operating parameter value or range for the inlet gas temperature:

NR 463.163(14)(a) (a) Continuously measure and record the temperature at the inlet to the lime-injected fabric filter every 15 minutes during the HCl and D&F performance tests.