Chapter NR 463

NR 463.17(2)(i) (i) The operation, maintenance and monitoring (OM&M) plan, including site-specific monitoring plan for each group 1 furnace with no add-on air pollution control device.

NR 463.17(2)(j) (j) Startup, shutdown and malfunction plan, with revisions.

NR 463.17 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; correction in (1) (b) made under s. 13.92 (4) (b) 7., Stats., Register December 2008 No. 636.

NR 463.18 NR 463.18 Reports.

NR 463.18(1) (1) Startup, shutdown and malfunction plan and reports. The owner or operator shall develop a written plan as described in s. NR 460.05 (4) (c) that contains specific procedures to be followed for operating and maintaining the source during periods of startup, shutdown and malfunction, and a program of corrective action for malfunctioning process and air pollution control equipment used to comply with the standard. The owner or operator shall also keep records of each event as required by s. NR 460.09 (2) and record and report if an action taken during a startup, shutdown or malfunction is not consistent with the procedures in the plan as described in s. NR 460.05 (4) (c). In addition to the information required in s. NR 460.05 (4) (c), the plan shall include both of the following:

NR 463.18(1)(a) (a) Procedures to determine and record the cause of the malfunction and the time the malfunction began and ended.

NR 463.18(1)(b) (b) Corrective actions to be taken in the event of a malfunction of a process or control device, including procedures for recording the actions taken to correct the malfunction or minimize emissions.

NR 463.18(2) (2) Excess emissions and summary report. The owner or operator shall submit semiannual reports according to the requirements in s. NR 460.09 (5) (c), except that the semiannual reports shall be submitted within 60 days after the end of each 6-month period instead of within 30 days after the calendar half as specified in s. NR 460.09 (5) (c) 5. When no deviations of parameters have occurred, the owner or operator shall submit a report stating that no excess emissions occurred during the reporting period. Reports shall be submitted in accordance with all of the following:

NR 463.18(2)(a) (a) A report shall be submitted if any of the following conditions occur during a 6-month reporting period:

NR 463.18(2)(a)1. 1. The corrective action specified in the operation, maintenance and monitoring (OM&M) plan for a bag leak detection system alarm was not initiated within one hour.

NR 463.18(2)(a)2. 2. The corrective action specified in the OM&M plan for a continuous opacity monitoring deviation was not initiated within one hour.

NR 463.18(2)(a)3. 3. The corrective action specified in the OM&M plan for visible emissions from an aluminum scrap shredder was not initiated within one hour.

NR 463.18(2)(a)4. 4. An excursion of a compliant process or operating parameter value or range, including lime injection rate or screw feeder setting, total reactive chlorine flux injection rate, afterburner operating temperature, fabric filter inlet temperature, definition of acceptable scrap or other approved operating parameter.

NR 463.18(2)(a)5. 5. An action taken during a startup, shutdown or malfunction was not consistent with the procedures in the plan as described in s. NR 460.05 (4) (c).

NR 463.18(2)(a)6. 6. An affected source, including an emission unit in a secondary aluminum processing unit, was not operated according to the requirements of this subchapter.

NR 463.18(2)(a)7. 7. A deviation from the 3-day, 24-hour rolling average emission limit for a secondary aluminum processing unit.

NR 463.18(2)(b) (b) Each report shall include each of these certifications, as applicable:

NR 463.18(2)(b)1. 1. For each thermal chip dryer: “Only unpainted aluminum chips were used as feedstock in any thermal chip dryer during this reporting period.”

NR 463.18(2)(b)2. 2. For each dross-only furnace: “Only dross and salt flux were used as the charge material in any dross-only furnace during this reporting period.”

NR 463.18(2)(b)3. 3. For each sidewell group 1 furnace with add-on air pollution control devices: “Each furnace was operated such that the level of molten metal remained above the top of the passage between the sidewell and hearth during reactive fluxing, and reactive flux, except for cover flux, was added only to the sidewell or to a furnace hearth equipped with an add-on air pollution control device for PM, HCl, and D&F emissions during this reporting period.”

NR 463.18(2)(b)4. 4. For each group 1 melting and holding furnace without add-on air pollution control devices and using pollution prevention measures that processes only clean charge material: “Each group 1 furnace without add-on air pollution control devices subject to emission limits in s. NR 463.13 (9) (b) processed only clean charge during this reporting period.”

NR 463.18(2)(b)5. 5. For each group 2 furnace: “Only clean charge materials were processed in any group 2 furnace during this reporting period, and no fluxing was performed or all fluxing performed was conducted using only nonreactive, non-HAP-containing and non-HAP-generating fluxing gases or agents, except for cover fluxes, during this reporting period.”

NR 463.18(2)(b)6. 6. For each in-line fluxer using no reactive flux: “Only nonreactive, non-HAP-containing, non-HAP-generating flux gases, agents, or materials were used at any time during this reporting period.”

NR 463.18(2)(c) (c) The owner or operator shall submit the results of any performance test conducted during the reporting period, including one complete report documenting test methods and procedures, process operation and monitoring parameter ranges or values for each test method used for a particular type of emission point tested.

NR 463.18(3) (3) Annual compliance certifications. For the purpose of annual certifications of compliance required by s. NR 439.03 (1) (c), the owner or operator shall certify continuing compliance based upon, but not limited to, both of the following conditions:

NR 463.18(3)(a) (a) Any and all periods of excess emissions, as defined in sub. (2) (a), that occurred during the year were reported.

NR 463.18(3)(b) (b) All monitoring, recordkeeping and reporting requirements were met during the year.

NR 463.18 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09.

NR 463.19 NR 463.19 Records.

NR 463.19(1) (1) 

NR 463.19(1)(a) (a) The owner or operator shall maintain files of all information, including all reports and notifications, required by s. NR 460.09 (2) and this subchapter.

NR 463.19(1)(b) (b) The owner or operator shall retain each record for at least 5 years following the date of each occurrence, measurement, maintenance, corrective action, report or record. The most recent 2 years of records shall be retained at the facility. The remaining 3 years of records may be retained off site.

NR 463.19(1)(c) (c) The owner or operator may retain records on microfilm, computer disks, magnetic tape or microfiche.

NR 463.19(1)(d) (d) The owner or operator may report required information on paper or on a labeled computer disk using commonly available and department compatible computer software.

NR 463.19(2) (2) In addition to the general records required by s. NR 460.09 (2), the owner or operator of a new or existing affected source, including an emission unit in a secondary aluminum processing unit, shall maintain records of all of the following:

NR 463.19(2)(a) (a) For each affected source and emission unit with emissions controlled by a fabric filter or a lime-injected fabric filter each of the following as applicable:

NR 463.19(2)(a)1. 1. If a bag leak detection system is used, the number of total operating hours for the affected source or emission unit during each 6-month reporting period, records of each alarm, the time of the alarm, the time corrective action was initiated and completed and a brief description of the cause of the alarm and the corrective actions taken.

NR 463.19(2)(a)2. 2. If a continuous opacity monitoring system is used, records of opacity measurement data, including records where the average opacity of any 6-minute period exceeds 5%, with a brief explanation of the cause of the emissions, the time the emissions occurred, the time corrective action was initiated and completed and the corrective action taken.

NR 463.19(2)(a)3. 3. If an aluminum scrap shredder is subject to visible emission observation requirements, records of all observations made using Method 9 in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04 (13), including records of any visible emissions during a 30-minute daily test, with a brief explanation of the cause of the emissions, the time the emissions occurred, the time corrective action was initiated and completed and the corrective action taken.

NR 463.19(2)(b) (b) For each affected source with emissions controlled by an afterburner, both of the following:

NR 463.19(2)(b)1. 1. Records of 15-minute block average afterburner operating temperature, including any period when the average temperature in any 3-hour block period falls below the compliant operating parameter value with a brief explanation of the cause of the excursion and the corrective action taken.

NR 463.19(2)(b)2. 2. Records of annual afterburner inspections.

NR 463.19(2)(c) (c) For each scrap dryer, delacquering kiln or decoating kiln and group 1 furnace, subject to D&F and HCl emission standards with emissions controlled by a lime-injected fabric filter, records of 15-minute block average inlet temperatures for each lime-injected fabric filter, including any period when the 3-hour block average temperature exceeds the compliant operating parameter value +14°C (+25°F), with a brief explanation of the cause of the excursion and the corrective action taken.

NR 463.19(2)(d) (d) For each affected source and emission unit with emissions controlled by a lime-injected fabric filter, the requirements in subd. 1. and either subd. 2. or 3.:

NR 463.19(2)(d)1. 1. Records of inspections at least once every 8-hour period verifying that lime is present in the feeder hopper or silo and flowing, including any inspection where blockage is found, with a brief explanation of the cause of the blockage and the corrective action taken, and records of inspections at least once every 4-hour period for the subsequent 3 days. If flow monitors, pressure drop sensors or load cells are used to verify that lime is present in the hopper and flowing, records of all monitor or sensor output including any event where blockage was found, with a brief explanation of the cause of the blockage and the corrective action taken.

NR 463.19(2)(d)2. 2. If the lime feeder setting is monitored, records of daily inspections of feeder setting, including records of any deviation of the feeder setting from the setting used in the performance test, with a brief explanation of the cause of the deviation and the corrective action taken.

NR 463.19(2)(d)3. 3. If the lime addition rate for a noncontinuous lime injection system is monitored pursuant to the approved alternative monitoring requirements in s. NR 463.15 (22), records of the time and mass of each lime addition during each operating cycle or time period used in the performance test and calculations of the average lime addition rate in lb/ton of feed or charge.

NR 463.19(2)(e) (e) For each group 1 furnace, with or without add-on air pollution control devices, or in-line fluxer, records of 15-minute block average weights of gaseous or liquid reactive flux injection, total reactive flux injection rate and calculations, including records of the identity, composition and weight of each addition of gaseous, liquid or solid reactive flux, including records of any period the rate exceeds the compliant operating parameter value and corrective action taken.

NR 463.19(2)(f) (f) For each continuous monitoring system, records required by s. NR 460.09 (3).

NR 463.19(2)(g) (g) For each affected source and emission unit subject to an emission standard in kg/Mg (lb/ton) of feed or charge, records of feed or charge, or throughput, weights for each operating cycle or time period used in the performance test.

NR 463.19(2)(h) (h) Approved site-specific monitoring plan for a group 1 furnace without add-on air pollution control devices with records documenting conformance with the plan.

NR 463.19(2)(i) (i) Records of all charge materials for each thermal chip dryer, dross-only furnace, and group 1 melting and holding furnaces without air pollution control devices processing only clean charge.

NR 463.19(2)(j) (j) Operating logs for each group 1 sidewell furnace with add-on air pollution control devices documenting conformance with operating standards for maintaining the level of molten metal above the top of the passage between the sidewell and hearth during reactive flux injection and for adding reactive flux only to the sidewell or a furnace hearth equipped with a control device for PM, HCl and D&F emissions.

NR 463.19(2)(k) (k) For each in-line fluxer for which the owner or operator has certified that no reactive flux was used, one of the following:

NR 463.19(2)(k)1. 1. Operating logs which establish that no source of reactive flux was present at the in-line fluxer.

NR 463.19(2)(k)2. 2. Labels required pursuant to s. NR 463.14 (2) which establish that no reactive flux may be used at the in-line fluxer.

NR 463.19(2)(k)3. 3. Operating logs which document each flux gas, agent or material used during each operating cycle.

NR 463.19(2)(L) (L) Records of all charge materials and fluxing materials or agents for a group 2 furnace.

NR 463.19(2)(m) (m) Records of monthly inspections for proper unit labeling for each affected source and emission unit subject to labeling requirements.

NR 463.19(2)(n) (n) Records of annual inspections of emission capture and collection and closed vent systems.

NR 463.19(2)(o) (o) Records for any approved alternative monitoring or test procedure.

NR 463.19(2)(p) (p) Current copy of all required plans, including any revisions, with records documenting conformance with the applicable plan, including all of the following:

NR 463.19(2)(p)1. 1. Startup, shutdown and malfunction plan.

NR 463.19(2)(p)2. 2. Operation, maintenance and monitoring (OM&M) plan.

NR 463.19(2)(p)3. 3. Site-specific secondary aluminum processing unit emission plan, if applicable.

NR 463.19(2)(q) (q) For each secondary aluminum processing unit, records of total charge weight, or if the owner or operator chooses to comply on the basis of aluminum production, total aluminum produced for each 24-hour period and calculations of 3-day, 24-hour rolling average emissions.

NR 463.19 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09.

NR 463.20 NR 463.20 Applicability of general provisions. The requirements of the general provisions in ch. NR 460 that are applicable to the owner or operator subject to the requirements of this subchapter are shown in ch. NR 460 Appendix RRR.

NR 463.20 History History: CR 04-023: cr. Register December 2008 No. 636, eff. 1-1-09; correction made under s. 13.92 (4) (b) 1., Stats., Register December 2008 No. 636; correction made under s. 35.17, Stats., Register June 2015 No. 714.

subch. III of ch. NR 463 Subchapter III — Iron and Steel Foundries

NR 463.21 NR 463.21 What this subchapter covers.

NR 463.21(1) (1) What is the purpose of this subchapter? This subchapter establishes national emission standards for hazardous air pollutants (NESHAP) for iron and steel foundries. This subchapter also establishes requirements to demonstrate initial and continuous compliance with the emissions limitations, work practice standards and operation and maintenance requirements in this subchapter.

NR 463.21(2) (2) Am I subject to this subchapter? You are subject to this subchapter if you own or operate an iron and steel foundry that is, or is part of, a major source of hazardous air pollutant (HAP) emissions. Your iron and steel foundry is a major source of HAP for purposes of this subchapter if it emits or has the potential to emit any single HAP at a rate of 10 tons or more per year or any combination of HAP at a rate of 25 tons or more per year or if it is located at a facility that emits or has the potential to emit any single HAP at a rate of 10 tons or more per year or any combination of HAP at a rate of 25 tons or more per year.

NR 463.21(3) (3) What parts of my foundry does this subchapter cover?

NR 463.21(3)(a) (a) The affected source is a new or existing iron and steel foundry.

NR 463.21(3)(b) (b) This subchapter covers emissions from metal melting furnaces, scrap pre-heaters, pouring areas, pouring stations, automated conveyor and pallet cooling lines, automated shakeout lines and mold and core making lines. This subchapter also covers fugitive emissions from foundry operations.

NR 463.21(3)(c) (c) An affected source is existing if you commenced construction or reconstruction of the affected source before December 23, 2002.

NR 463.21(3)(d) (d) An affected source is new if you commenced construction or reconstruction of the affected source on or after December 23, 2002. An affected source is reconstructed if it meets the definition of “reconstruction’’ in s. NR 463.22.

NR 463.21(4) (4) When do I have to comply with this subchapter?

NR 463.21(4)(a) (a) Except as specified in par. (b), if you have an existing affected source, you shall comply with each emissions limitation, work practice standard and operation and maintenance requirement in this subchapter that applies to you no later than April 23, 2007. Major source status for existing affected sources shall be determined no later than April 23, 2007.

NR 463.21(4)(b) (b) If you have an existing affected source, you shall comply with the work practice standards in s. NR 463.23 (2) (b) or (c), as applicable, no later than April 22, 2005.

NR 463.21(4)(c) (c) If you have a new affected source for which the initial startup date is on or before April 22, 2004, you shall comply with each emissions limitation, work practice standard and operation and maintenance requirement in this subchapter that applies to you by April 22, 2004.

NR 463.21(4)(d) (d) If you have a new affected source for which the initial startup date is after April 22, 2004, you shall comply with each emissions limitation, work practice standard and operation and maintenance requirement in this subchapter that applies to you upon initial startup.

NR 463.21(4)(e) (e) If your iron and steel foundry is an area source that becomes a major source of HAP, you shall meet the requirements of s. NR 460.05 (3) (c).

NR 463.21(4)(f) (f) You shall meet the notification and schedule requirements in s. NR 463.27 (1).

NR 463.21 Note Note: Several of these notifications must be submitted before the compliance date for your affected source.

NR 463.21 History History: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07.

NR 463.22 NR 463.22 What definitions apply to this subchapter? For terms not defined in this section, the definitions contained in chs. NR 400 and 460 apply to the terms in this subchapter, with definitions in ch. NR 460 taking precedence over definitions in ch. NR 400. 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. In this subchapter:

NR 463.22(1) (1) “Automated conveyor and pallet cooling line” means any dedicated conveyor line or area used for cooling molds received from pouring stations.