Chapter NR 463

NR 463.25(4)(f) (f) You may use a previous performance test conducted since December 22, 2002 to establish an operating limit, provided the test meets the requirements of this subchapter.

NR 463.25(5) (5) How do I demonstrate initial compliance with the emission limitations that apply to me?

NR 463.25(5)(a) (a) You have demonstrated initial compliance with the emissions limits in s. NR 463.23 (1) (a) if you do the following, as applicable:

NR 463.25(5)(a)1. 1. For each electric arc metal melting furnace, electric induction metal melting furnace, or scrap preheater at an existing iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)1.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.005 gr/dscf.

NR 463.25(5)(a)1.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0004 gr/dscf.

NR 463.25(5)(a)2. 2. For each cupola metal melting furnace at an existing iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)2.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.006 gr/dscf.

NR 463.25(5)(a)2.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0005 gr/dscf.

NR 463.25(5)(a)3. 3. For each cupola metal melting furnace or electric arc metal melting furnace at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)3.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.002 gr/dscf.

NR 463.25(5)(a)3.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0002 gr/dscf.

NR 463.25(5)(a)4. 4. For each electric induction metal melting furnace or scrap preheater at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)4.a. a. The average PM concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (a), did not exceed 0.001 gr/dscf.

NR 463.25(5)(a)4.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.00008 gr/dscf.

NR 463.25(5)(a)5. 5. For each pouring station at an existing iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)5.a. a. The average PM concentration in the exhaust stream, measured according to the performance test procedures in sub. (3) (a), did not exceed 0.010 gr/dscf.

NR 463.25(5)(a)5.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0008 gr/dscf.

NR 463.25(5)(a)6. 6. For each pouring area or pouring station at a new iron and steel foundry you demonstrate one of the following:

NR 463.25(5)(a)6.a. a. The average PM concentration in the exhaust stream, measured according to the performance test procedures in sub. (3) (a), did not exceed 0.002 gr/dscf.

NR 463.25(5)(a)6.b. b. The average total metal HAP concentration in the exhaust stream, determined according to the performance test procedures in sub. (3) (b), did not exceed 0.0002 gr/dscf.

NR 463.25(5)(a)7. 7. For each building or structure housing any emission source at the iron and steel foundry, the opacity of fugitive emissions discharged to the atmosphere, determined according to the performance test procedures in sub. (3) (c), did not exceed 20% averaged over 6-minutes, except for one 6-minute average per hour that did not exceed 27% opacity.

NR 463.25(5)(a)8. 8. For each cupola metal melting furnace at a new or existing iron and steel foundry, the average VOHAP concentration, determined according to the performance test procedures in sub. (3) (d), did not exceed 20 ppmv corrected to 10% oxygen.

NR 463.25(5)(a)9. 9. For each scrap preheater at an existing iron and steel foundry that does not meet the work practice standards in s. NR 463.23 (2) (e) 1. or 2., and for each scrap preheater at a new iron and steel foundry that does not meet the work practice standard in s. NR 463.23 (2) (f), the average VOHAP concentration determined according to the performance test procedures in sub. (3) (d), did not exceed 20 ppmv.

NR 463.25(5)(a)10. 10. For one or more automated conveyor and pallet cooling lines that use a sand mold system or automated shakeout lines that use a sand mold system at a new foundry you demonstrate both of the following:

NR 463.25(5)(a)10.a. a. You have reduced the data from the CEMS to 3-hour averages according to the performance test procedures in sub. (3) (e).

NR 463.25(5)(a)10.b. b. The 3-hour flow-weighted average VOHAP concentration, measured according to the performance test procedures in sub. (3) (e), did not exceed 20 ppmv.

NR 463.25(5)(a)11. 11. For each TEA cold box mold or core making line in a new or existing iron and steel foundry, the average TEA concentration, determined according to the performance test procedures in sub. (3) (f) did not exceed 1 ppmv or was reduced by 99%.

NR 463.25(5)(b) (b) You have demonstrated initial compliance with the operating limits in s. NR 463.23 (1) (b) if you do the following, as applicable:

NR 463.25(5)(b)1. 1. For each capture system subject to the operating limit in s. NR 463.23 (1) (b) 1. a., you have established appropriate site-specific operating limits in your operation and maintenance plan according to the requirements in s. NR 463.23 (3) (b) and have a record of the operating parameter data measured during the performance test in accordance with sub. (4) (a).

NR 463.25(5)(b)2. 2. For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2. for pressure drop and scrubber water flow rate, you have established appropriate site-specific operating limits and have a record of the pressure drop and scrubber water flow rate measured during the performance test in accordance with sub. (4) (b).

NR 463.25(5)(b)3. 3. For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 3. for combustion zone temperature, you have a record of the combustion zone temperature measured during the performance test in accordance with sub. (3) (d) 4.

NR 463.25(5)(b)4. 4. For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 4. for combustion zone temperature, you have established appropriate site-specific operating limits and have a record of the combustion zone temperature measured during the performance test in accordance with sub. (4) (c).

NR 463.25(5)(b)5. 5. For each acid wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5. for scrubbing liquid flow rate and scrubber blowdown pH, you satisfy both of the following:

NR 463.25(5)(b)5.a. a. You have established appropriate site-specific operating limits for the scrubbing liquid flow rate and have a record of the scrubbing liquid flow rate measured during the performance test in accordance with sub. (4) (d).

NR 463.25(5)(b)5.b. b. You have a record of the pH of the scrubbing liquid blowdown measured during the performance test in accordance with sub. (3) (g) 3.

NR 463.25(6) (6) How do I demonstrate initial compliance with the work practice standards that apply to me?

NR 463.25(6)(a) (a) For each iron and steel foundry subject to the certification requirement in s. NR 463.23 (2) (b), you have demonstrated initial compliance if you have certified in your notification of compliance status that: “At all times, your foundry will purchase and use only metal ingots, pig iron, slitter or other materials that do not include post-consumer automotive body scrap, post-consumer engine blocks, post-consumer oil filters, oily turnings, lead components, mercury switches, plastics or free organic liquids.”

NR 463.25(6)(b) (b) For each iron and steel foundry subject to the requirements in s. NR 463.23 (2) (c) for a scrap inspection and selection plan, you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status:

NR 463.25(6)(b)1. 1. That you have submitted a written plan to the department for approval according to the requirements in s. NR 463.23 (2) (c).

NR 463.25(6)(b)2. 2. That you will operate at all times according to the plan requirements.

NR 463.25(6)(c) (c) For each furan warm box mold or core making line in a new or existing foundry subject to the work practice standard in s. NR 463.23 (2) (d), you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status:

NR 463.25(6)(c)1. 1. That you will meet the no methanol requirement for the catalyst portion of each binder chemical formulation.

NR 463.25(6)(c)2. 2. That you have records documenting your certification of compliance, such as a material safety data sheet, provided that it contains appropriate information, a certified product data sheet or a manufacturer’s hazardous air pollutant data sheet, onsite and available for inspection.

NR 463.25(6)(d) (d) For each scrap preheater at an existing iron and steel foundry subject to the work practice standard in s. NR 463.23 (2) (e) 1. or 2., you have demonstrated initial compliance if you have certified one of the following in your notification of compliance status:

NR 463.25(6)(d)1. 1. That you have installed a gas-fired preheater where the flame directly contacts the scrap charged, you will operate and maintain each gas-fired scrap preheater so that the flame directly contacts the scrap charged and you have records documenting your certification of compliance that are onsite and available for inspection.

NR 463.25(6)(d)2. 2. That you will charge only material that is subject to and in compliance with the scrap certification requirements in s. NR 463.23 (2) (b) and you have records documenting your certification of compliance that are onsite and available for inspection.

NR 463.25(6)(e) (e) For each scrap preheater at a new iron and steel foundry subject to the work practice standard in s. NR 463.23 (2) (f), you have demonstrated initial compliance if you have certified in your notification of compliance status that you will charge only material that is subject to and in compliance with the scrap certification requirements in s. NR 463.23 (2) (b) and you have records documenting your certification of compliance that are onsite and available for inspection.

NR 463.25(7) (7) How do I demonstrate initial compliance with the operation and maintenance requirements that apply to me?

NR 463.25(7)(a) (a) For each capture system subject to an operating limit in s. NR 463.23 (1) (b), you have demonstrated initial compliance if you have done both of the following:

NR 463.25(7)(a)1. 1. Certified both of the following in your notification of compliance status:

NR 463.25(7)(a)1.a. a. That you have submitted the capture system operation and maintenance plan to the department for approval according to the requirements of s. NR 463.23 (3) (b).

NR 463.25(7)(a)1.b. b. That you will inspect, operate and maintain each capture system according to the procedures in the plan.

NR 463.25(7)(a)2. 2. Certified in your performance test report that the system operated during the test at the operating limits established in your operation and maintenance plan.

NR 463.25(7)(b) (b) For each control device subject to an operating limit in s. NR 463.23 (1) (b), you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status:

NR 463.25(7)(b)1. 1. That you have submitted the control device operation and maintenance plan to the department for approval according to the requirements of s. NR 463.23 (3) (b).

NR 463.25(7)(b)2. 2. That you will inspect, operate and maintain each control device according to the procedures in the plan.

NR 463.25(7)(c) (c) For each bag leak detection system, you have demonstrated initial compliance if you have certified all of the following in your notification of compliance status:

NR 463.25(7)(c)1. 1. That you have submitted the bag leak detection system monitoring plan to the department for approval according to the requirements of s. NR 463.23 (3) (b).

NR 463.25(7)(c)2. 2. That you will inspect, operate and maintain each bag leak detection system according to the procedures in the plan.

NR 463.25(7)(c)3. 3. That you will follow the corrective action procedures for bag leak detection system alarms according to the requirements in the plan.

NR 463.25(7)(d) (d) For each pouring area and pouring station in a new or existing foundry, you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status report:

NR 463.25(7)(d)1. 1. That you have submitted the mold vent ignition plan to the department for approval according to the requirements in s. NR 463.23 (3) (b).

NR 463.25(7)(d)2. 2. That you will follow the procedures for igniting mold vent gases according to the requirements in the plan.

NR 463.25 History History: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07.

NR 463.26 NR 463.26 Continuous compliance requirements.

NR 463.26(1) (1) What are my monitoring requirements?

NR 463.26(1)(a) (a) For each capture system subject to an operating limit in s. NR 463.23 (1) (b) 1., you shall install, operate and maintain a CPMS according to the requirements in sub. (2) (a) and both of the following requirements, as applicable:

NR 463.26(1)(a)1. 1. If you use a flow measurement device to monitor the operating limit parameter, you shall at all times monitor the hourly average rate.

NR 463.26 Note Note: For example, the hourly average actual volumetric flow rate through each separately ducted hood or the average hourly total volumetric flow rate at the inlet to the control device.

NR 463.26(1)(a)2. 2. For dampers that are not manually set and remain in the same position, you shall make a visual check at least once every 24 hours to verify that each damper for the capture system is in the same position as during the initial performance test. Dampers that are manually set and remain in the same position are exempt from the requirement to install and operate a CPMS.

NR 463.26(1)(b) (b) For each negative pressure baghouse or positive pressure baghouse equipped with a stack that is applied to meet any PM or total metal HAP emissions limitation in this subchapter, you shall at all times monitor the relative change in PM loadings using a bag leak detection system according to the requirements in sub. (2) (b) and do all of the following:

NR 463.26(1)(b)1. 1. Monitor the pressure drop across each baghouse cell each day to ensure pressure drop is within the normal operating range identified in the manual.

NR 463.26(1)(b)2. 2. Confirm that dust is being removed from hoppers through weekly visual inspections or other means of ensuring the proper functioning of removal mechanisms.

NR 463.26(1)(b)3. 3. Check the compressed air supply for pulse-jet baghouses each day.

NR 463.26(1)(b)4. 4. Monitor cleaning cycles to ensure proper operation using an appropriate methodology.

NR 463.26(1)(b)5. 5. Check bag cleaning mechanisms for proper functioning through monthly visual inspection or equivalent means.

NR 463.26(1)(b)6. 6. Make monthly visual checks of bag tension on reverse air and shaker-type baghouses to ensure that bags are not kinked, kneed or bent, or lying on their sides. You do not have to make this check for shaker-type baghouses using self-tensioning, spring-loaded, devices.

NR 463.26(1)(b)7. 7. Confirm the physical integrity of the baghouse through quarterly visual inspections of the baghouse interior for air leaks.

NR 463.26(1)(b)8. 8. Inspect fans for wear, material buildup and corrosion through quarterly visual inspections, vibration detectors or equivalent means.

NR 463.26(1)(c) (c) For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2., you shall at all times monitor the 3-hour average pressure drop and scrubber water flow rate using CPMS according to the requirements in sub. (2) (c).

NR 463.26(1)(d) (d) For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 3., you shall at all times monitor the 15-minute average combustion zone temperature using a CPMS according to the requirements of sub. (2) (d).

NR 463.26(1)(e) (e) For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 4., you shall at all times monitor the 3-hour average combustion zone temperature using CPMS according to the requirements in sub. (2) (d).

NR 463.26(1)(f) (f) For each wet acid scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5., you shall do both of the following at all times:

NR 463.26(1)(f)1. 1. Monitor the 3-hour average scrubbing liquid flow rate using CPMS according to the requirements of sub. (2) (e) 1.

NR 463.26(1)(f)2. 2. Monitor the 3-hour average pH of the scrubber blowdown using CPMS according to the requirements in sub. (2) (e) 1., or measure and record the pH of the scrubber blowdown once per production cycle using a pH probe and meter according to the requirements in sub. (2) (e) 2.

NR 463.26(1)(g) (g) For one or more automated conveyor and pallet cooling lines and automated shakeout lines at a new iron and steel foundry subject to the VOHAP emissions limit in s. NR 463.23 (1) (a) 10., you shall at all times monitor the 3-hour average VOHAP concentration using a CEMS according to the requirements of sub. (2) (g).

NR 463.26(2) (2) What are the installation, operation and maintenance requirements for my monitors?

NR 463.26(2)(a) (a) For each capture system subject to an operating limit in s. NR 463.23 (1) (b) 1., you shall install, operate and maintain each CPMS according to the following requirements, as applicable: